Ball Nose, Flat Bottom and Back Draft Automatic Cutter Replacement Program
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- Candice Russell
- 5 years ago
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2 all Nose, Flat ottom and ack raft utomatic utter Replacement Program With the purchase of apra all Nose, Flat ottom, ack raft and High-Feed Inserts, receive FR or discounted replacement all Nose, ack raft and Flat ottom utters!* Here s how it works: HN R-N FR-N NR-N very time you buy 30 inserts apra will give you a FR corresponding Steel cutter body.* OR apra will give you 50% OFF the purchase of any replacement arbide ore or Solid arbide Shank tool.* * Notes: UTTR STION MUST INIT T TIM OF ORR Insert sizes can be mixed, however the FR cutter body must accommodate the smallest insert size ordered. For example, ordering twenty 3/4" inserts and ten 1/2" inserts entitles the purchaser to a FR 1/2" Steel cutter body. FR or half-price holders are not eligible for exchange once order is filled. HF FR- NR- R- Terms and onditions: Pertains to all Nose, ack raft, Flat ottom and High-Feed cutting tool products only. Product must be drop shipped to end user only. apra reserves the right to cancel program without notice. lanket orders and specials are not eligible for this program. all Nose holders requested as part of the replacement program are not eligible for return or exchange; correct cutter selection must be made at the time of order. Index Insert Ordering Information 3-5 Insert Grade Selection 5 utter ody Ordering Information 6-9, 12 Screw-on Heads & Modular xtensions Spare Parts & Tools 12 pplication Information 13 Feed, Speed & iameter ompensation 14 Troubleshooting Information 15 nti-seize Grease pplication 15 Recommended utting Speeds 16 2
3 3Three Steps to Quick & asy Ordering Step One: hoose Your Inserts Step Two: hoose Your Insert Grade Step Three: hoose Your utter ody With three quick steps and plenty of insert and cutter choices, apra makes it easy to find exactly what you need and get your cutting tools on time. 1Step One: hoose Your Inserts HN Series Helical utting dge all Nose Inserts* NW Improved Tip Geometry for etter Surface Finishes and onger Tool ife Optimize performance in all all Nose applications: Smoother cutting action Reduced chatter leaner surface finish Heavier cutting capability Increased metal removal Reduced stress on work materials Reduced tool pressure and heat onger tool life iameter 3 /8" 1 /2" 5 /8" 3 /4" 1" 1 1 /4" Helical (HN) HN-0375 HN-0500 HN-0625 HN-0750 HN-1000 HN mm 12mm 16mm 20mm 30mm 32mm Metric HN-10MM HN-12MM HN-16MM HN-20MM HN-25MM HN-30MM HN-32MM * For insert grades and coatings, see chart on page 5. Refer to back cover for speed recommendations by material. More insert options follow on page 4. 3
4 1Step One: hoose Your Inserts Standard all Nose Inserts NR-N NR- iameter 3 /8" 1 /2" 5 /8" 3 /4" 1" 1 1 /4" Without hipbreaker NR-0375-N NR-0500-N NR-0625-N NR-0750-N NR-1000-N NR-1250-N iameter 5 /16" 3 /8" 1 /2" 5 /8" 3 /4" 1" 1 1 /4" hipbreaker NR NR NR NR NR NR NR Metric Without hipbreaker Metric hipbreaker 10mm 12mm 16mm 20mm 30mm 32mm NR-10MM-N NR-12MM-N NR-16MM-N NR-20MM-N NR-25MM-N NR-30MM-N NR-32MM-N 8mm 10mm 12mm 16mm 20mm 32mm NR-08MM- NR-10MM- NR-12MM- NR-16MM- NR-20MM- NR-25MM- NR-32MM- Use NM 1250 cutter body and size 32 insert screws. ack raft (R) Inserts (back draft angle: 4 per side) R-N R- iameter 3 /8" 1 /2" 5 /8" 3 /4" 1" Without hipbreaker R-0375-N R-0500-N R-0625-N R-0750-N R-1000-N hipbreaker R R R R orner Radius 1 /32 1 /16 1 /8 () () R.062 (Flat efore 7 ack raft) 7.00 P-Tipped Inserts** R-P iameter 3 /8" 1 /2" 3 /4" Without hipbreaker R-0375-N-P R-0500-N-P R-0750-N-P orner Radius 1 /32 1 /16 **Note: O of P-Tipped Inserts is.125" Flat ottom (FR) Inserts FR-N iameter 3 /8" 1 /2" 5 /8" 3 /4" 1" Without hipbreaker FR-0375-N FR-0500-N FR-0625-N FR-0750-N FR-1000-N hipbreaker FR FR FR FR orner Radius 1 /32 1 /16 1 /8 FR- 4
