Reaming Technical Guide INCH

Transcription

1 Reaming Technical Guide INCH

2 The Anatomy of a Reamer Use this diagram when describing features of a Solid Carbide Reamer. Diameter (D1) Shank Diameter (D) Tip Length (L1) Shank Length (LS) Max Reaming Depth (L4) Overall Length (L) Use this diagram when describing features of a Brazed-Tipped Reamer. Diameter (D1) Shank Diameter (D) Tip Length (L1) Max Reaming Depth (L4) Shank Length (LS) Overall Length (L) Reamers Function Surfaces Fp = passive force = radial force Fv = penetrative force Fd = resultant force Minor Cutting Edge Cutting Face Circular Land Major Cutting Edge d Primary Clearance Land Secondary Clearance Land 2

3 3 Tolerance Charts Tolerances Shafts: e h h h h h h k k k m Tolerances Holes: P H H H H H H H H e h h h h h h k k k m Tolerances Nominal Size (mm), 3, 3, 6, 6, 1, 1, 18, 18, 3, 3, 5, 5, 8, P H H H H H H H12 +,1 +,12 +,15 +,18 +,21 +,25 +,3 H13 +,14 +,18 +,22 +,27 +,33 +,39 +,46 k m Tolerances Nominal Size (mm), 3, 3, 6, 6, 1, 1, 18, 18, 3, 3, 5, 5, 8, Tolerances Nominal Size (inch) Tolerances Nominal Size (inch)

4 Reamers Manufacturing Tolerances Excerpt from DIN 142: Principles for the determination of the manufacturing tolerances of reamers. The manufacturing tolerances indicated in this standard are assigned to certain tolerance zones of the holes to be reamed. Generally, they ensure that the reamed hole lies within the relevant tolerance zone and that the reamer can be used most economically. Besides the manufacturing tolerance, it has to be considered that the size of the reamed hole also depends on other factors, e.g. angle on the edge, lead angle of the reamer, clamping of the workpiece, toolholder, condition of the machine tool, lubrication, and material of the workpiece to be reamed in. Therefore, special cases can occur, where other manufacturing tolerances are more favorable. With regard to an economic way of manufacturing and storekeeping, as well as the possibility to have interchangeable reamers of different manufacturers, other manufacturing tolerances should only be required in exceptional cases. Determination of the maximum and minimum permitted sizes of reamers: Tolerance Zone of Reamer Tolerance Zone of Hole The maximum permitted diameter, D1max, of the reamer is 15% of the respective drilling tolerance (,15 IT) below the maximum permitted size of the hole (see picture). Here, the value,15 IT is rounded to the next highest whole or half µm value so that the results for D1max are even µm values. The minimum permitted diameter D1min of the reamer is 35% of the respective hole tolerance (,35 IT) below the maximum permitted diameter of the reamer D1max.,15 IT,35 IT Maximum Permitted Size of the Hole Minimum Permitted Size of the Hole Zero Line D1 Maximum Permitted Diameter of the Reamer D1 Minimum Permitted Diameter of the Reamer Lower Deviation Nominal Diameter D1 Upper Deviation Description (excerpt): In special cases, reamers with maximum and minimum sizes, which differ from the standard, are ordered, the ISO-symbol for the drilling tolerance zone has to be replaced by the upper and lower deviation of the reamer in µm, e.g. for a reamer with a nominal diameter of 2mm, upper deviation = + (p) 25 µm and lower deviation = + (p) 15 µm: reamer 2 p 25 p 15 DIN In the description, the plus sign is replaced by a p and the minus sign is replaced by an m. 4

5 Causes of and remedies for reaming problems: Problem Cause Possible Remedy Hole diameter too large 1. Reaming tool running out-of-center. 2. Concentricity of pilot hole and ream machining unsatisfactory. 3. Built-up edge. 4. Unsuitable cooling lubricant. 5. Reaming tool diameter too large. Use equalizing adapter. Re-align, use floating head. Change cooling lubricant. Change cutting speed. Measure reamers and send for repairs. d Nom Hole diameter too small 1. Reamer worn. 2. Unsuitable cooling lubricant. 3. Reaming allowance too small. Replace and refit tool. Change cooling lubricant. Increase reaming allowance. d Nom Conical hole profile wider towards drill runout 1. Concentricity of pilot hole and reaming unsatisfactory. 2. Positioning accuracy of pilot hole to reaming. Re-align, use equalizing adapter. Correct positioning accuracy. d Nom Conical hole profile wider at drill entry point 1. Concentricity of pilot hole and reaming unsatisfactory. 2. Reaming tool skim cutting with ledger. Re-align, use floating head. Securely clamp reaming tool axially. d Nom Hole out-of-center and/or showing chatter marks 1. Reaming tool running out-of-center. 2. Slanted cutting surface/asymmetrical cutting. 3. Workpiece twisted. Use equalizing adapter. Spot face as drilling preparation. Take the direction of impact into account when clamping the workpiece. Surface quality does not meet specification 1. Tool cutters worn. 2. Reaming tool running out-of-center. 3. Incorrect technology data (cutting parameters). 4. Inadequate chip evacuation. Use equalizing adapter. Re-align, use floating head. Change cooling lubricant. Change cutting speed. Measure reamers and send for repairs. Feed grooves 1. Built-up edge. Change cooling lubricant. Change cutting speed. 5

6 Custom Reaming Tools Machining Questionnaire for Custom Reaming Tools Please make a copy of this form and give it to your WIDIA Representative or Authorized WIDIA Distributor. Name: Company: Address: Phone/Fax: 1. Workpiece material Material: MPa or psi: Heat treatment/hardness: 2. Machining Drill diameter: Drilling tolerance: Hole depth: Surface requirement: R z : R a : Hole length: Hole type: 3. Production quantity Hole number/year: 4. Tool interface Interface designation and size: (e.g., straight shank 2) Date: 5. Machine tool Machining: Horizontal: r Vertical: r Tool: Rotating: r Stationary: r Internally cooled tools: Yes: r No: r Cooling lubricant: Oil: r Emulsion: r Cooling lubricant pressure: p [bar]: Machine manufacturer/type: Spindle interface: (e.g. HSK 63) Premachining: Drilled: r Spindle: r Cutting parameters: Variable: Yes: r No: r Machining of drill hole base: Yes r No r For any crossholes or interruptions in the bore, please provide a sketch If not variable: n [rev/min] F [mm/min] Please provide a sketch of the chuck with any foul conditions and machine tasks. Include all relevant dimensions as well as forming and positioning tolerances. 6

7 Custom Reaming Tools Ø Ø Z = º Ø Ø Ø Required Details: Material to Be Worked: Type of Tool: Right Hand Spiral r Left Hand Spiral r Straight Fluted r Internal Coolant: Yes r MMKS r No r Fixture: Grade: HM/TCT Coating: r PKD/PCD r Nor CBN r DCFD r Shank According to DIN 6535: HA r HB r HE r Other Information: Custom Solution Reamers Available Upon Request 7

8 Contacts for Our Distribution Partners Authorized WIDIA Distributors should contact their local WIDIA Representative or one of the below contacts for additional information. Country Language Phone Fax Australia English * * ap.techsupport@ Austria German * eu.techsupport@ Belgium English/French * eu.techsupport@ China Chinese * w-cn.techsupport@ Denmark English * na.techsupport@ Finland English * na.techsupport@ France French * eu.techsupport@ Germany German * eu.techsupport@ India English no fax number in.techsupport@ Israel English * na.techsupport@ Italy Italian * eu.techsupport@ Japan English * * ap.techsupport@ Korea (South) English * * ap.techsupport@ Malaysia English * * ap.techsupport@ Netherlands English * na.techsupport@ New Zealand English * * ap.techsupport@ Norway English * na.techsupport@ Poland Polish * eu.techsupport@ Russia (landline) Russian landline: * eu.techsupport@ Russia (cell phone) Russian cell phone: * eu.techsupport@ Singapore English * * ap.techsupport@ South Africa English * na.techsupport@ Sweden English * na.techsupport@ Taiwan English * * ap.techsupport@ Thailand English * * ap.techsupport@ United Kingdom English * na.techsupport@ Ukraine Russian * eu.techsupport@ USA English * na.techsupport@ *Noted phone and fax numbers are not toll free.

9 Top Ream System TRF and TRM TRF and TRM Common reamers of this category have single tips, brazed onto a steel body. The new WIDIA TRF and TRM reamers have a solid carbide disc brazed onto the steel body instead. This allows for more regrinds than a regular tipped reamer, which brings down the cost-per-hole significantly. Additionally, the new coating WU5PR holds the surface finish more than twice as long as conventional coatings applied on reamers, depending on the workpiece material. Disc Style Versus Regular Tipped Reamers Stronger brazing joint than conventional tipped reamers. Practically no influence of temperature on runout. More rigidity and less vibrations due to full carbide front-end. Minimum of four regrinds possible versus regularly tipped reamers with an average of three regrinds, depending on wear situation. No damage of flutes, compared to the steel portion of regularly tipped reamers when chips constantly rub across. 9

10 New Coating WU5PR The new disc style design combined with the new reaming coating WU5PR allows for significant cost-per-hole improvements. WU5PR was specifically developed for reaming applications and shows superior results versus usual market grades applied on reamers. Holds surface finish more than 3x as long in steel compared to regular TiAlN thin coatings. Holds surface finish more than 2x as long in cast iron compared to regular TiAlN thin coatings. 1

11 Top Ream System TRF TRF In comparison to solid carbide reamers or single-tipped reamers, TRF is the economic alternative without any disadvantages in regards to productivity or hole quality. Solid carbide disc at front instead of single-tipped carbide blanks. Unique coating, specially developed for reaming applications. High-speed and high-performance ready. Superior surface finish due to lapped ground leads. Improved hole straightness and roundness due to unequal flute spacing (less vibrations) and runout <3 microns. Helical and straight flutes for chip control in through and blind holes. Customization All diameters between " (14 42,5mm). Variation of leads and cylindrical margin for application-specific optimization. 11

12 WORLD HEADQUARTERS WIDIA Products Group Kennametal Inc. 16 Technology Way Latrobe, PA 1565 USA Tel: w-na.service@ EUROPEAN HEADQUARTERS WIDIA Products Group Kennametal Europe GmbH Rheingoldstrasse 5 CH 8212 Neuhausen am Rheinfall Switzerland Tel: w-ch.service@ ASIA-PACIFIC HEADQUARTERS WIDIA Products Group Kennametal (Singapore) Pte. Ltd. 3A International Business Park Unit #1-2/3/5, ICON@IBP Singapore Tel: w-sg.service@ INDIA HEADQUARTERS WIDIA Products Group Kennametal India Limited CIN: L2719KA1964PLC1546 8/9th Mile, Tumkur Road Bangalore Tel: w-in.service@ Reaming Technical Guide INCH 216 WIDIA Products Group l All rights reserved. l A EN_in