Super Radius Mill. TD4N type. Super Radius Mill TD4N type. New Product News No.1604E

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1 Super Radius Mill type Super Radius Mill type New Product News No.1604E

2 Te c h n o l o g y JM4160 Stainless steel Pat. No JS4045 GX2140 Carbon steel Alloy steel Features JP4120 Pre-hardened steel Hardened steel 30 45HRC 01 Roughing Hardened steel 45 55HRC Applications Cast iron Reduces uncut remnants on work pieces The cutting edge shape was reviewed for so that uncut remnants are reduced. This enables the load on the next process to be reduced by up to 40%compared to conventional products. Since it is difficult to create tool shape definitions in CAM for the complicated cutting edge shapes of high-feed tools, in many cases the tools are used with the definition for a simple R radius tool. The differences between this definition and the actual tool shape result in uncut remnants that cannot be seen on CAM and become more work for the next process. Features 02 Tool definition shape R on CAM Conventional high-feed tool Maximum remains 0.5mm Maximum remains 0.2mm Economical 4-corner inserts with chip breakers for various applications By making it possible to use both the front and back sides of inserts, 4 corners can be used. The inserts are provided with a large rake angle which exhibits an excellent cutting force reduction effect even when compared to general positive-shape inserts. Front back Corner identification marks Features of insert breaker C breaker Corresponds to our general-purpose high-feed-type inserts (EDNW, EPNW, WDNW, SDNW), and is resistant to chip jamming, vibrations, and crater wear. B breaker Magnified view of cutting edge cross section Positive rake angle Enables reduced cutting force when cutting work materials such as stainless steel, etc. that require free-cutting performance. Comparison of cutting force Resultant force C breaker Cutting force N (kgf) 02 C breaker 10%Down B breaker B breaker 2000

3 Features 03 arge tip diameter for excellent handling Compared to conventional high-feed tools, has a large tip diameter, which suppresses the generation of uncut remnants which easily occur on the bottom surface of machined areas. In addition, since the cutting width (ae) can be set to a large value, this is also effective for improving machining efficiency. Photograph of machined surface at corner (viewed from above) 04 Tip diameter Flat area Uncut remnants Tool diameter Features Conventional 5mm Excellent chip discharge characteristics Reduces the occurrence of sudden problems due to jamming of cutting chips. In addition, good chip removal makes it possible to further improve cutting performance. Tool with small chip pockets If cutting chips are not discharged well, jamming of the cutting chips between the tool and wall occur, which can become the cause of sudden damage such as chipping, etc. Crushed cutting chips Good chip discharge characteristics are achieved by providing large chip pockets and controlling the chip discharge direction. Cutting chips which were discharged well AJ Coating series PVD Technology The topmost surface of the low-wear-effect coating exhibits excellent welding resistance. Employs an AlTi with a high Al content to improve heat resistance and chipping resistance. Photograph of coating structure PVD Technology General purpose for steel Grade for machining pre-hardened or hardened materials JP4120 Highly versatile with excellent cutting performance on pre-hardened steel or hardened steel at hardnesses of 30 to 50 HRC. PVD Technology Grade for machining stainless-steel materials JM4160 Combination with carbide material having excellent toughness improves chipping damage that occurs during stainless-steel machining, etc. JS4045 JS4045 adopts heat resistant layer, reduces the crater wear by high-feed-rate processing.combining with C breaker is ideal for high-performance machining of carbon steel. 03

4 ine Up Shank type 20 (32)- Numeric figure in a circle and Alphabetical character comes in a square. 1 ls Fig.1 (Standard type) φdc2 φdc1 1 ls Fig.2 (Undercut type) φdc2 φdc1 With center through-hole Size Type Item Code Stock No.of Tool Tip Overall Below Shank Flutes Shank dia. Shape diameter diameter length neck length φdc2 φdc1 1 ls 2016S S S Fig S S Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig.2 Shank type ong Regular :Stocked Items. Modular type 20 M- f C 2 M (Notch width) E Recommended insert ENMU0603ER-B/C Numeric figure comes in a circle. φdc2 φdc1 1 φd 2 φdb With center through-hole Size Item Code Stock No.of Tool Tip Below Flutes diameter diameter neck φdc2 φdc1 f 1 2 φd2 φdb M C E 2016M M M M M M M M M M M M M M M M M M M M :Stocked Items. Note Do not apply lubricants to the threaded section or end surface sections in contact with the dedicated shank/arbor for modular mills. Recommended insert ENMU0603ER-B/C Parts Parts Shape In consideration of reducing environmental loads, the screwdriver and screw anti-seizure agent are now sold separately to avoid sending unnecessary duplicate tools. We hope you will understand our reasoning. Clamp screw Fastening torque (N m) Not included with product (sold separately) Screw Driver Screw anti-seizure agent Item Code T8 P-37 Note The clamp screw is a consumable part. Since replacement life depends on the use environment, it is recommended that it be replaced at an early stage. 04