5 1Step One: hoose Your Inserts HF Series High-Feed Inserts Ultimate roughing capability for smaller-diameter applications: 3 /8" to 1" diameter Use for cavity/core roughing, pocketing, detail area roughing and helical interpolation Must be run with a NM cutter body (will not fit M cutters) ia. 3 /8" 1 /2" 5 /8" 3 /4" 1" Insert HF-0375 HF-0500 HF-0625 HF-0750 HF-1000 Uses utter NM0375 / GWR10** NM0500 / GWR12** NM0625 / GWR16** NM0750 / GWR20** NM1000 / GWR25** Program Radius.0295".0558".0766".0852".1104" orner Radius.020".034".048".062".076" FPT Max. O.013".020".025".028".033" ** MO, Undersized utters or Metric. ** PR recommends a maximum 1 ramp angle on these inserts. 2Step Two: hoose Your Insert Grade all Nose, ack raft, Flat ottom and High-Feed Insert Grades Uncoated (ase Grade) F1 with oating escription Micro-grain tungsten carbide with high edge strength and good toughness. Good for machining steels, stainless steels, high-temperature alloys, cast iron and nonferrous materials. Titanium carbon nitride (TiN) is a functional hard coating offering an optimal FPX combination of hardness, toughness and antifriction characteristics. TiN is recommended for high shock resistance. xcellent titanium grade. High-performance, medium-temperature grade. Optimum performance and wear FPO resistance in most soft steels, soft stainless steels and cast irons. luminum titanium nitride (ltin) is recommended when extra hardness and heat FP resistance are required. ltin makes both machining at higher speeds and dry machining possible. Premium high-temperature grade. Unbeatable performance and wear resistance in FP-GH high-heat applications such as harder steels, tough stainless steels and hightemperature alloys. V-applied P (diamond) coating. xcellent wear resistance in nonmetallic FP materials such as graphite, epoxy-based resins and plastics. Only available for R-0375-N, R-0500-N and R-0750-N inserts. Premium diamond-tipped grade for carbon or light aluminum milling. Use in P dedicated holder for the optimum in wear resistance, up to 100 times standard PV-coated inserts. Specifications (-2), (K10) 3000 HV, 750 F,.4 o 3200 HV, 1850 F,.4 o 3600 HV, 2000 F,.4 o 3600 HV, 2000 F,.2 o V iamond oating razed-on iamond Tips "FP-GH" and "FP" coatings are best suited for higher operating speeds (temperatures) and harder materials. "FPO" and "FPX" coatings are best suited for low to medium operating speeds (temperatures) and softer materials. Other coatings available on request. ontact apra for details. 5
6 3Step Three: hoose Your utter ody STNR SHNK Tools starting with "S" are short effective-reach cutters, designed for optimum strength and limited clearance utting ia. Part Number utting ia. all Nose nd Mills Standard Shank Straight nd Shank ffective T ngle Overall NM SS NM SS NM SS S-NM SS NM SS NM SS S-NM SS NM SS NM SS NM SS S-NM SS NM SS NM SS NM SS S-NM SS NM SS NM SS 0.547" 0.547" 0.547" 1.070" 1.070" 1.750" 1.750" 0.615" 0.615" 0.615" 40" 40" 2.000" 2.500" 10" 1.380" 2.500" 1.340" 1.750" 3.000" 1.710" 2.000" 3.750" 5.000" 1.940" 2.500" " 5.250" 6.000" 5.500" 6.250" 8.250" 9.000" 6.250" 7.500" 9.000" " 9.000" chieve Higher Performance with arbide ore utter odies! Optimize performance with arbide ore tooling: reduced deflection increased stiffness less chatter utting ia. arbide ore all Nose nd Mills Standard Shank Part Number utting ia. Straight nd Shank ffective T ngle Overall -NM SS -NM SS -NM SS -NM SS -NM SS -NM SS -NM SS 1.070" 1.070" 1.750" 1.750" 40" 40" 3.000" 2.000" 3.750" 5.000" 2.500" " 6.250" 7.500" 9.000" 9.000" *Note: ll apra all Nose end mills accept either inch or metric inserts of like sizes. xample: NM0750 and GWR20 accept either a 3/4" or 20mm diameter insert. NM0500 and GWR12 accept either a 1/2" or 12mm diameter insert. 6
