NEW. MILLLINE High Speed Milling Cutter. Exceptional productivity for aluminum and non-ferrous machining. Keeping the Customer First
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1 Keeping the Customer First Tungaloy Report No. 429-US MILLLINE High Speed Milling Cutter NEW Exceptional productivity for aluminum and non-ferrous machining NEW CHIPBREAKER
2 Outstanding productivity in deman high helical ramping, straight ram Features Exceptional productivity for aluminum and non-ferrous material machining Can be applied to rough and finish machining Available in various corner radii (.015" -.196") Secure, stable and unique "V" bottom insert design No movement during high ramp machining Inserts Polished rake face Helical cutting edge and high positive rake angle Wiper face Fully ground periphery Higher relief angle for high ramping capability V-shaped bottom for rigid clamping Various Corner Radii Body 2 face radial contact for precise 90 degree machining Coolant direct to cutting edge Simplified screw clamping design for improved insert seating Wide axial support for superior surface finish Counter Force Centrifugal Force V-shaped pocket enables stable high speed machining 2
3 ding applications such as ping and step milling! FE Model Analysis Tool: EPV16R125U0125W02 Insert: XVCT R-AJ Cutting Condition - Feed.006 IPT/tooth, RPM 20,000, Depth of cut.197, Width of cut.394, Ramping -V Shaped Design General Type Insert Movement (ramping down cutting) 3.0 μm 10.5 μm Cutting force Cutting force Stress of Screw 100% 120% Surface Roughness Test (Average roughness, Ra) Tool: EPV16R125U0125W02 Insert: XVCT R-AJ - Material: Aluminum alloy, RPM 6,000, Rd=1.0", Dry, All inserts clamped RMS 2.5 Ap=.059 RMS 2.0 Ap= XVCT R-AJ Competitor A Competitor B fz fz 3
4 Target - General application - Multi purpose milling Pocket milling Slotting Profiling Helical ramping Shouldering Face milling Straight ramping - Where productivity needs to be increased while maintaining accurate machining and high surface quality. - Roughing and finishing with one tool. - Reducing tool numbers in the machine magazine by replacing solid carbide end mills for finishing operation. - Components that require high precision such as aerospace frame part. Safety guidelines 1. Use only original inserts and cutters including components. 2. Insert pocket must be cleaned before clamping insert. 3. Clamp torque of screw: 4.5Nm (46 kgf.cm, 40 in.lbs.) 4. For safety reasons, it is recommended to use a new screw after every insert change. 5. Since maximum RPM values were determined based on the burst test, using RPM beyond maximum values may cause insert breakage, machine damage and personal injury. 6. Because XVCT insert has sharp cutting edge, always wear gloves for protection from injury when handling. 4
5 Insert r a d ap t d1 Cat. No. Stock Dimensions (inch) d d 1 t a r ap Grade XVCT160504R-AJ TH10 XVCT160508R-AJ TH10 XVCT160512R-AJ TH10 XVCT160516R-AJ TH10 XVCT160520R-AJ TH10 XVCT160524R-AJ TH10 XVCT160530R-AJ TH10 XVCT160532R-AJ TH10 XVCT160540R-AJ TH10 XVCT160550R-AJ TH10 End Mill Type Ø D Ø d K=90 l L Cat. No. Stock No. of Teeth Dimensions(inch) Max. Coolant Insert D d L l RPM EPV16R100U0100W with 38,000 EPV16R100U0100W02L with 38,000 EPV16R125U0125W with 34,000 EPV16R125U0125W02L with 34,000 XVCT1605 R-AJ EPV16R125U0125W with 34,000 EPV16R125U0125W03L with 34,000 EPV16R150U0125W with 30,000 EPV16R150U0125W03L with 30,000 Coolant through type Cutter body for XVCT 16 insert with corner radius more than.125" should be modified based on the following: Body radius = insert radius -.012" : Stocked items 5
