DRV DRV. MagicDrill. High Efficiency Indexable Insert Drill

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1 High Efficiency Indexable Insert Drill High Efficiency Indexable Insert Drill MagicDrill Economical Inserts with 4 Cutting Edges. Excellent Chip Evacuation with 6D Maximum Deep-Hole Drilling D to 6D Drilling Lineup 4 ypes of Chipbreakers for Various Machining pplications High Speed and Highly Efficient Machining vailable with the Combination of a CVD Outer Insert and PVD Inner Insert Highly Rigid Design with Chattering Resistance Excellent Hole ccuracy

2 High Efficiency Indexable Insert Drill MagicDrill Economical Inserts with 4 Cutting Edges. Excellent Chip Evacuation with 6D Maximum Deep-Hole Drilling High Speed and Highly Efficient Machining vailable with the Combination of CVD (Outer Edge) and PVD () Inserts Excellent Drilling Precision with Less Variation in Cutting Diameter Up to 6D Drilling Capabilities with a Low Cutting Force Design 1 Optimal Web hickness Reduces Chattering with a Low Cutting Force Design Comparison of Cutting Diameter Variation Web hickness Comparison (In-house Evaluation) (In-house Evaluation) Cutting Force Comparison (In-house Evaluation) 33% Competitor.,5 hrust Force (N) UP Cutting Diameter Variation (mm) 3, Competitor B.15.1, 1,5 1,.5,446 DOWN 1, Drilling Depth (mm) Cutting Conditions : Vc = 15 m/min, f =.6 mm/rev Cutting Dia. ø(5d), Wet Workpiece : S5C 39% Competitor C Cutting Conditions : Vc = m/min, f =.1 mm/rev Cutting Dia. ø(3d), Wet Workpiece : S5C Unique Insert Design to Control Chip Flow Outer Edge Smooth Chip Evacuation with Compact Chips Unique Insert Pattern to Differentiate between Outside and Inside Inserts U-shaped Cutting Edge Chip Shape Comparison of Outter Insert Cutting Edge (In-house Evaluation) :1mm 16% 47% Diameter of Chips Weight of Chips Competitor D:1mm Cutting Conditions : Vc = 15 m/min, f =.6 mm/rev, Cutting Dia. ø(3d), Wet Workpiece : S5C Excellent Chip Evacuation with 6D Maximum Deep-Hole Drilling Weight per Unit of Length for Chips Generated by the (In-house Evaluation) Pitch Comparison of Chips Generated by the (In-house Evaluation) 8mg/mm Spoon-shaped Cutting Edge 16% CompetitorE 151mg/mm 47% Diameter of Chips Weight of Chips Competitor E : mm : 1.mm Cutting Conditions : Vc = 5 m/min, f =.8 mm/rev, Cutting Dia. ø(5d), Wet Workpiece : SUS34 1

