MSRS90. Hi efficiency Notched and No-hand insert for MSRS90

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Gladys Howard
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1 MGCO MR90 Multiple Cutter i efficiency Notched nd Nohnd insert for MR90 1Notched insert reduces cutting force reduction t the first pss tle mchining without chtter 2mooth chip evcution Prevents frcture cused y iting chips 3MGCO for long tool life igh mchining efficiency nd cutting cost reduction Vrious expnsive possiilities. ville for vrious type of ppliction with custom order cutter Milling insert with cornerr (no hnd) ville for vrious type of ppliction such s shouldering (cutting ngle: 90 degrees), high feed cutting (30 degrees), plunging nd side cutter. (custom order)

MR90 Multiple Cutter Fetures of MR90 Vrious cutting edge length ccording to cutting conditions 4stge

i efficiency cutter with low cutting force nd smll virtion mooth chip evcution MGCO for long tool

5mm i efficiency Notched nd Nohnd insert Vrious expnsive possiilities due to nohnd insert with

strength nd frcture resistnce for long tool life 0 200 400 00 800 1000 1200 Oxidtion temperture (ºC)

8mm Notched insert reks chips into smll pieces nd reduces cutting force.

cutting edge strength nd notch reduces the cutting force For right/left hnd ville for vrious cutting

2 MR90 Multiple Cutter Fetures of MR90 Vrious cutting edge length ccording to cutting conditions 4stge type (ø80,ø100) ville in ddition to 1stge nd 2stge types. i efficiency cutter with low cutting force nd smll virtion mooth chip evcution MGCO for long tool life Mx 0mm Mx 1.5mm i efficiency Notched nd Nohnd insert Vrious expnsive possiilities due to nohnd insert with cornerr MGCO for long tool life MGCO rdness(gp) ic icn in MGCO iln MGCO with high strength nd frcture resistnce for long tool life Oxidtion temperture (ºC) Notched insert for low cutting force 3.8mm Notched insert reks chips into smll pieces nd reduces cutting force. ville for high feed cutting due to lower cutting force t the first pss econd lnd improves the cutting edge strength nd notch reduces the cutting force For right/left hnd ville for vrious cutting ngle Cutting edge length 18mm first lnd rke fce Conventionl rke fce Improve the edge strength second lnd New design first lnd Low cutting force (effect of notched insert) Comprison of cutting force (N) (N) dge preprtion Notched insert relizes low cutting force nd smll virtion 1 evy virtion Comp. Low cutting force nd smll virtion MR90

3 ppliction rnge (stndrd toolholder) MR p X e(mm) MR90 MC fz(mm/t) Insert crosssection.(ville for vrious type of ppliction with new Inserts) ppliction Purpose 3 notches 4 notches Without notch Generl purpose 1st Recommendtion tndrd type NB3 + NB4 Low cutting force oriented mphsis on edge strength Low resistnce type Without notch (Possile to use notched insert) ( NB3P + NB4P or ) + NB3 NB4 Vrious expnsive possiilities (custom order nd stndrd) ide cutter igh feed cutter Plunge cutter pered cutter houlder cutter Bck milling cutter hft length determintion Fce mill Left hnd cutter Fce mill Right hnd cutter 2

MR90 Rke ngle.r. R.R. +7 1 2 1 1 2 1 3 G 3 5 G G fig.1 2 1 fig.2 fig.3 fig.4 3 G 4 4 4 ØC 1 ØC ØC1 ØC fig.5 fig. fig.7 fig.8 older dimension Description tock No. of Insert No. of Line No.

5 fig.1 1.4 0 90080R24 8 4 2 80 31.75 27 18 32 8 12.7 31 fig.2 1.2 90080R44 1 4 4 90 0 fig.3 1.5 90100R1 1 1.5 fig.1 2.3 70 90100R2 12 2 100 38.1 39 21 38 10 15.9 31 fig.2 2.1 90100R4 24 4 90 0 fig.

4 MR90 Rke ngle.r. R.R G 3 5 G G fig fig.2 fig.3 fig.4 3 G ØC 1 ØC ØC1 ØC fig.5 fig. fig.7 fig.8 older dimension Description tock No. of Insert No. of Line No. of tge Dimension(mm) ød ød ød1 ød2 ød3 ød4 ød5 ød G hpe Weight (kg) 3 Bore ød:mm Bore ød:inch With Crtridge Without Crtridge With Crtridge Without Crtridge MR 90080R fig R fig R fig R fig R fig R fig R fig R fig MR 9010R fig R fig R fig R fig R fig R fig R fig R MR 90080R14M fig R24M fig R44M fig R1M fig R2M fig R4M fig R18M fig R28M 受 fig MR 9010R18M fig R28M 受 fig R110M fig R210M 受 fig R112M fig R212M 受 fig R114M fig R214M 受 :tndrd tock :Mde to Order

5 pplicle Insert MGCO ngle( ) Dimension (mm) hpe Description ød PR1230 PR1210 PM 1801NNB4 PM 1801NNB3P 3 notches PM 1801NNB notches 3 notches Low resistnce type notches Low resistnce type PM 1801NNB4P Without notch PM 1801NV :tndrd tock Cution when instlling notched Insert It is importnt to instll the pproprite notched insert into the correct position. Filure to do so my result in dmge to the cutter ody. he pproprite insert is mrked on the pocket of the cutter ody. ow to instll the insert Refer Pge 5 No. of No. of No. of Insert Line tge Description MR 90100R R R4 24 No. of Inserts Notched NB3(P) NB4(P) pre prts pre Prts Clmp crew Wrench Crtridge Clmp crew Wrench ntiseize Compound rr Clmp crew Description MP 1 MR 90080R MR 90100R MP180M 1 MP180 2 B40140R D MR 90125R 8 MR 9010R 8 MR 90080R 4M MR 90100R M MR 90125R 8M MR 9010R 8M 90315R 14M for Crtridge Clmp ightening orque 90315R 14 With Crtridge Without Crtridge With Crtridge Without Crtridge (Only ottom edge should e used) B0120R 25L for Insert Clmp ightening orque MP1 MP180M 1 MP180 2 B40140R D for Crtridge Clmp ightening orque Note) *1: MP180M is only for MR90..R1..crtridge *2: MP180 is only for MR90..R2..ottom edge (1st stge) crtridge. his crtridge is used for ottom edge (1st stdge) only. ow to ttchcrtridge:o fix the crtridge, tighten the slnt screw t first, then tighten the other screw. 1 MP Cot ntiseize Compound (MP1) thinly on clmp screw when insert is fixed. 4

ow to instll the insert Instlltion of Notched Inserts

surfce numer to the numer on the holder me numer me

Remove chips or ny dust from the insert pocket. 2.

Plese use only the ttched wrench (25L) for insert

* Inserts might not e clmped properly when using

for Insert Clmp ightening orque ttched wrench (25L)

6 ow to instll the insert Instlltion of Notched Inserts When instlling the inserts, mtch the insert s top surfce numer to the numer on the holder me numer me numer Insert Replcement Procedure 1.Remove chips or ny dust from the insert pocket. 2.Instll inserts y pushing down the insert with finger. 3.Plese use only the ttched wrench (25L) for insert instlltion. * Inserts might not e clmped properly when using different wrench. for Insert Clmp ightening orque ttched wrench (25L) Other wrench 4.fter instlling the insert, ensure there is no gp etween the insert nd the crtridge. No gp Gp 5.fter ech use, dditionl clmping is recommended using the ttched wrench. 5

Recommended Cutting Conditions Feed Rte (mm/t) Cutting peed (m/min)

PR1230 MGCO PR1210 oft teel() 0.1~0.2~0.25 0.1~0.2~0.25 Cron teel(xxc) 0.

1~0.15~0.2 0.1~0.12~0.15 Gry Cst Iron(FC) 0.1~0.2~0.3 0.1~0.2~0.25 Nodulr Cst Iron(FCD) 0.

2 120~150~220 120~150~220 100~150~200 100~150~200 100~150~200 100~150~200

tinless teel(u304) Not Recommended Nonferrous Metls Not Recommended :1st

cutter 45 degrees fce mill Plunge cutter pered cutter ide cutter Vrious

7 Recommended Cutting Conditions Feed Rte (mm/t) Cutting peed (m/min) Workpiece Mteril tndrd type NB3 + NB4 Low resistnce type NB3P + NB4P PR1230 MGCO PR1210 oft teel() 0.1~0.2~ ~0.2~0.25 Cron teel(xxc) 0.1~0.2~ ~0.2~0.25 lloy teel(cm) 0.1~0.15~ ~0.15~0.2 Die teel(kd/nk) 0.1~0.15~ ~0.12~0.15 Gry Cst Iron(FC) 0.1~0.2~ ~0.2~0.25 Nodulr Cst Iron(FCD) 0.1~0.2~ ~0.18~ ~150~ ~150~ ~150~ ~150~ ~150~ ~150~ ~150~ ~150~ ~180~ ~180~ ~180~ ~180~220 tinless teel(u304) Not Recommended Nonferrous Metls Not Recommended :1st Recommendtion :2nd Recommendtion Vrious custom order cutters igh feed cutter 45 degrees fce mill Plunge cutter pered cutter ide cutter Vrious types of cutter design ville to meet with your conditions, such s cutting dimeter, cutting ngle nd cutting edge length (stges), etc.

