Tungsten Carbide End Mills UNIMAX Series

Transcription

1 Tungsten Carbide End Mills UNIMAX Series Diamond Coated 2 Flute UDC Series NEW NEW UDCBF UDCLBF UDCB UDCLB UDCLRS High-grade Ball End Mills High-grade Long Neck Ball End Mills Ball End Mills Long Neck Ball End Mills Long Neck Radius End Mills UDCMX Drills UDCT Thread Mills

2 Revolutionary Diamond coating offers excellent cutting performance Cutting is achieved using the latest Diamond coating - UDC A Strong and Powerful Diamond Coating - UDC!! EDM and UDCB Direct Milling Comparison Case Study Simulation of deep pocket milling with UDCB R3 UDCB R3 Ball End Mill Deep tapered circular pocket milling on Work Sample Work Size After milling Direct Milling of - No Grinding! The normal expectation when milling would be a powdered swarf. Machining Cost Machining Cost Reductions with time and cost savings: 80% cycle time and 60% machining cost reduction One tool-milling VM-40-removed.4cc of material! Advantages 80% cycle time reduction 60% machining cost reduction No substrate damage - Reduces polishing time - unlike EDM Excellent accuracy of the finished part By using a deep cut into the, UDCB creates a fan shaped chip, just like cutting steel! 0 EDM EDM Direct Milling 0 Direct Milling UDCB R0.5 Ball End Mill pcs(time) Unit Total Time pcs(time) Unit Total Time UDCB (R ) VM-40 90HRA Making Copper Electrode Material Machine Milling Carbide Machine Operator UDCB chip evacuation (a) Inside view of a curled chip (surface side) 30,000min - 0.mm EDM Total Operator Machine Operator Total UDCB (R3 4.2) VM-40 90HRA Air Blow 20,000min - 200mm/min 0.2mm 0.4mm Air Blow 52min,400mm 3 (.4cc) 26.9mm 3 /min Chip size (b) Outside view (tool / rake side) 2 3

3 UDCBF/UDCLBF Seamless surface finish 20 5 Taper milled with UDCBF R VF-0(93HRA) Ball End Mill UDCB: Coating damage on cutting edge causes milling gap. UDCBF: Uniform surface with excellent dimensional accuracy. UDCBF (R ) VF-0 93HRA 30,000min - Milling direction 0.02mm Air blow (Nozzle) 55min 5 second Gap Milling direction Cutting Resistance Comparison using UDCBF R Ball End Mill UDCBF (R ) Comparison of Edge Chipping using UDCBF R Ball End Mill Edge chipping on work material Surface Side 00μm 00μm Surface Side 00μm 00μm Comparison on Roughing using UDCBF & UDCLBF Minimized edge chipping UDCBF (R ) VM-40 90HRA 30,000min mm Air blow (Nozzle) More material removal amount X Direction Y Direction Z Direction VM-40 90HRA 30,000min - 0.mm Air blow (Nozzle) mm3 UDCBF (R ) UDCLB (R ) UDCLBF (R ) UDCLB (R ) UDCLBF (R ) VM-40 90HRA 30,000min - Special treatment on cutting edge reduces cutting resistance! All Flute 2.5mm Effective 4.0mm Effective 0.25mm Air blow (Nozzle) 4 5

