ALU-XP E T. The Alu-XP range: Exceptional performance and reliability.

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1 The Alu-XP range: Exceptional performance and reliability. At Europa Tool we recognise that manufacturing components consistently and cost effectively is essential. To this aim, we have produced all data in this catalogue in accordance with ISO ISO is an international technical standard for the representation and exchange of data about cutting tools and toolholders, which simplifies the data transfer between different software systems. We are working towards providing information for all our tools to this standard, making the interchange of tooling information more straightforward. Further details regarding this standard will be available in our main catalogues. Alu-XP tools with mirror polished flutes allow for smooth chip evacuation, giving better surface finish and wear resistance. Cutting edges are optimised to minimise vibration, and 3-flute tools have a tight diameter tolerance giving excellent process reliability. All tools are also available to order with optional X coating, which maintains the sharpness of the cutting edge whilst giving exceptional tool life. The tools in this catalogue are suitable for some for Copper and Acrylic. Please refer to our other catalogues for different materials. A-XP E T UROPA OOL

2 Material Group Examples 10. Steel P 4E = Europa Material Group. VDI = VDI 3323 material group E Magnetic soft steels Structural steels Plain carbon steels Alloy steels VDI 1, 2 3, E1 E2 OSOA12 230Mo7 10. E Alloy/Tempered Hardened steels Steel H S95, 98, 99 E24T BH11 BH13 830M E Stainless Steel M E56, 30. Cast Iron K 40. Titanium S 50. ickel S 60. Copper 70. Aluminium E3A, 4, 5, 6, 7, 8 060A35 040A10 E32 210M Hardened steels VDI 10, 11 38, 39 >45 HRc Hardox400 Hardox500 P20 E9, 10 E43 070M20 060A62 080M VDI Free machining 12 Austenitic 14 Martensitic/Ferritic S21 304S15 E58J 316S 321S17 420S37 Duplex, Super Duplex 15-5PH 17-4 PH S130 E16, 17, 19 BO1 BO2 D2 D3 E Grey cast iron soft Grey cast iron hard odular graphite odular graphite VDI , 18 19, 20 GG10 GG20 GG30 GG40 GG25 GG35 GF150 GGG40 GGG50 SG Iron E Titanium unalloyed Titanium alloys Titanium alloys VDI Pure Titanium TA1-9 Ti99.0 Ti6Al4V Ti6Al2Sn4Zr2Mo Ti4Al4Mo2Sn0.5Si Ti10Al2Fe3Al Ti5Al5V5Mo3Cr Ti7Al4Mo Ti3Al8V6Cr4Zr4Mo Ti6Al6V6Sn Ti15V3 Cr3Sn3Al E ickel unalloyed Heat resisting alloys Heat resisting alloys VDI 31, , 35 A11 A12 ickel 200 imonic 75 Hastelloy C Inconel 601, 617, 625 Incoloy 800, 825 Monel 400 imonic 80 Rene 41 Inconel 8, 750-X Incoloy 925 Monel K-500 Waspaloy GGG70 GGG80 Meehanite E Copper unalloyed Short chip alloys Long chip alloys Cu - Al - Fe alloys VDI Commercially pure C101 CZ120 PB104 G-CuSn5ZnPb CZ106 CZ108 CuZn37 Ampco18 Ampco20 Ampco26 E Aluminium, Aluminium, Aluminium, Aluminium, VDI unalloyed 21 Si <0.5% 22 Si % 23, 24 Si >10% 25 Al99.5H Al99.9 Al99.9Mg0.5 AlMn1 AlMn1Mg0.5 LM5, 10, HE9, 30 LM2, 4, 16, 18, G-AlSi10Mg G-AlSi12 G-MgAl6 LM6, 12, 13, 20, A-XP Optional X Coating: High performance for Aluminium. All the tools in this catalogue are available with optional X coating. It has a smooth coating surface with consistently sharp tool edges, even on smaller diameters - the sharper the edge and smoother the surface equals more efficient manufacturing and longer tool life. Single layer coating: µm High coating hardness: >5000HV Hot hardness: >500ºC. MQL and dry machining possible. Low tendency to adhesion. O Icon guide Material Micro-grain Carbide eck Relief FHA 30º KCH 45º Helix Angle umber of Flutes Chamfer Angle Radius Machining Direction Shank Plain 6535-HA 6535HB Shank Flat 6535-HB Trochoidal Milling Side Milling Slotting A Knuckle Form 80. Synthetics O E 81 Thermosetting Thermoplastics Reinforced plastics VDI 30 plastics ylon Acetal Tufnol CFRP, GFRP Circuit Board Kevlar Graphite Synthetic Graphite 84 Corner Radius Planing Profiling 4For full material group tables, refer to main catalogues Europa Tool Co.,Ltd 3

