High Efficiency Finishing Special Shape Tool Series. GALLEA series. New Product News No.1711E

Transcription

1 igh Efficiency Finishing Special She Tool Series GALLEA series New Product News No.1711E 17-

2 Series type type type type type Combination of lens tool and barrel tool Concept of GALLEA series Comparison of barrel tool and ball-radius end mill Barrel tool Ball end mill Corner radius end mill Tool dia. Peripheral flute Tool dia. Tool dia. Corner radius 3 Cusp height Cusp height Cusp height Pitch Pitch Pitch When contour milling with the same theoretical cusp height, the barrel tool can be machined with a pitch of about 1.7 times compared with the ball end mill of the same diameter, and about 3 times as compared with the 3 radius end mill. Comparison of lens tool and ball end mill Lens tool Ball end mill Tool dia. Lens Tool dia. 15 Pitch 1.4 times Pitch Cusp height Can be machined with pitch of about 1.4 times compared with the ball end mill of same diameter. Because of be able to increase the pitch, achining time can be reduced regardless of feed speed. 02

3 type type Seamless igh efficiency for 5-axis machining The same size GALLEA series as φ60 ball end mill. φ60 Ball End ill Offset the tool radius difference. 15 φ 形 φ 形 Usable range of barrel egde. Usable range of barrel edge. φ 形 Usable range of lens edge. ow can finishing time be reduced? Large pitch! Small cusp! Conventional pitch and cusp height Pitch of GALLEA series Possible to reduce the polishing time in case of same pitch condition 03

4 List of GALLEA series ed In 3-axis machining usable range of Barrel edge Blue In 3-axis machining usable range of Lens edge / Tip edge Barrel P (G) 71 (T) (G) 78 (T) Finishing machining time reduced by 70% 0 For tilted wall finishing 0 φ 1 Corner radius end mill Cutting conditions vf=00/min n=4min -1 = achining time simulation = Approx. 150 min. GALLEA ax. external diameter φ Outer peripheral flute Cutting conditions vf=00/min n=4min -1 Cutting time = Approx. 40 min. = Barrel For tilted wall finishing 75.1 (φ) 75.0 (φ) 74.8 (φ35) 74.7 (φ40) 0 P.8 igh-performance tilted wall finishing! Enables machining at a larger pitch than ball end mills or radius end mills. Series expansion toward larger diameters φ φ φ35 φ40 Economical 2-corner specification Unique insert holding surface enables realization of 2-corner specification. Barrel, lens P Lens 0 For tilted wall and curved surface finishing Combination of lens tool and barrel tool. Precision type Lens tool Gently curved surface + Barrel tool Wall surface = Lens type Can be machined with a single tool. 90 Ter Barrel P. Two types of process are possible with one tool that can fully utilize the merit of 5-axis machining Since it can work for 2 types of process without tool change, machining surface steps can be minimized. Tip For tilted wall, curved surface and corner finishing 0 This tool can take a larger pitch with a barrel which larger than the tool radius. Tip The tip can be used as a ball end mill for corner processing. 90 Tangent Barrel P.16 achieves high-efficiency and high-quality machining for tilted section Tip can finish curved connecting faces to high quality Employs unique high helix she and realizes low cutting force Tip 0 For tilted wall, curved surface and corner finishing 04

5 Overview of GALLEA series SKD11 Stamping die (Corner) Stamping die (Wall surface, gently-curved surface) Work ardness Pre-hardened steel Forging die and plastic mold (Wall surface, corner) Plastic mold (Wall surface, gently-curved surface and corner) Die casting dies Blisk, Impeller (Blade she) Parts, Die mold (Tire mold, Bathtub) achine structual conponents Carbon steel Stamping die (Corner) Stamping die (Wall surface, gently-curved surface) FC/FCD Cast iron Tool diameter Chart of tool dia. and barrel for GALLEA series () Tool dia. () G T/G T G 28 T T G T/G T G

