HSC-11 Milling tool for aluminium machining

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1 Milling tool for aluminium machining

2 CERATIZIT secrets of success Secrets of success INTRODUCTION CERATIZIT is your partner for exceptional hard material solutions. Hard materials and tools from CERATIZIT our solutions to complex problems are an integral part of our customers success. Our products guarantee: economy long life speed! And it is precisely this combination which gives our business partners a direct competitive advantage. Premier performance is only possible through a total appreciation of the requirements of our business partners. A performance achieved through fl exible thinking and continuous Corporate values The views and focus of our business partners matter Innovative and fl exible thinking matters Communication matters Employee development matters Professionalism matters Our environment matters Tailored cutting tool solutions dialogue with our customers. A pioneering spirit and a deep understanding of powder metallurgy characterize the history of CERATIZIT. One of the attributes of our company philosophy is the search for perfection: target oriented sustainably passionately! Intensive research and development activities, taking into account the precise requirements and working processes of the customer, are today s investment for the solutions of tomorrow and beyond. Cutting materials, coatings, inserts, tooling systems and machining solutions all this is included in the cutting tool division at CERATIZIT. Worldwide well-known companies process advanced materials applying cutting tool products from CERATIZIT: from the automotive industry to the aerospace industry, mechanical engineering and tool construction to the oil industry. The basis of these long-term business relations is the faith of the customers in the extensive know-how of the carbide specialists. 2

System advantages The targets Increase in productivity through reduction of machining time, simultaneously top quality standards are maintained with regard to surface

Roughing and finishing with only one tool Universal application Highly precise component parts Efficient use of machine Reduced machining costs per workpiece Solid

3 System advantages The targets Increase in productivity through reduction of machining time, simultaneously top quality standards are maintained with regard to surface finish and dimensional accuracy of the workpiece High process reliability with calculable tool changing intervals Maximised chip removal rate per tool diameter Roughing and finishing with only one tool Universal application Highly precise component parts Efficient use of machine Reduced machining costs per workpiece Solid carbide milling cutter no longer necessary for finishing operation Machining costs per workpiece -30% bis -60% The result Economy INTRODUCTION Milling strategy Conventional 3

System advantages The system TOOLS The tool shanks have been optimised in every respect for the special stress factors which occur during high-speed milling.

4 System advantages The system TOOLS The tool shanks have been optimised in every respect for the special stress factors which occur during high-speed milling. Particular attention has been attached to material selection, heat treatment and manufacturing tolerances. The construction process is supported by an accompanying FEM analysis of each tool. INTRODUCTION Based on centrifugal force tests the maximum rpm values were determined; in this way application safety has been maximised. Tools with round shank (C) For use in shrink, expansion and collet chucks Attachment of Weldon clamping faces possible (N.B. conventional RPM only) Shank tolerance h6 Tool diameter 16 mm 32 mm Working length 25 mm 63 mm Tools with threaded shank (G) For the application with an extension in order to achieve large overhangs (e.g. in the field of mould & die making) Suitable for the most common systems Tool diameter 16 mm 40 mm Working length dependant upon extension 4

System advantages The system Tools in monobloc version (M) First choice for high-speed cutting (HSC) HSK63A shank Maximum system rigidity and

range Application together with milling adapters according to DIN / MAS-BT, HSK etc.

extraordinarily precise position and accurate repeatability of the insert.

5 System advantages The system Tools in monobloc version (M) First choice for high-speed cutting (HSC) HSK63A shank Maximum system rigidity and precision Tools with fixation hole (A) Tool diameter 25 mm 50 mm Working length 50 mm 100 mm Mainly for face milling in the larger diameter range Application together with milling adapters according to DIN / MAS-BT, HSK etc. Tool diameter 40 mm 100 mm INSERT SEAT Utilizing easy screw clamping, the precisely milled support face and 3 contact points ensure an extraordinarily precise position and accurate repeatability of the insert. 1/2 Radial contact points > Guarantee 90 corner angles and exact radial run-out 3 Axial contact point > Guarantees precise axial run-out INTRODUCTION 4 Optimised coolant hole > Coolant / lubricant direct to cutting edge Indexable inserts of systems MaxiMill and MaxiMill are interchangeable. 5

System advantages The system INSERTS The particularly sophisticated geometry represents a milestone in the manufacturing technology of carbide inserts.

