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

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Daisy Tucker
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1 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 fficiency with ignificnt Reduction in Cutting Costs

90 Multiple Cutting dge Lengths Aville 1, 2,

reduced virtion mooth chip evcution MGACOAT

2 90 Multiple Cutting dge Lengths Aville 1, 2, nd 4-tge (Ø3.00in, Ø80mm, Ø100mm) 90 F e t u r e s i-efficiency cutter with low cutting forces nd reduced virtion mooth chip evcution MGACOAT technology for extended tool life ingle tge MAX Axil D.O.C. 0.65" 4-tge MAX Axil D.O.C. 2.36" 1

90 i-fficiency Notched N e u t r l - n d e d I n s e r t s Neutrl-hnded inserts offer expnsive

30 20 10 TiC TiCN TiN MGACOAT TiAlN MGACOAT comines high strength nd frcture resistnce for long tool life

inserts rek chips into smller pieces nd reduce cutting forces.

150in New, doule-lnd edge prep improves the cutting edge strength, while smll notch helps to reduce

3 90 i-fficiency Notched N e u t r l - n d e d I n s e r t s Neutrl-hnded inserts offer expnsive possiilities for custom-designed cutters MGACOAT Technology for extended tool life MGACOAT rdness(gp) TiC TiCN TiN MGACOAT TiAlN MGACOAT comines high strength nd frcture resistnce for long tool life Oxidtion temperture (ºC) Notched inserts for lower cutting forces Notched inserts rek chips into smller pieces nd reduce cutting forces. Aville for high feed cutting due to lower cutting forces t workpiece entry in New, doule-lnd edge prep improves the cutting edge strength, while smll notch helps to reduce cutting forces Neutrl insert hnd cutters rke fce first lnd rke fce second lnd first lnd Aville for vrious cutting ngles Cutting edge length 0.709in Conventionl 51% New Design Low Cutting Forces (effect of notched inserts) Comprison of cutting forces (N) (N) dge Preprtion Notched inserts provide lower cutting forces nd reduce virtion evy virtion Competitor A Low cutting forces nd reduced virtion 90 2

90 90 Appliction Rnge (stndrd toolholder) MR Axil

inserts ville for numerous pplictions Appliction 3

4 90 90 Appliction Rnge (stndrd toolholder) MR Axil Rdil (D.O.C.) X (D.O.C.) MC 90 Feed(ipt) Insert Cross-ection With new inserts ville for numerous pplictions Appliction 3 notches 4 notches olid dge Generl purpose 1st Recommendtion NB3 + NB4 NB3P + NB4P Low cutting force mphsis on edge strength ( or ) + NB3 NB4 -V 3

5 Vrious Cutting P o s s i i l i t i e s 90 ide cutter Plunge cutter igh feed cutter Tpered cutter Bck milling cutter houlder cutter etting hft Length Fcemill Left nd Fcemill Right nd Custom-Design nd tndrd 4

6 Toolholders G 3 5 G G Rke Angle A.R. R.R. fig fig.2 fig.3 fig G fig.5 fig.6 fig.7 fig Ø101.6mm Ø172.8mm Toolholder Dimension (Inches) No. of No. of No. of Dimension (inch) Weight Description tock Inserts Flute tge (ls) G R-1-4T Fig R-2-4T Fig R-4-4T Fig R-1-6T Fig R-2-6T Fig R-1-8T Fig R-1-8T Fig R-1-10T Fig R-1-12T Fig Toolholder Dimension (Metric) Description tock No. of Inserts No. of Line No. of tge Dimension (mm) G hpe : tock td. hpe Weight (kg) 5 Bore :inch Bore :mm With Crtridge Without Crtridge With Crtridge Without Crtridge 90080R-1-4T Fig R-2-4T Fig R-4-4T Fig R-1-6T Fig R-2-6T Fig R-4-6T MTO Fig R-1-8T Fig R-2-8T MTO Fig R-1-8T Fig R-2-8T MTO Fig R-1-10T Fig R-2-10T MTO Fig R-1-12T Fig R-2-12T MTO Fig R-1-14T Fig R-2-14T MTO R-1-4T-M Fig R-2-4T-M Fig R-4-4T-M Fig R-1-6T-M Fig R-2-6T-M Fig R-4-6T-M MTO Fig R-1-8T-M Fig R-2-8T-M MTO Fig R-1-8T-M Fig R-2-8T-M MTO Fig R-1-10T-M Fig R-2-10T-M MTO Fig R-1-12T-M Fig R-2-12T-M MTO Fig R-1-14T-M Fig R-2-14T-M MTO : World xpress MTO : (Mde to Order)

Insert Lineup Applicle Inserts Dimension (in) Angle ( ) MGACOAT hpe Description A T ød rε α PR1230 (teel) PR1210 (Cst Iron, Titnium) PMT 180616N-NB3 3 notches 0.709 0.250 0.268 0.

