MFWN SERIES. New high efficient 90 milling tool. Economical 6 edges

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Colleen Blankenship
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1 MFWN SERIES New high efficient 90 milling tool Economical 6 edges Long tool life with MEGACOAT NANO MEGACOAT uvelle fraise performante à surfacer dresser 90 6 arêtes économiques. Durée vie accrue avec Megacoat Nano. Nuova fresa a 90 ad elevata efcienza Economica: 6 taglienti. Lunga vita utensile con Megacoat Nano. Nueva herramienta fresadora de 90º de alta eciencia Económico 6 puntas. Larga vida de herramienta con Megacoat Nano. TZZ

Inserto bilaterale economico a 6 taglienti.

Low cutting force due to large rake angle.

Basse forze di taglio per mezzo dell ampio angolo di attacco.

Cutting Force Efforts de coupe Forza di taglio Fuerza de CorteP

Competitor B (negative Type) Dynamic Slant Design Vc = 180m/min apxae

2 Economical doublesided 6edge insert. Plaquette économique réversible à 6 arêtes. Inserto bilaterale economico a 6 taglienti. Placa económica 6 puntas de doble cara. Low cutting force due to large rake angle. Faible effort en raison d'un angle de coupe très positif. Basse forze di taglio per mezzo dell ampio angolo di attacco. Baja fuerza de corte por su gran ángulo de corte. Cutting Force Efforts de coupe Forza di taglio Fuerza de CorteP Dynamic Slant Design reduces impact force when cutting edge enters the workpiece. L hélice optimisée permet d améliorer l entrée dans la pièce usinée en réduisant les chocs. Design ad inclinazione dinamica riduce lo shock durante la fase di contatto del pezzo. Diseño Sesgado Dinámico reduce impacto de choque cuando la punta de corte penetra la pieza de trabajo. Cutting Force (N) GM Chipbreaker Competitior A (positive Type) Competitor B (negative Type) Dynamic Slant Design Vc = 180m/min apxae = 7x110 mm fz = 0.2mm/t Workpiece Material: C Cutter Ø 125mm Surface Roughness Etat de surface Rugosità super ciale Aspereza de Super cie Cutting ise Bruit d usinage Rumore di taglio Ruido de corte MFWN NO chattering Competitor C Sound Pressure Level 3mm Overhang chattering occured GM Chipbreaker Competitior D (negative Type) Competitor E (negative Type) Vc = 200m/min apxae = 3x15 mm fz = 0.1mm/t Workpiece Material: C Cutter Ø 80mm 7teeth 2

MEGACOAT NANO for Extended Tool Life MEGACOAT NANO pour optimiser la durée de vie MEGACOAT NANO per incrementare la vita utensile MEGACOAT NANO para vida de herramienta extendida PR1525 for steel and

3 MEGACOAT NANO for Extended Tool Life MEGACOAT NANO pour optimiser la durée de vie MEGACOAT NANO per incrementare la vita utensile MEGACOAT NANO para vida de herramienta extendida PR1525 for steel and stainless steel. PR1510 for cast iron PR1525 pour les aciers et inox. PR1510 pour les fontes. PR1525 per acciaio e acciaio inossidabile. PR1510 per ghisa. PR1525 para acero y acero inoxidable. PR1510 para acero fundido. High hardness and superior oxidation resistance Dureté supérieure et meilleur résistance à l oxydation. Elevata durezza e superiore resistenza all ossidazione. Alta dureza y superior resistencia a la oxidación MEGACOAT NANO TiCN MEGACOAT TiAIN TiN MEGACOAT low Oxidation Resistance high Fracture Resistance Résistance à la rupture Resistenza alla frattura Resistencia a Fracturas Vc = 100m/min, apxae = 2x100 mm, fz = 0.2~0.45mm/t Workpiece Material: 42CrMo4 (38~42HS), DRY Interruption with a slot on the workpiece GM Chipbreaker GH Chipbreaker Available for further cutting Fracture occurred Feed rate (mm/t) Competitor F (Positive) Competitor G (Negative) Cutting Time (min) Stable clamping with optimal insert face design. Fixation optimisée pour une meilleure stabilité de la plaquette. Bloccaggio stabile attraverso il design ottimizzato sul petto dell'inserto. FIjación estable con un diseño óptimo de cara de placa. 4 Chipbreakers for Various Application 4 géométries pour les différentes applications 4 rompitrucioli per varie applicazioni 4 Rompevirutas para Varias Aplicaciones Chipbreaker Application Shape 8 MAX.ap 8mm General Purpose 6 Low Cutting Force 4 Heavy Milling 2 SurfaceFinish Oriented Feed per tooth (mm/t) High Speed Camera 3

4 MFWN Face Mill Rake Angle ( ) A.R. (Max.) +13 ød= 10 ød=80 9 ød=100 8 R.R ød=125 7 ød= Fig. 1 Fig. 2 Fig. 3 Fig. 4 Dimension S: 8mm (GM, SM, GH, GL Chipbreaker) Toolholder Dimension Description Standard of Insert Dimension (mm) ød ød ød1 ød2 H E a b ød3 ød4 Drawing (kg) weight Shim Coolant Hole Coarse Pitch METRIC Fine Pitch Extra Fine Pitch Coarse Pitch INCH Fine Pitch Extra Fine Pitch MFWN 900R3TM Fig R4TM R5TM Fig R6TM R8TM R10TM Fig R12TM MFWN 900R4TM Fig R5TM R7TM Fig R8TM R10TM R12TM Fig R14TM MFWN 900R5TM Fig R7TM R9TM Fig R12TM R14TM R16TM Fig R18TM MFWN 90080R4T Fig R5T Fig R6T R8T Fig R10T Fig.4 902R12T MFWN 90080R5T Fig R7T Fig R8T R10T Fig R12T Fig.4 902R14T MFWN 90080R7T Fig R9T Fig R12T R14T Fig R16T Fig.4 902R18T : Std. Item: Check Availability 4

Spare Parts Spare Parts Description Clamp Screw TT Wrench DTM Shim Shim Screw Wrench Antiseize Compound Mounting bolt Coarse Pitch Fine Pitch Extra Fine Pitch MP1 MFWN 900R3TM HH10x30 90080R4TM

0 Nm Recommended torque for insert clamp Recommended torque for shim clamp 902R12TM MFWN 900R4TM HH10x30 90080R5TM SB140TR TT15 HH12x35 90100R7TM MP1 4.

5 Nm Recommended torque for insert clamp 902R18TM Coat Antiseize Compound (MP1) thinly on clamp screw. Recommended cutting conditions see page 7 How to replace a shim (for coarse pitch) 1.

While aligning the surface of the shim with the mark on it to the corresponding constraint surface (See Fig. 1) and lightly pressing the shim towards the constraint surface (See Fig. 2).

5 Spare Parts Spare Parts Description Clamp Screw TT Wrench DTM Shim Shim Screw Wrench Antiseize Compound Mounting bolt Coarse Pitch Fine Pitch Extra Fine Pitch MP1 MFWN 900R3TM HH10x R4TM SB140TR TT15 MFWN90 SPW70 LW5 HH12x R5TM MP1 4.2 Nm 6.0 Nm Recommended torque for insert clamp Recommended torque for shim clamp 902R12TM MFWN 900R4TM HH10x R5TM SB140TR TT15 HH12x R7TM MP1 4.2 Nm Recommended torque for insert clamp 902R14TM MFWN 900R5TM SB140TR TT15 HH10x R7TM SB40140TRN DTM15 HH12x R9TM MP1 3.5 Nm Recommended torque for insert clamp 902R18TM Coat Antiseize Compound (MP1) thinly on clamp screw. Recommended cutting conditions see page 7 How to replace a shim (for coarse pitch) 1. Remove dust and chips from the insert mounting pocket. 2. The shim must be mounted in proper direction. While aligning the surface of the shim with the mark on it to the corresponding constraint surface (See Fig. 1) and lightly pressing the shim towards the constraint surface (See Fig. 2). Insert the screw into the hole of the shim and tighten (See Fig. 3). When tightening the screw, make sure that the screw is vertical to the bearing surface (See Fig. 3). recommended torque is 6.0Nm. 3. After tightening the screw, make sure that there is no clearance between the shim seat surface and the bearing surface. If there is any clearance, remove the shim and mount it again according to the above steps. Shim Shim screw Identifying mark Constraint surface Wrench Fig. 1 Fig. 2 Fig. 3 MFWN with shank Toolholder Dimension Description Standard. of Insert Dimension (mm) Rake Angle ( ) ød ød L l S A.R. (MAX) R.R. Coolant Hole Clamp Screw Spare Parts Wrench Antiseize Compund MP1 MFWN 900RS323T RS324T RS325T SB140TR TT Nm Recommended torque MP1 MP1 Coat Antiseize Compound (MP1) thinly on clamp screw. : Std. Item: Check Availability 5

How to mount inserts 1. Remove dust and chips from the insert mounting pocket. 2. After applying antiseize compound on portion of taper and thread attach the screw to the front end of the wrench.

When tightening the screw, make sure that the wrench is parallel to the screw. Remember that the screw hole of the holder for Extra Fine Pitch is inclined to the bearing surface. ( See Fig.2 and Fig.

After tightening the screw, make sure that there is no clearance between the insert seat surface and the bearing surface of the holder or between the insert side surfaces and the constraint surface

4) The insert corner identification is stamped on the top surface of the insert. Fig. 1 Fig. 3 Fig. 4 Fig.