Precise repeatability, the position of the cutting edge in relation to the shank of the milling INTRODUCTION tool and the quality of the cutting edges are only some of the parameters which

6 System advantages The system INSERTS The particularly sophisticated geometry represents a milestone in the manufacturing technology of carbide inserts. Only the application of state-of-the-art production methods ensures that the high quality standards in volume production are maintained. Precise repeatability, the position of the cutting edge in relation to the shank of the milling INTRODUCTION tool and the quality of the cutting edges are only some of the parameters which continuously need to be controlled during the process. Insert size 11 = usable length of cutting edge 10 mm Radius r = 0,2 / 0,4 / 0,8 / 1,2 / 1,6 / 2,0 / 2,5 / 3,2 / 4,0 / 5,0 mm Rake angle 22 Fine grain carbide ISO K10 / CERATZIT H216T Microfinish rake face in order to avoid built-up edges Integrated wiper facet 6

7 System advantages Application Although it has been designed for HSC machining, the system can also be utilised for conventional milling. Both geometry and grade of the insert are ideally suited for application on aluminium, other non ferrous metals and plastic. Universal application being a system concept. Face milling Angled ramping Slot milling Peripheral milling Helical plunge milling Pocket milling CUTTING DATA FOR ALUMINIUM: a pmax up to 10 mm f max up to 0.25 mm n max up to 56,000 min -1 (depending on the tool diameter, shank version, clamping, etc.) INTRODUCTION Chip removal rates above 4,000 cm 3 /min possible Applying an emulsion as full lubricant or minimum quantity lubrication, provides a better result than dry machining. 7

System advantages CERATIZIT services SUPPORT Our CERATIZIT product and application specialists look forward to supporting you with regard to the optimisation of your milling strategies.

INTRODUCTION SOFTWARE SIM-MILL: Calculation of dynamic behaviour considering the spindle position and the geometrical factors of the tooling system (without complex tests).

8 System advantages CERATIZIT services SUPPORT Our CERATIZIT product and application specialists look forward to supporting you with regard to the optimisation of your milling strategies. Their long-standing experience together with international know-how represent a solid foundation for a result-oriented cooperation with our customers. INTRODUCTION SOFTWARE SIM-MILL: Calculation of dynamic behaviour considering the spindle position and the geometrical factors of the tooling system (without complex tests). This results in considerable effects on spindle protection and tool life as well as improved surface quality of the workpiece. Unfavourable application area vibrations a p [mm] n [min -1 ] Safe area for disturbance-free machining Favourable machining area WinTool: An electronic catalogue which supports you when specifying cutting tools. It is possible to produce data sheets relating to complete tool assemblies. WinTool CD in 4 languages no.: 136 Techstore: The on-line availability check and possibility to order 24 hours a day is only one of the numerous features. You will be provided with a maximum of up-to-the-minute information and services with only a few mouse clicks. 8

System advantages CERATIZIT services ADDITIONAL LITERATURE / INFORMATION ABOUT MILLING Catalogue Tools and inserts for milling no.: 126 Tizilogue CD no.

detailed knowledge of the tools and application processes. It is indispensable to observe the maximum rpm and safety standards in order to avoid severe process disturbance.

9 System advantages CERATIZIT services ADDITIONAL LITERATURE / INFORMATION ABOUT MILLING Catalogue Tools and inserts for milling no.: 126 Tizilogue CD no.: 209 Detailed information about components and machining methods for project planning Please refer to your CERATIZIT contact person TRAINING Demanding applications such as HSC milling require detailed knowledge of the tools and application processes. It is indispensable to observe the maximum rpm and safety standards in order to avoid severe process disturbance. INTRODUCTION At the CERATIZIT cutting tool lab standards for safe tool application are developed. State-of-the-art machines and facilities create the necessary conditions for extensive performance tests and are utilised to train our customers and application specialists. 9

10 Application example Finish milling One of the characteristics of the system is the precision of the main cutting edge. In the future it will be possible to carry out numerous fi nish milling processes using indexable insert milling cutters. The following example shows how to achieve excellent surface quality without applying solid carbide milling cutters. The target was to increase productivity by reducing the machining time. Tools APPLICATION Face milling: AHPC.40.R und XDHX FN-27P H216T Pocket milling and fi nishing and bottom faces: CHSC.25.R und XDHT 11T332FN-27P H216T Finishing of side faces: CHSC.16.R und XDHT 11T332FN-27P H216T Application data for finish milling Bottom face Side face Material Aluminium Workpiece Component Machine Starrag Heckert Rev number n [rev/min] Feed rate V f [m/min] 7.2 [m/min] 4.8 Cutting speed V c [m/min] 1885 [m/min] 1206 Depth of cut a p [mm] 1.0 [mm] 6.5 Width of cut a e [%] 60 [%] 10 Feed per tooth f z [mm] 0.15 [mm] 0.10 Result Surface quality of bottom face R a = 0.8 µm Surface quality of side face R a = 1.2 µm The entire mechanical machining procedure was carried out with an indexable insert milling cutter. It was not necessary to apply a solid carbide milling cutter for the final finishing process. 10

11 Inserts -27P -F20 CTW4615 H216T r Type, d l s l 1 d 1 [mm] description [mm] [mm] [mm] [mm] [mm] 0.20 XDHT 11T302FR-27P R XDHT 11T304FR-27P R XDHT 11T308FR-27P R XDHT 11T312FR-27P R XDHT 11T316FR-27P R XDHT 11T320FR-27P R XDHT 11T325FR-27P R XDHT 11T332FR-27P R XDHT 11T340FR-27P R XDHT 11T350FR-27P R XDKT 11T302FR-F20 R XDKT 11T304FR-F20 R XDKT 11T308FR-F20 R XDKT 11T320FR-F20 R XDKT 11T325FR-F20 R Steel Stainless Cast iron r Non ferrous metals RR Heat resistant Hard materials Main application Extended application International CERATIZIT range, for present availability see price list Ordering example: 10 pieces XDHT 11T302FR-27P H216T INSERTS CHSC/ GHSC/ M AHSC/

12 Tools C l 1 Ød1 a DIN 1835B ØdA l 2 -A TOOLS d 1 Type, l 1 l 2 d A a n max [mm] description [mm] [mm] [mm] [mm] min -1 z 16 CHSC.16.R A XD_T 11T CHSC.16.R A XD_T 11T CHSC.18.R A XD_T 11T CHSC.18.R A XD_T 11T CHSC.19.R A XD_T 11T CHSC.19.R A XD_T 11T CHSC.20.R A XD_T 11T CHSC.20.R A XD_T 11T CHSC.22.R A XD_T 11T CHSC.22.R A XD_T 11T CHSC.25.R A XD_T 11T CHSC.25.R A XD_T 11T CHSC.25.R A XD_T 11T CHSC.25.R A XD_T 11T CHSC.32.R A XD_T 11T CHSC.32.R A XD_T 11T CHSC.32.R A XD_T 11T CHSC.16.R B XD_T 11T CHSC.20.R B XD_T 11T CHSC.25.R B XD_T 11T CHSC.32.R B XD_T 11T3.. Ordering example: 1 piece CHSC.16.R A-25 Supply details: cutter body and clamping screws for inserts d 1 [mm] XD_T 11T /M2,5X5,6/TP /TORX 8IP DMSD 1,8Nm/SORT 8IP XD_T 11T /M2,5X7,3/TP /TORX 8IP DMSD 1,8Nm/SORT 8IP XD_T 11T3.. 12

Tools G Ød1 ØdG ØdA a l 2 d 1 Type, l 2 d A d G a n max [mm] description [mm] [mm] [mm] [mm] min -1 z 16 GHSC.16.R.02-11 27 8.5 8 10 56200 2 XD_T 11T3.. 18 GHSC.18.R.02-11 27 8.5 8 10 53000 2 XD_T 11T3.

13 Tools G Ød1 ØdG ØdA a l 2 d 1 Type, l 2 d A d G a n max [mm] description [mm] [mm] [mm] [mm] min -1 z 16 GHSC.16.R XD_T 11T GHSC.18.R XD_T 11T GHSC.20.R XD_T 11T GHSC.25.R XD_T 11T GHSC.32.R XD_T 11T GHSC.40.R XD_T 11T3.. Ordering example: 1 piece GHSC.16.R Supply details: cutter body and clamping screws for inserts n max = depends on the overhang and number of interfaces in the complete tool TOOLS d 1 [mm] XD_T 11T /M2,5X5,6/TP /TORX 8IP DMSD 1,8Nm/SORT 8IP XD_T 11T /M2,5X7,3/TP /TORX 8IP DMSD 1,8Nm/SORT 8IP XD_T 11T3.. 13