Use Cution when instlling notched inserts: 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.

7 Insert Lineup Applicle Inserts Dimension (in) Angle ( ) MGACOAT hpe Description A T ød rε α PR1230 (teel) PR1210 (Cst Iron, Titnium) PMT N-NB3 3 notches PMT N-NB4 4 notches PMT N-NB3P 3 notches Low resistnce PMT N-NB4P 4 notches Low resistnce PMT N-V Without notches : tock td. Use Cution when instlling notched inserts: 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. The pproprite insert is mrked on the pocket of the cutter ody. ow to instll the insert, Refer to Pge 8 Description Totl No. of tges R-1-4T 1 No. of Flutes No. of Inserts No. of Inserts NB3(P) Notched NB4(P) R-2-4T R-4-4T

8 MP-1 Prts pre Prts (Inch) pre Prts Insert Clmp crew Wrench Crtridge Crtridge crew Wrench Anti-seize Compound Arr Clmp crew Description R-1-4T Without Crtridge R-2-4T R-4-4T R-1-6T R-2-6T B-60120TR TT-25L MP R-1-8T With Crtridge R-1-8T R-1-10T R-1-12T MAP-1806M B-40140TR DT15 - pre Prts (Metric) pre Prts Insert Clmp crew Wrench Crtridge Crtridge crew Wrench Anti-seize Compound Arr Clmp crew Description (For ottom edge of pplicle 1, 2, or 4 stge cutters) MP-1 Without Crtridge With Crtridge Without Crtridge 90080R- -4T 90100R- -6T R- -8T 90160R- -8T 1 MAP-1806M * B-40140TR DT-15 ~ 90315R- -14T 90080R- -4T-M 90100R- -6T-M 90125R- -8T-M B-60120TR TT-25L 7.5Nm for Insert Clmp Tightening Torque 3.5Nm for Crtridge Clmp Tightening Torque MP With Crtridge 90160R- -8T-M MAP-1806M * 1 2 MAP-1806 * B-40140TR DT-15 ~ 3.5Nm 90315R- -14T-M for Crtridge Clmp Tightening Torque - Note) *1: MAP-1806M is only for pplicle..r-1..cutters *2: MAP-1806 is only for pplicle..r-2..ottom edge (1st stge) crtridge. This crtridge is used for ottom edge (1st stge) only. ow to ttch crtridge: To fix the crtridge, tighten the slnt screw first, then tighten the other screw. MP-1 Apply light coting of Anti-seize Compound (MP-1) on the clmp screw when insert is fixed. 7

Instlling Insert ow to Instll the Insert Instlltion

the insert s top surfce numer to the numer on the

Remove dust nd chips from the insert mounting pocket.

3. Plese use only the T-wrench (TT-25L) provided for

*Inserts might not e clmped properly when using

Provided T-wrench (TT-25L) Other wrench When

9 Instlling Insert 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 Remove dust nd chips from the insert mounting pocket. Instll inserts y pushing down the insert with finger. 3. Plese use only the T-wrench (TT-25L) provided for insert instlltion. *Inserts might not e clmped properly when using different wrench. 4. Provided T-wrench (TT-25L) Other wrench When instlling the insert, ensure there is no gp etween the insert nd the crtridge. No Gp Gp 5. After ech use, dditionl clmping is recommended using the T-wrench provided. 8

004~0.008~0.010 0.004~0.008~0.010 Alloy teel (CM) 0.

10 Cutting Conditions Recommended Cutting Conditions Feed Rte (ipt) Cutting peed (sfm) Workpiece Mteril tndrd type NB3+NB4 Low resistnce type NB3P+NB4P PR1230 MGACOAT PR1210 oft teel () 0.004~0.008~ ~0.008~0.010 Cron teel (xxc) 0.004~0.008~ ~0.008~0.010 Alloy teel (CM) 0.004~0.006~ ~0.006~0.008 Die teel (KD/NAK) 0.004~0.006~ ~0.005~0.006 Gry Cst Iron (FC) 0.004~0.008~ ~0.008~0.010 Nodulr Cst Iron (FCD) 0.004~0.008~ ~0.007~ ~490~ ~490~ ~490~ ~490~ ~590~ ~590~ ~490~ ~490~ ~490~ ~490~ ~590~ ~590~720 tinless teel (U304) Non-ferrous Metls Vrious Custom Order Cutters Not Recommended Not Recommended :1st Recommendtion :2nd Recommendtion igh Feed Cutter 45 Fce Mill Plunge Cutter Tpered Cutter ide Cutter Custom-mde cutters cn e designed to meet your cutting requirements, such s cutting dimeter, cutting ngle, nd cutting edge length (stges), etc. 9

Cse tudies Cse tudies Ductile Iron, 60-40-8 Chrome-Moly teel Industril prts Cutter nd inserts 90100R-1-6T(ø100mm 6 flutes) PMT180616N-NB3/NB4 (PR1210) Vc=490sfm p e=0.236" 2.559" fz=0.006ipt (Vf=16.

685" 500mm 90(PR1210) Chip removl 15.7in³/min. 90(PR1230) Chip removl 12.2in³/min. Competitor A 6.5in³/min. Competitor B 9.3in³/min. Results 90 douled the cutting efficiency compred with comp. A. Comp. A required 2 psses (pxe=0.

11 Cse tudies Cse tudies Ductile Iron, Chrome-Moly teel Industril prts Cutter nd inserts 90100R-1-6T(ø100mm 6 flutes) PMT180616N-NB3/NB4 (PR1210) Vc=490sfm p e=0.236" 2.559" fz=0.006ipt (Vf=16.929in/min) Mchined urfces Construction mchine prts Cutter nd inserts 90125R-1-8T(ø125mm 8 flutes) PMT180616N-NB3/NB4 (PR1230) Vc=660sfm p e=0.394" 1.968" fz=0.004ipt (Vf=15.748in/min) " 500mm 90(PR1210) Chip removl 15.7in³/min. 90(PR1230) Chip removl 12.2in³/min. Competitor A 6.5in³/min. Competitor B 9.3in³/min. Results 90 douled the cutting efficiency compred with comp. A. Comp. A required 2 psses (pxe=0.118"x2.56"). 90 completed the cut in only 1 pss. Cutting time reduced Customer vlution Results 90 improved cutting efficiency to 1.3 times tht of comp. B. Comp. B: pxe=0.197"x1.968" Tool cost reduced to 1/3 since comp. B is 2-edge insert. 90 reduced mchining cost s well s improving cutting efficiency. Customer vlution Tool teel tructurl teel hip prts Cutter nd inserts 90160R-1-8T(ø160mm 8 flutes) PMT180616N-NB3/NB4 (PR1230) Vc=490sfm p e=0.394" 0.394~1.968" fz=0.004ipt (Vf=9.449in/min) Mchined urfce " 2000mm " Power genertor prts Cutter nd inserts 90125R-1-8T(ø125mm 8 flutes) PMT180616N-NB3/NB4 (PR1230) Vc=530sfm p e=0.394" 0~0.787" fz=0.006ipt (Vf=19.685in/min) ø (PR1230) Chip removl 7.32in³/min. 90(PR1230) 12 fces /edge Competitor C 3.66in³/min. Competitor D 8 fces / edge Results 90 douled the cutting efficiency compred with comp. C. Comp. C: pxe=0.197"x0.394~1.968", 90 douled the xil D.O.C. due to low cutting forces. 90 cn increse the D.O.C. s well s cutting speed (Vc=490). This resulted in totl cutting efficiency improvement. (time reduction) Customer vlution Results 90 improved tool life to 1.5 times tht of comp. D. Comp. D required 2 psses (pxe=0.472"x0~0.394") with low feed rte (Vf=15.748in/min). 90 improved cutting efficiency. (time reduction) Comp. D ws very noisy due to lrge cutting forces. 90 reduced the cutting force nd noise level s well. Customer vlution 10

cuttingtools@kyocer.com Wesite: www.kyocer.com/cuttingtools Distriutor Wesite: http://mykicc.

12 Kyocer Industril Cermics Corp. Cutting Tool Division 100 Industril Prk Rod endersonville, NC mil: Wesite: Distriutor Wesite: Customer ervice: Option 1 Technicl upport: Option 2 Kyocer Industril Cermics Corp. 09/12, 7.5K Printed in U..A.

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

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