High productivity with newly designed wiper edge geometry

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Frederica Lee
5 years ago
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1 Positive wiper insert WP High productivity with newly designed wiper edge geometry Excellent surface roughness and smooth chip control during high feed machining. High quality surface finish with no galling. High machining accuracy with low cutting forces.

2 Positive wiper insert High productivity with newly designed wiper edge geometry. 1 Excellent surface roughness during high feed machining Dual-dot structure One dot offers stabilized chip control at low feed rates, while a second dot controls chips at higher feeds. Wiper edge comparison (In-house evaluation) 2 Sharp wiper edge design Excellent surface finish and low cutting forces with sharp wiper edge design. Surface roughness Rz (μm) 2 Non-wiper edge 1 1 Wiper edge Cutting conditions: Vc = 2 m/min, ap =.3 mm Toolholder: A2R-SCLCR9-22AE, insert: CCMT9T34 type 2 Stable chip control in a wide range of feed rates Smooth chip control from low feed to high feed rate. Chip control comparison (In-house evaluation) Competitor A Cutting conditions: Vc = 2 m/min, ap =.3 mm, wet; toolholder: A2R-SCLCR9-22AE; insert: CCMT9T34 type; workpiece: 1CrMo4 1

3 Excellent surface finish WP chipbreaker offers excellent surface roughness across a wide range of cutting conditions. Surface finish comparison (In-house evaluation) 2 f =.1 mm/rev f =.

2 μm Cutting conditions: Vc = 1 m/min, ap =.

3 3 Excellent surface finish WP chipbreaker offers excellent surface roughness across a wide range of cutting conditions. Surface finish comparison (In-house evaluation) 2 f =.1 mm/rev f =.4 mm/rev Surface roughness Rz (μm) 1 1 Competitor B Competitor C Rz = 2.7 μm Competitor B Rz = 1.4 μm Competitor C Rz = 6.7 μm Competitor B Rz = 1. μm Competitor C Rz = 1.6 μm Rz = 13.2 μm Cutting conditions: Vc = 1 m/min, ap =. mm, wet; toolholder: A2R-SCLCR9-22AE; insert: CCMT9T34 type; workpiece: 1CrMo4 4 Reduces surface finish galling WP chipbreaker reduces tearing of the finished surface by controlling adhesion with the newly designed wiper edge. (In-house evaluation) Competitor D (Wiper edge) Cutting conditions: Vc = 8 m/min, ap =.73 mm, f =. mm/rev, wet Insert: CCMT9T34 type; workpiece: St4 (Steel pipe) High machining accuracy with low radial forces Prevents tool deflection by reducing radial forces. Cutting force comparison (In-house evaluation) f =.1 mm/rev Radial force 1 14% 1 DOWN Cutting force (N) Cutting Force (N) Radial force 14% DOWN f =.4 mm/rev Principal force Radial force Feed force Competitor E Competitor E Cutting conditions: Vc = 2 m/min, ap =.3 mm, wet; toolholder: A2R-SCLCR9-22AE; insert: CCMT9T34 type; workpiece: 1CrMo4 2

WP chipbreaker reduced the cutting time by more than % by increasing feed rate and reducing number of cuts (2 passes to 1 pass). Wiper edge also improved surface roughness.

