MEW End Mill. Double sided inserts with 4 cutting edges

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1 MEW End Mill Double sided inserts with cutting edges

Double sided insert with cutting edges Kyocera s

equivalent to positive type inserts. A.R.

Competitor F (egative type) Competitor G (Positive

type type Chipbreaker Application he M GM MAX.

2 Double sided insert with cutting edges Kyocera s unique molding technology reduces cutting force equivalent to positive type inserts. A.R. Max+ Tough cutting edge 9 High rake angle lowers cutting force. Unique mold technology MEW GM Chipbreaker Competitor F (egative type) Competitor G (Positive type) chipbreakers for various plication type type Chipbreaker Application he M GM MAX. mm M GM MAX. mm GM General Purpose GH GH M Low Cutting Force GH Tough Edge Cutting Condition Vc=m/min ae=φd/

Minimized chattering and improved surface finish mooth surface

$Comparison of fracture resistance Cutting Force () 1 1 1 1 17%$ Competitor A (egative type) 9% Competitor B (egative type) Equivalent

(Positive type) MEW GM Chipbreaker Competitor D (egative type)

(mm) Feed Rate (mm/t)..5 Vc=m/min ae= mm fz=.

5mm/t CrMo (7~9Hs) Cutterφ MEGACOAT AO for Extended Tool Life High

PR5 for stainless steel PR5 for steel. PR for cast iron.

3 Minimized chattering and improved surface finish mooth surface finish, without chattering. Less burrs due to sharp cutting. MEW Competitor H MEW Competitor I Comparison of cutting force Comparison of fracture resistance Cutting Force () % Competitor A (egative type) 9% Competitor B (egative type) Equivalent to positive type inserts % 9% MEW GM Chipbreaker Competitor C (Positive type) MEW GM Chipbreaker Competitor D (egative type) Competitor E (egative type) 5 Further machining possible Cutting Time (mm) Feed Rate (mm/t)..5 Vc=m/min ae= mm fz=.mm/t C5 Cutterφ Vc=1m/min ae= mm fz=.~.5mm/t CrMo (7~9Hs) Cutterφ MEGACOAT AO for Extended Tool Life High hardness and superior oxidation resistance. PR5 for stainless steel PR5 for steel. PR for cast iron. CA55 for Heat resistant Alloy. MEGACOAT Multilayered coating technology 5 MEGACOAT AO Hardness (GPa) 5 TiC Ti TiAI MEGACOAT 1 1 Carbide substrate.nm low Oxidation Temperature ( C) Oxidation Resistance high

4 MEW End Mill φd. ℓ φd h + L φd. Fig. 1 φd h + ℓ L Fig. Fig. φd. φd h + ℓ L Fig. 5 Fig. Fig. MEW 11T 11T 1T T 5T 5T 5T 5T 5T 55T MEW 11T T T 55T 55T T T MEW T 5517T MEW 5T 5T T T 5T MEW 55T T T MEW W5T WT MEW 1W1T WT WT 5W5T 5W5T WT MEW 5W5T WT o of Insert 5 5 Dimension (mm) ød ød L l Rake Angle ( ) A.R. (MAX) R.R Coolant Hole ame hank ize ame hank ize Weldon Reduced ame hank hank ize Reduced hank Long Cylindrical Reduced hank tandard Toolholder Dimension Drawing o Fig.1 Fig. Fig. Fig. Fig. Fig. Fig Fig.5 Fig. Fig. (min1) Max. Revolution,75, 1, 9, 7,5 5,,,9,,5,75 1, 1, 7,5 7,5,9,9 1, 7,5 5,, 5, 5, 17, 5,,,, 5,,75 1, 1, 7,5 7,5,9 5,, Caution about the Max. Revolution When running an end mill or a cutter at the maximum revolution, the insert or cutter may be damaged by centrifugal force. : td. Item : Check Availability

MP1 MEW Face Mill φd b H E a φd φd1 φd Fig. 1 Toolholder Dimension tandard o of Insert Dimension (mm) Rake Angle ( ) ød ød ød1 ød H E a b A.R. (MAX) Caution about the Max.

5 MP1 MEW Face Mill φd b H E a φd φd1 φd Fig. 1 Toolholder Dimension tandard o of Insert Dimension (mm) Rake Angle ( ) ød ød ød1 ød H E a b A.R. (MAX) Caution about the Max. Revolution When running an end mill or a cutter at the maximum revolution, the insert or cutter may be damaged by centrifugal force. R.R. Coolant Hole Drawing (kg) (min 1 ) weight Max. Revolution MEW RTM 5.1, R5TM., 5 +7 Fig.1 5R5TM , RTM.5,5 MEW RTM ,75 5RTM , R5TM 5 + Fig.1.5 1, RTM ,5 1 5 RT , pare Parts and Applicable Inserts pare Parts Applicable Inserts Clamp crew Wrench Antiseize Compund Mounting bolt MEW _T MEW R_M B5TRP DTPM R_M MP1 HHx5 1. m 5R_M Recommended torque for insert clamp R_M HHx MEW _T MEW R_M B9TRP DTPM HHx5 5R_M MP1.5 m R_M Recommended torque for insert clamp HHx R_(M) HH1x5 MP1 Coat Antiseize Compound (MP1) thinly on portion of ter and thread when insert is fixed. General Purpose Low Cutting Force Tough Edge..ERGM 5..ERGM..ERM 5..ERM..ERGH 5..ERGH Recommended Cutting conditions see page 7 Wrenches and clamp screws are Torx Plus. 1) ee Fig. 1 for Torx Plus Wrench. (Blue grip) ) ee Fig. for Torx Wrench. (Black grip) IP Fig. 1 Torx Plus Wrench (For MEW) T Fig. Torx Wrench (Do OT use it for MEW) : td. Item : Check Availability 5

MEW (screw on type) EW ød +. A L1 M1 H ød1 A B ød1 AA cross section L Toolholder Dimension tandard o. of Insert Dimension (mm) Rake Angle ( ) ød ød1 ød1 L L1 M1 H B A.R. (MAX) MEW 1MT 1 1.7.5 5 M P1.

6 MEW (screw on type) EW ød +. A L1 M1 H ød1 A B ød1 AA cross section L Toolholder Dimension tandard o. of Insert Dimension (mm) Rake Angle ( ) ød ød1 ød1 L L1 M1 H B A.R. (MAX) MEW 1MT M P1.5 1 MT M P1.5 9 R.R. Coolant Hole Applicable Inserts Max. spindle revolution (min 1) MT M P , 5M1T M1 P ,5,75 1, M1T 17 M1 P 1,9 MEW 5M1T M1 P , + 5 M1T 17 M1 P 1, Caution about the Max. Revolution When running an end mill or a cutter at the maximum revolution, the insert or cutter may be damaged by centrifugal force. pare Parts and Applicable Inserts Clamp crew pare Parts Wrench Antiseize Compound Applicable Inserts General Purpose Low Cutting Force Tough Edge MEW 1MT MT MT B5TRP DTPM 5M1T for Insert Clamp Recommended torque is 1. m. M1T MEW 5M1T B9TRP DTPM for Insert Clamp M1T Recommended torque is.5 m. MP1 MP1 ERGM 5ERGM ERM 5ERM ERGH 5ERGH Coat Antiseize Compound (MP1) thinly on portion of ter and thread when insert is fixed. crew on type Identification ystem MEW 1 M T eries Cutting Dia. Thread Insert ize o. of Flute : td. Item : Check Availability

BT Arbor EW L Applicable End Mill Applicable Arbor ød1 ød1 l1 l M1 Coolant Hole (Center Through ytem) Toolholder Dimension tandard Dimension (mm) L ød1 ød1 l1 l M1 Coolant Hole Arbor size Applicable

7 BT Arbor EW L Applicable End Mill Applicable Arbor ød1 ød1 l1 l M1 Coolant Hole (Center Through ytem) Toolholder Dimension tandard Dimension (mm) L ød1 ød1 l1 l M1 Coolant Hole Arbor size Applicable End Mill BTK M M P1.5 MEW1M M M P1.5 BT MEWM M 1.5 M1 P1.75 MEW5M1 BTK M M P1.5 MEW1M M M P1.5 MEWM 9 BT M M1 P1.75 MEW5M1 M M1 P MEWM1 Effective depth of assembled tool Applicable End Mill Arbor Cutting Dia. ød Dimension L1 M L ød BTK M5 MEW1M ø M5 MEWM ø.. L1 M L M MEW5M1 ø BTK M55 MEW1M ø M MEWM ø.7.7 M5 MEW5M1 ø M MEWM1 ø Arbor Identification ystem BT K M 5 Arbor ize Twoface clamping spindle Thread Length L : td. Item : Check Availability 7

8 Applicable Inserts Classification of usage P Carbon teel / Alloy teel Mold teel M tainless teel : Roughing / 1st Choice : Roughing / nd Choice : Finishing / 1st Choice : Finishing / nd Choice (In case hardness is under 5HRC) K Gray Cast Iron odular Cast Iron onferrous Material Heatresistant Alloy Titanium Alloy H Hard Materials Insert (rε) MEGACOAT AO CVD PR5 PR5 PR CA55 ERGM. ERGM. General Purpose.9 1ERGM φ. ERM.. Low Cutting Force ERGH. Tough Edge 5ERGM. 5ERGM. 5ERGM 1. General Purpose.7 1. φ. 51ERGM ERM. Low Cutting Force 5ERGH. Tough Edge : tandard Item Chipbreaker Application Range type type M GM MAX. mm M GM MAX. mm GH GH Cutting Condition Vc=m/min ae=φd/

9 ~ ~ ~ ~ Recommended Cutting Conditions Chipbreaker GM M GH fz (mm/t) Vc (m/min) Recommended Insert Grade Workpiece Material Toolholder s MEGACOAT AO CVD MEW1~MEW1 MEW~MEW5 MEWR~MEWR PR5 PR5 PR CA55 Carbon teel.~.1~..~.~.5 1~1~5 Alloy teel.~.1~.1.~.~. ~1~ Mold teel.~.~.1.~.1~. ~1~1 Austenitic tainless teel.~.~.1.~.1~. ~1~ ~1~ Martensitic tainless teel.~.~.1.~.1~. ~~5 1~~ Precipitation Hardened tainless teel.~.~.1.~.1~. 9~1~ Gray Cast Iron.~.1~.17.~.1~.5 1~1~5 odular Cast Iron.~.~.1.~.~. ~~ ibase Heat resistant Alloy.~.~.1.~.1~. ~~5 ~~5 Titanium Alloys.~.~.1.~.~. ~~ ~5~7 Carbon teel.~.1~.17.~.~. 1~1~5 Alloy teel.~.~.1.~.1~.1 ~1~ Mold teel.~.~.1.~.1~. ~1~1 Austenitic tainless teel.~.~.1.~.1~. ~1~ ~1~ Martensitic tainless teel.~.~.1.~.1~. ~~5 1~~ Precipitation Hardened tainless teel.~.~.1.~.1~. 9~1~ ibase Heat resistant Alloy.~.~.1.~.1~.1 ~~5 ~~5 Titanium Alloys.~.~.1.~.1~.1 ~~ ~5~7 Carbon teel.~.1~..~.~.5 1~1~5 Alloy teel.~.1~.1.~.~. ~1~ Mold teel.~.~.1.~.1~. ~1~1 Austenitic tainless teel.~.~.1.~.1~. ~~ Gray Cast Iron.~.1~..~.~. 1~1~5 odular Cast Iron.~.~..~.1~.5 ~~ Titanium Alloys.~.~.1.~.1~.1 ~5~7 Machining with coolant is recommended for ibase Heat Resistant Alloy and Titanium Alloy. : 1st Recommendation : nd Recommendation Cutting Performance houldering (ae=φd/) lotting houldering (ae=φd/) lotting MEW1 MEW1 MEW MEW5 MEW T MEW55 17T Long hank MEWR MEWR MEW5 MEW5 MEWR MEWR Cutting Conditon: Vc=1m/min, GM Chipbreaker, Workpiece C5, Overhang Length 1.End mill: Overhang length is "l" of the dimension list.face mill: Overhang length is "H" of the dimension list + minimum arbor overhang

How to mount inserts 1. Remove dust and chips from the insert mounting pocket.. Apply antiseize compound on portion of ter and thread of clamp screw.

b) While lightly pressing the insert against the constraint surfaces, put the screw into the hole of the insert and tighten. (ee Fig. 1.

. When tightening the screw, make sure that the wrench is parallel to the screw. For recommended torque, refer table on page 5.

insert side surfaces and the constraint surface of the holder.

How to attach modular type head 1. When clamping the head on the arbor, make sure there is no dust or chips inside (Fig. 1).