3 3 : PVD(PR1535) CVD Insert on the Outer Edge for Highly Efficient Machining Outer Edge : CVD (C5D/C415D) High Speed and Highly Efficient Machining vailable with the Combination of CVD (Outer Edge) and PVD () Inserts Recommended Cutting Conditions (Maximum Value) UP UP Wear Resistance Comparison (In-house Evaluation).4 8 (C5D) 55%.3 Wear (mm) Vc (m/min) 3 New Grades Developed for Drilling 18 1 Competitor F(CVD) Competitor G(CVD)..1 CVD(C5D) PVD(PR15) Cutting ime (min) Cutting Dia. ø(3d) Workpiece : S5C 4 1 Cutting Conditions : Vc = m/min, f =.1 mm/rev, Cutting Dia. ø(3d), Wet Workpiece : SCM44H Economical 4-edge Inserts 4 ypes of Chipbreakers for Various Machining pplications General Purpose GM Chipbreaker ough Edge GH Chipbreaker Chipbreaker for Steel Machining Stable Deep-hole Machining with Low Cutting Force B Edge Shape Optimized for Various Machining pplications Negative Land with Strong Edge - Section B For Stainless Steel Machining SM Chipbreaker Stable Chip Control when Machining Gummy Stainless Steel Reduces Chip Clogging in the Holder Body C Sharp Cutting and Large Rake ngle C 1st Recommendation for Machining Cast Iron Good for Continuous Steel Machining Reduced Defects Common in hrough-hole Machining B-B Section Chip Control Comparison (In-house Evaluation) Outer Edge Competitor I (SM Chipbreaker) Competitor H Cutting Conditions : Vc = 1 m/min, f =.1 mm/rev Cutting Dia. ø(3d), Drilling Depth 6 mm Wet Workpiece : SUS34 For Machining Soft Steel and SS Material XM Chipbreaker (In-house Evaluation) (SM Chipbreaker) Inner Edge C-C Section Comparison of Remaining Chips Remaining Chips Cutting Conditions : Vc = 15 m/min, f =.8 mm/rev Cutting Dia. ø5(5d), Drilling Depth 98 mm Wet Workpiece : SUS34 Chip Control Comparison (In-house Evaluation) Stable Chip Control of Outer Cutting Edge Outer Edge D E D E D-D Section E-E Section Excellent Chip Control with the Changing Width of the Chipbreaker Inner Edge (XM Chipbreaker) Competitor J Cutting Conditions : Vc = m/min, f =.1 mm/rev Cutting Dia. ø16(3d), Drilling Depth 48 mm Wet Workpiece : SS4 Chipbreaker Selection Chart P.3

4 Case Studies Case Studies Housing SCM4 Vc = 15 m/min (n = 1,66 min -1 ) f =.8 mm/rev (Vf = 133 mm/min) Drilling Depth 45 mm Wet (External Coolant) S5-4M-4-7 SCM731GM-I PR1535 SCM735GM-E PR15 Nipple SCF Vc = 3 m/min (n = 3,33 min -1 ) f =.13 mm/rev (Vf = 433 mm/min) Drilling Depth 6 mm (4D) 3 mm (D) Wet (Internal Coolant) S5-M-4-6 (4D) S5-M--6 (D) SCM61-GM-I PR1535 SCM65-GM-E PR15 Process Drilling Depth 3 mm (D) Process1 Drilling Depth 6 mm (4D) Cutting ime (ø4-4d) Competitor K (ø4-4d) 16 sec 35 sec 5% or More Cutting ime Cutting ime (ø4-4d/d) Competitor L (ø-4d/d) 1 sec sec 4% Cutting ime Chattering and chip biting occurred in low rigidity workpiece of Competitor K. Speed was reduced to V c = 6 m/min. finely divided chips for stable machining at Vc = 15 m/min. (User Evaluation) Chattering and deflection occurred with Competitor L. showed stable machining and a shorter cutting time even when the cutting conditions were increased to 1.6 times or more. (User Evaluation) Chipbreaker Selection Chart P (Carbon Steel lloy Steel) M (Stainless Steel) K (Cast Iron) Low Carbon Steel Material where Chips are Easily Elongated(SCM415,SS4 etc.) Medium to High Carbon Steel (S45C,SCM44 etc.) Non Heat reated Defect Resistance Oriented or Heat reated Resistance Oriented Defect Resistance Oriented No Interruption Interrupted Wiper Edge For Soft Steel XM Chipbreaker Wiper Edge SM Chipbreaker General Purpose GM Chipbreaker ough Edge GH Chipbreaker Wiper Edge SM Chipbreaker General Purpose GM Chipbreaker ough Edge GH Chipbreaker Chip Biting Defect For Soft Steel XM Chipbreaker ough Edge GH Chipbreaker 3