3 APPLICATIO GUIDE IDEX O MACHIIG GUIDE SIGLE FTE ROUTER Series (TSYC) Item Description Page o Long Length 2.0mm mm P Short Length 45º Helix ø3.0mm mm P Long Length 45º Helix ø1.0mm mm P Long Series 45º Helix ø1.0mm mm P Extended eck 30º Helix Corner Radius ø4.0mm mm P.10 2 FTE o o o o Extended eck 50º Helix Ball ose ø6.0mm mm P.11 3 FTE o o o o Long Length 45º Helix ø3.0mm mm Long Length 45º Helix Corner Radius ø3.0mm mm Long Series 45º Helix ø3.0mm mm Extended eck 45º Helix ø3.0mm mm Extended eck 45º Helix Corner radius ø6.0mm mm Extended eck 40º Helix Ball ose ø2.0mm mm P.12 P P P P P Long Length 3 Flute 30º Helix ø6.0mm mm P Extended eck 3 Flute 30º Helix ø6.0mm mm P.23 Cutting Data P Troubleshooting P.28

4 A-XP A-XP ZEFP 1 KCH 45º FHA 30º ZEFP 2 Series o cutting conditions: page 24 Series o cutting conditions: page 26 Designed for aluminium and non-ferrous materials such as acrylic. 1 flute allows for excellent chip evacuation. KCH Corner protected. ORODE CHAMFER WIDTH CHW TC(mm) TC 0.00 / h6 ORODE To order X coated use code , followed by diameter code. TC(mm) TC IFORCED Cutting EDGE 6 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 7

5 A-XP A-XP ZEFP 2 KCH 45º ZEFP 2 KCH 45º Series o Series o cutting conditions: page 26 4cutting conditions: page 26 Corner protected. Long series. Corner protected. KCH KCH ORODE CHAMFER WIDTH CHW To order X coated use code , followed by diameter code. TC(mm) TC ORODE CHAMFER WIDTH CHW To order X coated use code , followed by diameter code. TC(mm) TC IFORCED Cutting EDGE IFORCED Cutting EDGE 8 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 9

6 A-XP A-XP ZEFP 2 FHA 30º ZEFP 2 FHA 50º Series o Series o cutting conditions: page 27 4cutting conditions: page 24 Excellent surface finishes, superior chip removal. Corner radius. eck relief. eck relief. ORODE CORER RADIUS ORODE RADIUS To order X coated use code , followed by diameter code. TC(mm) Radius (mm) TOLL TO TC ± h6 4To order X coated use code , followed by diameter code. TC(mm) Radius (mm) TOLL TO TC 0.00 / h6 o o o o o o o o 10 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 11

7 A-XP A-XP FHA 40º Series o Corner protected. Series o cutting conditions: page 27 eck relief. ORODE To order X coated use code , followed by diameter code. TC(mm) TC ORODE RADIUS To order X coated use code , followed by diameter code. TC(mm) Radius (mm) TOLL TO TC 0.00 / h6 IFORCED Cutting EDGE o o o o 12 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 13

8 A-XP A-XP Series o Series o Corner protected. ORODE CORER RADIUS ORODE CORER RADIUS To order X coated use code , followed by diameter code. TC(mm) Radius (mm) TOLL TO TC 0.00 / h6 4To order X coated use code , followed by diameter code. TC(mm) Radius (mm) TOLL TO TC 0.00 / h6 14 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 15

9 A-XP A-XP Series o Series o Long series. Corner protected. Long series. Corner protected. ORODE To order X coated use code , followed by diameter code. TC(mm) TC ORODE To order X coated use code , followed by diameter code. TC(mm) TC IFORCED Cutting EDGE IFORCED Cutting EDGE 16 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 17

10 A-XP A-XP Series o Series o Long series. Corner protected. Long series. Corner protected. ORODE To order X coated use code , followed by diameter code. TC(mm) TC ORODE To order X coated use code , followed by diameter code. TC(mm) TC IFORCED Cutting EDGE IFORCED Cutting EDGE 18 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 19

11 A-XP A-XP Series o Series o Corner radius. eck relief. Corner radius. eck relief. ORODE CORER RADIUS ORODE CORER RADIUS To order X coated use code , followed by diameter code. TC(mm) Radius (mm) TOLL TO TC 0.00 / h6 4To order X coated use code , followed by diameter code. TC(mm) Radius (mm) TOLL TO TC 0.00 / h6 20 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 21

12 A-XP A-XP KCH 45º FHA 30º 6535HB A KCH 45º FHA 30º 6535HB A Series o , cutting conditions: page 26 Corner protected. KCH KCH Series o , cutting conditions: pages 26 Corner protected. eck relief. 6535HB ORODE ORODE CHAMFER WIDTH CHW To order X coated use code or , followed by diameter code. TC(mm) 6.0, 8.0, / , 14.0, / / TC h6 6535HB ORODE ORODE CHAMFER WIDTH CHW To order X coated use code or , followed by diameter code. TC(mm) 6.0, 8.0, / , / / TC h6 22 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 23

13 A-XP A-XP ( 1 Flute Router) , , ( 3 Flute 45º Helix, Long, ecked & Long Series) CUTTIG CODITIOS vc (m/min) n fz f (mm/min) vc (m/min) vc (m/min) n fz f (mm/min) vc (m/min) CUTTIG CODITIOS O Thermoplastics, Thermosetting plastics, Acrylics n fz n fz f (mm/min) f (mm/min) SIDE CUTTIG SLOTTIG 1.5 x D D x D 0.15 x D 0.5 x D D ( 2 Flute 50º Helix, Ball ose) 4The feed rate for long series and long necked tools should be reduced by up to 50% vc (m/min) , ( 3 Flute 45º Helix, Corner Radius & ecked Corner Radius) Copper and Copper alloys n fz f (mm/min) vc (m/min) n fz f (mm/min) vc (m/min) n fz f (mm/min) vc (m/min) n fz x D SIDE CUTTIG f (mm/min) SLOTTIG 0.5 x D 2.5 x D 0.15 x D 0.5 x D D Recommended cutting depths are maximum depths, and speeds and feeds are a starting point based on these depths. All recommendations are based on ideal machining conditions. Adjustments may need to be made according to your set-up. For long series and long necked tools it may be necessary to reduce feed rate by up to 50%. v c - cutting speed (m/min) n - RPM (rev/min) f z - feed per tooth (mm) f - feed rate (mm/min) a p - axial depth a e - radial depth 4The feed rate for long series and long necked tools should be reduced by up to 50% 24 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 25

14 A-XP A-XP , , , ( 3 Flute Roughing) ( 2 Flute Corner Radius) CUTTIG CODITIOS vc (m/min) n fz f (mm/min) vc (m/min) vc (m/min) n fz f (mm/min) vc (m/min) CUTTIG CODITIOS n n fz fz f (mm/min) f (mm/min) SIDE CUTTIG SLOTTIG SIDE CUTTIG SLOTTIG 1.5 x D 0.5 x D 1.5 x D D 1.2 x D a e : ø4.0mm - ø10.0mm = 0.25 x D a e : ø12.0mm - ø20.0mm = 0.5x D a e 0.5 x D D , , ( 2 Flute 45º Helix, Short, Long & Long Series) ( 3 Flute 40º Helix, Ball ose) vc (m/min) vc (m/min) n fz Copper and Copper alloys n fz f (mm/min) vc (m/min) f (mm/min) vc (m/min) n fz n fz f (mm/min) f (mm/min) SIDE CUTTIG SLOTTIG 1.0 x D a e : ø3.0mm - ø10.0mm = 0.25 x D a e : ø12.0mm - ø20.0mm = 0.15x D a e 0.5 x D D 0.2 x D 0.5 x D 4The feed rate for long & long series tools should be reduced by up to 50% 26 Europa Tool Co.,Ltd Europa Tool Co.,Ltd 27

15 A-XP TROUBLESHOOTIG Problem Instance of problem Solution options Tool breaks Cutting edge breaks Heavy tool wear Poor surface finish Poor accuracy Chattering At start or end During cutting Changing direction Corner chipping Break at depth Centre chipping Break ting edge Good finish but rough Chip welding Scoring Excessive cut marks Undersize ot perpendicular Reduce overhang Use shorter tool Use lower feed rate Check tool for wear and replace sooner Check toolholder for wear and replace Reduce overhang Use shorter tool Use lower feed rate Check coolant flow Check tool for wear and replace sooner Check toolholder for wear and replace Use lower feed rate when changing direction Use circular interpolation if possible Reduce overhang Use shorter tool Use climb milling Use climb milling Use lower cutting speed Use larger tool if possible Use higher cutting speed If noisy during cutting, use higher feed rate Check coolant flow Check toolholder for wear and replace Use larger tool if possible Use lower feed rate Use lower cutting speed Check toolholder for wear and replace Check coolant flow Use lower cutting speed Use conventional milling Use higher feed rate Check coolant flow Use lower feed rate Check coolant flow Use higher cutting speed Use higher feed rate Use conventional milling Check coolant flow Use climb milling Check coolant flow Use smaller radial depth for finishing Use higher cutting speed Use lower feed rate Use conventional milling Use smaller radial depth for finishing Check toolholder for wear and replace Reduce overhang Use higher cutting speed Use smaller radial depth for finishing Check toolholder for wear and replace Reduce overhang Use higher cutting speed Use lower feed rate Check tool for wear and replace sooner Use higher or lower cutting speed Use higher feed rate Check toolholder for wear and replace Reduce overhang Use climb milling 28 Europa Tool Co.,Ltd