Keeping the Customer First Tungaloy Report No. 369-J Tungaloy Report No. 372-US Face milling cutter NEW New grades TEN / EEN type extended version
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1 Keeping the Customer First Tungaloy Report No. 369-J 37-US cutter NEW TEN / EEN type New grades extended version Highly productive and economical face milling cutter!
2 T UNGALOY Features Double sided pentagonal insert Remarkable performance levels! Insert inclination reduces the cutting forces Extremely rigid cutting tool Rigid clamping with large contact area High rigidity enables high productivity Wide clamping area Extra close pitch cutter available Increased number of inserts for improved productivity!! The extra close pitch SS-FiT system improves rigidity and performance Coarse pitch Close pitch
3 Pitch Close Coarse Milling cutter Shell type Lf Shell type ødb ød a ødc ød1 b R ap 7 Shank type ød1 ødc ap 7 Lf L Rs Max. depth of cut : Max. ap =.5" TEN9R... *TEN9R... CSTR-4L1 BT15S BT15M H-TBS Cat. No. No. of Dimensions (inch) Weight Center bolt Stock Air hole Inserts ØDc ØD1 ØDb Ød r Lf b a (Ib) (option) TEN9RU75A with C.375x1.15H TEN9R5U75A with C.375x1.15H TEN9R3U1A with C.5x1.375H TEN9R4U15A with TMBA-.75H *TEN9R5U15A with TMBA-.75H *TEN9R6UA without - TEN9RU75A with C.375x1.15H TEN9R5U75A with C.375x1.15H TEN9R3U1A with C.5x1.375H TEN9R4U15A with TMBA-.75H *TEN9R5U15A with TMBA-.75H *TEN9R6UA without - * Cat. No. of Torx bit is different from other items. (Please see the above table 1) øds Shell type Components (Table 1) Wrench Descriptions Applicable cutter Clamping screw Torx bit Grip Mono block type substitution wrench Parts Cat. No. T-15D Shank type No. of Dimensions (inch) Weight Parts Cat. No. Stock Inserts ØDc ØD1 ØDs rs Lf L (Ib) Air hole Clamping Wrench screw (Substitution) EEN9R15U15W with CSTR-4L1 T-15DB EEN9R15U15W with (T-15D) Inserts A T A T A T rε =.31" =.31".55".15" =.31".55" Fig. 1 MJ (General) rε Fig. W (Wiper) Grades Cat. No. Coated Cermet Carbide Dimensions (inch) Shape Accuracy Honing NEW NEW NEW A T AH75 AH1 AH14 T1115 T313 NS74 TH1 PNCU95GNER-MJ C with Fig. 1 PNCU95GNER-W C with Fig. PNCU95GNFR-AJ C without Fig. 3 : Stocked items rε Fig. 3 AJ (For aluminum) 3
4 Practical examples Workpiece type Milling cutter Insert Grade Machine parts TEN9R4U15A8 PNCU95GNER-MJ AH1 No. 3B (HB) 8" Fixing plate TEN9R5U15A1 PNCU95GNER-MJ AH (3HB) 3" 4" 6" Cutting conditions Cutting speed: Vc (sfm) Feed per tooth: fz (ipt) Feed speed: Vf (ipm) Depth of cut: ap (inch) Cutting width: ae (inch) Process Coolant Machine Two.16" passes Dry Vertical M/C, CAT5 Dry Vertical M/C, CAT5 Results %! Vf = 5 6 ipm DoPent improves productivity and tool life by 13% %! Vf = 17 3 ipm High feed & high density cutter improve productivity significantly. Workpiece type Milling cutter Insert Grade Balancing weight TEN9R5U15A6 PNCU95GNER-MJ AH75 15 (15HB) Motorcycle parts TEN9R5U15A1 PNCU95GNFR-AJ TH1 775 (HB) 3" 5" 8.5" 3" Cutting conditions Cutting speed: Vc (sfm) Feed per tooth: fz (ipt) Feed speed: Vf (ipm) Depth of cut: ap (inch) Cutting width: ae (inch) Process Coolant Machine Eight.16" passes Roughing:.1, Finishing:.4 Roughing: 3, Finishing: 1 Roughing:.8, Finishing: ~ 3. Dry Wet Vertical M/C, CAT5 Vertical M/C, CAT4 Results %! Vf = 45 ipm The twice of productivity is achieved due to higher cutting speed and feed %! Higher feed improves productivity in roughing by 19%, also reduces total cycle time significantly. 4