7 3Step Three: hoose Your utter ody OVRSIZ SHNK Tools starting with "S" are short effective-reach cutters, designed for optimum strength and limited clearance utting ia. Part Number utting ia. all Nose nd Mills Oversized Shank Straight nd Shank ffective T ngle Overall NM OS NM OS NM OS S-NM OS NM OS S-NM OS NM OS NM OS NM OS S-NM OS NM OS S-NM OS NM OS NM OS 0.313" 0.375" 0.375" 0.375" 0.280" 0.335" 0.335" ed 0.414" ed 0.547" ed ed 1.070" n/a n/a n/a n/a 1.750" 0.415" 0.365" 0.365" n/a n/a 0.615" n/a n/a 40" 1.910" 1.340" 1.880" 1.380" 2.500" 2.310" 3.130" 3.500" 3.000" 3.880" 6.000" " 3.500" 6.000" 5.880" 6.000" 6.000" 7.500" 9.500" 9.440" 8.250" 9.440" " 1 chieve Higher Performance with arbide ore utter odies! Optimize performance with arbide ore tooling: reduced deflection increased stiffness less chatter utting ia. arbide ore all Nose nd Mills Oversized Shank Part Number utting ia. Straight nd Shank ffective T ngle Overall -NM OS -NM OS -NM OS -NM OS -NM OS -NM OS -NM OS 1.070" 1.750" 40" 3.500" 6.500" 6.500" 7.500" " 9.500" 8.250" " " " 1 More cutter options follow on page 8. *Note: ll apra all Nose end mills accept either inch or metric inserts of like sizes. xample: NM0750 and GWR20 accept either a 3/4" or 20mm diameter insert. NM0500 and GWR12 accept either a 1/2" or 12mm diameter insert. 7
8 3Step Three: hoose Your utter ody SOI RI utting ia. chieve Maximum Performance with Solid arbide utter odies! Optimize performance with arbide Shank tooling: reduced deflection increased stiffness less chatter heat shrink toolholding capability (all Nose with Solid arbide Shank only) * Keep brazed joint a minimum of 2" away from heat shrink toolholder. S (Solid arbide Shank) tooling is suitable for FINISHING PPITIONS ONY. S tooling is NOT suitable for roughing and applications with significant heat. Solid arbide all Nose nd Mills Standard Shank Part Number utting ia. Straight nd Shank ffective T ngle Overall S-NM SS S-NM SS S-NM SS S-NM SS S-NM SS S-NM MM-SS S-NM SS S-NM SS S-NM SS S-NM MM-SS S-NM SS S-NM SS S-NM MM-SS 0.375" 0.375" 0.335" 0.335" 0.547" 0.365" 0.365" 0.615" 0.375" 0.375" 12mm 18mm 3.000" 3.500" 4.000" 1.450" 4.000" 2.250" 6.000" 2.250" 3.000" 3.000" " 3.950" 6.500" 7.500" " " 7.500" " " See page 5 for available insert grades. *Note: ll apra all Nose end mills accept either inch or metric inserts of like sizes. xample: NM0750 and GWR20 accept either a 3/4" or 20mm diameter insert. NM0500 and GWR12 accept either a 1/2" or 12mm diameter insert. 8
9 3Step Three: hoose Your utter ody UNRSIZ SHNK Save time and money by using apra's Undersized Shank Holders They give you INSTNT RN! S N Undersized Shank GWR utters Holder S N Insert Screw iameter ffective Overall Shank iameter Neck iameter 1/2" or 12mm 5/8" or 16mm 3/4" or 20mm 1" or US-GWR MM-RZ US-GWR MM-RZ US-GWR MM-RZ US-GWR MM-RZ 0.98" 2.05" 2.56" 2.76" 5.91" 7.09" 9.06" 9.84" 11mm 15mm 18mm 24mm 0.41" 0.57" 0.71" 0.89" GWS 12 GWS 16 GWS 20 GWS 25 *Note: Tool neck diameter is exaggerated to show clearance available with undersized shank cutters. K RFT & FT OTTOM utting ia. For use with R and FR inserts only. Part Number ack raft and Flat ottom utters utting ia. Straight nd Shank ffective T ngle Overall arbide Shank arbide Shank arbide Shank M OS M SS S-M SS S-M SS S-M SS2 M SS M SS M SS 0.375" 0.335" 0.547" 0.547" 0.365" 0.615" 0.615" 25" 4.000" 2.050" 1.875" 2.250" 3.000" " 6.000" 3.950" 9.000" " More cutter options follow on page 10. *Note: ll apra all Nose end mills accept either inch or metric inserts of like sizes. xample: NM0750 and GWR20 accept either a 3/4" or 20mm diameter insert. NM0500 and GWR12 accept either a 1/2" or 12mm diameter insert. 9