4 UDCB/UDCLB/UDCLRS One tool removed 2.8cc of material! Super durable deep milling! Pocket milled with UDCB R3 4.2 Ball End Mill VF-20(92.5HRA) Hexalobular milled with UDCLB R0.5 5 & R0.5 2 Long Neck Ball End Mills VF-20(92.5HRA) After milling Milling Conditions Process Process 2 Process 3 Roughing Max 3.5mm depth Roughing Max 6mm depth Finishing R0.5 ball End Mill reaches deep into the pocket (6mm) with a great depth of cut. Tapered square pocket milling Size: 25x25x5mm depth Outside ball taper 5 Corner R3.5mm Bottom R3.2mm UDCB (R3 4.2) Super Micro Grain VF HRA 20,000min - 200mm/min 0.2mm 0.4mm Air Blow 37min 2,800mm 3 (2.8cc) 20.4mm 3 /min UDCLB mm UDCLB Super Micro Grain VF HRA 30,000min mm 0.03mm 0.005mm Air Blow 58min 64min 34min 52.8mm 3 20mm 3.6mm 3 Size: φ9, 6mm depth Total:56min Total:274.4mm 3 Ultra Micro Features, made easy! Binderless (90HRA~) Lens Array milled with UDCB R0.5 & R Ball End Mills Micro Needles milled with UDCLB R0.5 5 Long Neck Ball End Mill VF-20(92.5HRA) 5 axis machining provides high quality curved surface. Actual cycle time: 8h 49min Size:25mm 25mm : Air blow Overall size : 6 6 5mm depth Pin size : Tip diameter: 0.2mm Pin length: 5mm Root diameter: 0.34mm Milling Process Milling Mode (min - ) ap ae Max 2.5mm depth UDCLB (R0.5 5mm) 2 Max 5.0mm depth Z-Level High Efficiency Roughing UDCB (R.4) 30, Super Micro Grain VF HRA 30,000min - Z-Level Re-machining 30, mm Curve Control Along Surface 30, Air Blow (Bottom 0.02mm) Z-Level Finishing 30, min 80.mm 3 39min 76.5mm 3 Z-Level Finishing 30, One tool for and 2. Total 2 tools are used. 6 7

5 2 Flutes High-grade Ball End Mills for and Hard Brittle Materials UDCLRS 2 CR Long Neck Radius End Mill Mirror surface finish with zero pits! UDCBF NEW Patent pending Material Applications Highly Recommended Recommended Suggested After Finishing Surface Quality SKSCM PREHARDENED HARDENED HPM 55HRC 60HRC 70HRC DCB/DCLB series are highly recommended for Glass Filled Plastic milling. Milling Conditions Axial Depth ap Milling Size Milling Distance Roughing Parameter 20,000min - 750mm/min 0.9mm 0.0mm Air Blow 0mm 8mm.8mm 6m UDCLRS Super Micro Grain Finishing Parameter 20,000min - 00mm/min 0.0mm Surface 0.9mm Side 0.0mm Oil mist 0.0mm Surface Side (0.0mm 5 Times) 44mm 3 - One End Mill for both roughing and finishing processes. Total 2 tools are used. Overhang: 5mm - Work sample after finishing process Ra: 0.00μm(0nm) Rz: 0.078μm(78nm) Cut-off length: 0.08mm Ra: 0.069μm Rz: 0.535μm Cut-off length: 0.25mm Versatile coating! * Ball type End Mills for milling and Hard Brittle (Non-Metallic) Materials. Upgraded version of UDCB. New Diamond coating and flute design increase material removal amount. Chip pocket designed on tool tip improves the surface finishing quality. Special cutting edge treatment helps to avoid the edge chipping & level gap. Recommended to use on semi-roughing & finishing process. #00 φd0.993 R / and Ball R accuracy measurements are printed on the label to support High Precision milling. Total 4 models Model Number Radius of Ball Nose of Cut Shank Taper Angle The shank taper angle shown is not an exact value and to avoid contact with the workpiece, we recommend the user controls the precise value of this angle. Shank taper angle should not make contact with the work piece. These milling parameters are based on VF-20,VM-40(CIS standard) and are for reference only. life may differ depending on the type of material. For best results, fine parameter adjustments may be required, depending on the Carbide material; milling shape and strategy; machine rigidity and spindle capability. Overall Shank (min - ) 2 a p Axial Depth Unit a e Radial Depth Alumina/Zirconia Hexalobular milled with UDCB R Ball End Mill Hexalobular Al2O3 Alumina Size: φ9mm 2.2mm depth ZrO2 Zirconia *Designed for the materials stated in the application chart of each series. Al2O3 Alumina /ZrO2 Zirconia 30,000min - Air Blow (Nozzle) 98min 88.4mm 3 0.9mm 3 /min Note: This application requires a high cutting force. A machine with poor rigidity and high vibration is not recommended. Allow sufficient machine and spindle warm-up time for stability and to remove any expansion of the main spindle before running the program. setting length should achieve the least possible overhang. Avoid contact with the coated area of the shank. This will prevent tip vibration and tool jamming in the collet /holder. Run-out and vibration should be checked dynamically at the tool point while mounted in the machine and both should achieve the lowest level possible. Use an inclined or helical approach (Recommended inclination angle: < degree). Decrease both spindle speed and feed rate proportionally. Air blow is highly recommended for longer tool life. Both oil mist and oil coolant are alternatives. Preliminary results show some benefits with water soluble coolant on Hard Brittle (Non-Metallic) Materials. Carbide milling creates heavier chips and accurate positioning of the coolant nozzle to the milling point is required to force chip evacuation. Remove chips to prevent heat generation and ignition during milling process. Use protective items such as safety glasses and a face guard at all times. Feed2 : Approach feed and contact time on the surface : Axial Depth : Radial Depth=Pf 8 9

