TR4D. High Feed Radius Mill. New Product News No. H1901A

Transcription

1 TR4D High Feed Radius Mill New Product News No. H1901A

2 Technology Applications Roughing Copper Carbon steel Alloy steel Stainless steel Pre-hardened steel Hardened steel Hardened steel Tool steel Hardened steel 3045HRC 4555HRC 5562HRC Features 01 Pocket Stability Superior pocket stability enables higher feed rate. Comparison from general steel to pre-hardened steel feed/tooth 1.0 ASR,ASRT,ASRF TR4D Thick Oversize seating area 200HB Work hardness (HRC) Features 02 Options Options - 2 geometries & 3 insert grades cover various applications. Tougher edge for general usage Standard type Suitable for pre-hardened steel Low cutting force type (-P) P breaker is recommended for continuous cutting with sufficient clamping of workpiece. Features 03 Cutter body assortment Line up includes: Inch and metric shell mill coupling Without and with insert clamps where extreme rigidity needed based on the application. Multiple pitch options plus variable pitch to reduce vibration. 02

3 Features 04 Application ❶ Max feed per tooth: fz = /tooth (mm/tooth) It is necessary to adjust the feed rate according to machining situation ❷ For best milling performance, recommend max cutting depth ap=7 (1.2mm) ❸ Number of corners: 4 corners (single-side) Economical multi-corner ❹ Strong points of single sided inserts compared to double-sided inserts 1) Large chip pocket for chip evacuation 2) Optimized rake angle reduces chip jamming 3) Higher clamping security than a 2 sided insert. 4) All corners can be fully used up 5) Large ramping angle AJ Coating Series New AJ coating is now applied to all 4100 series inserts. AJ coating features High AlTiN PVD coating technology that delivers both improved heat resistance and coating adhesion. To further increase performance, 4100 series inserts have a special surface treatment that reduces friction and minimizes welding. Coating structure Welding-resistant low-cutting-force coating surface layer PVD Technology Grade for machining pre-hardened or hardened materials Highly versatile with excellent cutting performance on pre-hardened steel or hardened steel. (30-50 HRC). Coating with excellent wear resistance and chipping resistance PVD Technology Grade for machining stainless-steel materials Carbide features a tough substrate to handle demanding stainless materials topped with AJ coating engineered specially for stainless materials. PVD Technology purpose for steel is an existing PVD coated steel grade selected for the TR4D cutter due to its exceptional toughness in interrupted or unstable applications. should be used when encounters chipping. 03

4 Line up Shell Mill type ( I)TR4D4 B(M)- With air hole With air hole DCSFMS DCSFMS DCON DCON LB KWW LB KWW CBDP CBDP LF LF DCCB DCCB DCX DCX with clamp piece set Multi-flutes (no clamp piece set) Inch Order No. Stock # of Flutes Dimensions (Inch) DCX DCSFMS LF CBDP KWW LB DCON DCCB Fig. ITR4D4032B ITR4D4032B ITR4D4040B ITR4D4040B-6 ITR4D4048B-5 ITR4D4048B SDNW120520TR SDNW120520TR-P ITR4D4048B ITR4D4064B ITR4D4064B Metric Order No. Stock # of Flutes Dimensions (mm) DCX DCSFMS LF CBDP KWW LB DCON DCCB Fig. TR4D4050BM TR4D4050BM TR4D4063BM-4 TR4D4063BM SDNW120520TR SDNW120520TR-P TR4D4080BM TR4D4100BM Recommendation Turn the insert counterclockwise upon insert indexing. Inventory maintained in US 04

5 IC IC S S P M K Steel Stainless steel Cast Iron/Ductile Cast Iron : Cutting Oder No. Tolerance class AJ Coated JS Coated Dimensions (mm) Dimensions (Inch) IC S IC S Shape SDNW120520TR SDNW120520TR-P N Material Name ISO Classification Coating Name Coating Type Application Features P10-M10-K10 AJ Coating PVD For pre-hardened steel (35-50HRC) and alloy steel. Uses fine grain substrate and AJ coating. Suitable for cutting of common steels through pre-hardened steels. M40 AJ Coating PVD purpose for stainless steel. Uses high toughness substrate and AJ coating. Suitable for cutting of stainless steels. P30-K30 JS Coating PVD purpose for steel. Uses tough substrate and JS coating. Suitable for general steel cutting. Parts Parts Screw The clamp screw is a consumable part. Clamp screw replacement is dependent on use. We recommend replacing screw at signs of wear on screw seat chamfer. Clamp Piece Set Wrench Screw Anti-Seizure Agent Shape Fastening torque (N m) Order No CM T15 P37 Programming guidance In CAM, define the tool shape as an.1299" (R3.3mm) radius shape. Use with axial-direction cutting depth ap of 1.2mm (7") or less. Corner R Definition in CAM Remains (Inch/mm) Over Cut (Inch/mm) When setting with corner R3.3mm (.1299") When corner R is set large.1181" (R3.0mm).0386" / 0.98mm " (R3.3mm).1378" (R3.5mm).0368" / 0.935mm.0356" / 0.904mm " / 0.032mm Over cut.1575" (R4.0mm).0326" / 0.829mm.0067" / 0.169mm.1772" (R4.5mm).0296" / 0.753mm.0133" / 0.339mm R3.3 Remains Programming R Remains.1969" (R5.0mm).0268" / 0.681mm.0197" / 0.501mm Max 0.935mm (.0368") 05

6 Recommended Cutting Conditions Inch Face Milling, Side Milling Work Material Structural Steel (200HB or less) (<30HRC) (3040HRC) 300 series Stainless Steel (WET) Cast Iron/ Ductile Cast Iron Hardened Steel (4050HRC) Grade Vc (SFM) Feed per Tooth fz(inch/t) Cutter Dia. Overhang ratio φ2"(4nt) φ2"(5nt) φ2.5"(4nt) <3Dc 35Dc 57Dc >7Dc <3Dc 35Dc 57Dc >7Dc <3Dc 35Dc 57Dc >7Dc Red indicates primary recommended insert grade. φ2.5"(6nt) <3Dc 35Dc 57Dc >7Dc θ Ramp angle θ Ramping Hole.Dia. Tool Diameter Max ramp angle θ Hole Dia. (inch) Hole Dia. (mm) 2" or 50mm "3.780" 8296mm 2.5" or 63mm "4.803" mm 3" or 80mm "6.142" mm 4" or 100mm "7.717" mm Please set the ramp angle within the above range on table. we recommend to use less than 1. Pilot hole is necessary if the hole diameter is larger than that range. Helical milling 06

7 Work Material Structural Steel (200HB or less) (<30HRC) (3040HRC) 300 series Stainless Steel (WET) Cast Iron/ Ductile Cast Iron Hardened Steel (4050HRC) Grade Vc (SFM) Feed per Tooth fz(inch/t) Cutter Dia. Overhang ratio φ3"(5nt) φ3"(7nt) φ4"(6nt) <3Dc 35Dc 57Dc >7Dc <3Dc 35Dc 57Dc >7Dc <3Dc 35Dc 57Dc >7Dc φ4"(8nt) <3Dc 35Dc 57Dc >7Dc

8 Recommended Cutting Conditions Metric Face Milling, Side Milling Work Material Structural Steel (200HB or less) (<30HRC) (3040HRC) 300 series Stainless Steel (WET) Cast Iron/ Ductile Cast Iron Hardened Steel (40 50HRC) Grade Vc (m/min) Feed per Tooth Cutter Dia. Overhang Ratio Red indicates primary recommended insert grade. φ50mm(3nt) φ50mm(4nt) φ63mm(4nt) <3Dc 35Dc 57Dc >7Dc <3Dc 35Dc 57Dc >7Dc <3Dc 35Dc 57Dc >7Dc θ Ramp angle θ Ramping Hole.Dia. Tool Diameter Max ramp angle θ Hole Dia. (inch) Hole Dia. (mm) 2" or 50mm "3.780" 8296mm 2.5" or 63mm "4.803" mm 3" or 80mm "6.142" mm 4" or 100mm "7.717" mm Please set the ramp angle within the above range on table. we recommend to use less than 1. Pilot hole is necessary if the hole diameter is larger than that range. Helical milling 08

9 Work Material Structural Steel (200HB or less) (<30HRC) (3040HRC) 300 series Stainless Steel (WET) Cast Iron/ Ductile Cast Iron Hardened Steel (40 50HRC) Grade Vc (m/min) Feed per Tooth Cutter Dia. Overhang Ratio φ63mm(5nt) φ80mm(5nt) φ100mm(6nt) <3Dc 35Dc 57Dc >7Dc <3Dc 35Dc 57Dc >7Dc <3Dc 35Dc 57Dc >7Dc

10 Filed Data No. User name Work (mold type / parts) Competitor Tools & cutting conditions Evaluation Tools TR4D4100B-6 (φ3.937"-6 flutes) SDNW120520TR-P: 1 Company A Plastic mold (for automotive bumper) Pre-hardened steel (42HRC) - Cutting conditions vc:107m/min (351 sfm), fz:1.8mm/t (.071 in/tooth) OH:408mm (16 in) (4D) ap ae = mm (.039 in x 2.56 in) Tools TR4D4080B-5 (φ3.15" -5 flutes) SDNW120520TR-P: Achieved high efficiency stable cutting with long projection Cutting conditions vc:100m/min (328 sfm), fz:1.7mm/t (.067 in/tooth) OH:408mm(5D) ap ae = mm (.039 x 5 in) 2 Company B Shear blade SCM440 (47 48HRC) Competitor G 3 corner High-feed tools Tools TR4D4063BM-5 (φ2.48" -5 flutes) SDNW120520TR: vc:119m/min (390 sfm) fz:0.8mm/t (.031 in/t) ap ae = mm (.039 x 1.73 in) 1.5 times longer tool life against competitors 3 Company C Forging dies (for crank shaft) H13 (46 48HRC) Competitor Y 4 corner High-feed tools Tools TR4D4100B-6 (φ3.937"-6 flutes) SDNW120520TR : Cutting conditions vc:101m/min (331 sfm) fz:0.42mm/t (.017 in/t) ap ae = mm (.59 x 2.76 in) Achieved stable cutting with 1.2 times efficiency It was well received since small and curlled cutting chips were generated 4 Company D Lens mold 4140(A) Competitor J 3 corner High-feed tools Tools TR4D4063BM-5 (φ2.48" -5 flutes) SDNW120520TR: Cutting conditions vc:131m/min (430 sfm) fz:1.2mm/t (.47 in/t) ap ae = mm (3.071 x 1.97 in) Achieved stable cutting with 1.6 times efficiency It was well received since machining noise and cutting chipps are small 10

11 High Feed Tools Lineup Application Matrix: Rough Machining Feature Holder Type Economical (no. of corners) High accuracy (Less uncut remnants) Supports for highhardened steel Efficiency (no. of Flutes) Tool dia. No. of corners Shape Inscribed circle code Programing R Max cutting depth TD4N 50HRC High efficiency multiflutes.625" 1.5" 16mm 42mm " or mm " or 1.0mm ASR MULTI 62HRC High efficiency multiflutes.625" 2.5" 16mm 66mm " or mm.06" or 1.5mm ASRF-mini 62HRC.75"2.5" 20mm 63mm " or mm 7" or 1.2mm ASR 60HRC.75" 4" 20mm 100mm " or 3.0mm.078" or mm IASRT 62HRC 2" 5" " or 3.0mm.078" or mm IASRF 60HRC 1.25" 4" " or 4.5mm.078" or mm TR4D 50HRC High efficiency multiflutes mm100mm or 3.3mm 7 or 1.2mm For details of tool specifications, please check on catalog or website ( The diagrams and table data are examples of test results, and are not guaranteed values. "Epoch", and are registered trademarks of Mitsubishi Hitachi Tool Engineering, Ltd. in Japan. Safety Considerations 1. Handling (1) When removing tool from packaging, be careful not to drop the tool on your foot or fingers. (2) When actually setting the inserts, be careful not to touch the cutting flute directly with your bare hands. 2. Mounting (1) When preparing to use, be sure that the insert is firmly screwed in the pocket and cutter is properly mounted on the tool holder. (2) If abnormal chattering occurs during use, stop the machine immediately, identify the cause of the chatter and take corrective action. 3. Usage (1) Before use confirm all dimensions, verify work material and programmed tool rotation. (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 appropriate 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) s are made of hard material and may break and be expelled from cutter at high speeds. Since there is a danger of injury to workers from chip evacuation, insert breakage or fire safety precautions must be observed at all times. Including, but not limited to: safety glasses, machine enclosures or other means to create a safe environment for work. If you have questions on safety, contact your supervisor. Do not use where there is a risk of fire or explosion. Do not use non-water-soluble cutting oils. Such oils may result in fire. (4) Do not use the tool for any purpose other than that for which it is intended, and do not modify it. 11

12 Los Angeles Head Office Slater Avenue Fountain Valley, CA 92708, USA Tel: Fax: Customer Service for Mitsubishi Hitachi Tool Engineering, Ltd. Products Gardenbrook Road, Suite 120 Novi, MI 48375, USA Tel: Fax: Toronto (Customer Service) 3535 Laird Road, Units 15 & 16 Mississauga, Ontario, L5L 5Y7, CANADA Tel: Fax: Mexico Office MMC METAL DE MEXICO, S.A. DE C.V. Av. La Canada No.16 Parque Industrial Bernardo Quintana El Marques, Queretaro C.P MEXICO Tel: Fax: DISTRIBUTED BY: (Manufacturer) st Edition NO. H1901A-1