Technical Information for Power Buster

Size: px

Start display at page:

Download "Technical Information for Power Buster"

Annis Gordon
5 years ago
Views:

Technical Information for ower Buster Recommended cutting condition ISO Workpiece NC5330 NC335 0.0040.

008 vg(sfm) High speed NC5330 NC335 Carbon steel 919755591 820656525 755591492 591492394 Die steel Gray cast iron alleable cast iron Nodular cast iron 919722591 820656525 755591492 525427361

1 Technical Information for ower Buster Recommended cutting condition ISO Workpiece NC5330 NC vg(sfm) High speed NC5330 NC335 Carbon steel Die steel Gray cast iron alleable cast iron Nodular cast iron Low speed Continuous Intermittent ower Buster Test Cylinder block for ship engine (Cast iron) Cutting width () = 6.3inch 2 Cutting depth () = 0.4inch 2 Item ower Buster Conventional tool Diameter(ØD) 8inch 8inch 12 tooth 12 tooth Grade vc NC sfm 0.009ipt VD coating for Cast iron 427sfm 0.006ipt 480% 4.8 min 0.4inch x 2 passes 28.2min/ea 0.16inch x 5 passes 137.5min/ea productivity ower buster 100% Conventional tool 4.8 times productivity increased Onesided 4 corner insert(without nick) AA 45 cutter Heavy machinery part () Cutting width () = 6.3inch 2 Cutting depth () = 0.4inch 2 Item ower Buster Conventional tool Diameter(ØD) 5inch 5inch 8 tooth 8 tooth Grade vc NC sfm 0.006ipt VD coating for Cast iron 492sfm 0.004ipt 290% 2.9 min 0.2inch x 2 passes 5min/ea 0.1inch x 4 passes 14.7min/ea productivity ower buster 100% Conventional tool 2.9 times productivity increased Doublesided 8 corner insert(without nick)aa 45 cutter 50

Technical Information for Rich ill Chip breaker Insert Cutting edge Features Insert Cutting edge Features For aluminum A Light cutting F Due to sharp cutting edge and buffed surface, it has good chip

can be suitable for excellent surface roughness operation B Features of insert Insert Cutting edge Features A ViewA ViewB Chip breaker High rake chip breaker & positive setting angle for low cutting

Features High rake angle makes positive setting angle for low cutting load Suitable for facing and chamfering R8A A=45 R8 A=15 R8Q A=2 Recommended cutting condition ISO Grade SN()X1206A()NNF

2 Technical Information for Rich ill Chip breaker Insert Cutting edge Features Insert Cutting edge Features For aluminum A Light cutting F Due to sharp cutting edge and buffed surface, it has good chip flow and welding resistance Due to low cutting load, it is good for light cutting and difficulttocut material General cutting Wiper W It is suitable design for general milling Specialized edge design can be suitable for excellent surface roughness operation B Features of insert Insert Cutting edge Features A ViewA ViewB Chip breaker High rake chip breaker & positive setting angle for low cutting load Designed wiper technology in minor cutting edge for improved surface roughness Low cutting load due to the positive setting and high rake angle chip breaker Features of cutter She Cutting edge Features High rake angle makes positive setting angle for low cutting load Suitable for facing and chamfering R8A A=45 R8 A=15 R8Q A=2 Recommended cutting condition ISO Grade SN()X1206A()NNF SN()X1206A()NN SNX1206A()NNA ax SN()X1507A()NNF SN()X1507A()NN ax vc(sfm) vc(sfm) vc(sfm) vc(sfm) vc(sfm) NC ~ ~ ~ ~ ~ ~ 490~ ~ ~ ~0.010 R8A 655~ ~ 490~ ~ ~ ~ 490~ ~ ~ ~ ~ ~ 490~ ~0.014 R8A 0.295inch C ~ ~ ~ ~ R8 490~ ~ ~ ~ R8 490~ ~ ~ ~ ~ ~ ~ ~ inch R8Q C ~ ~ ~ ~ ~ ~ ~ ~0.014 Rich ill RH8 Screw on clamping system Adopting stable clamping system Reinforced rigidity and enhanced clamping power Appling shim system, prevent cutter damage when insert breaks Adopting exchangeable shim Using various kinds of cutter (Approach angle 45, 15, 2 ) Stable clamping power with insert Screw Insert Shim Screw Shim 54 RH8A (AA 45 ) RH8(AA 15 ) RH8Q(AA 2 )