6 type odular type - - C L1 L2 Numeric figure in a circle L2 C L1 and Alphabetical character comes in a square E(Notch width) φdc φdb φdc φdb Basic type Offset type Type Item code Stock No.of flutes φdc Size () φdb L1 L2 C E Insert Basic type Offset type G G-3- G-4- G-4- T T-3- T XPW0903- XPW0903- YPW0903- YPW0903- :Stocked Items. Note Do not ply lubricants such as grease, etc. to the contact faces and modular screws of the modular mill, special shanks and special arbor. Inserts Basic type XPW0903- Offset type P K SUS, etc. ardened steels Type Basic type Item code XPW0903- XPW0903- T315 :General cutting, First recoended :General cutting, Second recoended Size () 9.5 YPW Offset type YPW0903- YPW0903- :Stocked Items. Parts To reduce environmental loads, drivers and screw anti-seizure agent are sold separately. We ask for your understanding and cooperation. She Clamp screw Not included with product (sold separately) Screw driver Screw anti-seizure agent Cutter body Fastening torque (N m) T8 P-37 06

7 ecoended cutting conditions Work material Alloy steels (<C) Alloy steels (~45C) Stainless steels SUS Cast iron FC FCD ardened steels (45~55C) ecoended grade T315 T315 T315 ed indicates primary recoended grade. Cutting condition fz(/t) fz(/t) fz(/t) fz(/t) fz(/t) φ16 11,950 4,780 ~ 7,970 3,190 ~ 9,960 3,990 ~ 11,950 5,980 5 φ 9,560 5,740 efer right table ~ 3,8 efer right table ~ 7,970 4,790 efer right table ~ 9,560 7,170 5 φ 6,1 ~ 5,0 4,080 ~ 5,0 ~ 5 efer right table ~ 4, , 5 ~ 3, ,800 5 ~ 3, ,9 5 efer right table ~ ~ ~ Determine the value based on the desired cusp height by selecting it from the table below or by calculating it using the equation below. Insert When overhang length is 3Dc or greater, adjust the values shown in the table at left according to the table below. Overhang ratio <3Dc 3Dc ~ 5Dc 5Dc ~ 6Dc 6Dc ~ 7Dc 7Dc~ 0% 70% 60% 50% 45% Cusp height () Item code XPW0903- XPW = 2 ( 2 -(-) 2 ) : Tool :Cusp height Note 1Use the propriate coolant for the work material and machining she. 2These conditions are for general guidance; in actual machining conditions adjust the parameters according to your actual machine and work-piece conditions. 3To prevent tool breakage due to chips clogging tool flutes, always be sure to use an air blower, etc. to remove chips. 4Ensure to index the insert at the correct time to ensure safety of the tool-body % 70% 60% 50% 45% Flute tip she definitions for programing Tool maximum inclination angle θ rε rε Tool dia. Dc Basic type h center height A Tool maximum inclination angle θ rε rε Tool dia. Dc h Offset type center height A otation locus she will be different depending on the combination of insert and tool diameter. efer to the table below. Basic type Offset type Insert item code XPW0903- XPW0903- YPW0903- YPW0903- Tool dia.dc () φ16 φ φ φ16 φ φ φ16 φ φ φ16 φ φ () h () rε () A () θ

8 type odular type - Numeric figure in a circle and Alphabetical character comes in a square C L1 L2 C L1 L2 E(Nocth width) φdc φdb φdc φdb φ, φ φ35, φ40 Type Item code No. of Size () Stock flutes φdc φdb L1 L2 C E Insert Offset type YPW :Stocked Items. Inserts φ3.4 P K SUS, etc. ardened steels 商品コード Item code 精度 Tolerance class 材種 Grade T315 :General cutting, First recoended :General cutting, Second recoended YPW13- :Stocked Items. Parts To reduce environmental loads, drivers and screw anti-seizure agent are sold separately. We ask for your understanding and cooperation. Clamp screw Not included with product (sold separately) Screw driver Screw anti-seizure agent She Cutter body - Fastening torque (N m) T P-37 Flute tip she definitions for programing 08 Tool maximum inclination angle Tool dia. Dc θ rε rε h Offset type center height otation locus she will be different depending on the combination of insert and tool diameter. efer to the table below. Offset type Insert item code Tool dia. Dc () () h () θ φ YPW13- φ φ35 φ

9 ecoended cutting conditions Work material Alloy steels (<C) Alloy steels (~45C) Stainless steels SUS Cast iron FC FCD ardened steels (45~55C) ecoended grade T315 T315 T315 Cutting conditions fz(/t) fz(/t) fz(/t) fz(/t) fz(/t) ed indicates primary recoended grade. φ φ φ35 φ40 9,560 5,740 6,1 5,460 5,460 4,780 5,740 efer to the table at right. < 3,8 < 5,0 4,080 < 3,640 3,640 < 3,190 3,8 efer to the table at right. < 7,970 4,790 < 5,0 < 4,550 4,550 < 3,990 4,790 efer to the table at right. < 9,560 7,170 5 < 5 < 5,460 6,8 5 < 4,780 7,170 5 efer to the table at right. < 3, ,800 5 < 3, ,9 5 < 2, ,7 5 < 2, ,800 5 efer to the table at right. < < < < Determine the value based on the desired cusp height by selecting it from the table below or by calculating it using the equation below. Insert Cusp height () Item code YPW = 2 ( 2 -(-) 2 ) : Tool :Cusp height When overhang length is 3Dc or greater, adjust the values shown in the table at left according to the table below. Note Overhang ratio <3Dc 3Dc ~ 5Dc 5Dc ~ 6Dc 6Dc ~ 7Dc 7Dc~ % 70% 60% 50% 45% 0% 70% 60% 50% 45% 1Use the propriate coolant for the work material and machining she. 2These conditions are for general guidance; in actual machining conditions adjust the parameters according to your actual machine and work-piece conditions. 3To prevent tool breakage due to chips clogging tool flutes, always be sure to use an air blower, etc. to remove chips. 4Ensure to index the insert at the correct time to ensure safety of the tool-body. Field Data Cutting of a 1 incline face Feed Achieves same surface roughness at 3 times the pitch of conventional tools. Feed Feed Work material:nak80 Tool 40-6 YPW13- Overhang length () Tool dia. () Cutting speed (m/min) Conventional radius mill a0.54μm = evolution Feed per Feed rate tooth (min-1) (/t) (/min) () 40-6 a0.54μm =0.6 () Coolant , Air blow Conventional 2 radius mill 09

10 type odular type - Numeric figure in a circle and Alphabetical character comes in a square C E(Nocth width) Sizes are added. φdc φdb L1 L2 Item code Stock No. of Size () Inserts φdc φdb L1 L2 C E Insert ZPW160-LB16 ZPW0-LB ZPW0-LB ZPW0-LB :Stocked Items of New Products. :Stocked Items. Note Do not ply lubricants such as grease, etc. to the contact faces and modular screws of the modular mill, special shanks and special arbor. P K SUS, etc. ardened steels Item code Inserts ZPW160-LB16 ZPW0-LB ZPW0-LB ZPW0-LB φdc Tolerance class Grade T T8 3 2 A accuracy:±0.01 :General cutting, First recoended 16 Sizes are added. :General cutting, Second recoended Size () 2 3 A φdc T Parts 形状 She 適用カッタ Cutter body Parts Clamp screw The insert can be attached to Ball Precision F (ABPF type) holders. For information on the detailed tool she, download the DXF data from the itsubishi itachi Tool Engineering home page. (itsubishi itachi Tool Engineering tool selection database TOOL SEAC: :Stocked Items of New Products. :Stocked Items. To reduce environmental loads, drivers and screw anti-seizure agent are sold separately. We ask for your understanding and cooperation. Fastening torque (N m) Not included with product (sold separately) Wrench Screw anti-seizure agent 5-T 1-TS 5-TA P-37 Comparison of machined surface with the same pick. Work material:fcd Tool :-16 ZPW0-LB T8 Conventional BE φ n=6,000min -1 vc=565m/min vf=6,000/min Pitch =0.6 emoval stock = Conventional BE Conventional BE Enlarged view a:0.8μm z:4.66μm a:0.36μm z:2.42μm Surface roughness is about 1/2 of the ball end mill.

11 ecoended cutting conditions ed indicates primary recoended grade. Work material ecoended grade Cutting condition φ16 Lens part φ φ φ φ16 Barrel part φ φ φ Alloy steels (<C) Alloy steels (~45C) Stainless steels SUS Cast iron FC FCD ardened steels (45~55C) ardened steels (55~62C) T8 T8 T8 T8 fz (/t) fz (/t) fz (/t) fz (/t) fz (/t) fz (/t) 14,340 7,170 5, ,180 5, , ,340 11, , , , ,470 5, , ,150 5, , ,470 9, ,0 3 2, , , ,180 4,590 5 efer below table 6,6 5 3,3 5 efer below table 8, ,150 5 efer below table 9,180 7, efer below table 4, ,640 0 efer below table 3, ,4 0 efer below table 3,8 5 5,5 5 2, , , , , 3 1, , ,0 0 11, ,970 3,190 9,960 3,990 11,950 5, , , 5 4, ,3 5 9,560 3,8 2,550 7,970 3,190 9,560 4, , ,0 5 3,060 efer below table 5,0 2,040 efer below table 2,550 efer below table 3,8 5 efer below table 3, efer below table 3,5 2, , efer below table 2,550 4,0 1,700 5,3 2,1 3, , , Lens adius (Bottom edge adius) adius (Peripheral edge adius) For machining shes that make heavy use of lens, refer to the "Lens part cutting conditions" in the above table. For machining shes that make heavy use of barrel, refer to the "Barrel part cutting conditions" in the above table. For machining shes that use both lens and barrel equally, refer to the "Lens part cutting conditions" in the table at left. When overhang length is 3Dc or greater, adjust the values shown in the below table according to the above table. Overhang ratio <3Dc 3Dc ~ 5Dc 5Dc ~ 6Dc 6Dc ~ 7Dc 7Dc ~ 0% 70% 60% 50% 45% 0% 70% 60% 50% 45% Determine the or value based on the desired cusp height by selecting it from the table below or by calculating it using the equation below. Insert Cusp height () Item code = 2 ( 2 -(-) 2 ) ZPW160-LB () ZPW0-LB : Tool :Cusp height ZPW0-LB ZPW0-LB Note 1Use the propriate coolant for the work material and machining she. 2These conditions are for general guidance; in actual machining conditions adjust the parameters according to your actual machine and work-piece conditions. 3To prevent tool breakage due to chips clogging tool flutes, always be sure to use an air blower, etc. to remove chips. 4Ensure to index the insert at the correct time to ensure safety of the tool-body. 11

12 type odular type - Numeric figure in a circle and Alphabetical character comes in a square C E(Nocth width) φdc φdb L1 L2 Item code Stock No. of flutes φdc Size () φdb L1 L2 C E Insert ZDW1-T ZDW160-T ZDW0-T ZDW0-T ZDW0-T φdc Inserts T 1 2 accuracy:±0.01(insert itself) :Stocked Items. 3 A P K SUS, etc. ardened steels Item code ZDW1-T ZDW160-T ZDW0-T ZDW0-T ZDW0-T Tolerance class The insert can be set with "ABPF-type" cutter body Use solid barrel end mill, "-type" for smaller diameter in size Grade T :General cutting, First recoended :General cutting, Second recoended Size() 2 3 A φdc T Cutter body Parts Parts She To reduce environmental loads, drivers and screw anti-seizure agent are sold separately. We ask for your understanding and cooperation. Not included with product (sold separately) Clamp screw Wrench Screw anti-seizure agent Fastening torque (N m) T 1-TS 5-TA P-37 Angle range of barrel and tip For information on the detailed tool she, download the DXF data from the itsubishi itachi Tool Engineering home page. itsubishi itachi Tool Engineering tool selection database ( TOOL SEAC: ) Tilt angle range of barrel and tip Angle range of tip that can be used as a ball end mill

