Milling Cutter for Heavy Roughing

Transcription

1 15 15 Milling Cutter for Heavy Roughing Notched insert reduces cutting force, chattering and enables efficient cutting. Large depth of cut and high feed rate enable high effi ciency cutting. TZE00047

2 changes Heavy Milling! Tough Edge with wider land. Maximum depth of cut is 12mm 1. Large depth of cut and high feed rate achieve high efficiency machining. Recommended depth of cut: 5 to 10mm. 12mm (Max.D.O.C. ) 15mm 18mm Lead angle: 75 degrees Large wiper edges achieve high feed rate. CornerR=1.2mm 6.35mm Tough insert with thickness of 6.35mm. A.R. +9 R.R. 9 (ø80) 5 (more than ø100) 2. Economical square inserts with four edges With two notches With three notches Without notches V 1

3 MonSteR M S R Square S Mill 3. Notched insert reduces cutting force, chattering and enables efficient machining. Notched Insert Notch effect The effects of the notch can be seen at more than 5mm of vertical depth of cut. (effects for appears from at least 2mm or more) Notched Notched 5mm 2mm With two notches With three notches 4. Design to suppress chattering with low cutting force. Possible to machine thinplate workpieces (low rigidity material such as can manufacturing equipment etc. ) Comparison of cutting force (radial force) Type suppresses chattering since less force to lift workpiece is needed during machining. (N) Direction to pull up workpiece Comp. A 9mm Overhang 120mm R8T Workpiece Material : C Vc=200m/min(n=398min 1 ) fz=0.15mm/t(vf=477mm/min), ap x ae=6x100mm (Machining of overhang from 15mm to 9mm) Direction to press down workpiece 2

4 E a b a b H H b ød ød1 3 S Fig.1 E Rake Angle( ) Description A.R. R.R. 180R ød ød1 b 15 3 S 5 Fig R ~ 15315R +9 5 øc ød ød1 4 S H E a G 4 6 S 15 Fig.3 H E a G G (The photograph shows the standard type.) øc øc1 ød ød1 15 Fig.4 Holder dimension Description Stock No. of Insert Dimension (mm) ød ød1 1 2 H E a b S øc øc1 G Shape Weight (kg) Multiedge type Standard type 180R4TM Fig R4TM R6TM Fig R8TM R10TM Fig.3 152R12TM R14TM Fig R6TM Fig R6TM R8TM Fig R10TM R12TM Fig.3 152R14TM R16TM Fig Arbor mounting bolts (HH12X35) are included in 180R T Type. : Standard Stock : made to order Cartridge is included in the standard type, but no Cartridge in the multiedges type. Holder dimension Description Stock No. of Insert Dimension (mm) ød ød1 1 2 H E a b S øc øc1 G Shape Weight (kg) Multiedge type Standard type 180R4T Fig R4T R6T Fig R8T R10T Fig.3 152R12T R14T Fig R6T Fig R6T R8T Fig R10T R12T Fig.3 152R14T R16T Fig Arbor mounting bolts (HH12X35) are included in 180R T Type. :Standard Stock : made to order Cartridge is included in the standard type, but no Cartridge in the multiedges type.

5 MP1 Parts Spare Part Description Clamp Screw Wrench Cartridge Clamp Screw Wrench Antiseize Compound Arbar Clamp Screw Standard type 180R (M) 15100R (M) ~ 15315R (M) SB60120TR TT25L MAP1806 SB40140TR DT15 for Insert Clamp Tightening Torque 7.5Nm for Insert Clamp Tightening Torque 3.5Nm MP1 HH12 35 Multiedge type 180R (M) 15100R (M) ~ 15315R (M) SB60120TR TT25L for Insert Clamp Tightening Torque 7.5Nm MP1 HH12 35 MP1 Coat Antiseize Compound (MP1) thinly on clamp screw when insert is fixed. Applicable Insert Dimension(mm) Angle( ) PVD Coated Shape Description A T X Z α β γ PR660 PR830 PR905 Applicable Toolholder Z β X SPMT 1806EDER R With two notchs γ A T α Z β X SPMT 1806EDER R M With three notchs γ A T α Z β X SPMT 1806EDERV R Without notch γ A T α :Standard Stock Insert Grades Combination of inserts Workpiece Material Steel Cast Iron Good wear resistance PR830 PR905 Good fracture resistance PR660 PR830 1st Recommendation + Emphasis on edge strength and biting or + V Emphasis on edge strength V Inserts are sold in 10 piece boxes.

