TRS SERIES. Coolant-Through - Three fluted - Carbide Drills TRS-HO-3D TRS-HO-5D TRS-HO-10D

Transcription

1 TR ERIE Coolant-Through - Three fluted - Carbide TR-HO-3D TR-HO-10D

2 TR redefines the meaning of high speed drilling 1 3 flutes 2 Coolant through 3 eed exceeding 10% of drill diameter 4 0,1 increment in sizes 3D & 5D

3 Three concepts differentiate the TR series from two-flutes & conventional drills 1 Higher Precision Better tapping process from improved pilot holes Reamer-less drilling can be achieved There are 2 keys to High Precision Drilling 1. Good biting properties to minimize deflection 2. table guide to keep the drilling process straight 2 flute drill TR This center fixes drill s entry point 2 flute drill TR There is no pivotal point 2 Directions vs 3 Directions! 2 Improved feed rate The higher the feed rate, the more the output Reduced cost per unit If we needed to drill 10mm through hole TR will complete the process in 10 revolutions with feed rate of 1mm/rev. Conventional Drill, on the other hand, will require 100 revolutions at 0.1mm/rev feed rate 10 revolutions = 10mm 10 revolutions = 1.0mm 3

4 Three concepts differentiate the TR series from two-flutes & conventional drills 3 Reduced work hardening Optimal conditions for thread making Improved tool life for succeeding cutting tools The cause of many Machining Problems is Work Hardening HARDENED LAYER Work Hardening can cause: 1. Unstable tapping quality for both cutting and forming taps 2. Increased machine load that often result in reduced tool life for the drill and succeeding cutting tools. 4

5 The WDI coating is effective in high feed drilling Comparison of the amount of work hardening versus feed per revolution in carbon steel. Work hardening rate comparison Work hardening layer depth comparison 300 two-flutes 12 two-flutes Work hardening layer depth comparison 12 6 Work hardening layer depth comparison Two-lute 10 Two-lute ,22 0,32 0,43 0,65 eed Rate (mm/rev) 2 0 0,22 0,32 0,43 0,65 eed Rate (mm/rev) 0,22 0,32 0,43 0,65 0,22 0,32 0,43 0,65 eed Rate (mm/rev) eed Rate (mm/rev) Tool ø10,8 Competitor A Two-lute Work Material 50c (DIN CK50) (AII 1050) Work Hardening Level Work Hardening Depth Work Hardening Depth Work Hardening Depth Drilling peed 100m/min (2.950min -1 ) eed Rate (Hv0,1) (μm) (Hv0,1) (μm) eed Variable (ee chart) f=0,22mm/rev Depth of Hole 25mm (Through) f=0,32mm/rev Coolant Water oluble f=0,43mm/rev 185 6, Machine Horizontal Machining Center f=0,65mm/rev These graphs shows the level and depth of work hardening in carbon steel when comparing the Mega Muscle drill versus 2 fluted drills. The amount of feed per revolution ranges from 0.22 to 0.65mm/rev. Regardless of the number of flutes, work hardening has the tendency to increase with the increase of the feed rate. It can be noted, when the same feed rate is applied to both drills, the 3 fluted type has a much lower work hardening effect. 3 fluted drills always achieve lower work hardening rates when compared to 2 fluted drills. Thus, it is best practice to keep the work hardening as low as possible when secondary operations such as tapping or reaming are required. The Mega Muscle Drill offers this process stability, reducing the burden of the taps and reamers increasing their tool life. 5

6 Unmatched Processing Efficiency eed rates of = 1480mm/min were achieved in this crankshaft application (carbon steel) Tool TR-HO-3D ø 10,3 400 Number of Holes Work Material 50C (DIN CK50 - AII 1050) Drilling peed 100m/min (2.950min -1 ) eed 1.480mm/min (0,5mm/rev) 560mm/min 0,19mm/rev TR-HO-3D (Holes) (Holes) Wear Continue Depth of Hole Coolant Machine 24mm (Blind) Water oluble Horizontal Machining Center 1,5 times the tool life 2,7 times the productivity Example of the hole processing for the mounting holes on the crankshaft flywheel. TR Drill achieved 1.5 times the tool life and 2.7 times the productivity over Competitor A's 2 fluted drill. With the ability to control work hardening, one has the ability to extend tool life on secondary processes such as tapping, thus decreasing overall tooling and part cost per unit. or example, by lowering the cutting speed to 80m/min, tool life of the drill and all secondary process tools can be extended. eed rates of of =1.480mm/min were achieved, with overall cutting lengths of 166m. Tool TR-HO-3D ø 10, Number of Holes Work Material 50C (DIN CK50 - AII 1050) Drilling peed 100m/min (3.090 min -1 ) TR-HO-3D (Holes) (Holes) Continue Wear eed 1.480mm/min (0,48mm/rev) (Holes) 397 (Holes) Abnormal Wear Breakage Depth of Hole 32mm (Through) Coolant Machine Water oluble Horizontal Machining Center Tool wear comparison TR-HO-3D 0,035 0,03 Changes in amount of hole oversize TR-HO-3D Oversize (mm) 0,025 0,02 0,015 0,01 15μm 6μm 0, Number of Holes Example of carbon steel processing. Because of the high feed rate of 0.48mm/rev, the competitor company's drill showed a large variation in hole expansion as well as low tool life. However, the Mega Muscle Drill was able to achieve 5200 holes (cutting length 166m) with stable hole sizes. The competitor A's hole expansion ranged up to 15um, while the TR Drill had only a 6um variation. 6

7 Drilling feeds exceeding mm/min eed rates of =1.140mm/min were achieved, with overall cutting lengths of 110m Tool ø 10,5 Number of Holes Work Material CM440 (Alloy teel) Drilling peed 80m/min (2.430min -1 ) (Holes) (Holes) Wear Wear eed Depth of Hole 1.140mm/min (0,47mm/rev) 50mm (Through) (Holes) (Holes) Breakage Breakage Coolant Machine Water oluble Horizontal Machining Center eed rates of =1010mm/min were achieved in 30HRC alloy steel. Tool ø 10,8 Number of Holes Work Material CM440 (30HRC) (Alloy teel) Drilling peed 70m/min (2.060min -1 ) (Holes) (Holes) Wear Wear eed Depth of Hole 1.010mm/min (0,49mm/rev) 50mm (Through) 174 (Holes) 300 (Holes) Breakage Abnormal Wear Coolant Machine Water oluble Horizontal Machining Center Tool wear comparison 0,05 Changes in amount of hole oversize 25μm 0,04 0,03 11μm Oversize (mm) 0,02 0, Number of Holes Example of hole processing in alloy steel. At high feed machining of 0.47mm/rev, 's drill was found to be unstable in hole size as well as having low tool life. However, the TR Drill exceeded 2200 (cutting length 110m) holes of tool life, limited by normal wear, thus decreasing overall tooling and part cost per unit. When comparing the hole expansion values, was found to have a large variation of up to 25µm.While the Mega Muscle Drill had up to 11µm. 7

8 140 TR-HO-3D CARBIDE WDI 30 HRINK IT h8 140 P.11 Coolant through, 3 flutes, high feed drilling, for 3XD drilling Innenkühlung, 3 chneiden, Hochleistungsbohrer, 3xD Alta prestazione Con foro di lubrificazione, 3 eliche, alto avanzamento, 3 D Haute performance Arrosage interne, 3 lèvres, perçage haute vitesse, perçage 3D Yüksek performans İçten soğutmalı, 3 ağızlı, yüksek kesme hızlı delme, 3D boy Indvendig køling, 3 skær, high feed boring, 3D Kylkanalsborr med 3-skär, hög matning, 3xD Altas prestaciones Refrigeración interna, 3 labios, para gran avance, tipo 3D Высокая производительность Трехзубые сверла с внутренними каналами и высокой подачей, 3D Wysoka wydajność Do wysokich posuwów wiercenia, trójostrzowe, chłodzenie wenętrzne, 3D D p I L EDP D L l d Price EDP D L l d Price , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , Applications - Anwendungen - Applicazioni - Applications - Applikation - Applikation - Aplicaciones - Применение - Uygulama - Zastosowania C 0.2% 0.25<C 0.4% C 0.45% CM ~35 HRC 35~45 HRC 45~50 HRC 50~70 HRC U KD GG GGG Cu Al AC Ti Tiall Inc 8

9 140 CARBIDE WDI 30 HRINK IT h8 140 P.11 Coolant through, 3 flutes, high feed drilling, for 5XD drilling Innenkühlung, 3 chneiden, Hochleistungsbohrer, 5xD Alta prestazione Con foro di lubrificazione, 3 eliche, alto avanzamento, 5 D Haute performance Arrosage interne, 3 lèvres, perçage haute vitesse, perçage 5D Yüksek performans İçten soğutmalı, 3 ağızlı, yüksek kesme hızlı delme, 5D boy Indvendig køling, 3 skær, high feed boring, 5D Kylkanalsborr med 3-skär, hög matning, 5xD Altas prestaciones Refrigeración interna, 3 labios, para gran avance, tipo 5D Высокая производительность Трехзубые сверла с внутренними каналами и высокой подачей, 5D Wysoka wydajność Do wysokich posuwów wiercenia, trójostrzowe, chłodzenie wenętrzne, 5D D p I L EDP D L l d Price EDP D L l d Price , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , Applications - Anwendungen - Applicazioni - Applications - Applikation - Applikation - Aplicaciones - Применение - Uygulama - Zastosowania C 0.2% 0.25<C 0.4% C 0.45% CM ~35 HRC 35~45 HRC 45~50 HRC 50~70 HRC U KD GG GGG Cu Al AC Ti Tiall Inc 9

10 140 TR-HO-10D CARBIDE WDI 30 HRINK IT h8 140 P.11 Coolant through, 3 flutes, high feed drilling, for 10XD drilling Innenkühlung, 3 chneiden, Hochleistungsbohrer, 10xD Alta prestazione Con foro di lubrificazione, 3 eliche, alto avanzamento, 10 D Haute performance Arrosage interne, 3 lèvres, perçage haute vitesse, perçage 10D Yüksek performans İçten soğutmalı, 3 ağızlı, yüksek kesme hızlı delme, 10D boy Indvendig køling, 3 skær, high feed boring, 10D Kylkanalsborr med 3-skär, hög matning, 10xD Altas prestaciones Refrigeración interna, 3 labios, para gran avance, tipo 10D Высокая производительность Трехзубые сверла с внутренними каналами и высокой подачей, 10D Wysoka wydajność Do wysokich posuwów wiercenia, trójostrzowe, chłodzenie wenętrzne, 10D D d l L EDP D L l d Price EDP D L l d Price , , , , Applications - Anwendungen - Applicazioni - Applications - Applikation - Applikation - Aplicaciones - Применение - Uygulama - Zastosowania C 0.2% 0.25<C 0.4% C 0.45% CM ~35 HRC 35~45 HRC 45~50 HRC 50~70 HRC U KD GG GGG Cu Al AC Ti Tiall Inc 10

11 Conditions TR-HO-3D/5D Mild teel - Low Carbon teel Carbon teel Alloys teel C ~150HB ~500 N/mm 2 35C 50C ~210HB ~710 N/mm 2 CM Cr NCM 16~28HRC 710~900 N/mm 2 Vc 80 ~ 120 m/min 80 ~ 120 m/min 60 ~ 90 m/min Ø ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0, ,46 ~ 0, ,46 ~ 0, ,46 ~ 0, ,49 ~ 0, ,49 ~ 0, ,49 ~ 0, ,48 ~ 0, ,48 ~ 0, ,48 ~ 0, ,54 ~ 0, ,54 ~ 0, ,54 ~ 0,72 TR-HO-3D/5D Alloys teel Cast Iron Ductile Cast Iron CM Cr NCM 28~35HRC 900~1100 N/mm 2 C250 ~350 N/mm 2 CD450 CD ~600 N/mm 2 Vc 60 ~ 90 m/min 80 ~ 120 m/min 60 ~ 100 m/min Ø ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0, ,46 ~ 0, ,46 ~ 0, ,46 ~ 0, ,49 ~ 0, ,49 ~ 0, ,49 ~ 0, ,48 ~ 0, ,56 ~ 0, ,48 ~ 0, ,54 ~ 0, ,63 ~ 0, ,54 ~ 0,81 TR-HO-10D Mild teel Low Carbon teel Carbon teel Alloys teel Cast Iron Ductile Cast Iron C ~150HB ~500 N/mm 2 35C 50C ~210HB ~710 N/mm 2 CM Cr NCM 28~35HRC 900~1100 N/mm 2 C250 ~350 N/mm 2 CD450 CD ~600 N/mm 2 Vc 80 ~ 120 m/min 80 ~ 120 m/min 60 ~ 120 m/min 80 ~ 120 m/min 60 ~ 100 m/min Ø ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0,60 11

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