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1 MillLine Tungaloy Report No. 429-US Exceptional productivity for aluminum and non-ferrous material machining!
2
3 MillLine V-shaped bottom secures insert on the cutter and supports high speed machining as well as helical ramping!
4 Outstanding productivity in demanding applications, such as high helical ramping, straight ramping and step milling! Secure, stable insert clamping design with unique V-shaped bottom V shape provides counter force against the cutting force and centrifugal force to stabilize the insert V-shaped clamping restricts insert movement even during high ramp machining and reduces shear force on the screw V-shaped insert bottom FE analysis Cutters V-shaped design General type Cutting force Centrifugal force Insert movement (down cutting) 3.0 µm Cutting force 10.5 µm Cutting force Counter force Stress on the screw 100% 120% Exceptional productivity is achieved with high cutting speeds (Vc) of up to sfm. Milling cutter Insert Workpiece Cutting speed Feed per tooth Depth of cut Width of cut : EPV16R125U0125W02 (ø1.25, z = 2) : XVCT160508R-AJ TH10 : Aluminum alloy : Vc = 6600 sfm : fz = ipt : ap = 0.2" : ae = 0.4" Special features of the insert pocket Coolant directed to the cutting edge Simplified screw clamping design for improved insert seating 2 face radial contact for precise 90 machining Wide axial support for superior surface finish V-shaped pocket enables stable, high speed machining 4
5 Excellent cutting edge geometry for aluminum and non-ferrous materials Helical cutting edge and high positive rake angle Polished rake face rε: 0.016" " Wiper edge Fully ground flank face High relief angle High positive, polished rake face prevents cutting edge built-up High cutting edge clearance allows steep ramping Comparison of maximum ramping angle Tool diameter ødc: ø1.500" Max. ramping angle θ Competitor A B C Applicable for a wide range of machining θ Max. ap Shouldering Pocket milling Straight ramping Slotting Profiling Helical ramping Face milling Target application Where productivity needs to be increased while maintaining accurate machining and high surface quality Components that require high precision, such as aerospace frame parts Excellent surface finish for both roughing and finishing Comparison of surface roughness Surface RoughnessRa (µm) ap = 0.059" Competitor A Competitor B Feed per toothfz (ipt) Surface RoughnessRa (µm) ap = 0.314" Competitor A Competitor B Feed per toothfz (ipt) Milling cutter Insert Workpiece Cutting speed Width of cut : EPV16R125U0125W02 (ø1.25", z = 2) : XVCT160508R-AJ TH10 : Aluminum alloy : Vc = 1970 sfm : ae = 1.00" 5
6 Cutter Bore type Max. ap = 0.512" " R Parts Descriptions Clamping screw Bit Wrench Grip Parts Cat. No. TPV16R TS40093I/HG BT15S H-TBS Cat. No. No. of Stock inserts Dimensions (in) ødc ødb ød r Lf b a Weight Air (lb) hole Max. RPM Center bolt (Option) Inserts TPV16R150U0075A with 30,000 TCS I XVCT TPV16R200U0075A with 27,000 SD XVCT TPV16R250U0100A with 24,000 SD XVCT TPV16R300U0100A with 21,000 SD XVCT TPV16R400U0150A with 19,000 SD XVCT TPV16R500U0150A with 17,000 SD XVCT Shank type R Max. ap = 0.512" " Parts Parts Cat. No. Descriptions EPV16R100 EPV16R125/150 Clamping screw TS40085I/HG TS40093I/HG Bit BT15S Wrench Grip H-TBS 6 Cat. No. No. of Dimensions (in) Stock Weight Air inserts ødc øds rs Lf L (lb) hole Max. RPM Inserts EPV16R100U0100W with 38,000 XVCT EPV16R100U0100W02L with 38,000 XVCT EPV16R125U0125W with 34,000 XVCT EPV16R125U0125W02L with 34,000 XVCT EPV16R125U0125W with 34,000 XVCT EPV16R125U0125W03L with 34,000 XVCT EPV16R150U0125W with 30,000 XVCT EPV16R150U0125W03L with 30,000 XVCT * When using inserts with corner radius rε 0.126", standard cutter body has to be modified with "R". "R" = rε " : Stockeditems
7 Inserts Cat. No. Accuracy Honing Grades Dimensions (in) TH10 A B T rε Max. ap Cutter XVCT160504R-AJ C without E/TPV16R XVCT160508R-AJ C without E/TPV16R XVCT160512R-AJ C without E/TPV16R XVCT160516R-AJ C without E/TPV16R XVCT160520R-AJ C without E/TPV16R XVCT160524R-AJ C without E/TPV16R XVCT160530R-AJ C without E/TPV16R XVCT160532R-AJ C without E/TPV16R XVCT160540R-AJ C without E/TPV16R XVCT160550R-AJ C without E/TPV16R : Stockeditems 7