5 Holder L3 L L1 ødc 1 oolholder Dimensions D (Drilling Depth : Dc) Description Stock No. of Inserts Dimensions (mm) Spare Parts Max. Radial Offset ødc L1 L L3 1 (mm) Clamp Screw Wrench pplicable Inserts S- 14M M M SB-37RP Outer Edge SCM45E SCM49I 155M S5-16M M M M SB-41RP Outer Edge SCM55E SCM51I 18M M S5-19M M M M M SB-555RP DPM-8 Outer Edge SCM65E SCM61I 15M M S5-5M M M M M SB-36RP Outer Edge SCM735E SCM731I 5M M M S3-7M M M M SB-3573RP Outer Edge SCM945E SCM941I 31M M : Standard Stock Estimated Cutting olerance (D) Dc ø14 - ø3 Estimated Cutting olerance (mm) +.3 he above values are estimates. hese values may change due to machine, workpiece, clamping power, and cutting conditions. 4

6 Holder L L3 L1 ødc 1 oolholder Dimensions 3D (Drilling Depth : 3 Dc) Description Stock No. of Inserts Dimensions (mm) Spare Parts Max. Radial Offset ødc L1 L L3 1 (mm) Clamp Screw Wrench pplicable Inserts S- 14M M M SB-37RP Outer Edge SCM45E SCM49I 155M S5-16M M M M SB-41RP Outer Edge SCM55E SCM51I 18M M S5-19M M M M M SB-555RP DPM-8 Outer Edge SCM65E SCM61I 15M M S5-5M M M M M SB-36RP Outer Edge SCM735E SCM731I 5M M M S3-65M M M M M M M SB-3573RP Outer Edge SCM945E SCM941I 3M M M M M Estimated Cutting olerance (3D) : Standard Stock Dc ø14 - ø3 Estimated Cutting olerance (mm) +.3 he above values are estimates. hese values may change due to machine, workpiece, clamping power, and cutting conditions. 5

7 Holder L3 L L1 ødc 1 oolholder Dimensions 4D (Drilling Depth : 4 Dc) Description Stock No. of Inserts Dimensions (mm) Spare Parts Max. Radial Offset ødc L1 L L3 1 (mm) Clamp Screw Wrench pplicable Inserts S- 14M M M SB-37RP Outer Edge SCM45E SCM49I 155M S5-16M M M M SB-41RP Outer Edge SCM55E SCM51I 18M M S5-19M M M M M SB-555RP DPM-8 Outer Edge SCM65E SCM61I 15M M S5-5M M M M M SB-36RP Outer Edge SCM735E SCM731I 5M M M S3-7M M M M SB-3573RP Outer Edge SCM945E SCM941I 31M M : Standard Stock Estimated Cutting olerance (4D) Dc ø14 - ø3 Estimated Cutting olerance (mm) +.35 he above values are estimates. hese values may change due to machine, workpiece, clamping power, and cutting conditions. 6

8 Holder L3 L L1 ødc 1 oolholder Dimensions 5D (Drilling Depth : 5 Dc) Description Stock No. of Inserts Dimensions (mm) Spare Parts Max. Radial Offset ødc L1 L L3 1 (mm) Clamp Screw Wrench pplicable Inserts S- 14M M SB-37RP Outer Edge SCM45E SCM49I S5-16M M M SB-41RP Outer Edge SCM55E SCM51I S5-19M M M SB-555RP DPM-8 Outer Edge SCM65E SCM61I M S5-3M M M SB-36RP Outer Edge SCM735E SCM731I 6M S3-7M M M M SB-3573RP Outer Edge SCM945E SCM941I 31M M : Standard Stock Estimated Cutting olerance (5D) Dc ø14 - ø3 Estimated Cutting olerance (mm) +.35 he above values are estimates. hese values may change due to machine, workpiece, clamping power, and cutting conditions. 7

9 Holder L3 L L1 ødc 1 oolholder Dimensions 6D (Drilling Depth : 6 Dc) Description Stock No. of Inserts Dimensions (mm) Spare Parts Max. Radial Offset ødc L1 L L3 1 (mm) Clamp Screw Wrench pplicable Inserts S- 14M M SB-37RP Outer Edge SCM45E SCM49I S5-16M M M SB-41RP Outer Edge SCM55E SCM51I S5-19M M M SB-555RP DPM-8 Outer Edge SCM65E SCM61I M S5-3M M M SB-36RP Outer Edge SCM735E SCM731I 6M S3-7M M M M SB-3573RP Outer Edge SCM945E SCM941I 31M M : Standard Stock Estimated Cutting olerance (6D) Dc ø14 - ø3 Estimated Cutting olerance (mm) +.45 he above values are estimates. hese values may change due to machine, workpiece, clamping power, and cutting conditions. 8