13 ecoended cutting conditions ed indicates primary recoended grade. Work material Alloy steels (<C) Alloy steels (~45C) Stainless steels SUS Cast iron FC FCD ardened steels (45~55C) ardened steels (55~62C) T8 T8 T8 T8 fz (/t) fz (/t) fz (/t) fz (/t) fz (/t) fz (/t) 19,9 1, , (140) 1, ,9 1, ,9 1, ,270 (0) 1, , (90) ,9 1, 13, (140) 1, 14,9 1, 14,9 1, 9,960 (0) 1,000 8, (90) 900 Tip ecoended Cutting grade conditions φ(1.2) φ16(1.6) φ(2) φ(2.5) φ(3) The ( ) values of vc indicate the cutting speed of the tip part. When overhang length is 3Dc or greater, adjust the values shown in the table at right according to the above table. 11,950 1, , (140) 1, ,950 1, ,950 1, ,970 (0) , (90) Tip ,560 1, ,9 700(140) 1, ,560 1, ,560 1, (0) , (90) ,970 1,280 7, (140) 1,0 7,970 1,280 7,970 1,280 5,3 (0) 850 4, (90) 770 φ 19,1 5, ,8 5 4, , , ,1 8, 3 1,700 7, ,490 Determine the or value based on the desired cusp height by selecting it from the table below or by calculating it using the equation below. Note Insert Item code ZDW1-T ZDW160-T ZDW0-T ZDW0-T ZDW0-T Barrel Cutting depth using barrel () Cusp height () efer to the blow table efer to the blow table efer to the blow table efer to the blow table efer to the blow table efer to the blow table Overhang ratio <3Dc 3Dc ~ 5Dc 5Dc ~ 6Dc 0% 70% 60% 0% 70% 60% Cutting depth using tip () Cusp height () , ,1 5, , ,340 5, , φ16 φ φ 14,340 11,470 9,180 4,3 3,450 2, efer to the blow table 8, ,490 5 efer to the blow table, ,1 5 efer to the blow table 11,470 4,590 efer to the blow table 5,0 3 1,0 6,6 5 1, , , ,180 3,680 4, efer to the blow table 5, ,1 4, , efer to the blow table Overhang ratio 6Dc ~ 7Dc 7Dc ~ 50% 45% 50% 45% = 2 Tip φ 2,0 5 5,5 5 1, , , ,060 3, , () : Tool :Cusp height 1Use the propriate coolant for the work material and machining she. 2These conditions are for general guidance; in actual machining conditions adjust the parameters according to your actual machine and work-piece conditions. 3To prevent tool breakage due to chips clogging tool flutes, always be sure to use an air blower, etc. to remove chips. 4Ensure to index the insert at the correct time to ensure safety of the tool-body. ( 2 -(-) 2 ) Set-up Procedures of Inserts Clamp screw (high precision screw) 1 Clean the insert seat: Using air-blow or alike, clean the seat. 3 Tighten the clamp screw with the special wrench. Please do not press down the insert during this tightening process. 2 Put in the insert with its top positioned to the screw-tightening side of the tool body. 4 This is the end of insert set-up. Top mark Tool body 13

14 odular Shank Carbide Shank L 3 L L1 L2 s L1 L2 L 3 L s φd 3 φds φd 3 φd 4 φds Type A L1 L2 L 3 L s φd 3 φd 4 φds Type B Type C Size () Item Code Stock Type Cutter body L3 L L2 L1 s φd3 φds φd4 ASC ASC ASC ASC ASC ASC ASC ASC ASC ASC Z ASC Z ASC Z ASC Z ASC Z ASC Z ASC ASC ASC ASC ASC ASC ASC ASC ASC ASC ASC ASC ASC ASC :Stocked Items (0) (1) (155) (155) (7) 145(152) 165(172) 185(192) 185(192) 150(158) (8) 170 0(8) 2 0(8) 270 0(8) 2 0(8) (183) 145 0(3) 215 0(3) (353) 315 0(3) (353) (3) 0(3) 0(3) 350(353) (403) 0(3) 350(353) (403) (50) 50 (26) 44 (70) (90) (50) (62) (87) (32) (7) 1 (7) (62) (88) 1 70 (38) 90 1 (8) (158) (188) (38) (88) (3) 80 35(38) (153) (183) (233) (38) 40(43) (3) 1 (3) 150 (153) 180 (183) 2 (233) 280 (283) (43) 80 1 (3) Dimensions in ( ) are when or is attached. Other shanks for modular mill, arbor can also be used. Please refer to pages D6 to D of the total catalog Use steel shank for short projection plication C A A A B B B B -6 G T G-3- T-3- G G-4- T