6 Face Mill Type Ø d H ap K=90 K=90 Ø D Cat. No. Stock Insert Teeth Dimensions(inch) D d H Max RPM Coolant Mounting Bolt TPV16R150U0075A ,000 with TCS I TPV16R200U0075A ,000 with SD06-46 TPV16R250U0100A ,000 with SD08-47 XVCT 1605 R-AJ TPV16R300U0100A ,000 with SD08-47 TPV16R400U0150A ,000 with SD12-82 TPV16R500U0150A ,000 with SD12-82 Components Screw Wrench TS 40085I/HG (Dia. 1.0) Torx Bit BT15S TS 40093I/HG (Dia. 1.25>) Grip H-TB : Stocked items 6
7 Ramping Data Straight Ramping Helical Ramping Step Milling Max. Ramp A L od1 Max. ap Pitch Step Max. ap XVCT 16 (.016" -.047" Radius) Cutter Dia.(D 1 ) Straight Ramp Down Helical Ramp Down Step Down Max. Ramp (A ) Max. ap (in) Min. Length (L) Min. Dia. Max. Dia Max. Pitch/Rev Max. ap XVCT 16 (.062" -.078" Radius) Cutter Dia.(D 1 ) Straight Ramp Down Helical Ramp Down Step Down Max. Ramp (A ) Max. ap (in) Min. Length (L) Min. Dia. Max. Dia Max. Pitch/Rev Max. ap
8 XVCT 16 (.118" -.125" Radius) Cutter Dia.(D1) Straight Ramp Down Helical Ramp Down Step Down Max. Ramp (A ) Max. ap (in) Min. Length (L) Min. Dia. Max. Dia Max. Pitch/Rev Max. ap XVCT 16 (.157" -.196" Radius) Cutter Dia.(D1) Straight Ramp Down Helical Ramp Down Step Down Max. Ramp (A ) Max. ap (in) Min. Length (L) Min. Dia. Max. Dia Max. Pitch/Rev Max. ap Recommended Cutting Conditions Material HB SFM Best grade Feed(IPT) Aluminum wrought alloy Not cureable TH Cured TH <=12% Si Not cureable TH Aluminum-cast, alloyed Cured TH >12% Si High temp TH >1% Pb Free cutting TH Copper alloys Brass TH Electrolytic copper TH Non-metallic Duroplastics, fiber plastics TH Hard rubber TH
9 Case Study 1 Cutting conditions Competitor Cutter TPV16R200U0075A04 D50 face mill Diameter (inch) Insert XVCT R-AJ TH10 12mm carbide insert No. of teeth 4 4 Cutting Speed (RPM 14,000) (RPM 14,000) fz (in/tooth) Table Feed (IPM) Depth of Cut (in) Width of Cut (in) Coolant Wet Wet Tool Life (hrs) 4hrs/corner 3hrs/corner Cutting time (min) Reduced cutting load enables higher DOC. Improved productivity with better tool life. Case Study 2 Cutting conditions Competitor Cutter EPV16R125U0125W endmill Diameter (inch) Insert XVCT R-AJ TH10 5/8 carbide insert No. of teeth 3 3 Cutting Speed(RPM) (RPM 9,000) (RPM 9,000) fz (IPT) Table Feed (IPM) Depth of Cut(inch) Rough.120, Finish.010 Rough.120, Finish.010 Width of Cut(inch) Varies Varies Coolant Wet Wet Tool Life (pcs) 3pcs/corner 3pcs/corner Reduced cutting load enables improved productivity via a higher feed rate. Case Study 3 Cutting conditions Competitor Cutter EPV16R100U0100W02 Solid carbide endmill Diameter (inch) /8 Insert XVCT R-AJ TH10 - No. of teeth 2 3 Cutting Speed(RPM) (RPM 10,000) (RPM 10,000) fz (IPT) Table Feed (IPM) Depth of Cut (inch) Width of Cut (inch) Varies Varies Coolant Wet Wet Cost reduction due to higher feed rate. Good surface quality due to unique insert geometry. 9
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Colibri Spindles ltd. Lavon Industrial Park, 2011800, Israel Tel +972 4 9089100 Fax +972 4 9589061 marketing@colibrispindles.com www.colibrispindles.com HSM JET SPINDLE TJS-CS01-07-2017 Case Study Summaries
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