Flexible tool overhang lengths possible by combining the modular extension arbor and shank with insert run-out adjustment mechanism

Transcription

1 Sumi Easy insert replacement Characteristics Achieves efficiency through high speed, high feeding ability!! (v c =50 to 500m/min, f = 0.4 to 1.2mm/rev) Compatibility with a wide range of cutting conditions allows less strict cutting conditions and coolant control Minimal cut edge length design eliminates biting and tearing for improved quality and reliability Adoption of indexable cutting edge design improves reliability of quality and tool life, eliminating variability in tool life among reground inserts. Cut edge diameters available from ø11.9 to ø140.6 mm Flexible tool overhang lengths possible by combining the modular extension arbor and shank with insert run-out adjustment mechanism Use different configurations to adjust tool overhang length A taper supports the insert by two faces (based on the HSK standard) for less-than 4 μm repeatability using random inserts Application Examples Work Cylinder barrel Connection rod Sliding yoke Front axle holder with guide pads Control valve Work Material FCD600 Forged S55C S45C Forged S58C Forged S55C Holder SRD SRG17.0H7-A01-T1212R1 SRD SRG29.0H7-A01-F0512R1 SRD SRG16.02Q+3-3-C01-F0512R1 SRD SRL28.0H7-B01-F0512R1 holder with guide pads SRL14.0H7-B01-F0512R1 Hole (mm) ø17.0 ø29.0 ø16.02 ø28.0 ø14.0 Hole Tolerance H7 H7 H7 H7 H7 Surface Roughness Ra/Rz Rz10.0 Ra0.8 Ra3.2 Ra3.2 Ra1.6 Circularity (μm) Cylindricity (μm) No. of Teeth v c (m/min) n (min -1 ) 2,772 1,318 2, ,230 f z (mm/t) v f (m/min) 3,326 1,582 1, ,368 a p (mm) Wet / Dry Wet Wet Wet Wet Wet Life, etc 57.9m 30.52m 15.8m 102

2 Sumi Sumi Configurations SRG Type (For Stop/Through Boring) 104 Toolholder SRD Type (For Through Boring) 106 Run-Out Adjustment Mechanism Arbor 107 BT/A Type SRL Type (For Through Boring) SRD-SD (Center Bolt Clamp Type) SRB Type (For Stop Boring) Taper Size : 40 to 50 HSK Type ø toø mm SRD-SD (Center Bolt Clamp Type) Applicable Range : ø to ø35.600mm Shank Length : 100 to 274mm Taper Size : 50 to 100 Head SRKG Type (For Through Boring) 108 SRA Type Run-Out Adjustment Mechanism Shank 108 BT/A Type Arbor SRKB Type (For Stop Boring) ZS(Cylindrical Shank) Type : ZS-20/25/32/40 Taper Size : 40 to 50 HSK Type Applicable Range : ø to ø mm Head Length : 30 to 60mm WD(Weldon Shank) Type : WD-20/25/32/40 Taper Size : 50 to 100 Use a compatible arbor that is commercially available. WN(Whistle Notch Shank) Type : WN-20/25/32/40 Applicable Range : ø to ø mm Shank Length : 80 to 160mm Head SRKG Type (For Through Boring) Run-Out Adjustment Mechanism Shank Arbor SRA Type BT/A Type SRKB Type (For Stop Boring) BM(Beta Module Shank) Type : BM-32/40/50/63 Applicable Range : ø to ø mm Shank Length : 55 to 160mm Taper Size : 40 to 50 HSK Type Applicable Range : ø to ø mm Head Length : 30 to 60mm Check Sizes When using a BM (Beta Module) type shank, choose a matching standard size. For BT40 B12 Type Extensions 109 For BT50 B13 Type Taper Size : 50 to 100 Shank Length : 40 to 75mm Shank Length : 35 to 180mm Multiple extensions can be connected together When increasing the overhang, we recommend reducing the number of extensions that are used in terms of rigidity. 103

