15 Lead Angle D1~D9 MSRS15 MSE15 D2-D8 D9

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Ethan Barrett
6 years ago
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1 15 1~9 15 MSE15 2~9 28 9

Heavy Milling Face Mill MonSteR M S R Square Mill

increased Square (4edge) type Face Mill 15 Roughing takes

472 in) Large depths of cut and high feed rates improve

Strong inserts due to 6.35mm (0.250") thickness.

Purpose Edge Strength Oriented Insert Type + + +

NB3 (3Notched) NB2T (2Notched) NB3T (3Notched) Ideal when

As many as four (or five) Notches help to alleviate the

good balance of strength and low cutting resistance

balanced Ideal for interrupted cutting Ideal when feed rate

increased by the edge shape and moderate rake angle of the

may be used when it is necessary to increase strength and

machining welded areas. or + About insert no.

2 Heavy Milling Face Mill MonSteR M S R Square Mill Conventional Tools Metal removal rate is drastically increased Square (4edge) type Face Mill 15 Roughing takes place in one pass. type changes heavy cutting! (Max. ap in) Large depths of cut and high feed rates improve metal removal efficiency. Recommended ap: 5~10mm ( ") Wide lands strengthen edges A.R. +9 R.R. 9 (ø80mm) 5 (> ø100mm) 0.472in (Max. ap) in CornerR = 0.047in 0.250in 75 Large wiper edges enable increased feed rates. Strong inserts due to 6.35mm (0.250") thickness. Chipbreaker Selection Low Cutting Force Oriented General Purpose Edge Strength Oriented Insert Type Applications NB2P (4Notched) NB3P (5Notched) NB2 (2Notched) NB3 (3Notched) NB2T (2Notched) NB3T (3Notched) Ideal when using extended arbors or for cutting thinplate workpieces As many as four (or five) Notches help to alleviate the shock when biting into the workpiece General purpose with good balance of strength and low cutting resistance Strength, cutting resistance, and chip control are all well balanced Ideal for interrupted cutting Ideal when feed rate is increased or workpiece material is Cast Iron Strength is increased by the edge shape and moderate rake angle of the chamfer edge Edge preparation 2 A supplemental chipbreaker may be used when it is necessary to increase strength and bite while focusing on low cutting resistance, as when machining welded areas. or + About insert no. of NB2P (4Notched) and NB3P (5Notched) In order to promote proper insert indexing to the corresponding pockets of the milling cutter, 2+ is marked for NB2P (4Notched) and 3+ is marked on NB3P (5Notched).

Notched inserts reduce cutting forces, chattering and enables efficient cutting

20in of vertical axial ap (effects for NB3 appears from at least 0.

08in esigned to suppress chattering by reducing cutting forces Possible to cut

chattering by generating less "lifting force" during cutting. 0.35in 0.

72in own Force 160R8T Workpiece Material: 1050 Steel Vc=675sfm(n=398RPM) fz=0.

94in (Cutting of unsupported overhang from a thickness of 0.600in to 0.

Chip Evacuation Higher productivity due to close pitch design esigned with

3 Notched inserts reduce cutting forces, chattering and enables efficient cutting Notched Inserts Notch effect The effects of the notch can be seen at more than 0.20in of vertical axial ap (effects for NB3 appears from at least 0.08 or more) Notched Notched NB2 NB3 0.08in esigned to suppress chattering by reducing cutting forces Possible to cut thinplate workpieces Comparison of cutting force (radial force) MSRS suppresses chattering by generating less "lifting force" during cutting. 0.35in 0.20in With two notches NB2 With three notches NB3 Lift Force 15 Overhang 4.72in own Force 160R8T Workpiece Material: 1050 Steel Vc=675sfm(n=398RPM) fz=0.006ipt(vf=18.78 ipm), ap ae= in (Cutting of unsupported overhang from a thickness of 0.600in to 0.350in) Competitor A Features of Toolholder esigned with large chip pockets Good Chip Evacuation Higher productivity due to close pitch design esigned with cartridges Prevents damage to base body Applicable insert number (Notch number) Insert Replacement Identification * epending on the cutting conditions, marks may not be transcribed. Insert number is transcribed as a result of the cutting tool load. 3

Heavy Milling Face Mill Fig.1 Fig.2 Rake Angle ( ) escription A.R. R.R. 080R +9 9 100R ~ 315R +9 5 (Coarse Pitch Shown) Fig.3 Fig.4 15 Toolholder imensions (Bore ød: Inch) escription Stock Unit No.

