B182E VFX VFX FOR HIGH EFFICIENCY ROUGH MACHINING OF TITANIUM ALLOYS

Transcription

1 VFX VFX FOR HIGH EFFICIENCY ROUGH MACHINING OF TITANIUM ALLOY B182E

2 VFX5/6 ERIE UNPARALLELED CHIP EJECTION PROPERTIE HELP RE-DEFINE THE PARAMETER FOR MACHINING TITANIUM ALLOY HIGH RIGIDITY DEIGN Arranging the inserts vertically absorbs the principal cutting force through the thickness of the insert and achieves extremely high rigidity. HIGHLY RELIABLE CLAMPING MECHANIM The insert seat has a curved seating face in the radial direction of the tool and a V-shaped seating face on the axis of rotation that can securely handle cutting forces from any direction. LOW REITANCE CONVEX CURVE CUTTING EDGE The curved cutting edge resembles the geometry of a solid end mill and achieves low cutting resistance that enables high quality machining. V formation of the clamping face Convex curve Cutting edge Cutting force IMPROVED CHIP REMOVAL WITH COOLANT nozzle The internal coolant is directed slightly above the rake face of the cutting edge so that it is aimed directly at the chip. Forcibly ejecting the chips prevents them from welding to the cutting edge, enabling higher efficiency machining. disoharge position CHANGEABLE COOLANT NOZZLE A replaceable nozzle is used for the internal coolant (hole diameter of the standard nozzle supplied: Ø 0.8). The coolant pressure can be adjusted by using a nozzle with a smaller or larger diameter. Nozzles with different diameters are available as options. 2

3 INERT L M H Produces compact chips without increases in cutting resistance. Excellent performance at large widths of cut and during slotting. Covers a wide range of cutting conditions and applications. Excellent chip separation and strong cutting edge. Highly efficient machining is possible at small widths of cut. Grade Width of cut: ae L MP9130 NEW M H MP9030 /MP9130 MP9030 /MP9130 NEW NEW 0.1D 0.3D 0.5D 0.7D 0.9D GENERAL PURPOE GRADE MP9030 NEW ADVANCED GRADE MP9130 NEW MP9030 uses an accumulated type coating based on a Ti compound that demonstrates excellent abrasion and fracture resistance during titanium alloy machining. The cemented carbide substrate also has properties balanced for wear and fracture resistance for superior performance when machining difficult-to-cut materials. A new and enhanced super fine cemented carbide substrate has increased toughness whilst maintaining hardness. The Al-Ti-Cr-N accumulated type coating ensures optimum heat and wear resistance. The combination of these properties gives excellent fracture resistance and a very low coefficient of friction for class leading welding resistance when machining titanium alloys. NEWLY DEVELOPED VFX5 3-FLUTE HOLDER During high chip volume applications such as slotting, chip evacuation performance is important and if insufficient can lead to chipping of the insert. To solve this problem a 3 flute cutter with maximised main flutes and chip pockets has been developed. Use of the new L breaker in conjunction with the 3 flute cutter will maximise the performance benefits. ub pocket 3

4 VFX5 CBDP L8 DC DAH KWW DCON DCFM HELL TYPE Right hand tool only. KAPR APMX LF KAPR:90 R ZEFP DC LF DCON CBDP DAH DCFM KWW L8 APMX WT * Teeth (kg) VFX5-040A03A026R VFX5-040A03A038R VFX5-050X03A026R VFX5-050X03A038R VFX5-050A04A026R VFX5-050A04A038R VFX5-050X04A038R VFX5-050A04A050R VFX5-063A05A026R VFX5-063A05A063R VFX5-080A06A075R PARE PART * WT : Tool Weight P6 *2 *3 Clamp crew Qty. eal Washer Wrench Nozzle Amount Anti-seize Lubricant Number of Insert Peripheral End Cutting Edge Cutting Edge *1 XNMU1607 oor-oo XNMU R-oo VFX5-040A03A026R T352 6 W8-1 TKY10D HD04004H08 9 MK1K HC VFX5-040A03A038R T352 9 W8-1 TKY10D HD04004H08 12 MK1K HC VFX5-050X03A026R T352 6 W12-1 TKY10D HD04004H08 9 MK1K HC VFX5-050X03A038R T352 9 W12-1 TKY10D HD04004H08 12 MK1K HC VFX5-050A04A026R T352 8 W10-1 TKY10D HD04004H08 12 MK1K HC VFX5-050A04A038R T W10-1 TKY10D HD04004H08 16 MK1K HC VFX5-050X04A038R T W12-1 TKY10D HD04004H08 16 MK1K HC VFX5-050A04A050R T W10-1 TKY10D HD04004H08 20 MK1K HC VFX5-063A05A026R T W12-1 TKY10D HD04004H08 15 MK1K HC VFX5-063A05A063R T W12-1 TKY10D HD04004H08 30 MK1K HC VFX5-080A06A075R T W16-1 TKY10D HD04004H08 42 MK1K HC *1 Only corner radius R0.8 can be used for the peripheral cutting edges. *2 Clamp Torque (Nm) : T352=2.5 *3 nozzles are available with varying diameters for adjusting coolant pressure. elect nozzles as required by the specification. et Bolt <1Mpa (<20 l/min.) tandard >5Mpa (>30 l/min.) >7Mpa (>50 l/min.) Nozzle Dia. Ø0.6mm Ø0.8mm Ø1.2mm Ø1.6mm HD04004H06 HD04004H08 HD04004H12 HD04004H16 * Clamp Torque (N m) : HD04004H = The part number for a blank screw without a through nozzle is H Note for insert with a corner radius of 3.2 and above, as corner radius increases the LF dimension increases. Corner radius: 3.2: LF+0.7mm Corner radius: 4.0: LF+1.5mm 4 : Inventory maintained. : Inventory maintained in Japan.

5 B B B INERT NEW MP9030 NEW MP9130 L LE W1 INL B RE Geometry M XNMU160708R-M L XNMU160712R-M XNMU160716R-M RE LE W1 * * XNMU160724R-M XNMU160732R-M XNMU160740R-M General purpose H L XNMU160708R-H INL W1 RE LE INL Cutting edge enhancement type L XNMU160708R-L L W1 RE LE INL Chip processing type * Note for insert with a corner radius of 3.2 and above, as corner radius increases the LF dimension increases. Corner radius: 3.2: LF+0.7mm Corner radius: 4.0: LF+1.5mm COMBINATION OF CUTTER AND INERT CORNER RADIU VFX5 Diameter Flutes Depth of cut Ø40-Ø80 3,4,5, mm VFX6 Diameter Flutes Depth of cut Ø63-Ø100 4,5, mm Breaker: M Breaker: M Breaker: H R0.8 R1.2 R1.6 R2.4 R3.2 R4.0 R1.2 R1.6 R2.4 R3.2 R4.0 R5.0 Breaker: H R0.8 R1.2 Breaker: L Breaker: L R0.8 R1.2 * Only the insert radius at the bottom insert can be changed. On the peripheral inserts please use R1.2 for VfX6 and R0.8 for VfX5 for perfect overlapping. : : Inventory maintained. : Inventory maintained in Japan. 5

6 RECOMMENDED CUTTING CONDITION Work Material Expected DC ZEFP Recommended Vc n APMX ae fz Vf Q Pc TL (mm) Insert (m/min) (min -1 Torque ) (mm) (mm) (mm/t.) (mm/min) (cm3/min) (kw) (%) (Nm) Titanium Alloy (Ti-Al-4V) Titanium Alloy (Ti-5Al-5V- 5Mo-3Cr) Ø 40 Ø 50 Ø 63 Ø 80 Ø 40 Ø 50 Ø 63 Ø 80 3 L M M H L M M H L M M H L M M H L M M H L M M H L M M H L M M H Please note that machining performance varies depending to the conditions such as machine rigidity, work clamping rigidity, coolant supply system, pressure and flow volume etc. 2. Internal coolant is recommended. Please use an FMH type arbor for through coolant. Using external coolant in combination with through coolant is even more effective. 6

7 VFX6 CBDP L8 DC DAH KWW DCON DCFM Right hand tool only. KAPR APMX LF HELL TYPE KAPR:90 R ZEFP DC LF DCON CBDP DAH DCFM KWW L8 APMX WT * Teeth (kg) VFX6-063A04A031R VFX6-063A04A060R VFX6-080A05A031R VFX6-080A05A075R VFX6-100A06A031R VFX6-100A06A090R * WT :ToolWeight PARE PART P9 *2 *3 Number of Insert End Cutting Peripheral Edge Cutting Edge *1 Clamp XNMU1909 XNMU1909 Amount eal Washer Wrench crew Nozzle Amount Anti-seize et Bolt Lubricant oor-oo 12R-oo VfX6-063A04A031R T450 8 W12-1 TKY20T HD04004H08 12 MK1K HC VfX6-063A04A060R T W12-1 TKY20T HD04004H08 20 MK1K HC VfX6-080A05A031R T W16-1 TKY20T HD04004H08 15 MK1K HC VfX6-080A05A075R T W16-1 TKY20T HD04004H08 30 MK1K HC VfX6-100A06A031R T W20-1 TKY20T HD04004H08 18 MK1K HC VfX6-100A06A090R T W20-1 TKY20T HD04004H08 42 MK1K HC *1 Only corner radius R1.2 can be used for the peripheral cutting edges. *2 Clamp Torque (Nm) : T450=5.0 *3 nozzles are available with varying diameters for adjusting coolant pressure. elect nozzles as required by the specification. <1Mpa (<20 l/min.) tandard >5Mpa (>30 l/min.) >7Mpa (>50 l/min.) Nozzle Dia. Ø0.6mm Ø0.8mm Ø1.2mm Ø1.6mm HD04004H06 HD04004H08 HD04004H12 HD04004H16 * Clamp Torque (N m) : HD04004H = The part number for a blank screw without a through nozzle is H Note for insert with a corner radius of 3.2 and above, as corner radius increases the LF dimension increases. Corner radius: 3.2: LF+0.7mm Corner radius: 4.0: LF+1.5mm Corner radius: 5.0: LF+1.5mm : : Inventory maintained. : Inventory maintained in Japan. 7

8 B B B INERT MP9030 NEW MP9130 L LE W1 INL B RE Geometry M XNMU190912R-M XNMU190916R-M XNMU190924R-M RE L LE W1 * XNMU190932R-M INL * XNMU190940R-M * XNMU190950R-M General purpose H XNMU190912R-H L INL W1 RE LE L W1 INL L XNMU190912R-L Cutting edge enhancement type RE LE * Note for insert with a corner radius of 3.2 and above, as corner radius increases the LF dimension increases. Corner radius: 3.2: LF+0.7mm Corner radius 4.0: LF+1.5mm Corner radius 5.0: LF+1.5mm Chip processing type 8 : : Inventory maintained. : Inventory maintained in Japan.

9 RECOMMENDED CUTTING CONDITION Work Material Expected DC ZEFP Recommended Vc n APMX ae fz Vf Q Pc TL (mm) Insert (m/min) (min -1 Torque ) (mm) (mm) (mm/t.) (mm/min) (cm3/min) (kw) (%) (Nm) Titanium Alloy (Ti-Al-4V) Titanium Alloy (Ti-5Al-5V- 5Mo-3Cr) Ø 63 Ø 80 Ø 100 Ø 63 Ø 80 Ø L M M H L M M H L M M H L M M H L M M H L M M H Please note that machining performance varies depending to the conditions such as machine rigidity, work clamping rigidity, coolant supply system, pressure and flow volume etc. 2. Internal coolant is recommended. Please use an FMH type arbor for through coolant. Using external coolant in combination with through coolant is even more effective. 9

10 VFX APPLICATION EXAMPLE Tool Workpiece Component Cutting peed Vc (m/min) Table Feed Vf (mm/min) Feed per Tooth fz (mm/tooth) Radial Depth of cut ae (mm) Axial Depth of cut ap (mm) VFX5-050A04A050R Titanium alloy (Ti-6Al-4V) Aerospace parts Wet cutting (Internal:3MPa) Results Efficiency was increased by a factor of % 100% Tool Workpiece Component Cutting peed Vc (m/min) Table Feed Vf (mm/min) Feed per Tooth fz (mm/tooth) Radial Depth of cut ae (mm) Axial Depth of cut ap (mm) VFX5-050A04A050R Titanium alloy (Ti-6Al-4V) Aerospace parts Wet cutting (External:1.5MPa) Results Efficiency increased by a factor of 1.5 and was also possible to achieve stable machining of thin walled parts. 50% 100% Tool Workpiece Component Cutting peed Vc (m/min) Table Feed Vf (mm/min) Feed per Tooth fz (mm/tooth) Radial Depth of cut ae (mm) Axial Depth of cut ap (mm) VFX5-050A04A050R Titanium alloy (Ti-6Al-4V) Aerospace parts Wet cutting (External:3MPa) Results It was possible to use 2 times increased cutting conditions for greater cost reduction. 50% 100% With reference to the above examples, adjust the cutting conditions according to the machine specifications, workpiece geometry and clamping method used. 10 : Mitsubishi Materials Tool : Conventional Tool

11 VFX APPLICATION EXAMPLE Tool Workpiece Component Cutting peed Vc (m/min) Table Feed Vf (mm/min) Feed per Tooth fz (mm/tooth) Radial Depth of cut ae (mm) Axial Depth of cut ap (mm) Results VFX6-080A05A075R Titanium alloy (Ti-5553) Aerospace parts Wet cutting (Internal:7MPa) With the same tool life (190 mins) as conventional tools, it was possible to use 1.2 times increased cutting conditions for greater efficiency. 50% 100% Tool Workpiece Component Cutting peed Vc (m/min) Table Feed Vf (mm/min) Feed per Tooth fz (mm/tooth) Radial Depth of cut ae (mm) Axial Depth of cut ap (mm) Results VFX6-063A04A060R Titanium alloy (Ti-6Al-4V) Aerospace parts Wet cutting (Internal:10MPa) At a metal removal rate of 120cm3 /min, tool life was constant at 60 mins and efficiency increased x 1.5. VFX was stable in tests at a max. metal removal rate of 400cm3 /min. 50% 100% Tool Workpiece Component Cutting peed Vc (m/min) Table Feed Vf (mm/min) Feed per Tooth fz (mm/tooth) Radial Depth of cut ae (mm) Axial Depth of cut ap (mm) VFX6-063A04A060R Titanium alloy (Ti-6Al-4V) Aerospace parts Wet cutting (External:1.5MPa) Results Three times tool life at cutting conditions improved by a factor of 2.7. Total cost reductions of 62%. 50% 100% With reference to the above examples, adjust the cutting conditions according to the machine specifications, workpiece geometry and clamping method used. : Mitsubishi Materials Tool : Conventional Tool 11

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