3 Sumi Sumi Carbon Steel, Alloy Steel Tempered Hardened Steel Stainless Ti Heat-resistant Cast Ductile Aluminum Copper Up to 0.28% From 0.29% Steel Up to 45HRC From 46HRC Steel Alloy Steels Iron Cast Iron Alloy Alloy Composite CFRP SRG Typegeneral purpose Straight Grooves : Stop Boring / Through Boring Fig 1 Fig 2 Stop Hole Conceptual Image of Chip Evacuation A01 Type C01 Type S02 Type Through Hole Chips Evacuated Toward Front Standard Type Emphasis on Surface Roughness Emphasis on Direct Line (SRG Type) (mm) Stock (A01 Type) (C01 Type) (S02 Type) Stock Stock F05T12 F05T12 F05T SRG 12.0H7-A01-12R1 SRG 12.0H7-C01-12R1 SRG 12.0H7-S02-12R H7-A01-12R1 13.0H7-C01-12R1 13.0H7-S02-12R H7-A01-12R1 14.0H7-C01-12R1 14.0H7-S02-12R H7-A01-12R1 15.0H7-C01-12R1 15.0H7-S02-12R H7-A01-12R1 16.0H7-C01-12R1 16.0H7-S02-12R H7-A01-12R1 17.0H7-C01-12R1 17.0H7-S02-12R H7-A01-12R1 18.0H7-C01-12R1 18.0H7-S02-12R H7-A01-12R1 19.0H7-C01-12R1 19.0H7-S02-12R H7-A01-12R1 20.0H7-C01-12R1 20.0H7-S02-12R H7-A01-12R1 21.0H7-C01-12R1 21.0H7-S02-12R H7-A01-12R1 22.0H7-C01-12R1 22.0H7-S02-12R H7-A01-12R1 23.0H7-C01-12R1 23.0H7-S02-12R SRG 24.0H7-A01-12R1 SRG 24.0H7-C01-12R1 SRG 24.0H7-S02-12R H7-A01-12R1 25.0H7-C01-12R1 25.0H7-S02-12R H7-A01-12R1 26.0H7-C01-12R1 26.0H7-S02-12R H7-A01-12R1 27.0H7-C01-12R1 27.0H7-S02-12R H7-A01-12R1 28.0H7-C01-12R1 28.0H7-S02-12R H7-A01-12R1 29.0H7-C01-12R1 29.0H7-S02-12R H7-A01-12R1 30.0H7-C01-12R1 30.0H7-S02-12R1 Please indicate F05 (PVD) or T12 (Coated Cermet) in the when ordering. (Example: SRG12.0H7-A01-F0512R1) [It is also possible to order uncoated cermet/dlc grades.] Work Hole Tolerance (mm) No. of Teeth Fig H H Actual reamer diameter is near the upper limit of H7 tolerance. Sumi Identification Details Specifying s Using Work Hole Tolerance The actual desired reamer diameter will be on the upper limit side of the median work tolerance, and will differ depending on diameter/tolerance range/grade. Please contact us for details. SR G A01 - F05 12R 1 Specifying s Using Desired By adding a "Q" after the diameter, it is possible to specify exact desired reamer dimensions. Uncoated types are available within ±2μ, thin-layer coated types within ±3μ, and thick-layer coated types within ±4μ. SR L 18.2 Q A01 - F05 12R 1 G = Straight, L = Lefthand helix Work Hole (mm) Tolerance (μm) +/- or standard (ex. H7) Approach Angle Code Grade Symbol Coating Code G = Straight, L = Lefthand helix Work Hole (mm) Tolerance (μm) +/- Approach Angle Code Grade Symbol Coating Code 104

4 Sumi Sumi Carbon Steel, Alloy Steel Tempered Hardened Steel Stainless Ti Heat-resistant Cast Ductile Aluminum Copper Up to 0.28% From 0.29% Steel Up to 45HRC From 46HRC Steel Alloy Steels Iron Cast Iron Alloy Alloy Composite CFRP SRL Type Priority On Chip Evacuation Left HelixThrough Boring Fig 1 Fig 2 Through Hole Conceptual Image of Chip Evacuation B01 Type Chips Evacuated Toward Back For Steel Through-Holes (SRL Type) Fig (mm) Stock (B01Type) Work Hole F05T12 Tolerance (mm) No. of Teeth 12.0 SRL 12.0H7-B01-12R H7-B01-12R H7-B01-12R H7-B01-12R H7-B01-12R H7-B01-12R H7-B01-12R1 H H7-B01-12R H7-B01-12R H7-B01-12R H7-B01-12R H7-B01-12R SRL 24.0H7-B01-12R H7-B01-12R H7-B01-12R H7-B01-12R1 H H7-B01-12R H7-B01-12R H7-B01-12R1 Please indicate F05 (PVD) or T12 (Coated Cermet) in the when ordering. (Example: SRG12.0H7-A01-F0512R1) [It is also possible to order uncoated cermet/dlc grades.] Actual reamer diameter is near the upper limit of H7 tolerance. Recommended Cutting Conditions ISO Work Material Grade Grade Made-to-order item (mm) ø to ø ø to ø ø to ø ø to ø ø to ø ø to ø ø to ø ø to ø ø to ø ø to ø ø to ø ø to ø (mm) No. of Teeth SRG type () and SRL type () are made-to-order items. When ordering, refer to " Identification Details" on page 104. * Cermet grades (T1200A and T1212R1) are available only up to ø mm. Depth of Cut a p (mm/radius) Below ø20 ø20 to ø35 ø35 or more Cutting Speed v c (m/min) 12 Feed Rate f z (mm/t) Carbon Steel SRG Type 0.05 to to to to to 0.25 F0512R1 Micro-Fine Grained Carbide + PVD SRL Type 0.05 to to to to to 0.35 SRG Type 0.05 to to to to to 0.25 T1200A Cermet SRL Type 0.05 to to to to to 0.35 SRG Type 0.05 to to to to to 0.20 P F0512R1 Micro-Fine Grained Carbide + PVD SRL Type 0.05 to to to to to 0.22 Alloy Steel SRG Type 0.05 to to to to to 0.20 T1200A Cermet SRL Type 0.05 to to to to to 0.25 Die Steel SRG Type F0512R1 Micro-Fine Grained Carbide + PVD 0.05 to to to to to 0.20 Tool Steel SRG Type F0512R1 Micro-Fine Grained Carbide + PVD 0.05 to to to to to 0.15 M Stainless Steel SRG Type F0512R1 Micro-Fine Grained Carbide + PVD 0.05 to to to to to 0.20 K Gray Cast Iron F0512R1 Micro-Fine Grained Carbide + PVD 0.05 to to to to to 0.30 SRG Type Ductile Cast Iron T1212R1 Coated Cermet 0.05 to to to to to 0.30 N Non-Ferrous Metal SRG Type F0510C Micro-Fine Grained Carbide + DLC 0.05 to to to to to