Cse studies FCD450 CM420 Industril prts Cutter nd inserts MR90100R1(ø100 edges) PM1801NNB3/NB4 (PR1210) Vc=150 m/min p e= 5 mm fz=0.

1mm/t (Vf=400mm/min) 500mm MR90(PR1210) Chip removl 258cc/min. MR90(PR1230) Chip removl 200cc/min. Comp.B 107cc/min. Comp.C 153cc/min.

Cutting time reduced Results MR90 improved cutting efficiency to 1.3 times compred with comp. C. Comp. C: pxe=5x50mm ool cost reduced to 1/3 since comp. C is 2cornered insert.

vlution y the user vlution y the user KD NCM hip prts Cutter nd inserts MR9010R18(ø10 8 edges) PM1801NNB3/NB4 (PR1230) Vc=150 m/min p e=10 10 ~50 mm fz=0.

15mm/t (Vf=500mm/min) 740 ø800 150 200 MR90(PR1230) Chip removl 120cc/min. MR90(PR1230) 12 fces /edge Comp.D 0cc/min. Comp. 8 fces / edge Results MR90 douled the cutting efficiency compred with comp.

8 Cse studies FCD450 CM420 Industril prts Cutter nd inserts MR90100R1(ø100 edges) PM1801NNB3/NB4 (PR1210) Vc=150 m/min p e= 5 mm fz=0.15mm/t (Vf=430mm/min) Mchining prt Construction mchine prts Cutter nd inserts MR90125R18(ø125 8 edges) PM1801NNB3/NB4 (PR1230) Vc=200 m/min p e=10 50 mm fz=0.1mm/t (Vf=400mm/min) 500mm MR90(PR1210) Chip removl 258cc/min. MR90(PR1230) Chip removl 200cc/min. Comp.B 107cc/min. Comp.C 153cc/min. Results MR90 douled the cutting efficiency compred with comp. B. Comp. B mchined with 2 psses (pxe=3x5mm). MR90 mchined with only 1 pss. Cutting time reduced Results MR90 improved cutting efficiency to 1.3 times compred with comp. C. Comp. C: pxe=5x50mm ool cost reduced to 1/3 since comp. C is 2cornered insert. MR90 reduced mchining cost s well s improving cutting efficiency. vlution y the user vlution y the user KD NCM hip prts Cutter nd inserts MR9010R18(ø10 8 edges) PM1801NNB3/NB4 (PR1230) Vc=150 m/min p e=10 10 ~50 mm fz=0.1mm/t (Vf=240mm/min) Worked urfce 2000mm 50 Power genertor prts Cutter nd inserts MR90125R18(ø125 8 edges) PM1801NNB3/NB4 (PR1230) Vc=10 m/min p e=10 0 ~20 mm fz=0.15mm/t (Vf=500mm/min) 740 ø MR90(PR1230) Chip removl 120cc/min. MR90(PR1230) 12 fces /edge Comp.D 0cc/min. Comp. 8 fces / edge Results MR90 douled the cutting efficiency compred with comp. D. Comp. D: pxe=5x10~50mm, MR90 cn increse p twice due to low cutting force. MR90 cn increse p s well s cutting speed (Vc=150). It resulted in totl cutting efficiency improvement. (time reduction) Results MR90 improved tool life to 1.5 times of comp.. Comp. mchined with 2 pss (pxe=12x0~10mm) with low cutting feed (Vf=400mm/min). MR90 improved cutting efficiency. (time reduction) Comp. cretes lrge noise due to lrge cutting force. MR90 reduced the cutting force nd noise s well. vlution y the user vlution y the user

MSRS90. Notched Inserts Reduce Cutting Forces When Entering the Workpiece Stable Machining without Chattering

MSRS90. Notched Inserts Reduce Cutting Forces When Entering the Workpiece Stable Machining without Chattering 90 Notched Inserts Reduce Cutting Forces When ntering the Workpiece tle Mchining without Chttering mooth Chip vcution Prevents Frcturing Cused y Biting Chips MGACOAT NANO For xtended Tool Life igh Mchining