10 How to mount inserts 1. Remove dust and chips from the insert mounting pocket.. Apply antiseize compound on portion of ter and thread of clamp screw. a) Attach the screw (magnetc head) to the front end of the wrench. b) While lightly pressing the insert against the constraint surfaces, put the screw into the hole of the insert and tighten. (ee Fig. 1.) c) Tighten M screws (B5TRP) slightly inclined from the insert surface (ee Fig. ).. When tightening the screw, make sure that the wrench is parallel to the screw. For recommended torque, refer table on page 5.. After tightening the screw, make sure that there is no clearance between the insert seat surface and the bearing surface of the holder or between the insert side surfaces and the constraint surface of the holder. If there is any clearance, remove the insert and mount it again according to the above steps. θ Wrench Clamp crew Fig. 1 θ Fig. How to attach modular type head 1. When clamping the head on the arbor, make sure there is no dust or chips inside (Fig. 1). Do OT put lubricant on the clamping portion.. Attach the head on the arbor and fix it using the wrench (Fig. ). ee table 1 for recommended torque. ote) The wrench is OT included in the products.. Confirm that the head is fixed firmly on the arbor (Fig. ). Fig.1 Ensure there are O chips between the arbor and head Table 1 Recommended Head Torque Thread Dia Tolerance Wrench Width Recommended torque m M 1 M M1 19 M1 9 Fig. ee Table 1 for the wrench size and recommended torque Fig. o space In between

Case tudies 1. 1. Constructions equipments part Vc=5/min xae=xmm fz=.1mm/t (Vf=1,5mm/min) with liquid coolant MEWT ERGM (PR5) Machine part Vc=5/min xae=xmm (Grooving) fz=.

11 Case tudies Constructions equipments part Vc=5/min xae=xmm fz=.1mm/t (Vf=1,5mm/min) with liquid coolant MEWT ERGM (PR5) Machine part Vc=5/min xae=xmm (Grooving) fz=.mm/t (Vf=,9mm/min) with air coolant MEWT ERGM (PR5) PR5 Chip Removal Rate = cc/min PR5 Chip Removal Rate = 1cc/min (stable milling) Competitor A (positive type) Chip Removal Rate = 7cc/min Competitor B (positive type) Chip Removal Rate = 11cc/min (unstable) MEW showed stable milling without chattering at higher feed improving productivity %. Burrs were prevented and excellent surface finish was achieved. o chattering with MEW, while Competitor B chattered at the same cutting condition. o burrs with MEW and excellent surface finish. 5PH (HRC) XCrMoV51 (5HRC) Aircraft part Vc=1/min xae=x5mm fz=.1mm/t (Vf=71mm/min) with liquid coolant MEWT 5ERGM (PR5) 1 5 Mold part Vc=/min xae=.5xmm fz=.1mm/t (Vf=mm/min) with air coolant MEWT ERGH (PR5) PR5 Chip Removal Rate = cc/min (further milling possible) PR5 Chip Removal Rate =cc/min (further milling possible) Competitor C (positive type) Chip Removal Rate = 7cc/min (unable to continue) Competitor D (positive type) Chip Removal Rate = 1cc/min (unable to continue) o chattering and more stable milling is possible with MEW. PR5 kept good cutting edge form, minimizing wear and adhesion. MEW doubled productivity and realized a drastic cost cutting, due to double sided insert. Vertical Milling ae Insert size Maximum width of Cut (ae) type type 5mm 7mm Ramping and helical milling not recommend because of interference between insert and workpiece. 11

12 GERMAY KYOCERA UIMERCO Tooling GmbH Hammfelddamm 1 euss Phone +9 () Fax +9 ()11 17 kutde@kyoceraunimerco.com ITALY KYOCERA UIMERCO Tooling GmbH, Italy Branch Via Torino 51 1 Milan Phone +9 5 Fax +9 kutde@kyoceraunimerco.com PAI KYOCERA UIMERCO Tooling GmbH, pain Branch Avenida Manacor 9 Las Matas, Madrid Phone Fax kutde@kyoceraunimerco.com POLAD KYOCERA UIMERCO Tooling p. z o.o. ul. Gwiaździsta, 51 Wrocław Phone (+) Fax (+) kutde@kyoceraunimerco.com FRACE KYOCERA Fineceramics.A.. 1 Rue de Villeneuve 95 Rungis Phone + () Fax + () kutde@kyoceraunimerco.com DEMARK KYOCERA UIMERCO Tooling A/ Drejervej DK751 unds Phone Fax umdk@unimerco.com ORWAY KYOCERA UIMERCO Tooling A/ Karihaugveien 9 Oslo Phone +7 7 Fax +7 9 umno@unimerco.com WEDE KYOCERA UIMERCO Tooling AB agaholmsvägen 9 55 Jönköping Phone + Fax + 1 umse@unimerco.com UITED KIGDOM KYOCERA UIMERCO Tooling Ltd. 1 Attercliffe Road heffield 7WW Phone + () Fax + () uksales@unimerco.com TZE51

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