5 MJ Variation of inserts AJ W (Wiper) Steel Stainless Cast iron Non-ferrous Width of land Rake angle Rake angle Steel Cast iron For general machining Excellent balance of edge sharpness and strength Depth of cut: ap (inch) 5 Cutting performance Comparison of application areas Conventional tool Feed per tooth: fz (ipt) Comparison of surface finish NS74 PVD Ra (µm) For aluminum machining Lapped rake face for reduced adhesion Metal removal rate (inch 3 /min) Comparison of metal removal rate Ra Rz NS74 Conventional (z = 8) (z = 7) 1 PVD Rz (µm) 5% UP Cutter Insert Cutting speed For finishing Provides excellent surface finish Tool Cutting speed Feed per tooth : 155 (HB) : ø4. : Vc = 66 sfm : fz =.16 ipt (z = 8) Conventional : fz =.1 ipt (z = 7) Depth of cut : ap =.16" Width of cut : ae =." Conventional tool: Milling cutter with 4-corner insert : TEN9R4U15A5 : PNCU95GNER-MJ : Low carbon steel (16HB) : Vc = 8 sfm Feed per tooth : fz =.6 ipt Depth of cut : ap =.1" Width of cut : ae = 3." Process : Coolant : Dry Machine : Vertical M/C, BT5, 3 kw
6 Standard cutting conditions s Hardness Selection criteria Recommended Cutting speed Feed per tooth HB grade Vc (sfm) fz (ipt) AH Low carbon steels Priority on impact resistance AH ~ (118, 86 etc.) Priority on wear resistance T Priority on surface quality NS AH High carbon steels Priority on impact resistance AH ~ 3 (F-618 etc.) Priority on wear resistance T Priority on surface quality NS AH Alloyed steels Priority on impact resistance AH ~ 3 (414, 434 etc.) Priority on wear resistance T Priority on surface quality NS AH Tool steels (A-6, D-1, D- etc.) ~ 3 Priority on impact resistance AH Priority on wear resistance T Stainless steels (3 Series, 34, 316 etc.) - AH Gray cast irons - AH Priority on wear resistance T Ductile cast irons - AH Priority on wear resistance T Aluminum alloys (Si < 13%) TH1 Aluminum alloys (Si 13%) Remove excessive chip accumulation with an air blast. When chips stick to the cutting edges (aluminum machining), use a water soluble coolant. When cutting an interrupted surface or a casting skin, the feed (fz) should be reduced below the recommended value shown in the above table. Installation of inserts with extra close pitch cutter The extra close pitch cutter has a slanted screw. Locate insert and then fasten the screw. (Fig. A) After fastening the screw, please ensure there is no gap between the cutter body and insert. (Fig. B) Notes for using wiper inserts When a fine surface finish is required, wiper insert PNCU95GNER-W is recommended. When using the wiper insert, install the insert as shown in Fig. C. Also ensure the groove is at the front of the insert as shown in Fig. D. The wiper insert has two corners available (Fig. D). Do not use the other corners as this may break the cutter body. Cutting conditions are limited by machine power, workpiece rigidity, and spindle output. When the cutting width, depth or overhang length is large, set Vc and fz to the lower recommended values and check the machine power and vibration. Locate insert and then fasten the screw. Fig. C Fig. A Mark Cutting edge Fig. D Fig. B Cutting edge Groove 376 N Ventura Drive, Arlington Heights, IL 64, U.S.A. Phone: Fax: Tungaloy Canada Tungaloy de Mexico S.A. Distributed by: Jun. 1 (TJ)
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