4 Case studies Hub C4 Vc = 16 m/min ap =.1 mm (1 pass) f =.8 mm/rev Wet A16Q-SCLCR9-18AE CCMT9T34WP TN62 Sleeve C4 Vc = 18 m/min ap =.2 mm f =.27 mm/rev Wet S16-SCLCR9 type CCMT9T34WP PV72 ø28 Competitor G (Wiper edge) TN62 Competitor F (No wiper) 2.3 sec. % and more Cutting time.6 sec. WP chipbreaker reduced the cutting time by more than % by increasing feed rate and reducing number of cuts (2 passes to 1 pass). Wiper edge also improved surface roughness. (User evaluation) WP chipbreaker improved chip control compared to competitor G. Machining efficiency was improved by increasing feed rate. Tool life extended to 1. times that of competitor G. (User evaluation) Corresponding toolholders / lead angles Applicable cutting edge angle Insert Cutting edge angle CCMT6/9 9 DCMX7/11 93 TCMX9/11 9 TPMX9/11 9 Cutting edge angle Applicable toolholder Insert Application Description Applicable A-SCLC-AE type S-SCLC-A type E-SCLC-A type HA-SCLC9 type CCMT6/9 ACLC-FF type External turning SCLC-FF type SCLC type S-SCLC type A-SDUC-AE type DCMX7/11 S-SDUC-A type E-SDUC-A type HA-SDUC11 type A-SDZC-AE type S-SDZC-A type E-SDZC-A type A-SDQC-AE type S-SDQC-A type E-SDQC-A type No Insert Application Description Applicable ADJC-FF type SDJC-FF type SDJC type S-SDUC type DCMX7/11 External turning SDLC-FF type S-SDLC type See caution SDXC type SDNC-F type No SDNC type A-STLC-AE type TCMX9/11 S-STLC-A type External turning STGC type No A-STLP-AE type S-STLP-A type E-STLP-A type TPMX9/11 S-STWP-E type S-STWP type C-STXP type No External turning STGP type No Caution: The SDLC-FF and S-SDLC toolholders have a lead angle. While the DCMX...WP can offer surface finish improvements over non-wiper inserts in those toolholders, optimum performance will be obtained by using a 3 lead angle, such as ADJC-FF, SDJC-FF, SDJC, S-SDUC, etc. 3

5 Setting conditions for wiper inserts Theoretical surface roughness Theoretical surface roughness Rz (μm) No wiper insert Corner-R (rε) =.4 CC type Corner-R (rε) =.2 CC type Corner-R (rε) =.4 CC type Corner-R (rε) =.8 DC/TC/TP type Corner-R (rε) =.4 The theoretical surface roughness of a wiper insert is lower than inserts without a wiper. When selecting a feed rate, see left chart for theoretical surface roughness WP chipbreaker edge position offset adjustment For D type and T type, cutting edge offsets are required. D type T type.1.2 Standard insert edge line Wiper insert edge line D type T type X-direction correction amount (mm).11.8 For D type and T type, program corrections are required for ramping and profiling. Z-direction correction amount θ Z-direction correction amount θ Ramping angle θ D type Profiling angle θ D type T type Profiling angle θ D type T type

6 Available inserts Usage classification: : Interruption / 1st choice : Interruption / 2nd choice : Continuous - light interruption / 1st choice : Continuous - light interruption / 2nd choice : Continuous / 1st choice : Continuous / 2nd choice P Carbon steel / alloy steel Shape Description M Dimensions (mm) I.C. Thickness Hole Stainless steel Corner-R (rε) Relief angle CCMT622WP WP CCMT9T34WP T38WP DCMX724WP DCMX11T34WP TCMX924WP TCMX1124WP TPMX924WP TPMX1134WP Cermet NANO cermet CVD coated carbide NANO TN62 PV72 CA1 CA1 CA2 CA3 PR142 PR122 : Available Recommended cutting conditions Workpiece Insert grade Cutting speed Vc (m/min) Min. - Recommendation - Max. ap (mm) Feed f (mm/rev) 3 2 TN PV CA ap (mm) 1 WP Carbon steel / alloy steel CA CA CA CCMT9T type: Steel PR PR Recommended insert grade Carbon steel / alloy steel Applications Target Base material Coating Recommended grade Continuous Surface quality Non-coated TN62 Cermet Wear resistance NANO PV72 Light interrupted Wear resistance (High speed) Fracture resistance (Small parts) Carbide CVD NANO CA1 / CA1 / CA2 / CA3 PR142 / PR KYOCERA Corporation TZE81

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