High Efficiency Drilling in Various Types of Machining

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1 TOOL NEWS Update B233G Solid Carbide Flat Bottom Drills Series Item Expansion High Efficiency Drilling in Various Types of Machining A

2 Solid Carbide Flat Bottom Drills Series High Efficiency Drilling in Various Types of Machining Spot Facing and Pilot Drilling Angled Surface Offset Circular Surface Shoulder High efficiency counter boring in various types of machining with excellent chipping resistance. Drilling Reform Thin Plate Intersecting Hole Eccentric Hole and Cast Hole Low cutting force provides less burr. Excellent performance in correction of eccentric hole and cast hole due to high position accuracy. 1

3 Features DC>3mm Small R Excellent Chip Control Combination of different radius sizes provides strong cutting edge and excellent chip control. Big R Work Material : AISI 15 Cutting Speed vc=5m/min Feed per Rev. fr=.7mm/rev New Z Thinning with Lower Thrust Force New thinning provides excellent chip evacuation. Gash Land for Stronger Corner Gash land ( degree rake) provides excellent chipping resistance. ZERO-μ Surface Smooth surface clearance provides reduced deflection and excellent position accuracy. 4 (μm) 4 (μm) 2 vc:5 fr: ø.2 vc:5 fr:.15 ø Conventional AISI angled surface DC 2 2

4 Longer Tool Life with Stable Cutting Coated Grade DP12 Newly developed coating for drills provides excellent wear resistance with low friction property, resulting in excellent versatility and extended tool life. 12 Multi-layer Accumulated Al-Ti-Cr-N Based PVD Coating Oxidation Temperature (Cº) DP12 Conventional PVD Coating Hardness (Hv) Cutting Performance Comparison of Thin Plate Machining in AISI 414 Flat tip geometry prevents burr formation in various types of applications. Conventional (Point Angle = 14 ) (Point Angle = 18 ) vc = 5m/min fr =.5mm/rev Large Burr Small Burr vc = 8m/min fr =.15mm/rev Drill : 6X2S6 Work Material : AISI 414 Hole Depth : 1mm (Thin Plate) Cutting Mode : Wet Cutting External Coolant (Water-soluble) Machine : Vertical MC (BT4) 3

5 NEW Features Small Dia. DC<3mm Excellent Chip Control Combination of different radius sizes provides strong cutting edge and excellent chip control. Thinning with Lower Thrust Force Ideal chip shape formed by the radius form, securing the chip pocket on the center part, thereby dramatically reducing the cutting resistance. Conventional Unique Sharp Cutting Edges The fl at lands on the cutting edge corners provide greater strength and sharpness, which can substantially reduce the formation of burrs. Sharp Cutting Edges with Long Tool Life Coated Grade DP12A DP12A is a PVD coated cemented carbide grade specialized for small diameter drills, with greatly improved wear resistance when drilling small-diameter holes at low speeds and low feed conditions. This provides high adhesion and stability even with sharp cutting edges. Conventional 1 holes 5 holes Drill : 1X2S3 Work Material : AISI 34 Hole Depth : 2mm Cutting Speed : vc=25m/min Feed per Rev. : fr=.7mm/rev Machine : Vertical MC (BT4) Al-Cr-N Based PVD Coating 4

6 Solid Carbide Flat Bottom Drills NEW for Small Diameter UWC DP1 18 SIG Thinning P M K N S H h6 External Coolant.75 <DC < DCON=3.6 DCON=4.8 Hole DC Order Number Depth LU LCF LH OAL DCON (L/D) Stock DP12A.75 2 a 75X2S a 8X2S a 85X2S a 9X2S a 95X2S a 1X2S a 15X2S a 11X2S a 115X2S a 12X2S a 125X2S a 13X2S a 135X2S a 14X2S a 145X2S a 15X2S a 155X2S a 16X2S a 165X2S a 17X2S a 175X2S a 18X2S a 185X2S a 19X2S a 195X2S a 2X2S a 25X2S a 21X2S a 215X2S a 22X2S a 225X2S a 23X2S a 235X2S a 24X2S a 245X2S a 25X2S a 255X2S a 26X2S a 265X2S a 27X2S a 275X2S a 28X2S a 285X2S a 29X2S a 295X2S DC SIG 18 LU LCF LH OAL DCON Type1 (mm) Type 5 a : Inventory maintained in Japan.