6 Recommended Cutting Condition Workpiece Material Feed Rate (mm/t) Recommended Insert Grades (Speed Vc:m/min) PVD Coated Carbide PR660 PR830 PR905 Carbon Steel 0.2 Alloy Steel 0.2 Die Steel ~200 1~ ~180 Gray Cast Iron 0.25 Nodular Cast Iron 0.2 1~200 1~2 Stainless Steel Not Recommended Nonferrous Material Not Recommended Cutter body advantage :1st Recommendation :2nd Recommendation Standard type Design of large chip pocket Good chip evacuation Multiedge type Adoption of cartridge (standard type) Damage prevention of base body Display the applicable insert number (Notch number) Higher productivity due to multiedge design More definite distinction at insert replacement Transcribe letters by using load during machining. 5 *Depending on the cutting conditions,marks are not transcribed.

7 Q&A Q1 What is the target cutting width toward diameter (ae)? A1 Recommendation is 70 to 80% of cutter diameter. Q2 Why is the cutting edge angle 75 degrees of type? A2 Type with 45 degree cutting edge angle suppresses the impact of cutting into workpiece, but has bigger radial force. Meanwhile, type with 90 degree cutting edge angle has smaller radial force, but bigger impact on cutting into workpiece. The cutter with 75 degree cutting edge angle generates small radial force even on large depth of cut, as well as less impact on approaching, and, due to its wellbalanced design, enables smooth machining. The chip evacuation volume with is much more than conventional tools. The chip evacuation per unit time is increased considerably. Conventional tools 6

8 Case studies C Plate Rail Vc=1m/min (n=382min1) apxae=10 125mm fz=0.2mm/t (Vf=458mm/min) Dry 6edges 15125R6T SPMT1806EDER SPMT1806EDER (PR830) Vc=1m/min (n=300min1) apxae=6 140mm fz=0.2mm/t (Vf=480mm/min) Dry 8edges 15160R8T SPMT1806EDER SPMT1806EDER (PR830) Upper side 0 cing Advan ivit y ct u d o r P es 4.4 tim Chip removal 572cc/min. Competitor Cutter A (Competitor Cutter A) ø125,6edges Vc=1m/min (n=382min1) ap ae=3 125mm fz=0.15mm/t (Vf=344mm/min) 129cc/min. (Evaluation by the user) (Competitor Cutter B) 2mmx3pass Vc=1m/min (n=300min1) ap ae=2 140mm fz=0.125mm/t (Vf=300mm/min) Industrial machinery components Gear Vc=100m/min (n=200min1) apxae=10 114mm fz=0.4mm/t (Vf=635mm/min) Dry 8edges 15160R8T SPMT1806EDER SPMT1806EDER (PR830) Vc=200m/min (n=255min1) apxae=10 200mm fz=0.17mm/t (Vf=600mm/min) Dry 14edges 152R14T SPMT1806EDER SPMT1806EDER (PR830) cing Advan ivit y ct u d o r P es 2.5 tim Chip removal 724cc/min. 84cc/min. (User comment) enabled one pass cutting, while it formerly took three pass. Still, the has less cutting noise. Productivity has improved 4.7 times. (Evaluation by the user) 290cc/min. Competitor Cutter D (Competitor Cutter C) 6inch Dia., 8edges Vc=2m/min (n=522min1) ap ae= mm fz=0.25mm/t (Vf=1016mm/min) (User comment) Although conventional type could not increase depth of cut due to high cutting force, has enabled to increase depth of cut without increasing spindle load. Productivity increased 2.5 times. (Competitor Cutter D) ø2,12edges Vc=120m/min (n=153min1) ap ae=5 200mm fz=0.25mm/t (Vf=459mm/min) (Evaluation by the user) cing Advan ivit y t c u d Pr o es 2.6 tim Chip removal 1200cc/min. Competitor Cutter C KYOCERA Fineceramics GmbH Hammfelddamm 6, Neuss, Germany Phone: +49 (0) Fax: +49 (0) / ceratip@kyocera.de cing Advan ivit y t c u d o Pr es 4.7 tim C45 Cast steel 140 Chip removal 403cc/min. Competitor Cutter B (User comment) Improvement of the condition to a large extent results in time reduction. Productivity has improved 4.4 times. Lower side 459cc/min. (User comment) Cutting noise is quiet even when cutting width is nearly 80% of cutter diameter. Productivity increased 2.6 times. (Evaluation by the user) KYOCERA Fineceramics SAS. 4, allee du Commandant Mouchotte Parayvieilleposte 91781,Wissous Cedex, France Phone: +33 (0) Fax: +33 (0) KYOCERA Fineceramics GmbH Italy Branch Office Via Torino 51, Milan, Italy Phone: Fax: KYOCERA Fineceramics GmbH sp. z o.o. Poland Branch Office Leg. ul.europejska 4, 55220, JelczLaskowice, Poland Phone: +48(0) Fax: +48(0) KYOCERA Fineceramics GmbH Spain Branch Office Avenida Manacor 4, Las Matas, Madrid, Spain Phone: Fax: