Features. May 1, No. 204-M-02

Transcription

1 May 1, 2009 No. 204-M-02 Features - High rake angle cutting edge realized high feed and multi functional machining due to reduced cutting load. - HRMD has improved economical aspect to use 6 cutting edges compared to HRM tool with positive insert. - Negative geometry has been designed for rigidity of cutting edge and double sided function. - HRMD insert with symmetrical cutting edge is applicable to be both-r and L type machining. - Simple screw on system and stable upholding are able to achieve strong clamping force. Facing Slotting Copying Ramping Helical cutting Through Coolant System

2 Features of insert Features of cutter Application area Features of insert Nose-R Security of rigid edge in ramping, pocket machining Round edge line suitable for high feed Insert geometry extrinsic to R/L type machining Chip breaker Reduction of cutting load due to high rake angle Improvement of chip flow Prevention of damage on clamping face of insert Minor cutting edge Improvement of surface roughness Design for decreasing thrust force Major cutting edge High feed by application of high rake cutting edge Realization of low cutting resistance in high feed Symmetrical insert design for R/L type tool Features of cutter Application area Through coolant system Direct cooling for improvement of chip control Longer tool life due to reduce cutting temperature 0.02 Simple screw on system Powerful clamping of screw on system Wide contact face for stable upholding Wide chip pocket for better chip evacuation Unique insert design and high tolerance of tip seat part guarantee high quality surface roughness

3 Corner R programming Recommended cutting condition Application example Corner R programming Cutting condition Approx R Max ap Max fz(mm/t) Input R Uncut WNMX09T316ZNN-MM WNMX130520ZNN-MM Information for uncut part by using "Input.R" for CAM program. Recommended cutting condition Uncut part can be changed by poor machine condition or weak clamp of workpiece, etc. workpiece Hardness Grade vc(m/min) fz(mm/t) General structural steel Under 200HB PC3500 PC (100~230) 1.0 ~ 2.0 P Carbon steel, Alloy steel High carbon steel, Alloy steel Under 30HRC 30~40HRC PC3500 PC3545 PC3500 PC (100 ~ 220) 160 (100~200) 1.0 ~ ~ 1.3 M Pre-hardened steel Stainless steel 40~50 HRC Under 270HB PC3500 PC5300 PC5300 PC (80~180) 120 (80~150) 0.6 ~ ~ 1.3 K Cast iron Under 350N/ PC3500 PC (100~220) 1.2 ~ 1.8 Machining example - I Cutting condition : HRMDCM13050HR-4 WNMX130520ZNN-MM (PC3500) Workpiece : DIN C45 (SM45C, HRC22) vc = 283m/min fz = 1.4mm/t vf = 10,097mm/min D.O.C : ap = 0.8mm(AR) ae = 35mm(RR) Machining type : mould machining, wet Equipment : horizontal machining center Tool overhang length : 250mm Productivity 40% up, Tool cost 5 times down Test result The same D.O.C as competitors, only vf was increased, machining time reduced by 40%, tool life increased by 60%. The numbers of corners per insert are increased by 3 times. Productivity up and tool cost down. Machining example - II Cutting condition : HRMDC13100HR-6 WNMX130520ZNN-MM (PC3545) Workpiece : DIN X2CrNi19-11 (STS304) vc = 130m/min fz = 1.2mm/t vf = 2,981mm/min D.O.C : ap = 1.0mm(AR) ae = 80mm(RR) Machining type : facing & side wall machining, dry Equipment : Vertical machining center Tool overhang length : 250mm Productivity 80% up, Tool cost 1.5 times down Test result Compared to face cutter(aa 45 ), D.O.C(ap x ae) was the same. Only vf was increased by 8 times. Machining time reduced by 80%. Tool life was the same but the number of cutting edges are increased by 1.5 times. Therefore, productivity improved and tool cost reduced. 3

4 HRMDCM09 Stock R L ød ød2 ød a b E F ød1 ød2 ap kg Bolt HRMDCM 09040HR HR HR HR HR HR HR HR HR HR SB0825 SB1025 SB1025 SB1230 SB1630 Parts Available insert Screw Wrench FTKA0307 TW09S WNMX-MM Coated PC3500 PC3545 PC8520 PC9530 WNMX09T316ZNN-MM Available arbor Available bolt Arbor HRMDCM 09040HR- BT30/BT40/BT50 FMC16 SK30/SK40/SK50 FMC HR HR HR HR- BT30/BT40/BT50 FMC22 SK30/SK40/SK50 FMC22 BT40/BT50 FMC27 SK30/SK40/SK50 FMC27 BT40/BT50 FMC32 SK40/SK50 FMC32 Dimensions a b L pitch SB SB SB SB

5 HRMDCM13 Stock R L ød ød2 ød a b E F ød1 ød2 ap kg Bolt HRMDCM 13050HR HR HR HR HR HR HR HR HR HR SB1025 SB1025 SB1230 SB1630 SB2040 MBA-M20 Parts Available insert Screw Wrench FTKA0412B TW15S WNMX-MM Coated PC3525 PC3545 PC8520 PC9530 WNMX130520ZNN-MM Available arbor Available bolt Arbor Fig.1 Fig.2 HRMDCM 13050HR HR- BT30/BT40/BT50 FMC22 SK30/SK40/SK50 FMC HR HR HR- BT40/BT50 FMC27 SK30/SK40/SK50 FMC27 BT40/BT50 FMC32 SK40/SK50 FMC32 BT40/BT50 FMC40 SK40/SK50 FMC40 Dimensions a b b1 C L pitch SB SB SB SB MBA-M Fig. 5

6 HRMDS09 Fig.1 Fig.2 Stock R L ød ød L ap kg Fig. HRMDS 0925HR-2S HR-2M HR-2L HR-2S HR-2M HR-2L HR-3S HR-3M HR-3L HR-3S HR-3M HR-3L HR-3S HR-3M HR-3L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-5S HR-5M HR-5L HR-5S HR-5M HR-5L HR-5S HR-5M HR-5L Parts Available insert Screw Wrench FTKA0307 TW09S WNMX-MM Coated PC3500 PC3545 PC8520 PC9530 WNMX09T316ZNN-MM 6

7 HRMDS13 Fig.1 Fig.2 Stock R L ød ød L ap kg Fig. HRMDS 1332HR-2S HR-2M HR-2L HR-2S HR-2M HR-2L HR-2S HR-2M HR-2L HR-3S HR-3M HR-3L HR-3S HR-3M HR-3L HR-3S HR-3M HR-3L HR-3S HR-3M HR-3L HR-3S HR-3M HR-3L HR-3S HR-3M HR-3L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-4S HR-4M HR-4L HR-5S HR-5M HR-5L HR-5S HR-5M HR-5L HR-5S HR-5M HR-5L Parts Available insert Screw Wrench FTKA0412B TW15S WNMX-MM Coated PC3500 PC3545 PC8520 PC9530 WNMX130520ZNN-MM 7

8 HRMDM09/13 Stock Dimensions ød ød ød1 L G M ap kg Available insert HRMDM 0925HR-M M HR-M M HR-M M HR-M M HR-M M HR-M M HR-M M HR-M M HR-M M HR-M M HR-M M WNMX09T316ZNN WNMX130520ZNN Parts Available insert Screw Wrench 09 Type FTKA0307 TW09S 13 Type FTKA0412B TW15S WNMX-MM Coated PC3500 PC3545 PC8520 PC9530 Type WNMX09T316ZNN-MM 09 Type Available adaptor WNMX130520ZNN-MM 13 Type HRMDM 0925HR-M12 MAT- M12 MAT- M HR-M HR-M HR-M HR-M HR-M HR-M HR-M HR-M HR-M HR-M16 Application example Tool designation HRMDM0932HR-M16 Adaptor Adaptor designation MAT-M S32S 8

9 Modular adaptor Modular adaptor Steel Fig 1. Straight Neck adaptor Fig 2. Taper Neck adaptor Stock Fig Dimensions M ød ød ød1 L MAT-M S10S 1 M MAT-M S12T 2 M MAT-M S16T 2 M MAT-M6B-020-S12S 1 M MAT-M6B-040-S12S 1 M MAT-M6B-065-S16T 2 M MAT-M6B-080-S16T 2 M MAT-M S16S 1 M MAT-M S16T 2 M MAT-M S16T 2 M MAT-M S20T 2 M MAT-M S25T 2 M MAT-M S20S 1 M MAT-M S20T 2 M MAT-M S20T 2 M MAT-M S25T 2 M MAT-M S25T 2 M MAT-M S32T 2 M MAT-M S25S 1 M MAT-M S25T 2 M MAT-M S25T 2 M MAT-M S25T 2 M MAT-M S32T 2 M MAT-M S40T 2 M MAT-M S32S 1 M MAT-M S32T 2 M MAT-M S32T 2 M MAT-M S32T 2 M MAT-M S40T 2 M S : Straight type T : Taper type Carbide Stock Dimensions M ød ød ød1 L MAT-M S16S-C M MAT-M S16S-C M MAT-M S16S-C M MAT-M S20S-C M MAT-M S20S-C M MAT-M S20S-C M MAT-M S25S-C M MAT-M S25S-C M MAT-M S25S-C M MAT-M S32S-C M MAT-M S32S-C M MAT-M S32S-C M MAT-M S16S-C-150 M MAT-M S16S-C-180 M MAT-M S16S-C-250 M MAT-M S20S-C-170 M MAT-M S20S-C-200 M MAT-M S20S-C-300 M MAT-M S25S-C-170 M MAT-M S25S-C-200 M MAT-M S25S-C-300 M MAT-M S32S-C-180 M MAT-M S32S-C-210 M MAT-M S32S-C-300 M

10 Code system Code system Cutter type HRM D C M H R 5 High Removal Milling Double sided insert Tool type C : Cutter Arbor type M : Metric A : Inch Insert I / C 13 : 12.7mm Tool diameter ISO : mm AISI : inch Coolant type H : Thru-hole Unmarked : No thru-hole Hand of tool R : Right L : Left Number of tooth 5 : 5 teeth Shank type HRM D S High Removal Milling Double sided insert Tool type S : Shank Insert I / C 09 : 9.525mm Tool diameter ISO : mm AISI : inch H R 2 S 32 Coolant type H : Thru-hole Unmarked : No thru-hole Hand of tool R : Right L : Left Number of tooth 2 : 2 teeth Tool length S : Standard M : Middle L : Long Shank diameter ø32 Modular head HRM D M H R M16 High Removal Milling Double sided insert Tool type M : Modular Insert I / C 13 : 12.7mm 09 : 9.525mm Tool diameter ISO : mm ANSI : inch Coolant type H : Thru-hole Unmarked : No thru-hole Hand of tool R : Right L : Left Screw size Modular adaptor MAT M S32 S C Modular adaptor Screw size Shank length Shank diameter Neck type T : Taper S : Straight Shank material None : Steel C : Carbide 10

11 Wear resistance test Toughness test Wear resistance test HRMD A-maker Tool life a corner 140% up Available corners 3 times up Cutting condition : HRMDCM13050HR-4 WNMX130520ZNN-MM (PC3500) Workpiece : KP4M (Mold Steel, HRC32) vc = 200m/min fz = 1.2mm/t ap = 1.2mm (AR) ae = 40mm (RR) Machining type : dry cutting, mould machining Work-piece size : 350 X 250 X 50mm Test Cutting length/ corner Available corners Performance HRMD 170 PASS 6 - Tool life per corner 140% increased A-maker 120 PASS 2 - Numbers of corners 3 times more Evaluation of toughness HRMD A-maker Tool life a corner 130% up Available corners 3 times up Cutting condition : HRMDCM13050HR-4 WNMX130520ZNN-MM (PC3500) Workpiece : KP4M (Mold Steel, HRC32) vc = 180m/min fz = 1.0mm/t ap = 1.2mm (AR) ae = 40mm (RR) Machining type : dry cutting, mould machining Workpiece size : 350 X 250 X 50mm Test Cutting length/ corner Available corners Performance HRMD 20 PASS 6 - Tool life per corner 130% increased A-maker 15 PASS 2 - Numbers of corners 3 times more 11

12 Ramping & Helical cutting technical data Tool pass diameter Ramping & Helical cutting technical data Ramping Helical cutting Tool pass diameter ØDc = Tool pass of tool center ØDh = Desirable hole diameter on workpiece ØD = Tool diameter Adjust feed to under 70% of recommended cutting condition when ramping & helical cutting. In helical ramping, max. cutting depth per 1 helical revolution of cutter should not exceed max. cutting depth as per insert size. in ramping, max. cutting depth for 1 ramping process should not exceed max. depth of cut as per used insert size. ød Tool diameter Valid cutting diameter Max. ap Ramping Max. angle Cutting Length Helical ramping Min. machined Max. machined diameter diameter HRMDS 0925HR HR HR HR HR HR HR HR HR HR HR HR HR HR HRMDCM 09040HR HR HR HR HR HR HR HR HR HR HEAD OFFICE Holystar B/D 953-1, Doksanbon-Dong, Geumcheon-Gu, Seoul, Korea TEL: FAX: , Website : CHEONGJU FACTORY 53-16, Songjeong-Dong, Hungduk-Gu, Chengju, Chungcheongbuk-Do, Korea TEL: FAX: export@korloy.com JINCHEON FACTORY 767-1, Gwanghyewon-Ri, Gwanghyewon-Myon, Jincheon-Gun, Chungcheongbuk-Do, Korea TEL: FAX: