KGD for Automatic Lathe

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Horatio Townsend
5 years ago
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1 Cutoff KGD Cutoff tool KGD for Automatic athe The World s Thinnest! Edge widths are available from 1.3mm Excellent chip control due to new PF/ PQ Chipbreaker Improved insert clamping force generated by an innovative toolholder design According to Kyocera's research, as of arch 13

$fracture resistance.$ Vc=80m/min f=variable Workpiece :

2 The World s Thinnest Edge widths a Choosing chipbreaker depending on application Cutting Force igh PQ for medium feed Edge Width mm PF for low feed PG for sharp cutting Edge Width mm Edge Width 1.3mm ow ow Feed Rate igh Excellent chip control due to new olded chipbreaker PF chipbreaker PQ chipbreaker Depression at center of chipbreaker curls chips at low feed range (f= mm/rev). Small corner R ()=0.03mm effectively reduces the boss remaining on the workpiece surface. Chipbreaker finely breaks chips with double the projection at medium feed range (f= mm/rev). Corner R ()=0.1mm combines both sharpness and fracture resistance. Chip shape Cutting Conditions Vc=80m/min f=variable Workpiece : S45C ø10 WET Oil base New 0.05mm/rev PQ chipbreaker 0.04mm/rev 0.0mm/rev 0.03mm/rev PF chipbreaker PF chipbreaker Competitor A New PQ chipbreaker Competitor B PG chipbreaker for nonferrous metals is now available. Applicable to various workpieces 1

are available from 1.3mm Benefits of the Thin Edge Width PF chipbreaker 1.

3mm Edge Width.mm Conventional When using 1.

Improved insert clamping force by innovative toolholder design Point 1 New

surface on the toolholder R shaped surface on the toolholder increases the

Insert Toolholder Back Side Front Side (insert side) The insert clamping

3 are available from 1.3mm Benefits of the Thin Edge Width PF chipbreaker 1.3mm mm inimizes wasted material during cutoff operation Image Edge Width 1.3mm Edge Width.mm Conventional When using 1.3mm width insert, see the recommended cutting conditions on page 6. Improved insert clamping force by innovative toolholder design Point 1 New Slit Design Point Toolholder clamps insert equally and firmly R shaped surface on the toolholder R shaped surface on the toolholder increases the contact area between the insert and toolholder. Insert Toolholder Back Side Front Side (insert side) The insert clamping force is improved by firmly fastening the front side (insert side) of the toolholder. Clamping Test (traversing) Depth of Cut ap Feed Rate f New Cutting Conditions 1mm 5mm/rev 0.3mm/rev Insert clamping force and installation is improved by increasing contact area between insert and toolholder 0.3mm/rev ap=1 3mm Workpiece : SK4 ø10 WET Oil base mm 5mm/rev 0.3mm/rev mm 5mm/rev 0.3mm/rev 3mm 5mm/rev 0.3mm/rev KGD Competitor C Competitor D According to our own research, as of arch 13

GD/GDG Shape anded insert shows Righthand ow Feed Rate 15 ead Angle ow Feed Rate Classification of usage :Continuous to light Interruption / 1st Choice :Continuous to light Interruption / nd Choice

θ PR115 GW15 GD 1316N003PF 0.03 1.3 1.0 1316N015PF 0.15 16 3.7 1516N003PF 0.03 1. 1516N015PF ±0.04 0.15 N003PF.0 5N003PF.5 0.03.1 4.3 30N003PF 3.0.3 GD 1316 R / 003PF15D 1.3 1.0 16 3.

4 GD/GDG Shape anded insert shows Righthand ow Feed Rate 15 ead Angle ow Feed Rate Classification of usage :Continuous to light Interruption / 1st Choice :Continuous to light Interruption / nd Choice :Continuous / 1st Choice :Continuous / nd Choice Description Edge Width(W) CornerR Tolerance () P N Carbon steel / Alloy steel Stainless Steel Nonferrous etals Dimension(mm) Angle( ) EGACOAT Carbide θ PR115 GW15 GD 1316N003PF N015PF N003PF N015PF ± N003PF.0 5N003PF N003PF GD 1316 R / 003PF15D R / 003PF15D 1. R / 003PF15D.0 ± R / 003PF15D R / 003PF15D GD N010PQ.0 Cutoff edium Feed Rate 15 ead Angle edium Feed Rate 5N010PQ.5 ± N010PQ GD R010PQ15D.0 5R010PQ15D.5 ± R010PQ15D GDG N005PG.0 5N005PG.5 ± ow Cutting Force 30N005PG GDG R005PG15D.0 15 ead Angle ow Cutting Force 5R005PG15D.5 ± R005PG15D Inserts are sold in 10 piece boxes. : Std. Item The cornerr() of PQ chipbreakers are small, designed for automatic lathe. PF chipbreaker has a large corner R() For cutting conditions, see page 6. Note) Using PF/P chipbreaker (for cutoff) for grooving cannot create a flat bottom (See figure below). Groove bottom created by PF/P chipbreaker 3

5 GD/GDS Classification of usage Continuous to light Interruption / 1st Choice Continuous to light Interruption / nd Choice Continuous / 1st Choice Continuous / nd Choice P Carbon steel / Alloy steel Stainless Steel K Cast Iron Angle Cermet EGACOAT Dimension mm Shape Edge Width W CornerR Description Tolerance W±0.03 θ TN90 PR N05P N030P R0P6D.5 ± R05P6D N05P 3.0 ± N030P GDS R0P6D.0 30R05P6D 3.0 ± R030P6D N040G 3.0 ± N040G GD R0P6D ± Cutoff 5N0P θ () GD N0P W±0.03 anded insert shows Righthand W±0.03 GDS N0P θ W±0.03 1edge Grooving and Cutoff W 1edge W For general purpose GD 4N0G 30N0G 30N040G 40N0G 40N040G 40N080G GDS N0G For general purpose 1edge ± Std. Item Inserts are sold in 10 piece boxes. Recommended Cutting Conditions of P / G chipbreaker Applicable Range Feed Rate mm/rev Recommended Insert Grade igh Cutting Force Workpiece EGACOAT PR115 PF P/G PF Alloy Steel PG ow ow Carbon Steel PQ 0.1 Feed rate f (mm/rev) PQ Stainless Steel igh Cast Iron P G Edge Width W mm Edge Width W mm Remarks ~4./ ④Width ②Accuracy Class G D ①Series Cutoff GD series ⑥and of Tool mm 30 3mm 40 4mm S 30 ③No. of edges Without Indication S 1edge ⑤Insert ength mm nd Recommendation ⑧Chipbreaker Symbol P CutOff P Grooving and Cutoff igh feed R Righthand N Neutral Wet st Recommendation Indication of Description 3.0/4.0 R 05 P 6D ⑦CornerR() 0 mm 5 5mm mm ⑨ead Angle Without Indication 0 6D 6 4

6 KGD (for automatic lathe) Edge Width :1.3 ~ 4.0mm Insert Setting Angle Insert Setting Angle anded insert shows Righthand Description Stock Cutting Dia. Dimension (mm) Edge Width W(mm) Screw Spare Parts Wrench R φdmax 1=h 3 4 B 1 F A IN. AX. KGD R / 1010JX JX KGD R / 1010JX JX SB401TR TW15S KGD R / 11F F KGD R / 1010JX JX JX KGD R / 1010JX JX JX SB401TR TW15S SB401TR TW15S KGD R / 11JX JX KGD R / 11F F SB401TR SB401TR TW15S TW15S KGD R / 1616JX3D JX3D JX3D mmwidth insert can be installed in KGD R / 11JX3, but is not recommended due to the toolholder s rigidity SE5015TR TW : Std. Item Toolholder Identification System Shank Size 16 16mm 4Applicable Inserts GD/GDS type Edge Width 3~4mm KGD R 1616 JX 3 D38 1Toolholder and R:Right hand :eft hand 3Toolholder Overhang ength 1mm 5Cutting Dia φdmax 38mm 5

7 Tips for achining Toolholder overhang () is designed to be the minimum length Advantage 1 Advantage Easy to use without constraint of overhang length depending on machine specification Controls chattering due to the minimum, optimal overhang length Product lineup with a maximum cutting diameter of 4mm Note) When machining the material greater than φ36mm with KGD R / 3D38 or KGD R / 3D4 toolholders, please use 1edge inserts. aximum workpiece diameter for inserts is φ36mm. Recommended Cutting Conditions of PF / PQ / PG chipbreaker Feed Rate(mm/rev) Recommended Insert Grade PF PQ PG Workpiece EGACOAT Carbide Edge Width W(mm) Edge Width W(mm) Edge Width W(mm) Remarks PR115 GW15 1.3/.0.5/ / /3.0 Carbon Steel Alloy Steel Stainless Steel Cast Iron 70~180 70~180 60~150 80~0 70~150 70~150 60~1 Aluminum Brass 0.01~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~100 0~ ~0 0.01~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~0.08 :1st Recommendation Wet :nd Recommendation Feed Rate of PF / PQ chipbreaker (Workpiece:S45C) Chipbreaker PF chipbreaker PQ chipbreaker Edge Width W (mm) 1.3/.5/3.5/3 Feed Rate(mm/rev)

8 Case Studies Pure Iron STK13A Solenoid Vc=114m/min f=0.06mm/rev KGDR1616JX GDN010PQ 10 Pipe Vc=115m/min f=0.035mm/rev KGDR11JX GDN010PQ ,000pcs 1,000pcs and more Competitor A 500~1,000pcs Competitor B 1,000pcs Tool life of Competitor A was unstable even at f=0.05mm/rev. Frequent fracture after machining pcs. KGD was stable at f=0.06mm and processed 00 pcs. KGD showed machining stability and better edge condition than Competitor B after machining 1000 pcs. SU Valve Vc=110m/min f=0.07~0.15mm/rev KGDRK3T GD30R003PF15D S45CF Cam Vc=14m/min f=0.05mm/rev KGDR1616X3D38 GD30N010PQ ,000pcs and more 500pcs Competitor C 13,000pcs Competitor D 400pcs KGD showed better edge condition against Competitor C after machining 13,000 pcs and further machining was possible. KGD improved tool life and cutoff surface roughness compared with Competitor D. Chip control was smooth. S48C SUS316 Valve Vc=80m/min f=0.035mm/rev KGD11JX GDN010PQ 4 16 Union Vc=70m/min f=0.06mm/rev KGD1616JX GDN010PQ ,300pcs 1,0pcs Conventional A 500pcs Competitor E 800pcs KGD showed.6 times longer tool life than Conventional A. KGD satisfied the required cutoff surface roughness Rz=5μm, although Conventional A cannot. KGD achieved times longer tool life compared with Competitor E. PQ chipbreaker controlled burr formation and improved surface finish, too. CP313

KTKF Lateral side screw clamp toolholder H8 KTKFS (for sub spindle tooling) Lateral side screw clamp toolholder H10

KTKF Lateral side screw clamp toolholder H8 KTKFS (for sub spindle tooling) Lateral side screw clamp toolholder H10 CutOff 1~30 Product ineup Guide for CutOff Summary of CutOff CutOff oolholders (for small diameter cutoff) 2 3 4~5 6~11 KKF ateral side screw clamp toolholder 8 KKFS (for sub spindle tooling) ateral side