7 UWC DP1 18 SIG Thinning P M K N S H DC SIG 18 LU LCF LH OAL DCON Type1 h6 External Coolant 3 <DC <6 6 < DC < 1 1 < DC < < DC < DCON=6 DCON=8, 1 DCON=12, 14, 16, 18 DCON= Hole DC Order Number Depth LU LCF LH OAL DCON (L/D) Stock DP a 3X2S a 31X2S a 32X2S a 33X2S a 34X2S a 35X2S a 36X2S a 37X2S a 38X2S a 39X2S a 4X2S a 41X2S a 42X2S a 43X2S a 44X2S a 45X2S a 46X2S a 47X2S a 48X2S a 49X2S a 5X2S a 51X2S a 52X2S a 53X2S a 54X2S a 55X2S a 56X2S a 57X2S a 58X2S a 59X2S a 6X2S a 61X2S a 61X2S a 62X2S a 62X2S a 63X2S a 63X2S a 64X2S DC SIG 18 LU LCF LH OAL DCON Type2 (mm) Type 6

8 Solid Carbide Flat Bottom Drills External Coolant DC SIG 18 LU LCF LH OAL Hole DC Order Number LU LCF LH OAL DCON Depth (L/D) Stock DP a 64X2S a 65X2S a 65X2S a 66X2S a 66X2S a 67X2S a 67X2S a 68X2S a 68X2S a 69X2S a 69X2S a 7X2S a 7X2S a 71X2S a 72X2S a 73X2S a 74X2S a 75X2S a 76X2S a 77X2S a 78X2S a 79X2S a 8X2S a 81X2S a 82X2S a 83X2S a 84X2S a 85X2S a 86X2S a 87X2S a 88X2S a 89X2S a 9X2S a 91X2S a 92X2S a 93X2S a 94X2S a 95X2S a 96X2S a 97X2S a 98X2S a 99X2S a 1X2S a 11X2S a 12X2S a 13X2S a 14X2S a 15X2S a 16X2S a 17X2S DCON Type1 DC SIG 18 LU LCF LH OAL DCON Type2 (mm) Type 7 a : Inventory maintained in Japan.

9 External Coolant (mm) Stock Hole DC Order Number LU LCF LH OAL DCON Depth (L/D) DP a 18X2S a 19X2S a 11X2S a 111X2S a 112X2S a 113X2S a 114X2S a 115X2S a 116X2S a 117X2S a 118X2S a 119X2S a 12X2S a 125X2S a 13X2S a 135X2S a 14X2S a 145X2S a 15X2S a 155X2S a 16X2S a 165X2S a 17X2S a 175X2S a 18X2S a 185X2S a 19X2S a 195X2S a 2X2S Type DC = Cutting Diameter LU = Usable Length LCF = Length Chip Flute LH = Neck Length OAL = Overall Length DCON = Connection Diameter SIG = Point Angle 8

10 Solid Carbide Flat Bottom Drills Recommended Cutting Conditions (mm) Work Material Mild Steels ( <18HB) AISI 11 etc. Carbon Steels, Alloy Steels (18 28HB) AISI 145, 414 etc. Carbon Steels, Alloy Steels (28 35HB) AISI 434 etc. DC L/D % % % n n n (min -1 fr (Min. Max.) ) (min -1 fr (Min. Max.) ) (min -1 fr (Min. Max.) ) (mm/rev) (mm/rev) (mm/rev).75 < (.1.5) 19.3 (.1.5) (.1.5) 1. < (.1.5) (.1.5) (.1.5) 1.5 < (.15.55) 1.35 (.15.55) (.15.5) 2. < (.2.6) 79.4 (.2.6) 67.4 (.2.6) 2.5 < (.3.7) 66.5 (.3.7) 57.5 (.3.7) 3. < (.4.8) 79.6 (.4.8) 68.6 (.4.8) 4. < (.6.1) 59.8 (.6.1) 51.8 (.6.1) 5. < (.8.13) 47.1 (.8.13) 41.1 (.8.13) 6. < (.1.15) (.1.15) (.1.15) 8. < (.13.17) (.13.17) (.13.17) 1. < (.15.2) (.15.2) 2.17 (.15.2) 12. < (.17.25) 19.2 (.17.25) 17.2 (.17.25) 16. < (.2.3) (.2.3) (.2.3) 2. < (.25.35) 11.3 (.25.35) 1.3 (.25.35) Work Material Austenitic Stainless Steels ( <2HB) AISI 34, 316 etc. Gray Cast Irons (<35MPa) AISI No45B etc. Ductile Cast Irons (<45MPa) AISI etc. DC L/D % % % n n n (min -1 fr (Min. Max.) ) (min -1 fr (Min. Max.) ) (min -1 fr (Min. Max.) ) (mm/rev) (mm/rev) (mm/rev).75 < (.3.11) (.1.5) (.5.15) 1. < (.3.11) (.1.5) (.5.15) 1.5 < (.5.15) (.15.55) 1.2 (.1.3) 2. < (.1.2) 95.4 (.2.6) 87.3 (.15.45) 2.5 < (.1.2) 79.5 (.3.7) (.25.65) 3. < (.1.3) 79.6 (.4.8) 68.5 (.4.6) 4. < (.2.4) 59.8 (.6.1) 55.6 (.5.8) 5. < (.3.5) 47.1 (.8.12) 44.8 (.6.1) 6. < (.4.6) (.1.14) 37.1 (.8.12) 8. < (.5.8) (.12.16) (.1.15) 1. < (.6.1) (.14.18) (.12.18) 12. < (.8.12) (.16.2) (.15.2) 16. < (.1.15) 14.2 (.18.24) 13.2 (.18.25) 2. < (.12.2) (.2.28) (.2.3) 9 Work Material Aluminum Alloys (Si<5%) AISI A661, 775 etc. DC L/D % n (min -1 fr (Min. Max.) ) (mm/rev).75 < (.1.3) 1. < (.1.3) 1.5 < (.1.3) 2. < (.3.7) 2.5 < (.4.9) 3. < (.4.9) 4. < (.6.1) 5. <2 7.1 (.8.13) 6. < (.1.16) 8. < (.13.2) 1. < (.16.24) 12. < (.2.28) DC α 16. < (.24.32) 2. < (.28.36) (Note 1) The recommended hole depth is DCx2. This should be the depth from the uppermost surface of the work material when machining on an angled surface. (Refer to diagram) (Note 2) The above cutting table assumes drilling on a fl at surface. For hole drilling on an angled surface, adjust the feed rate in accordance with the inclination angle. When the inclination angle α is 3 or less, adjust the feed rate to 7% or lower as a guideline. When the inclination angle α is greater than 3, adjust the feed rate to 5% or lower as a guideline. (Note 3) This product is a tool intended for hole drilling. It cannot be used for cross-feed machining or helical machining. DC x 2

11 Cutting Performance Comparison of Exit Burrs Generated in AISI 34 The unique cutting edge shape suppresses the formation of exit burrs. Inclination Angle 15 Conventional A Conventional B 3 Inclination Angle Hole Depth=4mm Inclination Angle 15 Hole Depth 5mm Cylindrical Hole Drilling Inclination Angle 3 Hole Depth 7mm Drill : 2X2S4 Work Material : AISI 34 Cutting Speed : vc=3m/min Feed per Rev. : fr=.1mm/rev Cutting Mode : Wet Cutting External Coolant (Water-soluble) Machine : Vertical MC (BT4) Comparison of Tool Life when Used on AISI 34 Excellent fracture resistance is achieved even when hole drilling cylindrical surfaces using small automatic lathes Inclination Angle Conventional A Conventional B times Tool Life No. of Holes 2 Holes 2 Holes Drill : 8X2S3 Work Material : AISI 34 Cutting Speed : vc=15m/min Feed per Rev. : fr=.1mm/rev Cutting Mode : Wet Cutting External Coolant (Water-insoluble) Machine : Small Automatic Lathes Conventional B 1

12 Solid Carbide Flat Bottom Drills Cutting Performance Comparison of Fracture Resistance in AISI 15 Achieved 1.3 times longer tool life compared to conventional products because of increased stability. Cutting Mode Drilling of ø14.5mm in groove with a width of 1mm. Conventional A Conventional B 1.3 times Tool Life ø14.5mm 1mm 19mm No. of Holes 132 holes Conventional A 88 holes Conventional B 132 holes Drill : 145X2S16 Work Material : AISI 15 Hole Depth : 24mm Cutting Speed : vc=35m/min Feed per Rev. : fr=.25mm/rev Cutting Mode : Wet Cutting External Coolant (Water-soluble) Machine : Vertical MC (BT5) Thrust Force Comparison in Shoulder Drilling New Z thinning with lower thrust force % Lower Cutting Resistance 2 Thrust (N) 15 6mm 1 3mm 5 Conventional Drill : 6X2S6 Work Material : AISI 15 Hole Depth : 6mm (l=dc 1 Cutting Speed : vc=5m/min Feed per Rev. : fr=.7mm/rev 11

13 Comparison of Fracture Resistance in AISI 34 Achieved double tool life compared to conventional products because of the outstanding fracture resistance properties. After 5 holes Machining Conventional Double Tool Life Chipping No. of Holes Drill : 6X2S6 Work Material : AISI 34 Hole Depth : 12mm DC 2 Cutting Speed : vc=35m/min Feed per Rev. : fr=.25mm/rev Cutting Mode : Wet Cutting External Coolant (Water-soluble) Machine : Vertical MC (BT5) Conventional After 25 holes Machining 12mm Tool Overhang : 32mm 9mm from a Center of the Drill Comparison of Machining for Angled Surface with 45 Angle in AISI 145 Controlled abnormal fracturing because of the excellent welding resistance properties. No. of Holes : Comparison of the cutting edge after 2 holes machining. Drill : 6X2S6 Work Material : AISI 145 Hole Depth : 12mm DC 2 Cutting Speed : vc=5m/min Feed per Rev. : fr=.7mm/rev Cutting Mode : Wet Cutting External Coolant (Water-soluble) Welding Conventional A Tool Overhang : 32mm Welding Conventional B Chipping 12mm 9mm from a Center of the Drill 12

14 Solid Carbide Flat Bottom Drills Application Example Drill 11X2S12 18X2S3 16X2S3 JIS SCM415 AISI 33 AISI 44 Pilot Drilling Workpiece No Image Cutting Conditions Component Ball Nut Bolt Nut Cutting Speed vc (m/min) Feed per Rev. fr (mm/rev) Hole Depth (mm) 5 Cutting Mode Wet Cutting Extarnal Coolant (Water-soluble) Wet Cutting Extarnal Coolant Wet Cutting Extarnal Coolant Machine Vertical MC Small Automatic Lathes Horizontal MC Number of Workpieces Large Burr Number of Workpieces Results Conventional The amount of hole curving has been reduced from.13 mm to.3 mm compared to conventional products, with a tool life which is 1.5 or more times longer. Conventional With the, there will be no accuracy errors even if used for continuous hole drilling on small automatic lathes, and the tool life will be double or more times longer. Conventional The is excellent at maintaining accuracy and the tool life becomes 1.5 times longer than conventional products. The above application examples are customer s applications, so it can be different from the recommended conditions. 13

15 Memo 14

16 A y Operational Guidance Drill Holding Drill Length Drill Installation Installation Tolerance Adjusting Screw DC NG Thrust bearing type collet chuck holds the drill securely. A > DC x 1.5 Do not clamp on the flutes. Run-out <.3mm Thin Workpiece Burring and Workpiece Chipping Coolant Method () Inclined Face Drilling NG If Bending Occurs DC x 1 OK Support the Workpiece z Lower the feed rate by 5% at the end of through cutting. xadd a chamfer. Two coolant positions, at the end and at the center are ideal. z x When machining a deep hole into an inclined surface, use drill (L/D=2) as a drill for a guide hole. Set the drill depth at approx. DC x 1 to obtain anaccurate guide hole. For Your Safety adon't handle inserts and chips without gloves. aplease machine within the recommended application range and exchange expired tools with new ones in advance of breakage. aplease use safety covers and wear safety glasses. awhen using compounded cutting oils, please take fire precautions. awhen using rotating tools, please make a trial run to check run-out, vibration and abnormal sounds etc. MITSUBISHI MATERIALS CORPORATION Overseas Sales Dept, Asian Region KFC bldg., 8F, Yokoami, Sumida-ku, Tokyo 13-15, Japan TEL FAX Overseas Sales Dept, European & American Region KFC bldg., 8F, Yokoami, Sumida-ku, Tokyo 13-15, Japan TEL FAX (Tools specifications subject to change without notice.) EXP-16-E E( - )