4 Heavy Milling Face Mill Fig.1 Fig.2 Rake Angle ( ) escription A.R. R.R. 080R R ~ 315R +9 5 (Coarse Pitch Shown) Fig.3 Fig.4 15 Toolholder imensions (Bore ød: Inch) escription Stock Unit No. of Inserts imension ø ø1 ød ød1 ød2 H E a b S ød3 ød4 ød5 ød6 øc øc1 G rawing Weight (kg) MSRS R4T R4T R6T Fig R8T inch R10T Fig R12T R14T Fig MSRS R6T R6T R8T Fig R10T inch R12T Fig R14T R16T Fig MSRS 15080R4T R4T R6T Fig R8T mm R10T Fig R12T R14T Fig MSRS 15080R6T R6T R8T Fig R10T mm R12T Fig R14T R16T Fig Mounting bolts (HH12X35) are included in 080RT. (HH1/21.25) are included with 3000RT. Cartridge is included in the coarse pitch cutters, but no Cartridge in the fine pitch. Applicable Inserts B18B19 SPMT1806EERNB2 SPMT1806EERNB3 SPMT1806ESRNB2T SPMT1806ESRNB3T SPMT1806EERNB2P SPMT1806EERNB3P SPMT1806EERV 4 4 : Stock Std. : World Express : Made to Order

5 Toolholder imensions (Bore ød: Metric) escription Stock No. of Inserts Spare Parts (InchSize) imension (mm) f f1 fd fd1 fd2 H E a b S fd3 fd4 fd5 fd6 fc fc1 G MSRS 15080R4TM R4TM Fig R6TM R8TM R10TM Fig R12TM R14TM Fig MSRS 15080R6TM R6TM Fig R8TM R10TM R12TM Fig R14TM R16TM Fig Mounting bolts (HH12X35) are included in 080RTM. (HH1/21.25) are included with 3000RT. Cartridge is included in the coarse pitch cutters, but no Cartridge in the fine pitch. Spare Parts (Inch) rawing Weight (kg) Applicable Inserts B18B19 SPMT1806EERNB2 SPMT1806EERNB3 SPMT1806ESRNB2T SPMT1806ESRNB3T SPMT1806EERNB2P SPMT1806EERNB3P SPMT1806EERV 15 escription Clamp Screw Wrench Cartridge Clamp Screw Wrench Antiseize Compound Mounting bolt MSRS R4T MSRS R4T R6T SB60120TR TT25L MAP1806 SB40140TR T R8T MP1 for Insert Clamp R10T for Shim Clamp Recommended Recommended torque torque 31.2 in/lb R12T 66 in/lb R14T MSRS R6T MSRS R6T SB60120TR TT25L R8T R10T MP1 for Insert Clamp R12T Recommended torque R14T 66 in/lb R16T Apply a thin coat of antisieze compound (MP1) on clamp screw when installing insert. HH1/21.25 HH3/42.3 HH1/21.25 HH3/ : Stock Std. : World Express : Made to Order 5

6 Heavy Milling Face Mill Spare Parts (MetricSize) Spare Parts (mm) escription Clamp Screw Wrench Cartridge Clamp Screw Wrench Antiseize Compound Mounting bolt MSRS 15080ROO(M) MSRS 15100ROO(M) ~ 15315ROO(M) SB60120TR TT25L MAP1806 SB40140TR T15 for Insert Clamp Recommended torque 7.5Nm for Shim Clamp Recommended torque 3.5Nm MP1 HH MSRS 15080ROO(M) MSRS 15100ROO(M) ~ 15315ROO(M) SB60120TR TT25L for Insert Clamp Recommended torque 7.5Nm Apply a thin coat of antisieze compound (MP1) on clamp screw when installing insert. MP1 HH