5 T Insert W Fig.1 Tougher edge C breaker ENMU0603ER-C W T Fig.2 Reduce cutting force B breaker ENMU0603ER-B W T P Carbon steels M SUS, etc. K FC FCD H Hardened steels Item Code Tolerance Class W T :General cutting, First recommendation :General cutting, Second recommendation AJ-Coated JS-Coated GX-Coated Size Shape JP4120 JM4160 JS4045 GX2140 W T ENMU0603ER-C Fig.1 M ENMU0603ER-B Fig.2 :Stocked Items. Note Please note that the GX2140 does not cause a reaction in conductive touch sensors. The Shanks for Modular Mill Carbide shank f Rs f Rs φd3 φd4 φd2 φd3 M Type A φd2 M Type B Item Code ASC Stock φd2 M 3 f Size 1 Below neck RS Shank length ASC ASC M ASC ASC ASC Z ASC Z M10 30 ASC Z ASC Z ASC Z M ASC Z ASC ASC M12 35 ASC ASC ASC M ASC ASC ASC ASC M ASC ASC ASC ASC M ASC φd3 Shank dia. φd4 Type Cutter body With/ without air hole A φ A φ A φ B φ B φ B B φ32 φ40 φ42 φ30 φ32 φ40 φ42 Note 1 Commercial milling chucks or shrink-fit holders can be used. 2 For the φ 40, φ 42 size, it is recommended that the protrusion length be 200mm or less. 3 Types for the dedicated arbor (HSK-A63) and for steel shanks are standard stock items. 05

6 Recommended Cutting Conditions Red indicates primary recommended insert grade. Work material Dc Recommended Diameter φ16( 2 flutes) φ20(3 flutes) φ25(4 flutes) φ32(5 flutes) φ40(6 flutes) inserts grade Overhang ratio ~ 3Dc 4Dc 7Dc ~ ~ 3Dc 4Dc 7Dc ~ ~ 3Dc 4Dc 7Dc ~ ~ 3Dc 4Dc ~ ~ 3Dc 4Dc 7Dc 7Dc ~ n (min-1 ) Vc(m/min) Carbon Steel Vf(mm/min) Alloy Steel GX2140 fz(mm/t) <30HRC JS4045 ap ae Q (cm3 /min) n (min-1 ) Vc(m/min) Alloy steel Vf(mm/min) JP4120 Tool steel fz(mm/t) JS HRC ap ae Q (cm3 /min) n (min-1 ) Vc(m/min) Pre-hardened Vf(mm/min) steel JP4120 fz(mm/t) Alloy steel JS4045 ap 40 50HRC ae Q (cm3 /min) n (min-1 ) Vc(m/min) Vf(mm/min) Stainless-steel JM4160 fz(mm/t) SUS ap ae Q (cm3 /min) n (min-1 ) Vc(m/min) Cast iron Vf(mm/min) JP4120 FC fz(mm/t) GX2140 FCD ap ae Q (cm3 /min) Maximum ap ap 1.0 Note 1 Use the appropriate coolant for the work material and machining shape. ae 2 These conditions are for general guidance; in actual machining conditions adjust the parameters according to your actual machine and work-piece conditions. 3 Please note that the GX2140 does not cause a reaction in conductive touch sensors. ap 4 To prevent tool damage due to chip clogging, always use a chip removal method such as an air blower, etc. 5 Ensure to exchange the insert at the correct time to ensure safety of the tool-body. 6 The following equation can be used to determine the metal removal rate per unit time Q: Q(cm3/min)=ap ae Vf(mm/min) / 1000 Do not set values higher than the maximum value. Regarding ramping and helical milling diameter θ Ramp angle θ Ramping Tool diameter φ16 φ18 φ20 φ22 φ25 φ28 φ32 φ35 φ40 φ42 Maximum ramp angle θ Hole Dia. Helical milling Hole Dia. 24 ~ ~ ~ ~ ~ ~ ~ ~ ~ 78 76~82 Cutting depth per rotation should be set to ap = 1 mm or less. Note It is recommended that the tool be used while performing sufficient chip removal and checking that there are no abnormal vibrations. Points requiring care when creating the machining program In CAM, define the tool shape as an R radius shape. apmax = 1.0mm Use with axial-direction cutting depths ap of 1.0mm or less. Tool definition shape on CAM Recommended Remains Over Cut R R R Remains 06 R2