6 How to mount inserts 1. Remove dust and chips from the insert mounting pocket. 2. After applying antiseize compound on portion of taper and thread attach the screw to the front end of the wrench. While lightly pressing the insert against the constraint surfaces, put the screw into the hole of the insert and tighten (See Fig. 1). 3. When tightening the screw, make sure that the wrench is parallel to the screw. Remember that the screw hole of the holder for Extra Fine Pitch is inclined to the bearing surface. ( See Fig.2 and Fig.3) For recommended torque, refer table on page After tightening the screw, make sure that there is no clearance between the insert seat surface and the bearing surface of the holder or between the insert side surfaces and the constraint surface of the holder. If there is any clearance, remove the insert and mount it again according to the above steps. 5. To change the cutting edge of the insert, turn the insert counterclockwise. (See Fig.4) The insert corner identification is stamped on the top surface of the insert. Fig. 1 Fig. 3 Fig. 4 Fig. 2 Applicable Inserts Classification of usage : Roughing / 1st Choice : Roughing / 2nd Choice : Finishing / 1st Choice : Finishing / 2nd Choice (In case hardness is under 45HRC) Carbon Steel / Alloy Steel P Mold Steel M Stainless Steel K N S Gray Cast Iron dular Cast Iron nferrous Metal Heatresistant Alloy Titanium Alloy H Hard Materials Insert Description MEGACOAT NANO PR1525 PR1510 WNMU ENGM General Purpose WNMU ENSM Low Cutting Force WNMU ENGH Tough Edge WNEU ENGL Surface Finish Oriented : Std. Item: Check Availability 6

7 Recommended Cutting Conditions Cutter and Insert Selection Purpose Cutter Chipbreaker Coarse Pitch Fine Pitch Extra Fine Pitch GM SM GH GL Steel or alloy steel (General) Steel and alloy steel (with low rigidity machine or unstable clamping) Steel or alloy steel (ap>4mm, fz>0.25mm/t) Surface Finish Oriented Stainless steel (General) Stainless steel (with low rigidity machine or unstable clamping) Cast iron (productivity oriented) Cast iron (ap>4mm fz>0.25mm/t) Vertical Milling Maximum width of Cut (ae) 8mm 7

8 Case Studies GG30 GG25 Machine part Vc=170/min apxae=2.5x130mm fz=0.183mm/t (Vf=0mm/min) with liquid coolant MFWN90160R8T WNMU080608ERGM (PR1510) Frame Vc=1/min apxae=4x160mm fz=0.24mm/t (Vf=715mm/min) with air coolant MFWN90160R10T WNMU080608ERGM (PR1510) PR1510 Chip Removal Rate = 1cc/min PR1510 Chip Removal Rate = 458cc/min (stable milling) Competitor A (positive type) Chip Removal Rate = 68cc/min Competitor B Chip Removal Rate = 282cc/min (negative type/vertical inserts) Competitor proceeded under low cutting conditions, as workpiece was slipping because of the unstable chucking. With MFWN stable cutting was possible at higher cutting conditions. While competitor B could not improve the cutting conditions due to chatttering, MFWN improved it by 160% with NO chattering. Manganese Steel Construction equipment s part Vc=1/min apxae=1x100mm fz=0.2mm/t (Vf=668mm/min) with air coolant MFWN90100R7T WNMU080608ERGM (PR1525) Machine part Vc=226/min apxae=1.5x80mm fz=0.16mm/t (Vf=1,000mm/min) with air coolant MFWN90080R7T WNMU080608ERGM (PR1525) PR1525 Machining efficiency = 2pc/edge PR1525 Machining efficiency = 3pc/edge Competitor C (negative type/vertical inserts) 1pc/edge Competitor D (positive type) 1pc/edge Despite instability with the long overhang of workpiece, MFWN doubled tool life, improving the efficiency by 1%. MFWN trippled tool life under same cutting conditions as Competitor D. KYOCERA Fineceramics GmbH Hammfelddamm 6, Neuss, Germany Phone: +49 (0) Fax: +49 (0) / ceratip@kyocera.de KYOCERA Fineceramics SAS. Parc Tertiaire Silic, 21 Rue de Villeneuve BP 90439, Rungis Cedex, France Phone: +33 (0) Fax: +33 (0) KYOCERA Fineceramics GmbH Poland Branch Office Leg. ul.europejska 4, 55220, JelczLaskowice, Poland Phone: +48(0) Fax: +48(0) KYOCERA Fineceramics GmbH Italy Branch Office Via Torino 51, Milan, Italy Phone: Fax: KYOCERA Fineceramics GmbH Spain Branch Office Avenida Manacor 4, Las Matas, Madrid, Spain Phone: Fax:

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