Technical Information for Rich ill Rich ill R16 Features conomical 16 cutting edges Reduces cost in medium cutting Wiper insert can be used for good surface roughness Optimal matching of the special

51inch Wiper insert is placed 0.05mm lower than facing insert in cutter When feed is bigger than wiper cutting edge length(0.

especially for Aluminum cutting Light cutting F Due to low cutting load, it is good for light cutting and difficulttocut material General cutting It is suitable design for general milling Wiper W It

Through coolant system reduces cutting heat and improves chip evacuation Decision Left hand Decision Recommended cutting condition ISO Grade C9530 C6510 ON(H)X060608 vc(sfm) 500 ~ 990 500 ~ 990 400 ~

3 Technical Information for Rich ill Rich ill R16 Features conomical 16 cutting edges Reduces cost in medium cutting Wiper insert can be used for good surface roughness Optimal matching of the special cutting edge geometry with variety of new grades provides consistence & long tool When it is used 16 corners, maximum cutting depth is 0.22inch, but it is used 8 corners, maximum cutting depth is 0.51inch Wiper insert is placed 0.05mm lower than facing insert in cutter When feed is bigger than wiper cutting edge length(0.28inch), 2 wiper inserts are placed in symmetrical position Chip breaker Insert Cutting edge Features Aluminum Cutting Light A With sharp edge plication the better productivity has been accomplished, especially for Aluminum cutting Light cutting F Due to low cutting load, it is good for light cutting and difficulttocut material General cutting It is suitable design for general milling Wiper W It has better surface roughness than,f chip breaker Instruction for wiper insert Hand Correct setting Incorrect setting Right hand Through coolant system Well designed chip pocket for better chip flow Through coolant system reduces cutting heat and improves chip evacuation Decision Left hand Decision Recommended cutting condition ISO Grade C9530 C6510 ON(H)X vc(sfm) 500 ~ ~ ~ ~ ~ ~ ~ ~ ON(H)X060608F vc(sfm) 660 ~ ~ ~ ~ ~ ~ ~ ~ ONHX060608W vc(sfm) 660 ~ ~ ~ ~ ~ ~ ~ ~ ON(H)X vc(sfm) 500 ~ ~ ~ ~ ~ ~ ~ ~ ON(H)X080608F vc(sfm) 660 ~ ~ ~ ~ ~ ~ ~ ~ ONHX080608W vc(sfm) 660 ~ ~ ~ ~ ~ ~ ~ ~ 55

4 Technical Information for Alpha ill Recommended depth of cut 1. Slotting 2. Shouldering 3. Shouldering Under 1.5D Under 1.2D Under ax. Cutting depth Recommended cutting condition(for multi edge type) Workpiece ild steel, Low carbon steel High carbon steel, Alloy tool steel Cast iron Aluminum alloy Hardened steel Tool Dia. Grades Fig. Ø0.75, 1.0 Ø1.25, 1.5 Ø2.0, 2.5 Ø3.0, 4.0 vc(sfm) vc(sfm) vc(sfm) vc(sfm) C9530 C6510 H01 200~ ~ ~ ~ ~ ~ ~ ~2, ~2, ~2, ~ ~ ~ ~ ~ ~ ~ 0.006~ 390~ ~ ~ ~ ~ ~ ~2, ~3, ~3, ~ ~ ~ ~ ~ 0.006~ 390~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~0.016 Recommended cutting condition(for single edge type) Workpiece ild steel, Low carbon steel High carbon steel, Alloy tool steel Cast iron Aluminum alloy Hardened steel Grades Fig. C9530 C6510 H01 Tool Dia. Ø0.75, 1.0 Ø1.25, 1.5 Ø2.0, 2.5 Ø3.0, 4.0 vc(sfm) vc(sfm) vc(sfm) vc(sfm) 200~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~2, ~2, ~2, ~ ~ ~ ~ ~ ~ 260~ ~ ~ ~ ~ ~ ~ ~ ~2,950 1,150~3,120 1,150~3, ~ ~ ~ ~ ~ 390~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

5 Technical Information for Alpha ill Cutting condition for ramping and helical operation 1. Ramping 2. Helical cutting for blind hole 3. Helical cutting for through hole Designation Tool Dia. D(min) aximum angle Ramping Lmin ax. desirable hole Dia. DHmax Helical cutting for blind hole ax. pitch dmax in. desirable hole Dia. DHmin ax. pitch dmax Helical cutting for through hole in. desirable hole Dia. DHmin ax. pitch dmax ASA 1043HS HS HS HS HS HS HS HS HS HS HS HS ACA 1150HS HS HS ASA 15050HS HS HS HS HS HS HS HS HS HS HS HS HS ACA 15150HS HS HS HS HS

6 Technical Information for Alpha ill Cutting condition for ramping and helical operation 1. Ramping 2. Helical cutting for blind hole 3. Helical cutting for through hole Designation Tool Dia. D(min) aximum angle Ramping Lmin ax. desirable hole Dia. DHmax Helical cutting for blind hole ax. pitch dmax in. desirable hole Dia. DHmin ax. pitch dmax Helical cutting for through hole in. desirable hole Dia. DHmin ax. pitch dmax ASA 2050HS HS HS HS HS HS HS HS HS HS HS ACA 2150HS HS HS HS HS ASA 3100HS HS HS HS HS ACA 3150HS HS HS HS HS ASA 2100H H ASA 3150H ASA 4125HS HS HS HS ACA 4200HS HS HS HS HS

Technical Information for Future ill Application range as per workpiece ax. available revolution Cutter diameter ax. revolution Cutting speed Steel, Carborn Steel Aluminum alloy Ø2.5 Ø3.0 Ø4.0 Ø5.

0 6,500 5,000 4,000 Future ill(fa) Features General milling cutter for high productivity Adjustable pitch of cutter and various chip breaker offer wide plication range.

7 Technical Information for Future ill Application range as per workpiece ax. available revolution Cutter diameter ax. revolution Cutting speed Steel, Carborn Steel Aluminum alloy Ø2.5 Ø3.0 Ø4.0 Ø5.0 Ø6.0 20,000 16,000 13,000 10,000 8,000 Alalloy Si Under 13% Alalloy Si Over 13% Steel, Carborn Steel Ø8.0 Ø10.0 Ø12.0 6,500 5,000 4,000 Future ill(fa) Features General milling cutter for high productivity Adjustable pitch of cutter and various chip breaker offer wide plication range. Light cutter body allows high speed cutting and can be used in low horse power machine Smooth cutting with low cutting load is accomplished with high rake angle Chip breaker Type Chip breaker Cutting edge Features of chip breaker Light cutting F Non C/B Superior surface roughness at finishing due to ground type cermet insert Superior cutting quality for light and difficulttocut material machining through the low cutting load of chip breaker General cutting Suitable for various cutting due to special she design for general cutting Roughing R Tough cutting edge provides stable cutting performance in severe interruption For aluminum A Superior cutting quality for aluminum due to sharp cutting edge and buffed surface STA: Sharp cutting edge due to high accurate grinding SXTA: Suitablecutting edge for roughing Recommended cutting condition ISO Grade C/B F R A vc(sfm) vc(sfm) vc(sfm) vc(sfm) Aluminum NC5330 C9530 NC335 H01 660~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 0.004~ 0.004~ 0.004~ 0.004~ 0.004~ 500~ ~ ~ ~ 0.004~ 0.004~ 1150~ ~

8 Technical Information for Future ill 200HB 30HRC 30~40HRC 40~50HRC 50HRC 270HB Tensile strength 350pa General structure steel General carbon steel Cast iron, Ductile cast iron 200HB 30HRC 30~40HRC 40~50HRC 50HRC 270HB Tensile strength 350pa General structure steel General carbon steel Cast iron, Ductile cast iron 350~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ Side milling, Slotting, Ramping, Copying Hardness Grades Workpiece Cutting speed (sfm) FR1000 FR1500 FR2000 FR2500 FR3000 FR4000 FR5000 FR6000 Workpiece Hardness Grades Cutting speed (sfm) FR1000 FR1500 FR2000 FR2500 FR3000 FR4000 FR5000 FR HB 30HRC 30~40HRC 40~50HRC 50HRC 270HB Tensile strength 350pa General structure steel General carbon steel Cast iron, Ductile cast iron Cutting speed (sfm) ocketing lunging Workpiece Hardness Grades Cutting speed (sfm) FR1000 FR1500 FR2000 FR2500 FR3000 FR4000 FR5000 FR6000 FR1000 FR1500 FR2000 FR2500 FR3000 FR4000 FR5000 FR6000 Recommended Cutting Condition Helical cutting Workpiece Hardness Grades 200HB 30HRC 30~40HRC 40~50HRC 50HRC 270HB Tensile strength 350pa General structure steel General carbon steel Cast iron, Ductile cast iron 117