14 Tools M l 1 Ød1 ØdA a l 2 l 3 HSK 63A TOOLS d 1 Type, d A l 1 l 2 l 3 a n max [mm] description [mm] [mm] [mm] [mm] [mm] min -1 z 25 MHSC.25.R H63A XD_T 11T MHSC.25.R H63A XD_T 11T MHSC.32.R H63A XD_T 11T MHSC.32.R H63A XD_T 11T MHSC.40.R H63A XD_T 11T MHSC.40.R H63A XD_T 11T MHSC.50.R H63A XD_T 11T MHSC.50.R H63A XD_T 11T3.. Ordering example: 1 piece MHSC.25.R H63A-50 Supply details: cutter body and clamping screws for inserts d 1 [mm] XD_T 11T /M2,5X5,6/TP /TORX 8IP DMSD 1,8Nm/SORT 8IP XD_T 11T /M2,5X7,3/TP /TORX 8IP DMSD 1,8Nm/SORT 8IP XD_T 11T3.. 14

Tools A Ød Ød A a h Ød 1 d 1 Type, h a d da [mm] description [mm] [mm] [mm] [mm] z 40 AHSC.40.R.04-11 50 10 38 16 4 XD_T 11T3.. 50 AHSC.50.R.04-11 50 10 43 22 4 XD_T 11T3.. 63 AHSC.63.R.05-11 50 10 48 22 5 XD_T 11T3.

15 Tools A Ød Ød A a h Ød 1 d 1 Type, h a d da [mm] description [mm] [mm] [mm] [mm] z 40 AHSC.40.R XD_T 11T AHSC.50.R XD_T 11T AHSC.63.R XD_T 11T AHSC.80.R XD_T 11T AHSC.100.R XD_T 11T3.. Ordering example: 1 piece AHSC.40.R Supply details: cutter body and clamping screws for inserts TOOLS d 1 [mm] XD_T 11T /M2,5X7,3/TP /TORX 8IP DMSD 1,8Nm/SORT 8IP /M8,0x30,0 XD_T 11T /M2,5X7,3/TP /TORX 8IP DMSD 1,8Nm/SORT 8IP /M10,0X31,0 XD_T 11T /M2,5X7,3/TP /TORX 8IP DMSD 1,8Nm/SORT 8IP S4/SW /SW XD_T 11T3.. 15

16 Application data Helical plunge milling TECHNICAL INFORMATION d 1 [mm] D max [mm] D min [mm] α Rmax [ ] , , , , , , , , , , , ,9 a p [mm] = D M x π x tan α R D M D max [mm] = maximum diameter for flat bottom ground D min [mm] = minimum hole diameter D M = D max - d 1 or D min - d 1 Axial plunging Angled ramping d 1 d 1 [mm] D [mm] α R max 360 [ ] , , , , , , , , , , , ,9 d 1 [mm] r 0,2-4,0 X max [mm] 16 1,7 18 2, , , , , , , , , , ,79 d 1 [mm] r 0,2-4,0 αr [ ] 16 18, , , , , ,3 32 6,8 40 4,8 50 3,5 63 2,5 80 1, ,3 16

17 TECHNICAL INFORMATION 17

18 Application data Cutting data tool/material TECHNICAL INFORMATION N v c (m/min) f z (mm) a p (mm) v c (m/min) f z (mm) a p (mm) v c (m/min) f z (mm) a p (mm) ,05-0,1 0,3-1, ,075-0,2 1, ,1-0, Cutting data grade/material Workpiece material Aluminium wrought alloys Aluminium cast alloys Copper and copper alloys (bronze, brass) Non metal materials non hardened hardened non hardened hardened non hardened Type of treatment / alloy < 12% Si < 12% Si > 12% Si machining alloy stock (1% Pb) brass, red bronze bronze lead-free copper and electrolytic copper thermosetting plastics fibre reinforced plastics hard rubber VDI 3323 group = full cooling = dry machining = minimum quantity lubrication Modification to basic body from insert radius r 3.2 mm onwards Hardness HB H216T / CTW4615 v c [m/min] v c [m/min] R 3,0 0,

19 Permissible RPM Rev numbers n [min -1 ] Tool dia. Ø [mm] n max. [min -1 ] [mm] l 2 = 1-2 x Ø l 2 = 2,5 x Ø l 2 = 3 x Ø l 2 = 4 x Ø l 2 = 5 x Ø The maximum number of revolutions stated on the tool must under no circumstances be exceeded. The number of revolutions is exclusively valid for the specific tool and must be adapted according to the selected tool shank, total overhang length and the respective machining situation. Please note the maximum permissible number of revolutions stated in the sales documentation of the tool shank. (permissible RPM) in relation to working length l 2 Only for special tools 1) l 2 = working length of the tool TECHNICAL INFORMATION 19