15 Steel Shank L 1 L 3 L L 2 s φd 3 φds φd 2 A type L 3 L 3 L L 1 L 2 L s L 1 L 2 s φds φd 2 φd 3 φd 4 φd 3 φds B type (Tered neck) φd 2 C type Item Code Stock L 3 Size() L L 2 L 1 s φd3 φds φd4 She Cutter body AS (1) 84 (26) 4 24() A -6 AS (7) 95 (32) 15 40(47) B G T AS (138) 0 (38) 50(58) C G-3- T-3- G AS (153) (38) 35 70(73) C G-4- T AS (153) 1 40(43) 70(73) C :Stocked Items. L 3 L L 1 L 2 s φd 3 φds D type φd 2 For neck section or total length, additional machining to user specifications is possible. Item Code Stock φd 2 L 3 Size() L L 2 L 1 s φd 3 φds Cutter body AS (403) (43) 90 67(70) :Stocked Items. Coercial milling chucks can be used. Dimensions in ( ) are when or is attached. 15

16 type Solid type 4 Flutes Item code T3 2 Stock φdc Tip 1 2 n φdn Tool dia. Dc 15 L Flute length Carbide Size () T3 Coated Under neck length n 72 C Neck dia. Dn φds elix 45 h5 Form tolerance:±0.01 Overall length L Shank dia. Ds 2.5--T T3 5--T T3-50-T : manufacturer stocked items. Contact with our sales office. There is no regrinding compatibility for this tool. For the large diameter in size, use the indexable end mill "". For information on the detailed tool she, download the DXF data from the itsubishi itachi Tool Engineering home page. (itsubishi itachi Tool Engineering tool selection database TOOL SEAC: achining method of When using with 5-axis machine By using the barrel with tilted tool axis, tilted section can be cut with large pitch. Furthermore, it is possible to cut with less machining steps by using the tip. When using with 3-axis machine enables to cut steep face with large pitch. owever, it is necessary to process the bottom corner section with a separate tool. Processable with igh helix she realized low cutting force Needs separate tool Cutting conditions 2 flutes Ball End mill Work material:yx33(58c) Tool:-50-T3 2 flutes Ball End ill She:See the figure right Condition: n=4780min -1 vf=956/min (Ball:vf=478) =0.5 =0.3 Contouring Down cut Cutting force (N) : 径方向 adial direction : 送り方向 Feed direction : 軸方向 Axial direction Time Time Incline angle 9 igh helix she reduces cutting force, 4 flutes improve efficiency 16

17 ecoended cutting conditions cutting condition Work material Carbon steel, Alloy steel (<35C) Pre-hardened steel (35~45C) ardened steel (45~55C) ardened steel (55~65C) ardened steel (65~72C) Tip 1 () () evolution Feed rate n vf min -1 /min 23,550 3, ,700 2, ,780 2, ,850 1, ,890 1, evolution Feed rate n vf min -1 /min evolution Feed rate n vf min -1 /min evolution Feed rate n vf min -1 /min evolution Feed rate n vf min -1 /min ~ 19,0 2,480 2 ~ 17,8 1,960 2 ~ 16,550 1, ~,7 1, ~ ~ 13,840 2,460 7 ~ 11,880 1,780 7 ~ 11,370 1, ~ 8,570 1, ~ ~, 2, ~ 9,1 1, ~ 7,040 1, ~ 6,490 1, ~ ~ ~ 6,9 5,0 1,780 1, ~ 0.45 ~ 6,190 4,5 1,390 1, ~ 0.45 ~ 4,460 3,5 1,2 1, ~ ~ 4,290 3, ~ ~ Tip cutting condition Work material Tip 1 () 2 () Carbon steel, Alloy steel (<35C) evolution Feed rate n vf min -1 /min Pre-hardened steel (35~45C) evolution Feed rate n vf min -1 /min ardened steel (45~55C) evolution Feed rate n vf min -1 /min ardened steel (55~65C) evolution Feed rate n vf min -1 /min ardened steel (65~72C) evolution Feed rate n vf min -1 /min ,3 2, , 2, ,000 1, ,700 1, ,800 1, ,680 2, , 2, , 2, , 1, , 1, ,080 3, , 2, ,700 2, ,900 2, , 1, , 3, ,000 2, , 1, ,0 1, ,000 1, , 3, ,000 2, ,000 1, ,560 1, ,9 1, Cutting condition for using both barrel and tip Work material Tip 1 () 2 () Carbon steel, Alloy steel (<35C) evolution n min -1 28,940,690 16,9 14,1,750 Feed rate vf /min Pre-hardened steel (35~45C) evolution n min -1 Feed rate vf /min ardened steel (45~55C) evolution n min -1 Feed rate vf /min ,8 2,780 2,9 2,640 2,360 23,850 17,6 14,450 11,970 9,050 2,270 2,390 2,460 2,0 1,950 21,9 15,690,9,800 7,760 1,9 1,950 2,040 1,6 1,450,6 14,940 11,470 9,380 7,040 For cutting depth (, ), refer to the above conditions for each section. ardened steel (55~65C) evolution n min -1 ardened steel (65~72C) Feed rate evolution vf n /min min -1 1,7 16,770 1,,090 1,750 9,950 1,480 1,290 5,560 Feed rate vf /min 1,260 1,0 1,280 1,1 980 Angle range of barrel and tip Depending on the cutting she, the contact section is divided into barrel and tip. Check the contact section and select the propriate cutting conditions according to each section. Tip Tip Determine the value based on the desired cusp height by selecting it from the table below. Tool Item code T T3 5--T T3-50-T3 Note Cusp height () Use the propriate coolant for the work material and machining she. 2Use a machine having as high rigidity and high accuracy as possible. 3These conditions are for general guidance; in actual machining conditions adjust the parameters according to your actual machine and work-piece conditions. 4If the rpm of the machine is low, lower the feed rate also to put the rpm and feed rate in the same ratio About tool she "" of has a she that connects "tip " and "tool diameter" with double arc. See the figure on the right. Tip Interface between tip and barrel Interface between tool diameter and barrel Tool dia. Neck dia. 17

18 Field data In 3-axis machining evaluation test of machining surface step between barrel and tip Cutting conditions Work material:skd61(52c) φ-t8 O=88 n=7,970min -1 vf=960/min Cusp height setting value:0.001 Air-blow, Down cut achining with barrel achining with tip a0.76μm She measuring result of linkage section Linkage section Good machined surface without machining step. odel machining of YX 33 with 5-axis machine Tool:-50-T3 achine:5-axis machine, Air blow Work material:yx33(58c) achining depth: Work size:about 90 Finishing time:about 2 hours. CAD/CA:hyperILL Process Tool Working area Flute she evolution n (min -1 ) Cutting speed vc (m/min) Feed rate vf (/min) Feed per tooth fz (/t) Depth of cut () Depth of cut () Cutting time (min) oughing GOF40--T adius 2, , Finishing ET adius 3, , Semi-finishing 5--T3 (O/:) ❶ ❷ Barrel edge Tip edge,560 15, ,440 2, Finishing T3 (O/:) ❸ ❹ Barrel edge Tip edge 11,370 18, ,640 1, Possible to finish tilted section and fillet section (connection surface) with one tool. Good machined surface without machining steps which caused by tool change. ❶,❸ ❷ ❹ The same tool could finish even fillet section. Surface roughness is good even when cutting with large pitch a:0.515μm z:2.574μm 18

19 Three-axis machining of auto mobile C pillar outer plate model Lens part Large pitch Small pitch Corner part Barrel part Combining high efficiency and high quality machining Work material : DAC (43C) achine : BT50 class CAD/CA : tebis Large pitch Corner part Small pitch Lens part Large pitch oughing1:about 4 hours. φ42 igh feed tool TD4N type Unequal part after roughing process can be machined with efficiency of 1.4 times the conventional ball end mill. oughing2:about 50 min. φ Ball end mill BCF type After roughing Surface roughness improved by 40% with the same processing time as conventional ball end mill. After finishing Semi-finishing finishing:about 8 hours. φ Ball end mill ABPF type φ GALLEA type ZPW0-LB φ16 Ball end mill ABPF type φ Ball end mill EBE φ6 Ball end mill EBE Total cutting time : About 13 hours Three-axis machining of automobile door panel model By separately using the GALLEA series and conventional tool, you can process the rest of fillets speedy and with high quality. For high hardened steel, can be processed with efficiency of about 1.4 times that of a conventional ball end mill of same diameter. Work material : SLD-AGIC (60C) achine : BT40 class CAD/CA : WorkNC Process oughing All Semifinishing Corner etc. Corner etc. Finishing All Corner etc. Tool 2P16S-4 EPW0402TN-2 JP45 - ZPW0-LB T8 EB4080-AT EB4050-AT - ZPW0-LB T8 EB4080-AT Cutting speed vc (m/min) evolution n (min -1 ) 1,290 3,183 5, 8, 3,183 6, Feed per tooth fz (/t) Feed rate vf (/min) 1,540 1,273 1,905 1,840 1,273 2,050 Depth of cut () 0.3 Depth of cut () Cusp height (μm) emoval stock () 0 0 Coolant Air-blow Air-blow Air-blow Air-blow Air-blow Air-blow Corner etc. EB4050-AT 160,0 1, Air-blow Total cutting time : About 4 hours 19