8 Standard cutting conditions ISO Workpiece materials Hardness Grades Chipbreaker Cutting speed Feed per tooth Aluminum alloy Cast aluminum alloy (Si 12%) Cast aluminum alloy (Si > 12%) Copper alloys (Pb > 1%) Copper alloys Duroplastics, fiber plastics Hard rubber HB 60 TH10 AJ 100 TH10 AJ 75 TH10 AJ 90 TH10 AJ 130 TH10 AJ 110 TH10 AJ 90 TH10 AJ 100 TH10 AJ - TH10 AJ - TH10 AJ Vc (sfm) fz (ipt) Safety guidelines 1. Use only the original inserts, cutters and spare parts. 2. Insert pocket must be cleaned before clamping the insert. 3. Clamp torque of screw should be 4.5 N m. 4. For safety reasons, use a new screw when changing the insert. 5. Maximum RPM values are determined based on the burst test. Using RPM beyond maximum values may cause insert breakage, machine damage or personal injury. 6. XVCT insert has sharp cutting edges. Always wear gloves for protection from injury when handling. 8
9 Tool dia.:ødc (in), Number of revolutions:n (rpm), Feed rate:vf (ipm), Depth of cut:ap = 0.630", No. of inserts: z ø1.000" ø1.250" ø1.500" ø2.000" ø2.500" ø3.000" ø4.000" ø5.000" z = 2 z = 2 z = 3 z = 3 z = 4 z = 5 z = 5 z = 6 z = 7 n Vf n Vf n Vf n Vf n Vf n Vf n Vf n Vf n Vf 19, , , , , , , , , Vc = 5,000 sfm, fz = ipt 12, , , , , , , , , Vc = 3,300 sfm, fz = ipt 12, , , , , , , , , Vc = 3,300 sfm, fz = ipt 10, , , , , , , , , Vc = 2,600 sfm, fz = ipt 7, , , , , , , , , Vc = 2,000 sfm, fz = 0.004ipt 6, , , , , , , , , Vc = 1,600 sfm, fz = ipt 7, , , , , , , , , Vc = 2,000 sfm, fz = ipt 6, , , , , , , , , Vc = 1,600 sfm, fz = ipt 3, , , , , , , , Vc =1,000sfm, fz = ipt 2, , , , , , Vc = 660 sfm, fz = ipt 9
10 Machining applications Shoulder milling Slotting Ramping Plunging and traversing Helical interpolation Hole enlarging Feed 10 Cat. No. Tool ø ødc (in) Corner radius rε (in) Max. depth of cut ap (in) Straight ramp down Max. ramping Min. length L (in) Step down Max. plunging A (in) Min. machining ød1 (in) Helical ramp down Min. pitch/rev P (in) Max. machining ød2 (in) Max. pitch/rev P (in) enlarging Max. width ae (in) angle θ EPV16R , º EPV16R º EPV16R º EPV16R º EPV16R , º EPV16R , º EPV16R , º EPV16R º EPV16R º EPV16R º EPV16R , º EPV16R , º T/EPV16R , º T/EPV16R º T/EPV16R º T/EPV16R º T/EPV16R , º T/EPV16R , º TPV16R , º TPV16R º TPV16R º TPV16R º TPV16R , º TPV16R , º TPV16R , º TPV16R º TPV16R º TPV16R º TPV16R , º TPV16R , º TPV16R , º TPV16R º TPV16R º TPV16R º TPV16R , º TPV16R , º TPV16R , º TPV16R º TPV16R º TPV16R º TPV16R , º TPV16R , º TPV16R , º TPV16R º TPV16R º TPV16R º TPV16R , º TPV16R , º Hole
11 1.181" 3.15" 6" 4" Practical examples Workpiece type Cutter Insert Grade Airplane part Airplane part TPV16R200U0075A04 (ø2.00", z = 4) EPV16R125U0125W03 (ø1.25", z = 3) XVCT160504R-AJ XVCT160530R-AJ TH10 TH " 8" Workpiece material 59" 36" Cutting conditions Cutting speed: Vc (sfm) Feed per tooth: fz (ipt) Depth of cut: ap (in) Width of cut: ae (in) Method of machining Coolant Machine Results Workpiece type Cutter Insert Grade Number of workpiece (pcs/corner) 7,200 3, Pocket milling Wet Vertical M/C, CAT Competitor Doubled tool life! Excellent sharpness drastically reduces cutting force, achieving longer tool life. Feed rate Vf(ipm) Robot component Robot component EPV16R100U0100W02 (ø1.00", z = 2) TPV16R200U0075A04 (ø2.00", z = 4) XVCT160504R-AJ XVCT160504R-AJ TH10 TH Aluminum alloy Pocket milling Wet Vertical M/C, CAT times productivity! Competitor Lower cutting force allows higher feed machining, providing higher productivity. 20" Workpiece material 3.150" 7.85" 20" Cutting conditions Cutting speed: Vc (sfm) Feed per tooth: fz (ipt) Depth of cut: ap (in) Width of cut: ae (in) Method of machining Coolant Machine Results Feed rate Vf(ipm) ,600 3, Pocket milling Wet Vertical M/C, CAT times productivity! Competitor Due to rigid clamping, excellent surface finish can be achieved even with higher feed rates. Feed rate Vf(ipm) Slot milling Wet Vertical M/C, CAT times productivity! Competitor Sharp cutting edge reduces cutting force. This feature allows the feed to be incrcased and achieves high productivity. 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 Feb (TJ)
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