10 Insert Usage Classification P : 1st Recommendation (High Speed and Highly Efficient Machining) : nd Recommendation (Stable Machining Oriented) Carbon Steel lloy Steel Mold Steel M Stainless Steel K Cast Iron Dimensions (mm) Shape pplication SCM General Purpose SCM ough Edge For Soft Steel Machining Outer Edge SCM SCM For Stainless Steel Machining SCM General Purpose SCM ough Edge For Soft Steel Machining Inner Edge SCM SCM For Stainless Steel Machining CVD Coated Carbide MEGCO NNO Description ngle MEGCO 45-GM-E GM-E GM-E GM-E GM-E GH-E GH-E GH-E XM-E XM-E XM-E SM-E SM-E SM-E SM-E SM-E GM-I GM-I GM-I GM-I GM-I GH-I GH-I GH-I XM-I XM-I XM-I SM-I SM-I SM-I SM-I SM-I PR15 C5D C415D PR1535 : Standard Stock 9

11 Recommended Cutting Conditions 1st Recommendation nd Recommendation Recommended Cutting Conditions (Wet) Workpiece Low Carbon Steel (SS4,S15 etc.) Recommended Insert Grade (Cutting Conditions Vc:m/min) Holder ype (Drilling Depth) Holder ype (Drilling Depth) PVD Coated Carbide CVD Coated Carbide Cutting Dia. D 3D 4D ød PR15 C5D C415D (mm) fz f(mm/rev) fz f(mm/rev) GM GH XM SM GM GH XM SM GM GH GM GH XM SM GM GH XM SM Carbon Steel (S45C etc.) lloy Steel (SCM,SCr etc.) Mold Steel (SKD etc.) Stainless Steel (ustinitic) Gray Cast Iron (FC) Nodular Cast Iron (FCD) Internal Coolant is Recommended Workpiece Low Carbon Steel (SS4,S15 etc.) ø14 - ø ø16 - ø ø19 - ø ø.5 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø Recommended Insert Grade (Cutting Conditions Vc:m/min) Holder ype (Drilling Depth) Holder ype (Drilling Depth) PVD Coated Carbide CVD Coated Carbide Cutting Dia. 5D 6D ød PR15 C5D C415D (mm) fz f(mm/rev) fz f(mm/rev) GM GH XM SM GM GH XM SM GM GH GM GH XM SM GM GH XM SM Carbon Steel (S45C etc.) lloy Steel (SCM,SCr etc.) Mold Steel (SKD etc.) Stainless Steel (ustinitic) Gray Cast Iron (FC) Nodular Cast Iron (FCD) Internal Coolant is Recommended Cutting Conditions by pplication ø14 - ø ø16 - ø ø19 - ø ø.5 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø ø14 - ø ø16 - ø ø19 - ø ø6.5 - ø pplication Plain Surface Slant Surface Half Cylindrical Hole Expansion Pre-Drilled Surface Concave Surface Stacked Plates shape of workpiece Cutting Conditions Vc(m/min) See recommended cutting conditions above 1 (PVD insert is recommended for outer edge) Not Recommended fz f(mm/rev) See recommended cutting conditions above Half of the above recommended conditions is recommended Concave Surface : Half of the above recommended conditions is recommended Solid Portion : See recommended cutting conditions onditions above Not Recommended Coolant (Internal Coolant) Yes Not Recommended 1