7 Field data 01 Shortened machining time Interrupted machining Cutting edge condition after 30 minutes of cutting Work material Pre-hardened steel 40HRC Tool 2032S-5 φ32-5 flutes ENMU0603EN-B JP4120 Cutting conditions VBmax=0.08mm vc=100m/min v f=9000mm/min fz=1.8mm/t a p a e=0.6 20mm 2mm Air-blow 90-minute machining time shortened to approx. 30 minutes. 02 Improved tool life Pocketing Cutting edge condition after 100 minutes of cutting Work material Carbon steel Tool 2020S-3 φ20-3 flutes ENMU0603EN-B JP4120 Cutting conditions VBmax=0.173mm vc=140m/min v f=5000mm/min fz=0.75mm/t a p a e=0.8 10mm 2mm Emulsion oil There is no major chipping and damage is improved. 03 High-performance machining when clamp rigidity is weak. ow clamp rigidity Conventional B Work material Mild Steels Tool 2032S-5 φ32-5 flutes ENMU0603EN-C JS4045 Cutting conditions Machining of 190 pcs. vc=200m/min v f=8000mm/min fz=0.8mm/t a p a e=0.5 20mm Emulsion oil Machining of 200 pcs. VBmax=0.075mm Even after machining 200 pcs., wear is small and good. High-feed tools lineup for Mitsubishi Hitachi Tool Handle a many kind of roughing machining needs with a plentiful lineup. Type Feature high Supports for Efficiency Economical accuracy (No. of high-hardened (No. of (ess uncut corners) steel Flutes) remnants) ASR Multi-Flutes ASR ASRT ASRF No. of corners φ φ φ20 63 Shape Inscribed circle code Programming Maximum R ap φ φ φ High Efficiency multiflutes 62HRC High Efficiency multiflutes 62HRC General 60HRC General 62HRC General 60HRC General ASRF-mini Insert Tool dia 50HRC Holder For details of tool specifications, please check on catalog or website 07

8 The diagrams and table data are examples of test results, and are not guaranteed values. "Epoch", and are registered trademarks of Mitsubishi Hitachi Tool Engineering, td. in Japan. Attentions on Safety 1. Attentions regarding handling (1)When removing the tool from the case(package), be careful not to drop it on your foot or drop it onto the tips of your bare fingers. (2)When actually setting the inserts, be careful not to touch the cutting flute directly with your bare hands. 2. Attentions regarding mounting (1)When preparing for use, be sure that the inserts are firmly mounted in place and that they are firmly mounted on the arbor, etc. (2)If abnormal chattering occurs during use, stop the machine immediately and remove the cause of the chattering. 3. Attentions during use (1)Before use, confirm the dimensions and direction of rotation of the tool and milling work material. (2)The numerical values in the standard cutting conditions table should be used as criteria when starting new work. The cutting conditions should be adjusted as appropriate when the cutting depth is large, the rigidity of the machine being used is low, or according to the conditions of the work material. (3)The inserts are made of a hard material. During use, they may break and fly off. In addition, cutting chips may also fly off. Since there is a danger of injury to workers, fire, or eye damage from such flying pieces, a safety cover should be installed and safety equipment such as safety glasses should be worn to create a safe environment for work. Do not use where there is a risk of fire or explosion. Do not use non-water-soluble cutting oils. Such oils may result in fire. (4)Do not use the tool for any purpose other than that for which it is intended, and do not modify it. CTI Tower 24F, 191/32 Ratchadapisek Road, Klongtoey, Klongtoey, Bangkok 10110, Thailand Tel +66-(0) Fax +66-(0) Specifications for the products listed in this catalog are subject to change without notice due to replacement or modification. Printed using vegetable oil ink. Printed in JAPAN ( M E -T 0) :FP