Stable parting-off operations due to unique clamping system
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1 GrooveLine Tungaloy Report No. 504-US DUOJUST-CUT Stable parting-off operations due to unique clamping system
2 ACCELERATED MACHINING
3 GrooveLine DuoJust-Cut, a new line of small tools with a durable insert with 2 cutting edges, that is excellent for parting miniature parts up to 0.630" diameter.
4 Great cutting performance in various parting-off operations 3 types of inserts that are available for different parting-off diameters. All 3 can be mounted in the same pocket of the toolholder. - Optimized overhang length for stable machining Regular-type toolholder Toolholder for sub-spindle JXPG06 Max. parting-off dia. ø0.236" JXPG12 Max. parting-off dia. ø0.472" JXPG16 Max. parting-off dia. ø0.630" Toolholder for sub-spindle - Works between main and sub-spindles Right hand Left hand 4 DuoJust-Cut
5 ACCELERATED MACHINING Unique clamping system for highly rigid clamping Holds the insert at 3 points - Unique clamping pocket protects unused cutting edge. - Even if the first cutting edge is chipped, the other unused cutting edge can be used because the insert is clamped in the center. SH725, new PVD grade for small lathes - PVD grade designed for precision part machining - Good balance between hardness and sharpness - High adhesion strength of the coating Application Range HIGH HIGH Hardness of layer Sharpness Cutting speed: Vc Vc (m/min) (sfm) LOW LOW Compressive residual stress on layer LOW HIGH (Image) Continuous cut Light-interrupted cut interrupted cut Provides stable machining on small lathes 5
6 CUTTING PERFORMANCE Cutting edge positions during machining Cutting edge position (inch) Competitor A Competitor B Measuring point Number of machined passes Process: Measure 1 machining Measure 2 Displacement of cutting edge position = Difference between Measure 1 & 2 Toolholder : JSXXL083-S Insert : JXPG16L20F / SH725 Workpiece material : 1045, 170HB Cutting speed : Vc = 330 sfm Feed : f = ipr Groove width : W = 0.079" Machining : Parting-off (ø0.630") Coolant : Wet Machine : Swiss lathe DuoJust-Cut s 3 point clamping system is highly rigid, providing stable machining with small displacement of the cutting edge position. Tool life of regular-type toolholder: Carbon steel Flank wear VB max (inch) Competitor B Competitor A Still possible to continue machining Number of workpieces (pcs/edge) SH725 1,800 pcs Competitor A Competitor B 1,800 pcs 10 pcs Toolholder : JSXXL083 Insert : JXPG16L20F / SH725 Workpiece material : 1045, 210HB Cutting speed : Vc = 500 sfm Feed : f = ipr ( ø0.08" : ipr) Groove width : W = 0.079" Machining : Parting-off (ø0.630") Coolant : Wet Machine : Swiss lathe DuoJust-Cut extends tool life and reduces flank wear on steel machining due to improved clamping rigidity and wear resistance. Tool life of regular-type toolholder: Stainless steel Number of workpieces (pcs/edge) Toolholder : JSXXL083 Insert : JXPG16L20F / SH725 Workpiece material : S30300, 230HB Cutting speed : Vc = 390 sfm Feed : f = ipr ( ø0.08" : ipr) Groove width : W = 0.079" Machining : Parting-off (ø0.630") Coolant : Wet Machine : Swiss lathe SH725 Competitor A Competitor B 70 pcs 60 pcs 10 pcs Tool life of DuoJust-Cut in stainless steel machining is longer than the competitors. 6 DuoJust-Cut
7 ACCELERATED MACHINING "J-series" Parting-off tool for swiss lathes TOOLHOLDERS - FOR PARTING-OFF DuoJust-Cut JSXXR/L L1 f b h2 h1 h Right-hand (R) shown. Designation h b f L1* h1 h2 Insert JSXXR/L JXPG06,12,16R/L JSXXR/L JXPG06,12,16R/L JSXXR/L JXPG06,12,16R/L * L1" is calculated with JXPG16*** insert. When JXPG12*** insert is used, "L1" is shorter 0.079". When JXPG06*** insert is used, "L1" is shorter 0.158". Note: The right hand insert (JXPG**R***) is used for the right hand toolholders (JSXXR***), and the left hand insert (JXPG**L***) is used for the left hand toolholders (JSXXL***). SPARE PARTS Designation Clamping screw Wrench JSXXR***** CSTC-4L100DL T-1008/5 JSXXL***** CSTC-4L100DR T-1008/5 HOW TO SELECT TOOLS Large-diameter machining of workpiece with rigitity Main-spindle tooling Sub-spindle tooling Small-diameter machining of workpiece with short overhang Sub-spindle tooling Workpiece with long overhang Short workpiece at the side of sub-spindle for with low rigitity the process after parting-off Application Main spindle Sub-spindle Main spindle Sub-spindle Main spindle Sub-spindle Main spindle Position of parting-off is at the side of the main spindle Position of parting-off is at the side of the sub-spindle Position of parting-off is at the side of the main spindle Position of parting-off is at the side of the sub-spindle Toolholder R-hand (JSXXR type) L-hand (JSXXL type) R-hand (JSXXR-S type) L-hand (JSXXL-S type) Insert Right-hand insert with lead angle to remove center core (JXPG**R***-15 type) Left-hand insert (JXPG**L*** type) Right-hand insert (JXPG**R*** type) Left-hand insert (JXPG**L*** type) 7