12 djustable Sleeve (Cutting Dia./Center Height djustment) ød ød1 L L4 L1 L3 Sleeve Dimensions Description Stock Dimensions (mm) ød1 ød L1 L L3 L4 Dia. djustment Range * Center Height djustment Range SHE * Dia. djustment Range refers to the cutting diameter. : Standard Stock 1 Diameter djustment For Machining Center Center Height djustment Fewer height adjustment problems for lathes ø3mm Drill Small Large ø9.8 ø3.4 Diameter djustment Range(mm) Center Height djustment Range(mm) Shank Dia. djustment Range Shank Dia. djustment Range ø ø ø5 ø3 ø ø5 ø3 ø How to Use 1 Hole Diameter djustment when Drilling 1. lign the scale at the flange periphery of the sleeve to the center of the coolant plug of the drill.(fig.1). When making the hole diameter bigger, rotate the sleeve in the (+) direction and to make it smaller, rotate the sleeve in the (-) direction. 3. When rotating the sleeve, insert the wrench supplied with the drill into the hole on the flange periphery to rotate the sleeve. 4. Using the bottom screw of the side-lock arbor, firmly tighten the drill directly through the sleeve's window. he upper screw should be tightened slightly so that the sleeve will not be damage. Bottom Screw (ighten Firmly) Caution) Not for use with collet chuck type arbor. Check the actual cutting diameter after adjusting. op Screw (ighten Slightly) Center-Height djustment for Lathes Fig.1 Reference Mark Fig. Most of the problems encountered with a turning lathe are center-height deviations. he center height is appropriate if a core of about mm diameter remains at the center of the hole. Center-height adjustment is necessary when no core remains or if the core diameter is more than 1mm. 1. lign the drill with the outer insert face parallel to the tool turret. (Fig.4). lign the scale (for the lathe) on the flange face of the sleeve to the center of the reference mark. 3. When no core remains, rotate the sleeve in the (+) direction to make the core larger, and when the core diameter is more than 1mm, rotate the sleeve in the (-) direction to make the core smaller. 4. When rotating the sleeve, insert the wrench supplied with the drill into the hole of the flange and then rotate the sleeve. 5. fter Completing the adjustment, tighten the drill directly through the window on the sleeve. Fig.3 Core Flat Surface Caution) Depending on amount of the center height adjustment, the hole diameter may change. It is recommended that the hole diameter is checked after the center height adjustment. Fig.4 Flange 11

13 Lathe Installation 1. he top face of the outer insert should be parallel to the X-axis to allow for offset cutting. (Cutting diameter can be changed by moving X-axis.). It is recommended to set the outer insert as shown in Fig.1 with the outer insert facing the operator. (Fig.1) (It is also possible to use it by setting it in 18 reverse position) If the lathe has two turrets, when installing the drill into the lower turret, the outer insert should be set to face the operator. (It is also possible to use it by setting at 18 reverse position) Moving Direction of X-axis urret Flat Surface Flange Outer Edge Cutting Diameter djustment Fig.1 Installed into the Lathe 1 Cutting Diameter djustment Smaller 1. Cutting diameter is adjusted by moving X-axis. he moving direction of the X-axis depends on the position of the toolholder.. For making the hole diameter larger, slide the tool along the X-axis toward the outer insert side.(fig.,fig.3) For making the hole diameter smaller, slide the tool along the X-axis in the opposite direction. (his movement of the axis is called Offset ) Be sure not to make the hole diameter smaller than the drill diameter by.mm or more. Otherwise, the toolholder will interfere with the drilled hole.(fig.4) Ex.) When using ø drill, the hole diameter must not be smaller than 19.8mm Flat Surface Fig. Outer Insert Facing Up Larger Flange Outer Edge Outer Edge Larger Flat Surface Smaller Flange Offset Limit of the Cutting Diameter For the maximum limit of the cutting diameter, refer to Max. Offset (Radial) in the oolholder Dimensions table. (he figure in the oolholder Dimensions table shows how much it is possible to offset the drill in the radial direction.) Ex.) When using ø drill, for example, it is possible to make a hole up to ø1.1 since "Max. Offset (Radial)" is +5mm. Interference Flat Surface Center of Drill Cutting Dia. Flange Outer Edge Center of Spindle Fig.3 Outer Insert Facing Down Fig.4 Excessive Offset (For Smaller Hole Diameter) Center Height djustment 1 Center Height of the Inner Insert When installing inner insert as shown in Fig.1, it will be set around.5mm below the Center of Spindle.(Fig.5) his is the normal position of the center height. However, in case that the turret of the lathe is out of the Center of Spindle, sometimes the inner insert may be set above or below the center. For stable machining, it is essential to check the Center Height carefully bout.5mm below the Center Center of Spindle How to Check the Center Height For checking the center height of the inner insert, see the core which remains at the center of the bottom of the drilled hole. If the center height is in the normal position, a core about mm in diameter, will remain after machining.(fig.6) djustment of center height is required if a large core diameter of 1 mm or more remains. * he drilled hole for verification purposes needs to be machined at approximately 1 mm in depth and at a feed rate of.1 mm/rev or lower. Core (bout mm in Diameter) Fig.6 Center Core Fig.5 Front View of the Drill 1