6 2 Flutes High-grade Long Neck Ball End Mills for and Hard Brittle Materials 2 Flutes Ball End Mills for and Hard Brittle Materials UDCLBF Material Applications Highly Recommended Recommended Suggested) SKSCM PREHARDENED HARDENED HPM 55HRC 60HRC 70HRC DCB/DCLB series are highly recommended for Glass Filled Plastic milling. Patent pending UDCB Material Applications Highly Recommended Recommended Suggested) SKSCM PREHARDENED HARDENED HPM 55HRC 60HRC 70HRC DCB/DCLB series are highly recommended for Glass Filled Plastic milling. Long Neck Ball type End Mills for milling and Hard Brittle (Non-Metallic) Materials. Upgraded version of UDCLB. New Diamond coating and flute design increase material removal amount. Chip pocket designed on tool tip improves the surface finishing quality. Special cutting edge treatment helps to avoid the edge chipping & level gap. Recommended to use on semi-roughing & finishing process. Ball type End Mills for milling and Hard Brittle (Non-Metallic) Materials. Developed to give improved hardness and durability, new Diamond coating also has outstanding adhesion to the cutting tool. By combining the new coating with optimum cutting geometries, the tool literally cuts the. Leaves a burr and pit free surface finish on semi-roughing & finishing process. #00 φd.994 R / and Ball R accuracy measurements are printed on the label to support High Precision milling. Total 5 models Model Number Radius of Ball Nose Milling Conditions for UDCLBF Model Number UDCLBF WORK MATERIAL Radius of Ball Nose Effective of Cut Effective Neck (min - ) Shank Taper Angle 0 Overall Shank Note: This application requires a high cutting force. A machine with poor rigidity and high vibration is not recommended. Allow sufficient machine and spindle warm-up time for stability and to remove any expansion of the main spindle before running the program. setting length should achieve the least possible overhang. Avoid contact with the coated area of the shank. This will prevent tip vibration and tool jamming in the collet /holder. Run-out and vibration should be checked dynamically at the tool point while mounted in the machine and both should achieve the lowest level possible. Use an inclined or helical approach (Recommended inclination angle: < degree). Decrease both spindle speed and feed rate proportionally. Air blow is highly recommended for longer tool life. Both oil mist and oil coolant are alternatives. Preliminary results show some benefits with water soluble coolant on Hard Brittle (Non-Metallic) Materials. Carbide milling creates heavier chips and accurate positioning of the coolant nozzle to the milling point is required to force chip evacuation. Remove chips to prevent heat generation and ignition during milling process. Use protective items such as safety glasses and a face guard at all times. The shank taper angle shown is not an exact value and to avoid contact with the workpiece, we recommend the user controls the precise value of this angle. Shank taper angle should not make contact with the work piece. CEMENTED CARBIDE 2 Effective by Inclined Angles Unit ap Axial Depth ae Radial Depth Feed2 : Approach feed and contact time on the surface : Axial Depth : Radial Depth=Pf Total 4 models Model Number Note: This application requires a high cutting force. A machine with poor rigidity and high vibration is not recommended. Allow sufficient machine and spindle warm-up time for stability and to remove any expansion of the main spindle before running the program. setting length should achieve the least possible overhang. Avoid contact with the coated area of the shank. This will prevent tip vibration and tool jamming in the collet /holder. Run-out and vibration should be checked dynamically at the tool point while mounted in the machine and both should achieve the lowest level possible. Use an inclined or helical approach (Recommended inclination angle: < degree). Decrease both spindle speed and feed rate proportionally. Air blow is highly recommended for longer tool life. Both oil mist and oil coolant are alternatives. Preliminary results show some benefits with water soluble coolant on Hard Brittle (Non-Metallic) Materials. Carbide milling creates heavier chips and accurate positioning of the coolant nozzle to the milling point is required to force chip evacuation. Remove chips to prevent heat generation and ignition during milling process. Use protective items such as safety glasses and a face guard at all times. Feed2 : Approach feed and contact time on the surface : Axial Depth : Radial Depth=Pf The shank taper angle shown is not an exact value and to avoid contact with the workpiece, we recommend the user controls the precise value of this angle. Shank taper angle should not make contact with the work piece. Radius of Shank Taper Overall Shank Ball Nose of Cut Angle (min - ) These milling parameters are based on VF-20,VM-40(CIS standard) and are for reference only. life may differ depending on the type of material. For best results, fine parameter adjustments may be required, depending on the Carbide material; milling shape and strategy; machine rigidity and spindle capability. #02 φ.992 R0.002 / and Ball R accuracy measurements are printed on the label to support High Precision milling. 2 a p Axial Depth Unit a e Radial Depth

