MFPN MFPN. Reduced chattering with low cutting force design. Milling with double sided 10-edge inserts

Transcription

1 Milling with doule sided 10-edge inserts MFPN MFPN Reduced chttering with low cutting force design conomicl 10-edge insert Low cutting force due to curved cutting edge design uppresses frcturing with dul ngle edge design NW N620M Cermet for milling NW MFPN66 66 cutting ngle

2 ighly efficient cutter with 66 cutting edge ngle MFPN66 NW conomicl inserts with 10 cutting edges. Reduces chttering with low cutting force design Reduces cutting costs when mchining uto prts nd other generl purpose mchining pplictions 1 conomicl inserts with 10 cutting edges For low to medium depth of cut Cost reduction in vrious pplictions from generl prts to utomotive prts mchining 2 Reduces chttering with low cutting force design For stinless steel mchining uppresses virtion for excellent surfce finish with 66 cutting edge ngle Cutting force comprison (Internl evlution) 400.R. Mx.+12 Cutting force (N) % elicl edge with.r. Mx MFPN66 Competitor (45 cutting edge ngle) hrust force is cutting resistnce. Cutting conditions: Vc = 200 m/min, fz = 0.15 mm/t, p = mm Cutting di. ø6 workpiece: C50 Long tool life with MGCO NNO coting technology Insert lineup lso contins cermet grde for etter surfce finish Cermet for milling N620M 1st recommendtion (Generl purpose) chipreker ough edge G chipreker For stinless steel mchining M chipreker xcellent wer resistnce nd dhesion resistnce igh qulity surfce finish 1

3 45 milling with doule sided 10-edge inserts MFPN45 Reduced chttering with low cutting force design nd excellent frcture resistnce conomicl 10-edge insert 1 conomicl 10-edge insert Resists chttering 2 Pentgonl doule-sided inserts provide excellent stility tle mchining t high feed mchining Low cutting forces due to curved cutting edge with high xil rke ngle (mx. 10 ) wo-fce contct +10 (.R.) Cutting force Mjor cutting edge Chip evcution (In-house evlution) Cutting force comprison (In-house evlution) fz = 0.2 mm/t fz = 0. mm/t MFPN Competitor Competitor B Cutting conditions: Vc = 150 m/min, fz = mm/t, p e = 110 mm Workpiece: C50 Cutting force (N) 2,000 1,600 1, % Principl force Feed force Bck force MFPN MFPN chipreker M chipreker Competitor C Cutting conditions: Vc = 150 m/min, fz = 0.1 mm/t, p e = mm Workpiece: C50 Competitor D Frcture resistnce Doule edge position reduces impct lod nd controls virtion when entering the workpiece Wiper edge Doule edge position econdry cutting edge Primry cutting edge Frcture resistnce comprison (In-house evlution) PNMU1205NR- (PR1225) Competitor (PVD negtive insert) Competitor F (PVD negtive insert) 0,000 6,000 9,000 12,000 No. of impcts Cutting conditions: Vc = 100 m/min, fz = mm/t, p e = mm (Workpiece with 20 mm width slot) Workpiece: 42CrMo4 (8 42 ) : No crcks : Crcks fz = 0.5 mm/t fz = 0.6 mm/t fz = 0.7 mm/t 2

4 4 Vrious chiprekers for wide rnge of pplictions Four unique chiprekers nd wiper insert cover wide rnge of milling pplictions Chipreker pplictions hpe Chipreker recommended pplictions Wiper insert recommended pplictions Generl 6 M 4 M G GL Low cutting force evy milling urfce finish oriented p (mm) 5 1 GL G p (mm) 2 1 W (PR15 series/c655) W (N100M) W Wiper insert for finishing fz (mm/t) fz (mm/t) For how to use wiper insert, see pge 7 MGCO NNO PR155 Frcture resistnt with tough sustrte nd high het-resistnt coting tle mchining of generl steel, mold steel, nd difficult-to-cut mterils oughening y new colt mixing rtio 1 *In-house evlution 2 tility Improvement igh toughness cride se mteril 2 % Frcture toughness * he corse grin structure nd uniform prticle size correspond to improved het resistnce, with conductivity vlues decresed y 11%. he uniform structure lso reduces crck propgtion. Crcking comprison y dimond indenter (In-house evlution) PR155 se mteril Conventionl mteril hock resistnce hort crcks Long crcks Coting properties (rsion resistnce) Coting properties (Deposition resistnce) rdness (GP) MGCO NNO icn iin in ,000 1,200 1,400 Oxidtion temperture ( C) Low Oxidtion resistnce igh rdness (GP) MGCO NNO icn iin in Wer coefficient (μ) igh Deposition resistnce Low chieve long tool life with the comintion of tough sustrte nd specil nno coting lyer. tle mchining with excellent wer resistnce.

5 Fce mill MFPN45.R..R. (M.) +10 = 6-10 = 80-8 R.R. = ø177.8 ø101.6 ø18 ø ø26 ø2 1 1 #1 #2 # #4 oolholder dimensions Corse pitch Fine pitch xtr fine pitch vilility No. of Dimensions (mm) hpe Weight R inserts (kg) MFPN 4506R-4-M # R-5-M R-6-M # R-7-M R-8-M R-10-M # R-12-M R-14-M MO #4 21. MFPN 4506R-5-M # R-6-M R-8-M # R-10-M R-12-M R-14-M # R-16-M R-18-M MO # MFPN 4506R-6-M # R-8-M R-10-M # R-1-M R-16-M R-18-M # R-20-M him Yes No No Dimension : 6 mm (, M, G chiprekers), 5 mm (GL chipreker), mm (W chipreker: PR15 series) : ville MO: Mde-o-Order 4

6 pre prts MFPN45 Clmp screw Wrench DM him him screw Wrench nti-eize compound Mounting olt Corse pitch Fine pitch xtr fine pitch MFPN 4506R-4-M 10 0 B-50140R W-15 MFPN-45 PW-7050 LW-5 MFPN R /L-5-(M) 12 5 MFPN R /L-6-(M) P-7 Recommended torque for Recommended torque for insert clmp 4.2 N m shim clmp 6.0 N m 4515R-14-(M) MFPN 4506R-5-M 10 0 B-50140R W-15 MFPN 45080R-6-(M) 12 5 MFPN 45100R-8-(M) P-7 Recommended torque for insert clmp 4.2 N m 4515R-18-(M) MFPN 4506R-6-M 10 0 B-40140RN DM-15 MFPN 45080R-8-(M) 12 5 MFPN 45100R-10-(M) P-7 Recommended torque for insert clmp.5 N m 45250R-20-(M) ~ ~ ~ Cot nti-seize compound (MP-1) thinly on portion of tper nd thred prior to instlltion. nd mill MFPN45 1 h6 l L oolholder dimensions vilility No. of inserts Dimensions (mm).r. pre prts Clmp screw Wrench nti-eize compound 1 L l.r. (M.) R.R. MFPN 45050R B-50140R W R (5) Recommended torque is 4.2 N m 45080R Dimension : 6 mm (, M, G chiprekers), 5 mm (GL chipreker), mm (W chipreker: PR15 series) Cot nti-seize compound (MP-1) thinly on portion of tper nd thred prior to instlltion. P-7 : ville Recommended chipreker Cutter type M (GL) G Corse pitch (with shim) Fine pitch (without shim) (Recommended under fz = 0.4 mm/t) xtr fine pitch (without shim) Not recommended 5

7 pplicle insert MFPN45 Clssifiction of usge : Roughing / 1st choice : Roughing / 2nd choice : Finishing / 1st choice : Finishing / 2nd choice (In cse hrdness is under 45RC) Insert P M K N teel Die steel ustenitic stinless steel Mrtensitic stinless steel Precipittion hrdened stinless steel Gry cst iron Nodulr cst iron Non-ferrous metls Ni-se het-resistnt lloy (Inconel 718, etc.) itnium lloy igh hrdness steel CVD coted Dimensions (mm) Cermet MGCO NNO MGCO cride N100M C655 PR155 PR1525 PR1510 PR1225 PR1210 PNMU 1205NR- Generl PNMU 1205NL Generl PNMU 1205NR-M Low cutting force PNMU 1205NR-G ough edge (evy milling) urfce finish oriented (Precision clss) PNU 1205NR-GL PNU 1205NL-GL 5.56 urfce finish oriented (Precision clss) r600 PNU 1205NR-W Wiper insert (2-edge) : ville Reference for selecting fce mill nd insert suitle for ech milling purpose Milling purpose Generl milling for steel nd lloy steel teel nd lloy steel (to prevent chttering due to low rigidity mchine or poor clmping power) Productivity oriented (Running cost decrese; over p = 4 mm, over fz = 0.5 mm/t) urfce finish oriented Generl milling for stinless steel tinless steel (to prevent chttering due to low rigidity mchine or poor clmping power) Cst iron (for processing efficiency improvement) Cst iron (Over p = 4 mm, over fz = 0.5 mm/t) Improved surfce finish in high efficiency milling Fce mill type Chipreker Corse pitch Fine pitch xtr fine pitch M G GL W 6