8 "J-series" Parting-off tool for sub-spindle in swiss lathes TOOLHOLDERS - FOR PARTING-OFF IN SUB-SPINDLE DuoJust-Cut JSXXR/L-S L1 h1 L3 f b h2 f2 f h L3 f2 Right-hand Left-hand Designation h b f L1* L3* h1 h2 f2 Insert JSXXR/L063-S / JXPG06,12,16R/L JSXXR/L083-S / JXPG06,12,16R/L * "L1" and "L3" are calculated with JXPG16*** insert. When JXPG12*** insert is used, "L1" and "L3" are shorter 0.079". When JXPG06*** insert is used, "L1" and "L3" are shorter 0.158". Note: The right hand insert (JXPG**R***) is used for the right hand toolholders (JSXXR***), and the left hand insert (JXPG**L***) is used for the left hand toolholders (JSXXL***). SPARE PARTS Designation Clamping screw Wrench JSXXR*****-S CSTC-4L055DL T-1008/5 JSXXL*****-S CSTC-4L055DR T-1008/5 HOW TO SELECT TOOLHOLDERS FOR SUB-SPINDLE L1 b Parting-off diameter Sub-spindle diameter Sub spindle dia. Max parting off dia. Shank size b Tool length L1 Insert Toolholder ø1.574 ~ ø JXPG06* JSXXR/L063-S ø1.574 ~ ø JXPG06* JSXXR/L083-S ø1.574 ~ ø JXPG12* JSXXR/L063-S ø1.574 ~ ø JXPG12* JSXXR/L083-S ø1.574 ~ ø JXPG16* JSXXR/L063-S ø1.574 ~ ø JXPG16* JSXXR/L083-S ø1.969 ~ ø JXPG06* JSXXR/L083-S ø1.969 ~ ø JXPG12* JSXXR/L083-S ø1.969 ~ ø JXPG16* JSXXR/L083-S ø1.969 ~ ø JXPG16* JSXXR/L083-S 8 DuoJust-Cut
9 ACCELERATED MACHINING INSERT JXPG06R/L-F (Sharp edge) JXPG12R/L-F (Sharp edge) rε rε rε W θ L W θ L W θ L Right-hand (R) shown. Right-hand (R) shown. Grade Dimensions (inch) Designation SH725 R L Dmax W rε L θ (deg) JXPG06R/L10F JXPG06R/L15F JXPG06R/L10F JXPG06R/L15F : Stocked items Note: Dmax: Max. parting-off dia. Grade SH725 Dimensions (inch) Designation R L Dmax W rε L θ (deg) JXPG12R/L15F JXPG12R/L20F JXPG12R/L15F JXPG12R/L20F : Stocked items Note: Dmax: Max. parting-off dia. JXPG16R/L-F(Sharp edge) rε W θ L Right-hand (R) shown. Grade Dimensions (inch) Designation SH725 R L Dmax W rε L θ (deg) JXPG16R/L15F JXPG16R/L20F JXPG16R/L15F JXPG16R/L20F : Stocked items Note: Dmax: Max. parting-off dia. 9
10 STANDARD CUTTING CONDITIONS ISO Workpiece materials Low carbon steels (1015, etc.) Carbon steels, Alloy steels (1055, etc.) Prehardened steels (NAK80, PX5, etc.) Stainless steels (S30400, etc) Aluminum alloys (5056, 6061, etc) Copper alloy (C2600, C280C, etc) Titanium alloys (Ti-6AI-4V, etc.) Grades Cutting speed Vc (sfm) Feed f (ipt) SH SH SH SH SH SH SH Superalloys (Inconel718, etc.) SH MAX. PARTING-OFF DIA. & DEPTH Main-spindle tooling Sub-spindle tooling ød1 ød " 0.031" Main spindle Sub-spindle Main spindle The cutting edge reaches 0.031" beyond the center line in parting-off. ød1 = Max. parting-off dia. 10 DuoJust-Cut
11 ACCELERATED MACHINING PRACTICAL EXAMPLES Workpiece type Toolholder Insert Grade Hydraulic component JSXXL083-S JXPG16L20F SH725 S30400 Torque limiter JSXXL083-S JXPG12L15F SH725 Low carbon alloy Workpiece material ø12 ø9.5 ø13.5 Cutting conditions Cutting speed: Vc (sfm) Feed : f (ipr) Groove width : W (inch) Machining Coolant Results Workpiece type Toolholder Insert Grade Tool life (pcs / edge) Parting-off Wet Competitor Injection parts JSXXL083-S JXPG12L20F SH725 S times tool life! DuoJust-Cut doubles tool life and provides excellent surface finish due to highly rigid insert clamping. Parting-off Wet Excellent chip control Competitor Chip control of DuoJust-Cut is better than the competitor s even in parting-off of thin workpiece. Also, the DuoJust-Cut insert with sharp cutting edge provides stable machining without chattering. Workpiece material ø6 ø18 Cutting conditions Cutting speed: Vc (sfm) Feed : f (ipr) Groove width : W (inch) Machining Coolant Results Tool life (pcs / edge) Parting-off Wet 1.3 times tool life! 0 Competitor DuoJust-Cut extends tool life to 130% and reduces burrs due to the sharp cutting edge. 11
12 Tungaloy America, Inc N Ventura Drive, Arlington Heights, IL 60004, U.S.A. Inside Sales: Technical Support: Fax: Tungaloy Canada 432 Elgin St. Unit 3, Brantford, Ontario N3S 7P7, Canada Phone: Fax: Tungaloy de Mexico S.A. C Los Arellano 113, Parque Industrial Siglo XXI Aguascalientes, AGS, Mexico Phone: Fax: Scan for instant web access follow us at: facebook.com/tungaloyamerica t w i t t e r. c o m / t u n g a l o y To see this product in action visit: Distributed by: DOWNLOAD Dr. Carbide App Apr (TA)
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