5 Sumi SRD Type (For Through Boring) SRB Type (For Stop Boring) LUX h6 LUX h6 Toolholder (ø to mm) Short Long Cap Screws and Wrenches Dimensions(mm) Carbide Shank SRD Carbide Shank SRB Shank Shoulder Length Length Below Neck Group No. Range Stock Stock Stock Stock LUX ø to ø SRD SRB (1) 0.9 ø to ø (1) 0.9 ø to ø (2) 1.5 ø to ø (2) 1.5 ø to ø (2) 1.5 ø to ø SRD SRB SRD HM SRB HM (1) 0.9 ø to ø HM HM (1) 0.9 ø to ø HM HM (2) 1.5 ø to ø HM HM (2) 1.5 ø to ø HM HM (2) 1.5 * Refer to the table at the bottom of page 107 for the applicable cap screw and wrench catalog numbers. Recommended Tightening Torque(Nm) SD Type (Center Bolt Clamp Type) Can be clamped using one center bolt to improve work efficiency Applicable to high-torque (high-load) machining Expansion SRD-SD Type (For Through Boring) SRB-SD Type (For Stop Boring) D2 h6 D2 h6 A LUX A LUX Steel Shank Toolholder SRD-SD/SRB-SD Series (Center Bolt Clamp Type) Short Long Spare Parts Dimensions (mm) Group No. SRD Type (For Through Boring) SRB Type (For Stop Boring) Shank Shoulder Length Length Below Neck Bolt Bolt Range Stock Stock LUX D2 A SRD SRB ø to ø SRD SD SRB SD (3) (3) 4.0 ø to ø SD SD (4) (7) 6.0 ø to ø SD SD (5) (8) 16.0 ø to ø SD SD (5) (8) 16.0 ø to ø SD SD (6) (9) 18.0 ø to ø SRD SD SRB SD (3) (3) 4.0 ø to ø SD SD (4) (7) 6.0 ø to ø SD SD (5) (8) 16.0 ø to ø SD SD (5) (8) 16.0 ø to ø SD SD (6) (9) 18.0 * Refer to the table at the bottom of page 107 for the applicable cap screw and wrench catalog numbers. Carbide Shank Toolholder SRD-SD/SRB-SD Series (Center Bolt Clamp Type) Long Recommended Tightening Torque(Nm) Spare Parts Dimensions (mm) Group No. SRD Type (For Through Boring) SRB Type (For Stop Boring) Shank Shoulder Length Length Below Neck Bolt Bolt Range Stock Stock LUX D2 A SRD SRB ø to ø SRD HMSD SRB HMSD (3) (3) 4.0 ø to ø HMSD HMSD (4) (7) 6.0 ø to ø HMSD HMSD (5) (8) 16.0 ø to ø HMSD HMSD (5) (8) 16.0 ø to ø HMSD HMSD (6) (9) 18.0 * Refer to the table at the bottom of page 107 for the applicable cap screw and wrench catalog numbers. Recommended Tightening Torque(Nm) 106 mark: Standard stocked item (expanded item)

6 Sumi BT/A Type HSK Type ød ød SW SW Arbor With Run-Out Adjustment Mechanism BT/A Type Stock Taper Size Size Range (Dimensions:mm) Cap ød Shoulder Length Adjustment Screw SW AAT60-40A ER to ER to ER to AAT60-50A ER to ER to HSK Type (Coolant tube sold separately.) Stock Taper Size Size Range Cap Shoulder Length ød AAH60-40A ER to Adjustment Screw SW ER to AAH60-63A ER to ER to ER to AAH60-100A ER to Parts ød ød d ød ød L Collet (Dimensions:mm) Size ød L ER ER ER = ød Ex. 1: ER25, d= These items are in stock in increments of 1 mm: from ø12 to ø16 mm from ø12 to ø20 mm from ø12 to ø26 mm. Seal Disc (Dimensions:mm) Size ød ER to ER to ER to 26.0 = ød Ex. 1: ER25, d= These items are in stock in increments of 1 mm: from ø12 to ø16 mm from ø12 to ø20 mm from ø12 to ø26 mm. Collet Cap (Dimensions:mm) Size ød d ER25 42 M32 x ER32 50 M40 x ER40 63 M50 x 1.5 Tightening Wrench Size ER ER ER40 Torque Wrench G SR 81 / SR 101 T Nm All in stock. All in stock. DBKGA For HSK arbors. Fig 1 Fig 2 Fig 3 Fig 4 Applicable Holder Torx Hole Torque Rating G SR 16 / SR 19 T 6 0.9Nm G SR 24 to SR Nm Coolant Tubes Taper Size 40 H H H Spare Parts C Cap Screws and Wrenches Group No. Cap Screw Fig Wrench Fig (1) (2) (3) (4) (5) (6) (7) (8) (9) C C C C C C C B C B C B 1 G G G G G G G G G Torx Hole T 6 T20 T30 T30 T20 T30 T Recommended Tightening Torque(Nm) 107

7 Sumi SRKG Type (For Through Boring) SRKB Type (For Stop Boring) S S Head (ø to ø140.6mm) Cap Screws and Wrenches Dimensions (mm) For Attachment For Center Locking Shank Length Shank Group No. Range Stock SRKG Stock SRKB Group No. Tightening Torque Tightening Torque S SRKG SRKB ø to ø SRKG SRKB (1) 1.5N (3) (8) ø to ø (1) 1.5N (4) (9) Refer to the ø to ø (1) 1.5N (5) (10) recommended ø to ø (2) 3.5N (6) (11) tightening torque in the ø to ø (2) 3.5N (7) (12) table at the bottom of ø to ø SRKG SRKB (2) 3.5N (7) (12) page 109. ø to ø (2) 3.5N (7) (12) * Refer to the table at the bottom of page 109 for the applicable cap screw and wrench catalog numbers.*: For SRKG Type : For SRKB Type SRA Type BM (Beta Module Shank) Type ZS (Cylindrical Shank) Type WD (Weldon Shank) Type WN (Whistle Notch Shank) Type Shank ( Run-Out Adjustment Mechanism) Shank Type BM ZS WD WN Spare Parts Dimensions (mm) Cap Screw Wrench Clamp Screw Shank Length Shank Range Stock SRA SRA BM BM ø to ø BM BM C G Z Z SRA BM BM ø to ø BM BM C G Z Z SRA BM BM ø to ø BM BM C G Z Z SRA BM BM ø to ø BM BM C G Z Z ø to ø SRA BM BM BM BM C G Z Z ø to ø SRA ZS ZS C G ø to ø SRA ZS ZS C G ø to ø SRA ZS ZS SRA ZS ZS ø to ø ZS ZS C G ø to ø SRA ZS ZS ZS ZS C G ø to ø SRA WD WD C G ø to ø SRA WD WD C G ø to ø SRA WD WD C G SRA WD WD ø to ø WD WD C G ø to ø SRA WD WD WD WD C G ø to ø SRA WN WN C G ø to ø SRA WN WN C G ø to ø SRA WN WN C G ø to ø ø to ø SRA WN WN WN WN SRA WN WN WN WN C G C G

8 Sumi B12 Type B13 Type B B LBX LPR LPR Extensions B12 Type Stock Shank Shank Overhang Length Body B LPR LBX Weight (kg) B BM BM B BM BM B BM BM BM BM B BM BM BM BM B BM BM BM BM BM BM B13 Type Stock Shank Shank Overhang Length Body B LPR LBX Weight (kg) B BM BM BM BM B BM BM BM BM B BM BM BM BM B BM BM BM BM B BM BM BM BM B BM BM BM BM BT/A Type HSK Type B B LBX LPR LBX LPR Arbor BETA Module BT/A Type Stock Taper Size Shank Overhang Length Body B LPR LBX Weight (kg) BT10-40A BM BM BM BM BM BM BT10-50A BM BM BM BM BM BM Spare Parts Fig 1 Fig 2 Fig 3 HSK Type (Coolant tube sold separately.) Stock Taper Size Shank Overhang Length Body B LPR LBX Weight (kg) BH10-50A BM BM BH10-63A BM BM BM BM BH10-100A BM BM BM BM BM Group No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Cap Screw C C C G C G C G C G C B C B C B C B C B C B Fig 1 Wrench G G G G G G G G G G G G Fig 2 3 Torx Hole Recommended Tightening Torque(Nm) Clamp Screw Coolant Tubes Size Z Z Z Z Z Z Taper Size For HSK arbors. H H H

9 Sumi Usage Instructions (Adjusting Run-Out) The run-out at the cut edge of a reamer should be zero to obtain optimum boring precision. To correct run-out in the holder or the machine's spindle, use of holders with a run-out adjustment mechanism, hydro chucks, and shrink-fitting is recommended. Various methods can be used to measure run-out on a Sumi SR type reamer. Sumi SR type reamers offer good run-out repeatability so it is recommended that inserts be replaced without removing the shank holder from the spindle. Run-Out Adjustment (1) High-accurate cut edge runout measurement method (for measuring the arc land on the insert) Measuring the lands immediately after the outer diameter of the insert has been chamfered eliminates all attachment errors. This allows for the most accurate runout measurement. (2) Simplified measurement method (for measuring the short taper of the holder) The short taper on the holder where the inserts are attached provides the easiest and most accurate measurement before attaching the inserts. (3) Simplified measurement method (for measuring the outer diameter of the holder) The high precision machined outer diameter of the shank holder provides a good estimate of the runout measurement. * Runout accuracy is higher in order of (1), (2) and (3). Run-Out Adjustment with a Shank with Run-Out Adjustment Mechanism (>ø35.6mm) (1) Tighten the center locking screw to torque value A in the table below, then attach the insert and measure the runout of the cut edge. (2) Verify the tooth where runout peaks and adjust with the adjustment screw. (3) Repeat this adjustment for each tooth as necessary. (4) Remove the adjusted insert, tighten the center locking screw to torque value B in the table below, then re-attach the insert. Adjustment screw Center locking screw Recommended Tightening Torque for Center Locking Screw (N m) Holder Size Cap Screw Size A B SRK 44 C G/B M SRK 52 C G/B M SRK 61 C G/B M SRK 81 C G/B M SRK 101 C G/B M G, B Adjustment screw 110

10 Sumi Troubleshooting for Failure Countermeasures Failure Countermeasures Large Hole Reduce the run-out as much as possible (use a holder with a diameter correction mechanism). Decrease the cutting speed. Increase the feed rate. Increase the coolant concentration. Reduce the machining allowance. Check the cutting edge for damage (the existence of built-up edges). Change the reamer diameter. Return Mark Reduce the run-out as much as possible (use a holder with a diameter correction mechanism). Check the cutting edge for damage (the existence of built-up edges). Reduce the machining allowance. Change to an insert with a sharper cutting edge. Decrease the return (lifting) feed. Tapered Hole Reduce the run-out as much as possible (use a holder with a diameter correction mechanism). Decrease the cutting speed. Decrease the feed rate. Adjust the coolant concentration. Review the pre-machining process. Review the clamping method of the workpiece. Compare the hole size between when the workpiece is clamped and unclamped. Check and correct the direction of chip evacuation. Irregular Cutting Noise Decrease the coolant concentration. Increase the machining allowance. Check the cutting edge for damage. Change the approach angle of the insert cutting edge. Chatter Mark on Machined Surface Reduce the run-out as much as possible (use a holder with a diameter correction mechanism). Change the approach angle of the insert cutting edge. Review the clamping method of the workpiece. Decrease the cutting speed. Increase the feed rate. Small Hole Replace the insert. Decrease the coolant concentration. Increase the machining allowance. Increase the cutting speed. Decrease the feed rate. Poor Surface Roughness Check the cutting edge for damage. Reduce the run-out as much as possible (use a holder with a diameter correction mechanism). Check whether the cutting conditions are within the recommended range. Change to internal coolant supply. Increase the coolant concentration. Important Notes About SD Type (Center Bolt Clamp Type) This product can be used for both through-hole and Blind-hole drilling. However, the head of the center bolt protrudes from the end of the body. Therefore, ensure clearance by referring to the protrusion amount of the center bolt (A) shown in the dimension table. Through-hole Stop-hole Obstacle Bottom Face of Workpiece 111