10 3Step Three: hoose Your utter ody RI OR MOUR XTNSIONS apra's arbide ore Modular xtensions re Ideal for Standard Inch nd Mill Holders Standard inch shanks, providing adaptation for end mill holders, milling chucks and heat-shrink holders 3 sizes to accommodate modular head sizes from 3 /4" to 1 1 /2" arbide core for enhanced vibration dampening capability; reduced deflection and improved rigidity Optional add-on extensions for additional 2" reach screw on to base extensions (for 3 /4" to 1 1 /2" modular heads) arbide ore Modular xtensions For Head ia. xtension Part No. Shank ia. ffective O Thread.750" / -M WOF -M WOF -M WOF 3.7" 4.7" 5.7" 6.0" 7.0" 8.0" M10 M12 M16 7/16" x 4.0" 7/16" x 5.0" 1/2" x 6.0" " dd-on xtensions For Head ia. xtension Part No. ffective Thread.750" / M " XTNSION PTR M " XTNSION PTR M " XTNSION PTR 2.0" 2.0" 2.0" M10 M12 M16 O ffective ffective arbide ore See next page for standard line of Modular Heads and xtensions. Mounting Thread H6 Tolerance Shank Shank 10
11 3Step Three: hoose Your utter ody SRW-ON MOUR HS & XTNSIONS apra's Screw-On Heads Fit Industry Standard utting Systems M (MOUNTING THR) ompatible with ISO standard modular cutting systems lose-tolerance mounting of heads minimizes runout and maximizes rigidity Provide significantly more effective reach than solid end mills Use standard inch wrench flats, no special metric wrenches needed all Nose Screw-On Heads ia. Holder M Flutes Wrench I.500"/12mm.625"/16mm.750"/20mm / /32mm GWR12-MO GWR16-MO GWR20-MO GWR25-MO GWR32-MO M8* M8* M10 M12 M " 1" 8" 1.65" 1.78" /8" 7/16" 9/16" 11/16" 15/16" * M8 modular extensions not available. Use ISO standard bars. Modular xtensions** Provide ven More utting Options M (MOUNTING THR, OTH NS) Made of high-density tungsten, providing extra resistance to deflection and chatter Machined on both ends; can be cut in half and used with two different modular heads Metric shank diameter provides clearance for each inch size modular head ** Using modular extensions at full length is not generally recommended. Use for very light cutting at significantly reduced speeds and feeds only. O Modular xtensions** Modular Head ia. Part No. O M S.750"/20mm / /32mm M MM-900 M MM-1100 M-125/150-25MM " 11" 12" M10 M12 M16 18mm S (SHNK IMTR) More cutter options follow on page
12 3Step Three: hoose Your utter ody MTRI ST S N S N ed Metric Holder Straight Metric Holder Holder S N Insert iameter ffective Overall Shank iameter Neck iameter Screw ed Solid Metric 8 mm GWR RZK 100mm 10mm 7mm GWS 08 10mm 12mm 12mm 16mm 20mm 20mm 32mm GWR RZ GWR RZ S-GWR MM-RZ GWR RZ S-GWR MM-RZ GWR RZ GWR RZ S-GWR MM-RZ GWR RZ Straight Solid Metric 130mm 47mm 150mm 38mm 180mm 52mm 180mm 57mm 250mm 65mm 230mm 70mm 250mm 76mm 250mm 70mm 250mm 10mm 12mm 12mm (RI) 16mm 18mm (RI) 20mm (RI) 32mm *Note: ll apra all Nose end mills accept either inch or metric inserts of like sizes. xample: NM0750 and GWR20 accept either a 3/4" or 20mm diameter insert. NM0500 and GWR12 accept either a 1/2" or 12mm diameter insert. 9mm 10.5mm 10.5mm 14.5mm 17mm 18mm 22.5mm 22mm 27.5mm GWS 10 GWS 12 GWS 12 GWS 16 GWS 18 GWS 20 GWS 25 GWS 25 GWS 32 Spare Parts & Tools Insert Screw GWS 08 GWS 10 GWS 12 GWS 16 GWS 20 GWS 25 GWS 32 Insert Size Inch Metric /32 ia. 3mm 4mm 5mm 5mm 5mm 6mm 8mm Major ia. 3mm 4mm 5mm 5mm 5mm 6mm 8mm Pitch.5mm.5mm.5mm.5mm.5mm.75mm.75mm Wrenches Torx T8F T15F T20F T20F T20F T30 T30 Torque Nm/in.lbs. Manual Manual 6.0/53 6.2/55 6.2/55 6.5/58 6.5/58 TORX is a registered trademark of amcar/textron. NOT: New cutter bodies may require additional torque to fully seat the inserts. Once new cutter pockets are "broken in," the recommended torque specs in the chart can be followed regularly. Miscellaneous escription Special nti-seize Grease atalog No. SG-120 T30 T20F T15F T10F* T8F GWS * T10 wrenches available for older-style insert screws. 12