20 Accessories Keys TECHNICAL INFORMATION Torque key with fi xed torque moment 1.8 Nm/15.9 in.lbs fi tted with holder and 5 Torx adapters Holder as substitute for fixed torque key version Torx Plus 8IP adapter for torque key with total length 50 mm Supplied in multiples of 5 Key TorxPlus 8IP Spare parts Clamping screw for inserts Special grease for clamping screw 5 g tube Power screw for A Coolant set for HSK monobloc adapter Special key for coolant set Ø mm: Ø mm: Ø 40 mm (SW 4): Ø mm (SW 5): DMSD 1.8NM DMSD-H DMSD-B 8IP-50mm /TORXPLUS/8IP /M2,5X5,5/TP /M2,5X7,3/TP08 KMS-HSK /MOLYKOTE /M8,0X30, /M10,0X31,0 SS-KMS-HSK63 20

Safety Torque moment for clamping screws The XDHT-11 insert is mounted onto the insert pocket with the specifi ed screw and a torque moment of 1.8 Nm (15.9 in.lbs.).

For safety reasons it is recommended to use a new screw after every insert change. All tools with HSK monobloc adapter are balanced to G 6.3 at CERATIZIT.

21 Safety Torque moment for clamping screws The XDHT-11 insert is mounted onto the insert pocket with the specifi ed screw and a torque moment of 1.8 Nm (15.9 in.lbs.). Failure to observe correct insert mounting procedure can result in insert breakage, machine damage and personal injury of the operator. For safety reasons it is recommended to use a new screw after every insert change. All tools with HSK monobloc adapter are balanced to G 6.3 at CERATIZIT. You will fi nd a quality certifi cate enclosed relating to the tool. You can find detailed information about balancing in our catalogue Tools and inserts for milling no.: 126 Note the HSC safety data sheet that is supplied with the HSC tool. Additional safety advice can be found in our catalogue Tools and inserts for milling no.: 126 Balancing Safety instructions TECHNICAL INFORMATION 21

22 Spindle nose adapters for shell mills HSK Shell mill adapter QA TECHNICAL INFORMATION Adapter according to DIN 6385 Please order coolant set and key separately. Sizes 40 and 60 with 4 additional threads for cutting heads with tool clamping according to DIN 2079 Type, description V = Prebalanced for n = 15,000 min -1 With internal coolant supply [mm] Drawing: HSK63A-QA16-50 HSK d h6 d 1 l 1 l 2 l 3 HSK63A-QA16-50-V HSK63A-QA22-50-V HSK63A-QA27-60-V HSK63A-QA32-60-V HSK63A-QA40-60-V HSK100A-QA16-50-V HSK100A-QA22-50-V HSK100A-QA27-50-V HSK100A-QA32-50-V HSK100A-QA40-60-V HSK100A-QA60-70-V

CERATIZIT - worldwide CERATIZIT - worldwide Production sites in the three big economic areas with a worldwide network of CERATIZIT sales and support engineers plus many CERATIZIT distribution

23 CERATIZIT - worldwide CERATIZIT - worldwide Production sites in the three big economic areas with a worldwide network of CERATIZIT sales and support engineers plus many CERATIZIT distribution partners guarantee customer vicinity. Find your personal distribution partner at: CERATIZIT - worldwide We maintain the dialogue with our customers and strive for long-term partnerships. CERATIZIT worldwide production sites and support centres CERATIZIT worldwide sales centres CERATIZIT worldwide distribution partner network Headquarters: CERATIZIT S.A. Parent company in Luxembourg CERATIZIT Luxemburg Sarl Route de Holzem, B.P. 51 L-8201 Mamer Tel.: Fax: info@ceratizit.com Contact for this product: CERATIZIT Austria Gesellschaft m.b.h. A-6600 Reutte/Tyrol Tel.: +43 (5672) Fax: +43 (5672) info.austria@ceratizit.com TECHNICAL INFORMATION 23

24 EN We reserve the right to make technical changes for improvement of the product.

HSC-11 Milling tools for aluminium machining

HSC-11 Milling tools for aluminium machining hard material matters Milling tools for aluminium machining CERATIZIT - the parent companies INTRODUCTION Headquarters and parent company in MAMER / Luxembourg Parent company in REUTTE / Austria Direct