7 2 Flutes Long Neck Ball End Mills for and Hard Brittle Materials Milling Conditions for UDCLB UDCLB Model Number UDCLB Radius of Ball Nose Effective (min - ) 2 ap Axial Depth ae Radial Depth Material Applications Highly Recommended Recommended Suggested) SKSCM PREHARDENED HARDENED HPM 55HRC 60HRC 70HRC DCB/DCLB series are highly recommended for Glass Filled Plastic milling. Long Neck Ball type End Mills for milling and Hard Brittle (Non-Metallic) Materials. Developed to give improved hardness and durability, new Diamond coating also has outstanding adhesion to the cutting tool. By combining the new coating with optimum cutting geometries, the tool literally cuts the. Leaves a burr and pit free surface finish on semi-roughing & finishing process. #003 φ0.90 R0.000 / and Ball R accuracy measurements are printed on the label to support High Precision milling. The shank taper angle shown is not an exact value and to avoid contact with the workpiece, we recommend the user controls the precise value of this angle. Shank taper angle should not make contact with the work piece. Total 37 models Unit Model Number Radius of Ball Nose Effective of Cut Neck Shank Taper Angle Overall Shank Effective by Inclined Angles No Interference No Interference No Interference No Interference No Interference No Interference No Interference No Interference No Interference No Interference No Interference These milling parameters are based on VF-20, VM-40(CIS standard) and are for reference only. life may differ depending on the type of material. For best results, fine parameter adjustments may be required, depending on the Carbide material; milling shape and strategy; machine rigidity and spindle capability. Note: This application requires a high cutting force. A machine with poor rigidity and high vibration is not recommended. Allow sufficient machine and spindle warm-up time for stability and to remove any expansion of the main spindle before running the program. setting length should achieve the least possible overhang. Avoid contact with the coated area of the shank. This will prevent tip vibration and tool jamming in the collet /holder. Run-out and vibration should be checked dynamically at the tool point while mounted in the machine and both should achieve the lowest level possible. Use an inclined or helical approach (Recommended inclination angle: < degree). Decrease both spindle speed and feed rate proportionally. Air blow is highly recommended for longer tool life. Both oil mist and oil coolant are alternatives. Preliminary results show some benefits with water soluble coolant on Hard Brittle (Non-Metallic) Materials. Carbide milling creates heavier chips and accurate positioning of the coolant nozzle to the milling point is required to force chip evacuation. Remove chips to prevent heat generation and ignition during milling process. Use protective items such as safety glasses and a face guard at all times. Feed2 : Approach feed and contact time on the surface : Axial Depth : Radial Depth=Pf 2 3

8 2 Flutes Long Neck Radius End Mills for and Hard Brittle Materials UDCLRS Additional 2 Models Long Neck Radius type End Mills for milling and Hard Brittle (Non-Metallic) Materials. Developed to give improved hardness and durability, new Diamond coating also has outstanding adhesion to the cutting tool. By combining the new coating with optimum cutting geometries, the tool literally cuts the. Leaves a burr and pit free surface finish on semi-roughing & finishing process. Material Applications Highly Recommended Recommended Suggested) SKSCM PREHARDENED HARDENED HPM 55HRC 60HRC 70HRC Side Milling / Flat Milling Axial Depth(mm Radial Depth(mmPf D Slotting Axial Depth(mm D : Outside #07φ0.79 R0.00 / and Ball R accuracy measurements are printed on the label to support High Precision milling. The shank taper angle shown is not an exact value and to avoidcontact with the workpiece, we recommend the user controls the precise value of this angle. Shank taper angle should not make contact with the work piece. Milling Conditions for UDCLRS Refer to page 6 for UDCLRS note. These milling parameters are based on VF-20, VM-40(CIS standard) and are for reference only. life may differ depending on the type of material. For best results, fine parameter adjustments may be required, depending on the Carbide material; milling shape and strategy; machine rigidity and spindle capability. Feed2: Approach Feed and contact time on the surface Total 30 models Unit Model Number Outside Coner Radius Effective of Cut Neck Shank Taper Angle Overall Shank Effective by Inclined Angles Model Number UDCLRS Spindle Speed (min - ) Z-Level Milling Flat Milling Side Milling Slotting ap ae ap ae ap ae ap 2 Axial Depth Radial Depth Axial Depth Radial Depth Axial Depth Radial Depth Axial Depth Additional model 4 5

9 UDCLRS Note This application requires a high cutting force. A machine with poor rigidity and high vibration is not recommended. Allow sufficient machine and spindle warm-up time for stability and to remove any expansion of the main spindle before running the program. setting length should achieve the least possible overhang. Avoid contact with the coated area of the shank. This will prevent tip vibration and tool jamming in the collet /holder. Run-out and vibration should be checked dynamically at the tool point while mounted in the machine and both should achieve the lowest level possible. Does not require to be slowed down in the approach sequence when slotting and side milling. Use an inclined or helical approach when Z-level milling (Recommended inclination angle: < degree). For flat and side milling, set the axial depth (ap) and radial depth (ae) to allow for the uncut material of the corner radius. Decrease both spindle speed and feed rate proportionally. Air blow is highly recommended for longer tool life. Both oil mist and oil coolant are alternatives. Preliminary results show some benefits with water soluble coolant on Hard Brittle (Non-Metallic) Materials. Carbide milling creates heavier chips and accurate positioning of the coolant nozzle to the milling point is required to force chip evacuation. Remove chips to prevent heat generation and ignition during milling process. Use protective items such as safety glasses and a face guard at all times. 6

10 Hole Before Threading (Helical Drilling) Thread Milling UDCLB UDCT M ,000min - 5,300min - 50mm/min VM-40 (90HRA) 30mm/min Vertical Distance Roughing: 0.mm/rev Finishing (Zero Cut): 0.3mm/rev.25mm/rev Air Blow (Nozzle) Hole Through Hole φ6.8 0mm depth 6 holes Through Hole 0mm depth 6 holes Thread milling 3 minutes/hole 6 holes/tool on thread milling 9 min 30 sec per hole 3 min per hole Hole Before Threading Thread Milling UDCMX UDCT M VM-40 (90HRA) 2,000min - 20,000min - 5mm/min 3mm/min Peck Amount 0.5mm Air Blow (Nozzle) Hole Specification Blind Hole (8mm depth 6 holes) Blind Hole (6mm depth 6 holes) 2 min 2 sec per hole 9 min 5 sec per hole 7

11 2 Flutes Drills for and Hard Brittle Materials Thread Mills for and Hard Brittle Materials UDCMX Material Applications Highly Recommended Recommended Suggested) Additional 8 Models UDCT Material Applications Highly Recommended Recommended Suggested) Additional 6 Models SKSCM PREHARDENED HARDENED HPM 55HRC 60HRC 70HRC SKSCM PREHARDENED HARDENED HPM 55HRC 60HRC 70HRC New Diamond coating offers excellent drilling performance on Cemented Carbide and Hard Brittle (Non-Metallic) Materials. By combining the new coating with optimum cutting geometries, the tool improves hole quality and longer tool life. Makes mechanical drilling cost competitive! Point Angle:30 Tolerance:0/-0.02 Thread Mills for and Hard Brittle (Non-Metallic) Materials. Direct milling offers higher efficiency and precision comparing to EDM and grinding process. Developed to give improved hardness and durability, the new Diamond coating also has outstanding adhesion to the tool. UDC series End Mills and Drills are recommended to drill holes before threading. #00 φd.9 Measured diameter is printed on the label. Model Number φd Flute l Overall L Shank φd (min - ) Peck Amount mm Model Number Thread M Pitch P φd Number of Flutes Effective l Shank Taper Angle Bta Overall L Shank φd Additional model Milling Conditions for UDCT Additional model These milling parameters are based on VM-40 (CIS standard) and are for reference only. life may differ depending on the type of material. For best results, fine parameter adjustments may be required, depending on the Carbide material; milling shape and strategy; machine rigidity and spindle capability. Note: Allow sufficient machine and spindle warm-up time for stability and to remove any expansion of the main spindle before running the program. setting length should achieve the least possible overhang. Avoid contact with the coated area of the shank. This will prevent tip vibration and tool jamming in the collet /holder. Run-out and vibration should be checked dynamically at the tool point while mounted in the machine and both should achieve the lowest level possible. Recommend using peck drilling cycle, but one-shot drilling may extend the tool life in some cases. Recommend shallower drilling than flute length to promote good chip evacuation. Recommend air blow. Preliminary results show some benefits with water soluble coolant on Hard Brittle (Non-Metallic) Materials. Remove chips to prevent heat generation and ignition during milling process. Use protective items such as safety glasses and a face guard at all times. Model Number Thread M Pitch φd These milling parameters are based on VM-40 (CIS standard) and are for reference only. life may differ depending on the type of material. For best results, fine parameter adjustments may be required, depending on the Carbide material; milling shape and strategy; machine rigidity and spindle capability. P Effective l Recommended of Hole Before Threading (mm - ) The shank taper angle shown is not an exact value and to avoid contact with the workpiece, we recommend the user controls the precise value of this angle. Shank taper angle should not makecontact with the work piece. 8 9

12 UDCT Note Note: This application requires a high cutting force. A machine with poor rigidity and high vibration is not recommended. Use a machine equipped with helical interpolating functions. Allow sufficient machine and spindle warm-up time for stability and to remove any expansion of the main spindle before running the program. setting length should achieve the least possible overhang. Avoid contact with the coated area of the shank. This will prevent tip vibration and tool jamming in the collet /holder. Run-out and vibration should be checked dynamically at the tool point while mounted in the machine and both should achieve the lowest level possible. Decrease both spindle speed and feed rate proportionally. The feed rate is measured at the center of the tool. The radial cutting depth is recommended to cut all at once. Do not cut several times. Adjust turning radius amount to meet required internal thread precision. Air blow is highly recommended for longer tool life. Both oil mist and oil coolant are alternatives. Preliminary results show some benefits with water soluble coolant on Hard Brittle (Non-Metallic) Materials. Carbide milling creates heavier chips and accurate positioning of the coolant nozzle to the milling point is required to force chip evacuation. Remove chips to prevent heat generation and ignition during milling process. Use protective items such as safety glasses and a face guard at all times. Advisory for Safe Use of UNIMAX Tungsten Carbide End Mills Correct application and operation is strongly advised to avoid clogging, abrasion, etc, that could cause serious accidents or injuries. Ignition or sparks generated during milling could lead to fire or extreme damage to the work piece. End Mills are made with very sharp cutting edges and must be handled with extra care. Advisory for regrinding UNIMAX Tungsten Carbide End Mills 260 N.Fee Ana St, Anaheim, CA Tel: Fax: & Specifications are subject to change without notice.