9 Technical Information for HRDouble Lmin = ØDc = ØDh ØD ØDc = Tool pass of tool center ØDh = Desirable hole diameter on workpiece ØD = Tool Dia. Adjust feed to under 70% of Recommended cutting condition when ramping & helical cutting In helical ramping, max. cutting depth per 1 helical revolution of cutter should not exceed max. cutting depth as per insert size in ramping, max. cutting depth for 1 ramping process should not exceed max. depth of cut as per used insert size Designation HRDSA 06068HR 06075HR 06087HR 06100HR 06112HR 06125HR 06137HR HRDSA 09100HR HR HR HR HR HR HR HR HR 13125HR HR HR HR HR HR 13250HR HRDCA 09200HR 09250HR 09300HR 09400HR 13200HR 13250HR 13300HR 13400HR 13500HR HRDCA 16300HR 16400HR 16500HR 16600R 16800R R R Tool Dia. ØD fficient cutting diameter ØDe ax. Ramping ax. angle α Cutting Length Lmin Helical ramping Dh in. Cutting diameter Dh ax. Cutting diameter

Technical Information for HRDouble Application area Copying Facing Slotting 0.10 0.08 0.06 0.04 0.02 16 type 13 type 09 type 06 type Ramping Helical cutting Through coolant system 0.02 0.04 0.06 0.08 0.10 0.12 0.

0 Carbon steel, High Carbon steel, Under 30HRC 30~40 HRC 590(330~720) 520(330~660) 1.0 ~ 1.5 0.8 ~ 1.3 rehardened steel 40~50 HRC 390(260~190) 0.6 ~ 1.

8 achining xample I Test result In comparing HRD with our competitor using the same cutting conditions, the cutting speed of HRD was higher with the same depth of cut ( ), the cycle time was reduced

HRD is economically more efficient due to the use of 6 cutting edges compared to DNW type with positive insert achining xample II Working condition Work piece : AISI 1045 (S45C, HRC22) Cutting speed

10 Technical Information for HRDouble Application area Copying Facing Slotting type 13 type 09 type 06 type Ramping Helical cutting Through coolant system (inch/t) Recommended cutting condition Workpiece Hardness Grades vc (sfm) General structural steel, ild steel Under 200HB 650(330~750) 1.0 ~ 2.0 Carbon steel, High Carbon steel, Under 30HRC 30~40 HRC 590(330~720) 520(330~660) 1.0 ~ ~ 1.3 rehardened steel 40~50 HRC 390(260~190) 0.6 ~ 1.2 Cast iron Under 270HB Under 350N/mm 2 390(260~490) 590(330~720) 0.8 ~ ~ 1.8 achining xample I Test result In comparing HRD with our competitor using the same cutting conditions, the cutting speed of HRD was higher with the same depth of cut ( ), the cycle time was reduced by 40% and the tool life was increased to over 60%. HRD is economically more efficient due to the use of 6 cutting edges compared to DNW type with positive insert achining xample II Working condition Work piece : AISI 1045 (S45C, HRC22) Cutting speed : vc = 930sfm = 0.055ipt vf = 398ipm = 0.032inch = 1.378inch Coolant: Dry, achining: Copying achine: Horizontal CT Overhang of tool: 10inch Tool information : HRDC13050HR4 WNX130520ZNN() roductivity : 40% increased Tool cost : 80% decreased Working condition Work piece : AISI 304 (STS304) Cutting speed : vc = 430sfm = 0.047ipt vf = 117ipm = 0.04inch = 3.15inch Coolant: Wet achining : Facing and Slotting achine: Vertical CT Overhang of tool: 10inch Tool information : HRDC13100HR6 WNX130520ZNN() roductivity : 80% increased Tool cost : 25% decreased 150 Test result In comparing HRD with our competitor using the same cutting conditions, the cutting speed of HRD was higher with the same depth of cut ( ), the cycle time was reduced by 80% and the tool life was same, but HRD is economically more efficient due to the use of 6 cutting edges compared to SDN type with positive insert