8 ow to use wiper inserts on MFPN45 ow to ttch wiper inserts on the MFPN45 cutter 1. Plese only use one wiper insert per cutter. If you use more thn 2 wiper inserts on one cutter, the workpiece surfce my ecome smered. 2. Comintion of wiper insert with other chiprekers.. Use tool presetter for mesuring protrusion mount of wiper edge. Recommended protrusion mount: 0.1 mm. Chipreker Comintion M W Recommended comintion Recommended comintion Using G + W nd GL + W re NO recommended. he down rrow symol ( ) indictes the wiper cutting edge. When mounting inserts, mke sure tht the rrow points downwrd. Improved surfce finish with wiper insert Chipreker comintion Insert urfce finish Workpiece surfce MFPN wiper insert PR1525 (PNMU- 9 inserts) (PNU-W 1 inserts) R = 0.48 μm Rz =.9 μm hiny surfce MFPN GL chipreker PR1225 (PNU-GL 10 inserts) R = 2.50 μm Rz = μm hiny surfce MFPN45125R-10 (10 inserts). Cutting conditions: Vc = 200 m/min -1 (n = 510 min -1 ), fz = 0.2 mm/t (Vf = 1,020 mm/min), p e = 100 mm, dry, workpiece: 17Cr Results ove re from n internl evlution. he surfce roughness lso depends on the workpiece, cutting conditions or conditions ccording to the ctul mchining sitution. When the surfce roughness is unstle, plese set the cutting speed higher, the feed rte lower, or use wiper insert (N100M). ow to mount inserts 1. Be sure to remove dust nd chips from the insert mounting pocket. 2. fter pplying nti-seize compound on portion of tper nd thred, while pressing the insert ginst the pocket wll, insert the screw into the hole of the insert nd tighten the screw with pproprite torque. ee #1 nd #2. Recommended tightening torque he torque for corse pitch nd fine pitch (using M5 screw) is 4.2 N m. he torque for extr fine pitch (using M4 screw) is.5 N m.. fter tightening the screw, mke sure tht there is no clernce etween the insert set surfce nd the ering surfce of the holder nd etween the insert side surfces nd the pocket wll of the holder. 4. o chnge the cutting edge of the insert, turn the insert counterclockwise (see #). Insert corner identifiction numer is stmped on the top surfce of insert with the exception of the M chipreker (#4). ide surfce of insert Pocket wll #1 #2 # #4 op surfce of insert Insert corner identifiction numer ow to replce shim (for corse pitch) 1. Be sure to remove dust nd chips from the insert mounting pocket. 2. he shim must e mounted in the proper direction. While ligning the surfce of the shim with the mrk on it to the corresponding pocket wll (see #5) nd lightly pressing the shim towrd the pocket wll, insert the screw into the hole of the shim nd tighten it (see #6). When tightening the screw, mke sure tht the screw is verticl to the ering surfce. Recommended torque is 6.0 N m.. fter tightening the screw, mke sure tht there is no clernce etween the shim set surfce nd the ering surfce. If there is ny clernce, remove the shim nd mount it gin ccording to the ove steps. him Identifying mrk older ody Pocket wll him screw Wrench #5 #6 7

9 Recommended cutting conditions MFPN45 1st recommendtion 2nd recommendtion Insert Workpiece Recommended feed (fz: mm/t) Recommended insert grde (Vc: m/min) MGCO NNO (MGCO) CVD coted cride PR155 PR1525 (PR1225) PR1510 (PR1210) C655 Cron steel lloy steel Die steel ustenitic stinless steel Mrtensitic stinless steel Precipittion hrdened stinless steel Gry cst iron Nodulr cst iron Ni-se het-resistnt lloy (Inconel 718, etc.) Cron steel lloy steel Die steel ustenitic stinless steel M *(GL) Mrtensitic stinless steel Precipittion hrdened stinless steel Gry cst iron Nodulr cst iron Ni-se het-resistnt lloy (Inconel 718, etc.) itnium lloy Cron steel lloy steel Die steel ustenitic stinless steel G Mrtensitic stinless steel Precipittion hrdened stinless steel Gry cst iron Nodulr cst iron Ni-se het-resistnt lloy (Inconel 718, etc.) he numer in old font is recommended strting conditions. djust the cutting speed nd the feed rte within the ove conditions ccording to the ctul mchining sitution * GL chipreker is recommended for surfce finish-oriented ppliction G chipreker is suitle for fine pitch cutter (fz 0.4 mm/t). It is not recommended for extr fine pitch cutter. Cse studies Construction mchine prt 42CrMo4 Cse 5CrNi Vc = 250 m/min p e = 2 ~ 75 mm fz = 0.15 mm/t Vf = 900 mm/min Dry MFPN4580R-6 (6 inserts) PNMU1205NR-M (PR1225) Vc = 90 m/min p e = mm fz = 0.19 mm/t Vf = 410 mm/min Dry MFPN45080R-6 (6 inserts) PNMU1205NR-M (PR1225) Chip removl rte Mchining efficiency PR1225 Competitor G 94 cc/min 202 cc/min x2.1 PR1225 Competitor (for roughing) 1.5 pcs/corner 1pcs/corner x1.5 MFPN cutter improved mchining efficiency 2.1 times of the competitor without chnging spindle lod. MFPN cutter ws very stle t the entrnce nd exit of the workpiece. It controls chtter nd remins stle even with low rigid mchine. (User evlution) ven when the cutting depth, cutting speed nd feed rte cnnot e rised due to the low rigidity of workpiece, MFPN fce mill enles stle milling without chttering nd lso hs n improved tool life of 1.5 times. (User evlution) 8

10 Fce mill MFPN66 Rke ngle.r. mx +12 = 50 : -9 = 6 : -8 = 80 : -7 R.R. = : #1 #2 # 4 66 oolholder dimensions vil- No. of Dimensions (mm) Weight hpe him ility inserts (kg) MFPN 66050R-4-M-G R-5-M-G # R-6-M-G No 66100R-7-M-G # R-9-M-G R-11-M-G #.8 MFPN 66050R-5-M-G R-7-M-G # R-9-M-G No 66100R-11-M-G # R-1-M-G R-15-M-G # 4 Dimension : 5 mm : ville Fine pitch xtr fine pitch pre prts MFPN66 Clmp screw Wrench nti-eize compound ror olt Fine pitch xtr fine pitch MFPN 66050R-4-M-G MFPN 6606R-5-M-G MFPN 66080R-6-M-G MFPN 66100R-7-M-G MFPN 66125R-9-M-G MFPN 66160R-11-M-G MFPN 66050R-5-M-G MFPN 6606R-7-M-G MFPN 66080R-9-M-G MFPN 66100R-11-M-G MFPN 66125R-1-M-G MFPN 66160R-15-M-G B-4090RP B-4090RP Recommended torque for insert clmp.5 N m Recommended torque for insert clmp.5 N m DPM-15 DPM-15 P-7 P Cot nti-seize compound thinly on portion of tper nd thred prior to instlltion. 9

11 l L nd mill MFPN66 1 #1 66 oolholder dimensions vilility No. of inserts Dimensions (mm) Rke ngle pre prts Clmp screw Wrench nti-eize compound 1 L l.r. (M) R.R MFPN 6602R-2-2-G B-4090RP DPM R-2--G Recommended torque for insert clmp.5 N m P-7 : ville pplicle inserts Clssifiction of usge : Roughing / 1st choice : Roughing / 2nd choice : Finishing / 1st choice : Finishing / 2nd choice (In cse hrdness is under 45RC) hpe P Cron steel / lloy steel Die steel ustenitic stinless steel M Mrtensitic stinless steel Precipittion hrdened stinless steel K Gry cst iron Nodulr cst iron (FCD) N Non ferrous metls Ni-se het-resistnt lloys (Inconel ) itnium lloy igh hrdness steel Dimensions (mm) MGCO NNO Cermet rε PR155 PR1525 PR1510 N620M PNMU 0905NR- Generl purpose PNMU 0905NR-M M Low cutting force PNMU 0905NR-G G ough edge (evy milling) : ville pplicle chipreker Fine pitch xtr fine pitch Cutter Insert M G fz = 0.2 mm/t is recommended 10

12 Recommended cutting conditions MFPN66 1st recommendtion 2nd recommendtion Coted cride Insert M G* Workpiece Feed (fz: mm/t) Recommended insert grde (Cutting conditions Vc: m/min) MGCO NNO PR155 PR1525 PR1510 Cron steel lloy steel Die steel ustenitic stinless steel Mrtensitic stinless steel Precipittion hrdened stinless steel Gry cst iron Nodulr cst iron Ni-se het-resistnt lloy (Inconel etc.) Cron steel lloy steel Die steel ustenitic stinless steel Mrtensitic stinless steel Precipittion hrdened stinless steel Gry cst iron Nodulr cst iron Ni-se het-resistnt lloy (Inconel, etc.) itnium lloy Cron steel lloy steel Die steel Gry cst iron Nodulr cst iron *When using G chipreker for fine pitch cutters, recommended feed is fz 0.2 (mm/t) 1st recommendtion 2nd recommendtion Cermet Insert Workpiece Feed (fz: mm/t) Recommended insert grde (Cutting conditions Vc: m/min) Cermet N620M Cron steel lloy steel Die steel st recommendtion he numer in old font is recommended strting conditions. djust the cutting speed nd the feed rte within the ove conditions ccording to the ctul mchining sitution Cutting with coolnt is recommended for Ni-se het resistnt lloy nd titnium lloy. Chipreker recommended pplictions Coted cride Cermet 5 G 5 p (mm) 0.5 M p (mm) fz (mm/t) fz (mm/t) he informtion contined in this rochure is current s of eptemer Dupliction or reproduction of ny prt of this rochure without pprovl is prohiited KYOCR Corportion