7 Applicable Inserts Applicable Inserts B18 Righthand inserts shown escription 2Notched 3Notched 2Notched / Tough Edge 3Notched / Tough Edge MSRS MSRS M For customordered lefthand cutter SPMT 1806EERNB2 SPMT 1806EERNB3 SPMT 1806ESRNB2T SPMT 1806ESRNB3T SPMT 1806ESLNB2T SPMT 1806ESLNB3T Applicable Inserts B19 escription MSRS MSRS M 4Notched / Low cutting force 5Notched / Low cutting force Solid Edge SPMT 1806EERNB2P SPMT 1806EERNB3P SPMT 1806EERV Chipbreaker Selection 2 15 Recommended Cutting Conditions Workpiece Material NB2P + NB3P fz (ipt) NB2 + NB3 NB2T + NB3T Carbon Steel Alloy Steel Mold Steel Recommended Insert Grades (Cutting Speed Vc: sfm) MEGACOAT PV Coated Carbide PR1225 PR1230 PR1210 PR660 PR830 PR ~600~ ~600~ ~525~ ~600~ ~600~ ~525~675 Gray Cast Iron Nodular Cast Iron ~600~ ~525~ ~525~ ~525~ ~475~ ~575~ ~575~ ~500~ ~575~ ~500~675 Stainless Steel Aluminum / Copper Not recommended Not recommended : 1st Recommendation : 2nd Recommendation 7 7

Heavy Milling Face Mill Case Studies Improved productivity / Shortened Cutting Time Plate Vc=492 sfm (n=382rpm) ap ae=0.39 4.92in fz=0.008 ipt (Vf=18.

008 ipt (Vf=18.90ipm) ry 8 flutes 160R8T SPMT1806EERNB2 SPMT1806EERNB3 (PR830) 1050 Steel Productivity improved by 4.7 times! Metal Removal Rate 24.59in 3 /min.

[User s Comments] Because conditions can be raised drastically, this cutter was very effective at reducing cycle time. Productivity improved by 4.4 times.

[User s Comments] MSRS can complete cutting with 1 pass what needed to be cut with 3 passes previously. Cutting sound of MSRS was still quiet. Productivity improved by 4.7 times.

8 Heavy Milling Face Mill Case Studies Improved productivity / Shortened Cutting Time Plate Vc=492 sfm (n=382rpm) ap ae= in fz=0.008 ipt (Vf=18.03ipm) ry 6 flutes 125R6T SPMT1806EERNB2 SPMT1806EERNB3 (PR830) Structural Steel Productivity improved by 4.4 times! Metal Removal Rate 34.91in 3 /min. Rail Vc=492 (n=300rpm) ap ae= in fz=0.008 ipt (Vf=18.90ipm) ry 8 flutes 160R8T SPMT1806EERNB2 SPMT1806EERNB3 (PR830) 1050 Steel Productivity improved by 4.7 times! Metal Removal Rate 24.59in 3 /min. Competitor s Cutter A [Competitor s Cutter A] ø125mm, 6 flutes Vc=492sfm (n=382rpm) ap ae= in fz=0.006ipt (Vf=13.54ipm) 7.87in 3 /min. [User s Comments] Because conditions can be raised drastically, this cutter was very effective at reducing cycle time. Productivity improved by 4.4 times. (Customer Evaluation) Competitor s Cutter B [Competitor s Cutter B] Machining at 0.08in 3 passes Vc=492sfm (n=300rpm) ap ae= in fz=0.005ipt (Vf=11.81ipm) 5.21in 3 /min. [User s Comments] MSRS can complete cutting with 1 pass what needed to be cut with 3 passes previously. Cutting sound of MSRS was still quiet. Productivity improved by 4.7 times. (Customer Evaluation) 15 Industrial Machine Components Vc=325 sfm (n=200rpm) ap ae= in fz=0.016 ipt (Vf=635mm/min) ry 8 flutes 160R8T SPMT1806EERNB2 SPMT1806EERNB3 (PR830) Cast Steel Productivity improved by 2.5 times! Metal Removal Rate 44.18in 3 /min. Gear Vc=675 sfm (n=255rpm) ap ae= in fz=0.007 ipt (Vf=23.62ipm) ry 14 flutes 250R14T SPMT1806EERNB2 SPMT1806EERNB3 (PR830) 1045 Steel Productivity improved by 2.6 times! Metal Removal Rate 73.23in 3 /min. Competitor s Cutter C 17.70in 3 /min. Competitor s Cutter 28.00in 3 /min. [Competitor s Cutter C] Ø6in, 8 flutes Vc=820sfm (n=522min 1 ) ap ae= in fz=0.010ipt (Vf=40.00ipm) [User s Comments] Before MSRS, ap could not be increased due to high cutting resistance, but MSRS can increase ap without increasing load on the main spindle. Productivity improved by 2.5 times (Customer Evaluation) [Competitor s Cutter ] ø250mm, 12 flutes Vc=400sfm (n=153rpm) ap ae= in fz=0.010ipt (Vf=18.07ipm) [User s Comments] Cutting sound is quiet even when cutting width is less than 80 % of cutter dia. Productivity improved by 2.6 times. (Customer Evaluation) Q&A Q1 A1 Q2 A2 What amount of cutting width (ae) is recommended in a radial direction? The estimated amount is 70 to 80% of diameter of the cutting tool. Why does the have a cutting angle of 75 (15 lead)? 45 cutting angles can reduce the impact in cutting a workpiece but also increase thrust force. On the other hand, a 90 cutting angle can reduce thrust forces but increases the impact when the insert cuts the workpiece. The 75 cutting angle of the can suppress both a thrust force and impact, offering a good balance and enabling smooth machining even in heavy cutting 8 8

MSE15 Endmill MSE15 Endmill (High Rake) Toolholder imensions escription Stock No. of Inserts imension (mm) Rake Angle ( ) Ø Ø1 Ød L S A.R. R.R. Spare Parts Clamp Set Wrench Shim Shim Screw MSE 1550 3 50 57 1563 3 63 71 158032 4 80 87 Applicable Inserts Applicable Inserts B13 32 120 40 8.

010 400~675 400~675400~820 Alloy Steel ~0.010 325~600 325~600325~725 Mold Steel ~0.008 325~600 325~600250~600 Cast Iron ~0.

9 MSE15 Endmill MSE15 Endmill (High Rake) Toolholder imensions escription Stock No. of Inserts imension (mm) Rake Angle ( ) Ø Ø1 Ød L S A.R. R.R. Spare Parts Clamp Set Wrench Shim Shim Screw MSE Applicable Inserts Applicable Inserts B CPS6M LW3 MSE4215 SP3X8 15 SEKN 42EFTR Recommended Cutting Conditions Workpiece Material fz (ipt) Stainless Steel ~ ~ ~675400~725 Carbon Steel ~ ~ ~675400~820 Alloy Steel ~ ~ ~600325~725 Mold Steel ~ ~ ~600250~600 Cast Iron ~ ~725 TN60 Recommended Insert Grades (Cutting Speed Vc: sfm) Cermet MEGACOAT PV Coated Carbide Carbide PC TN100M TC60 PR1225 PR1210 PR630 PR ~ ~ ~ ~ ~ ~ ~ ~500 Nonferrous Metals PR830 PR660 PR905 PW30 KW10 KP001 KP010 : 1st Recommendation : 2nd Recommendation 9 9

Milling Cutter for Heavy Roughing

15 15 Milling Cutter for Heavy Roughing Notched insert reduces cutting force, chattering and enables efficient cutting. Large depth of cut and high feed rate enable high effi ciency cutting. TZE00047 changes