Technical Information for rox ill Strong clamping due to the concave design of insert bottom rox ill Strong clamping due to the

insert provides good surface finish and low cutting load Specially designed for high speed machining of aluminum Suitable for square

prevent flying out of insert Chip Breaker 3 dimensional design for low cutting load Centrifugal force as per R Various inserts corner

R] Screw Torque = 4N m Indexable insert : 6.8g ax. R as per cutting diameter Recommended cutting condition 190 Cutting diameter ØD ax.

20,500 18,200 16,300 14,600 7,564 8,445 9,549 10,693 11,916 13,382 15,087 16,890 18,910 In case of actual machining accidental

or broken tool Aluminum alloy Copper alloy Thermo plastic Aluminum alloy Copper alloy agnesium alloy Duroplastics Workpiece Rm280 < a

11 Technical Information for rox ill Strong clamping due to the concave design of insert bottom rox ill Strong clamping due to the concave design of insert bottom Good chip flow and less build up edge acheived with the buffed surface of insert High rake angle of insert provides good surface finish and low cutting load Specially designed for high speed machining of aluminum Suitable for square shouldering and curved surface machining Clamping system for high speed Special design for strong clamping at high speed machining to prevent flying out of insert Chip Breaker 3 dimensional design for low cutting load Centrifugal force as per R Various inserts corner radius is available (R0.016 ~ R0.197) Clamping design as per F analysis Strong clamping of insert arking [ Designation ax. R] Screw Torque = 4N m Indexable insert : 6.8g ax. R as per cutting diameter Recommended cutting condition 190 Cutting diameter ØD ax. R 5000 type 6000 type n(min 1 ) vc(sfm) 3/ /4 1 1/ / /4 1 1/ / ,000 32,600 28,800 25,800 23,000 20,500 18,200 16,300 14,600 7,564 8,445 9,549 10,693 11,916 13,382 15,087 16,890 18,910 In case of actual machining accidental breakage of insert or tool could hpen even under the written R special cover or door is necessary to prevent damage from broken insert or broken tool Aluminum alloy Copper alloy Thermo plastic Aluminum alloy Copper alloy agnesium alloy Duroplastics Workpiece Rm280 < a Rm280 > a Long chipping Si <12% Si 12% Short chipping Cutting Speed vc(sfm) Feed

12 Technical Information for rox ill rox ill Ramping & Helical cutting technical data 1. Ramping 2. Blind hole Helical cutting 3. Thru hole Helical cutting Designation ØD Ramping Blind hole Helical cutting Thru hole Helical cutting α (max) Lmin ØDHmax dmax ØDHmin dmax ØDHmin dmax AXSA5075HR AXSA5100HR AXSA5125HR AXSA5150HR AXCA5200HR AXCA5250HR AXCA5300HR AXCA5400HR AXCA5500HR AXSA6100HR AXSA6125HR AXSA6150HR AXCA6200HR AXCA6250HR AXCA6300HR AXCA6400HR AXCA6500HR Lmin : when =0.394inch Lmin : inimum inclination cutting length α : ax. rampig angle : Depth of cut lunging, Slotting, Drilling technical data Uses Cutting condition for drilling 1. When drilling, grooving machining sequence is 2. When drilling, grooving, decrease the feed and cutting speed 30%~50% from the recommended data Holder Ø3/4 Ø1 Ø1 1/4 Ø1 1/2~5 Insert XT19 XT Type 6000 Type Copying Slotting & Shouldering Helical cutting Ramping 191

RM8 / RMH8 / RM4 / RM4Z / RM16 / RMT8. Rich Mill series Rich Mill Series

RM8 / RMH8 / RM4 / RM4Z / RM16 / RMT8. Rich Mill series Rich Mill Series 2 KPEM Rich Mill series Rich Mill Series RM8 / RMH8 / RM / RMZ / RM6 / RMT8. Rich mill series is one of innovations that provides more available cutting edges by double sided insert and longer tool life