13 pplication Information Technical onsiderations lways use anti-seize compound on threads and screw body. Thoroughly clean pocket and screw at each insert change. hange insert screw every 10 inserts. Use high quality tool holders for rigidity and concentricity: milling chucks, heat-shrink and mechanical shrink holders are recommended; collets and end mill holders are not recommended. utter bodies will wear and fatigue over time; inspect tool before each use. Recommendations Maximum epth of ut (O) for finishing should be less than or equal to 10% of ball diameter. Stepover should be greater than or equal to O. For roughing operations, maximum recommended Width of ut (WO) and O are 30% of ball diameter. Starting Feed per Revolution (FPR) should be 1% of ball diameter. xample:.750" diameter x.01 =.0075" FPR limb milling is preferred. When plunging with all Nose, use pecking cycle with a maximum of.005" FPR; maximum recommended depth is 30% of ball diameter. ack raft and Flat ottom Inserts are not designed for plunging; ramp in at a maximum angle of 2. ompensate for ffective utting iameter (see Table 1 and Fig.1 on p. 14). ompensate for chip thinning with Feed Rate djustment (see Table 2 on p. 14). Surface finish (RMS) is a function of stepover and feed per tooth. Try to work within recommended surface footage and chip loads. ecrease feed rate coming into corners to reduce chatter. For long-reach applications, utilize the arbide Shank/arbide ore cutting tools for increased rigidity and reduced chatter. ISIMR: Modern metal cutting techniques involve the potential use of very high operating parameters (speeds, feeds, depths of cut, etc.). This creates the potential for flying chips and debris, and can also create tool breakage due to a variety of causes. s such, any metal cutting operation should be executed in a completely enclosed (shielded) environment to protect against injury from flying objects. apra does not assume responsibility for any loss, damage or expense incurred in any use or handling of our product after purchase. Grinding produces hazardous dust. To avoid adverse health effects, use adequate ventilation and read material safety data sheet first. This product contains a chemical known to the state of alifornia to cause cancer. 13
14 Feed, Speed & iameter ompensation Table 1: ffective utting iameter () epth of ut (O) Insert iameter Select diameter of tool to be used. 2. etermine epth of ut (O) to be used. 3. Refer to Figure 1 and Table 1 to find the ffective utting iameter (). 4. Refer to Feed and Speed chart on back cover to select the surface footage to be used (SFM). 5. alculate RPM using the and SFM. (SFM x 3.82 / = RPM) 6. Refer to Table 2 to determine Feed Rate djustment (FR). 7. Refer to chart on back cover to select Feed per Revolution (FPR). alculate Inches per Minute (IPM). (RPM x FPR x FR = IPM) PTH OF UT Figure 1 INSRT IMTR FFTIV UTTING I. Table 2: Feed Rate djustment (FR) Insert iameter epth of ut (O) /4" /16" /8" /2" /8" /4" " /4" Use multiple above to calculate adjusted feed rate. *For a all Nose scallop height calculator, please refer to our speed and feed calculator at 14
15 Troubleshooting oncern Insert wear at tip Insert wear appears high (flank wear) Insert chipping uilt-up edge on insert Poor finish/chatter Tool shank breaks Possible ause Not enough chip load Not enough chip load Surface footage is high Incorrect grade or coating Surface footage is low Incorrect grade or coating Using style insert incorrectly Feed too high ow surface footage ight chip load (feed per tooth) Incorrect coating utter hung out too far xcessive runout Tool pressure too great Fatigued cutter body Solutions Verify correct speed and feed Increase feed rate ecrease RPM Increase O Verify correct speed and feed Increase feed rate ecrease RPM onsider different insert Verify correct speed and feed Increase spindle speed ecrease feed rate hange insert selection ecrease O Use N style insert Verify correct speed and feed Increase cutting speed Increase feed rate Select different coating Use arbide ore cutter body Reduce tool gage length heck tool holder wear ecrease O Reduce tool gage length ecrease feed rate How to pply nti-seize to all Nose Insert Screws 1. nti-seize must be applied before using tool for first time. 2. Remove screw from cutter body. 3. Generously apply anti-seize to entire length of screw body, not to just the threads (see diagram). 4. lean out insert pocket before assembly of insert/screw combination. 5. Place insert into cutter-body pocket. 6. Place screw with applied anti-seize into position in cutter body. Generously apply anti-seize to these surfaces with each insert change. 7. While gently pushing on the end of the TORX screwdriver/ wrench, begin tightening the screw (may turn with slight resistance in order to pull insert tight into the pocket). 8. Tighten screw to snug fit, taking care not to overtighten. Follow torque specifications shown above. 9. Repeat steps 2-8 for each insert change. 10. Replace screw with each new box of inserts to assure maximum performance. 15
16 Recommended utting Speeds MTRI GROUP xample F1 (uncoated) FPX FPO FP/ FP-GH P Geometry FPR PIN STS OY STS TOO & I STS < 3% 3%-6% 5%-1.5% Mo r NirMo 1008, 1018, , 1045, , 1070, , 4320, , , 8622, , 2, P20, W2,H13,S HN N HRN STS HN, N STINSS STS ST IRON UMINUM OYS OPPR OYS HIGH-TMP. OYS TITNIUM OYS Ferritic/ Martensitic ustenitic Precipitation Hardening (PH) Gray Malleable uctile uni:refer to High- Temp. lloys below 403, 416, 430, 430F, 434, 446, S , 303, 304, PH, 17-4PH, custom, 455, PH13-8 Mo, M lass xx, 436 Type 2 47, 220, S J , , S J T4, 6061-T6, 7075-T6 J463, 121, mpco 21, Wearite 4-13 Inconel 617, Monel K500, Waspaloy, uni Ti99.9, lpha lloy, Ti-6l-4V HN, N, HN, HN,N HN, HN, HN, RON GRPHIT HN, N, P ** est choice grades shown in bold text Refer to the iameter and Feed Rate djustment charts on page 14 for accurate RPM and IPM calculations SP ower Speed Ranges for: Heavier cuts, harder materials, larger diameter tools Medium Speed Ranges for: Semi-finishing Higher Speed Ranges for: ighter cuts, softer materials, smaller diameter tools F ower Feed Ranges for: Heavier cuts, harder materials, smaller diameter tools Higher Feed Ranges for: ighter cuts, softer materials, larger diameter tools The parameters provided are suggested operating parameters. ctual speeds and feeds will depend on many variables, such as rigidity, workpiece hardness, tool extension, machine accuracy, epth of ut, etc. Start at the middle of the SFM range and the low end of the FPR range. Next, increase FPR to optimize productivity and tool life. Higher SFM will provide higher output but will reduce tool life. Try different combinations to find the parameters that best suit your needs. apra all Nose finishing products are proudly made in the US. ringing etter Ideas to the utting dge 66 Granby Street, loomfield, T Fax mail info@dapra.com opyright 2014 apra orporation W
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