20 The diagrams and table data are examples of test results, and are not guaranteed values., Epoch, and are registered trademarks of itsubishi itachi Tool Engineering, Ltd. in Jan. Attentions on Safety 1. Cautions regarding handling (1) When removing the tool from its case (packaging), be careful that the tool does not pop out or is dropped. Be particularly careful regarding contact with the tool flutes. (2) When handling tools with sharp cutting flutes, be careful not to touch the cutting flutes directly with your bare hands. 2. Cautions regarding mounting (1) Before use, check the outside pearance of the tool for scratches, cracks, etc. and that it is firmly mounted in the collet chuck, etc. (2) When preparing for use, be sure that the inserts are firmly mounted in place and that they are firmily mounted on the arbor, etc. (3) If abnormal chattering, etc. occurs during use, stop the machine iediately and remove the cause of the chattering. 3. Cautions during use (1) Before use, confirm the dimensions and direction of rotation of the tool and milling work material. (2) The numerical values in the standard cutting conditions table should be used as criteria when starting new work. The cutting conditions should be adjusted as propriate when the cutting depth is large, the rigidity of the machine being used is low, or according to the conditions of the work material. (3) Cutting tools are made of a hard material. During use, they may break and fly off. In addition, cutting chips may also fly off. Since there is a danger of injury to workers, fire, or eye damage from such flying pieces, a safety cover should be attached when work is performed and safety equipment such as safety goggles should be worn to create a safe environment for work. (4) There is a risk of fire or inflaation due to sparks, heat due to breakage, and cutting chips. Do not use where there is a risk of fire or explosion. Please caution of fire while using oil base coolant, fire prevention is necessary. (5) Do not use the tool for any purpose other than that for which it is intended. 4. Cautions regarding regrinding (1) If regrinding is not performed at the proper time, there is a risk of the tool breaking. eplace the tool with one in good condition, or perform regrinding. (2) Grinding dust will be created when regrinding a tool. When regrinding, be sure to attach a safety cover over the work area and wear safety clothes such as safety goggles, etc. (3) This product contains the specified chemical substance cobalt and its inorganic compounds. When performing regrinding or similar processing, be sure to handle the processing in accordance with thelocal laws and regulations regarding prevention of hazards due to specified chemical substances. ead Office ulic yogoku Bldg. 8F, , yogoku, Sumida-ku, Tokyo, Jan International Sales Dept. : TEL FAX Official Web Site Database for selection Cutting Tool Products TOOL SEAC Search Web Europe C itachi Tool Engineering Europe Gmb Itterpark, ilden,germany. Tel +49-(0) Fax +49-(0) ITSUBISI ATEIALS U.S.A. COPOATION DETOIT OFFICE Customer service Gardenbrook oad, Suite 1, Novi, I U.S.A. Tel +1(248) 8-26 Fax +1(248) CICAGO OFFICE 1314B North Plum Grove oad, Schaumburg, IL U.S.A. Tel +1(847) Fax +1(248) China C itachi Tool Engineering(Shanghai),Ltd. 11F, Chuang Xing Financial Center, 288 Nanjing D (West) Shanghai, China 0003 Tel +86-(0) Fax +86-(0) C ardmetal(thailand)co.,ltd. T-Division CTI Tower 24 Floor, 191/32 atchadisek oad, Klongtoey, Klongtoey, Bangkok 1, Thailand Tel: +66-(0) Fax: +66-(0) itachi etals (India) Pvt. Ltd. Plot No 94 & 95,Sector 8, IT anesar,gurgaon-1, aryana, India Tel Fax America Thailand India DISTIBUTED BY: Specifications for the products listed in this catalog are subject to change without notice due to replacement or modification. Printed using vegetable oil ink. Printed in JAPAN 17-(K) 17-:FP