14 3 Center Height djustment 1. When there are no remaining cores and the vicinity of the drill center of the inner edge is damaged his happens when the inner insert is set above the center height.(fig.7) How to djust.install the drill rotated by 18 Most problems will be solved by this method(fig.8) B. If the core diameter becomes too large after the above adjustment, install the drill by rotating 9 counter-clockwise as shown in Fig.9 (outer edge is positioned lower) and adjust the center height by moving the tool in the X-axis direction. (However, this will make it impossible to adjust the cutting diameter) Caution: When installing the drill in the opposite direction (outer insert is positioned above), the cutting diameter will become smaller, which may cause the drill body to interfere with the drilled hole. he best solution is to readjust the center position of the turret itself. Fig.7 Insert breakage near the center of the drill 18 Rotation Initial Installation (Inner insert positioned higher than normal) Improved Position of Inner Insert (Inner Insert Positioned Lower than Normal) Center of Spindle Center of Spindle 9 Rotation Center Height djustment by Moving the ool Higher Below the Center Center of Spindle 9 Center of Drill Center of Drill Outer Edge Center of Drill Close-up Near the Center Close-up Near the Center Close-up Near the Center Inner Insert Positioned too Far below Center Fig.8 Fig.9. Core with Excessively Large Diameter (More than 1mm) his occurs when the inner insert is excessively below the center his condition causes poor chip evacuation and an adjustment is required. Inner insert is positioned excessively below the center. 9 Rotation Center Height djustment by Moving the ool Outer Edge Below the Center Higher 9 How to djust Outer Edge Install the drill rotating 9 as shown in Fig.1. (outer insert is positioned on the upper side) and adjust the center height by moving tool in the X-axis direction. (However, this will make it impossible to adjust the cutting diameter) Caution: When installing the drill in the opposite direction (outer insert is positioned lower), the cutting diameter will become smaller, which may cause the drill body to interfere with the drilled hole. he best solution is to readjust the center position of the turret itself. Fig.1 13

15 Insert Grade Selection Guide Select CVD for the outer edge when performing high speed and high efficiency machining. Machining for high efficiency, abrasion resistance and long tool life. Select PVD for the outer edge when for stable machining and a better surface finish. PVD is recommended for the outer edge if chattering occurs or machining with lathe is not available even if cutting conditions are increased. 1st Recommendation (High Speed and High Efficiency Machining) Stable Machining Oriented (1st Recommendation for Lathe Machining) Outer Edge : CVD(C5D/C415D) : PVD (PR1535) Outer Edge : PVD (PR15) : PVD (PR1535) Shape of the Hole Bottom Chip Size (SCM...) ød Chip Size (SCM...) ød Chip Size (SCM...) ød Chip Size (SCM...) ød ød Common for D, 3D, 4D, 5D and 6D drills. * he above values are estimate values. (Varies by approximately ±.1 mm depending on workpiece and cutting conditions, etc.) Cautions for Machining In case of through-hole machining, disc may be generated and ejected outward when drilling a hole. Be sure to install covers to protect against dangers if using a machine without the covers including general-purpose lathes, etc. Disc 14

16 17 KYOCER Corporation CP46