KGD for Automatic Lathe

Transcription

1 Cut-off Tool Cut-off Tool KGD KGD for Automatic athe Stable achining and ong Tool ife ower Production Costs Edge idths Available from 1.3 mm Excellent Chip Control ong Tool ife with EGACOAT NANO P1535 NE New Sub Spindle Toolholder Available NE PF Chipbreaker Corner 0.15 is Now Available

2 Cut-off Tool KGD for Automatic athe Edge idths Available from 1.3 mm Excellent Chip Control and Stable achining with ong Tool ife Point1 Chipbreaker ineup and Application igh P for edium-igh Feed ates Edge idth 2 mm~ Cutting Force PG for Sharp Cutting PF for ow Feed ates Edge idth 1.3 mm~ PQ for edium Feed ates Edge idth 2 mm~ Edge idth 2 mm~ ow ow Feed ate igh Point2 Excellent Chip Control with New olded Chipbreaker PF Chipbreaker Depression at center of chipbreaker curls chips at low feed range (f = mm/ rev). Small corner () = 0.03 mm, 0.15 mm effectively reduces the boss remaining on the workpiece surface. PQ Chipbreaker Chipbreaker finely breaks chips with double the projection at medium feed range (f = mm/rev). Corner () = 0.1 mm combines both sharpness and fracture resistance. Point3 Strong Insert Clamping Force New Slit Design Insert clamping force is improved by firmly fastening the front side (insert side) of the toolholder. Toolholder clamps insert equally and firmly. adial-shaped Surface on Toolholder Insert clamping force and installation are improved by increasing contact area between the insert and toolholder. adial-shaped surface on the toolholder increases the contact area between the insert and toolholder. Toolholder Back Side Front Side (Insert Side) Clamping Force Comparison (Traversing) Cutting conditions: Vc = 80 m/min, f = ~ 0.3 mm/rev, ap = 1 ~ 3 mm, wet (oil base) (In-house Evaluation) orkpiece: SK4 (ø10) Depth of Cut (ap) 1 mm 1.5 mm 2 mm 3 mm Feed ate (f) 5 mm/rev 0.3 mm/rev 5 mm/rev 0.3 mm/rev 5 mm/rev 0.3 mm/rev 5 mm/rev 0.3 mm/rev KGD Competitor A Competitor B Insert Stable achining 1

3 EGACOAT NANO P1535 Combination of tough substrate and special nano layer coating enables long tool life and stable machining of stainless steel. Point 1 Point 2 UP Toughening with a New Cobalt ixing atio Comparison with Kyocera s Conventional Grade 23% * Fracture Toughness* Improved Stability by Optimization and omogenization of the Particle atrix Cracking Comparison by Diamond Indentor (In-house Evaluation) Conventional material P1535 UP Shock esistance Point 3 ong Tool ife and Stable achining with EGACOAT NANO ong Cracks Short Cracks Coating Property ardness (GPa) TiCN TiAIN TiN EGACOAT NANO EGACOAT ,000 1,0 1,400 Oxidation Temperature ( C) ow Oxidation esistance igh EGACOAT Base ayer Structure P1535 is a good solution for unstable conditions such as early fracturing and variable tool life during steel machining. ear esistance Evaluation (In-house Evaluation) Fracture esistance Comparison (In-house Evaluation) ax. ear (mm) Poor Chip Control 0.15 Poor Chip Control Tool ife 2 Times Still achinable Number of Passes P1535 Conventional J Competitor K ,000 Number of Impacts No Fracturing Cutting Conditions: n = 1,273 min -1 (Vc = 80 m/min), f = mm/rev, wet (oil base) orkpiece: SUS304 (ø) Cutting Conditions: Vc = 80 m/min, f = 0.12 mm/rev, wet (water soluble) orkpiece: SUS304 (ø50, width: 10 mm 4 slots) Case Studies achine Part SUS304 Vc = 130 m/min f = 0.04 mm/rev wet GD30-025P-6D P1535 ø8 ø30 Joint SUS304 Vc = 80 m/min f = 0.05 mm/rev wet GDN-010PQ P1535 ø16 Number of orkpieces P pcs/edge Tool ife 2 Times Number of orkpieces P1535 1,000 pcs/edge Tool ife 25% Competitor E 0 pcs/edge Competitor F 800 pcs/edge Compared to Competitor E, P1535 showed good edge condition and doubled the tool life even at higher feed rates. (f = 0.03mm/rev 0.04mm/rev) (User Evaluation) P1535 extended the tool life by 25% compared to Competitor F. PQ chipbreaker showed smooth chip control and cutting edge condition was good without sudden fracturing. (User Evaluation) 2

4 GD/GDG Shape ight-handed Insert Shown Usage Classification : Continuous to ight Interruption / 1st Choice : Continuous to ight Interruption / 2nd Choice : Continuous / 1st choice : Continuous / 2nd choice Description Edge idth () Tolerance P N Dimensions (mm) Corner () Carbon Steel / Alloy Steel Stainless Steel Non-ferrous etals Angle ( ) EGACOAT NANO EGACOAT Carbide P1535 P1225 P1215 G15 GD 1316N-003PF 1.3 ± N-015PF 1.3 ± GD 1516N-003PF 1.5 ± N-015PF 1.5 ± ± GD N-003PF 2.0 ± N-015PF 2.0 ± GD 25N-003PF 2.5 ± N-015PF 2.5 ± ow Feed ate 2-edge GD 30N-003PF ± N-015PF ± GD 1316 /-003PF-15D 1.3 ± GD 1516 /-003PF-15D 1.5 ± PF-15D 1.5 ± GD /-003PF-15D 2.0 ± PF-15D 2.0 ± GD 25 /-003PF-15D 2.5 ± PF-15D 2.5 ± Cut-off 15 ead Angle ow Feed ate 2-edge NE ± GD 30 /-003PF-15D ± PF-15D ± GD N-010PQ GD 25N-010PQ edium Feed ate 2-edge GD 30N-010PQ 0.1 GD -010PQ-15D GD PQ-15D ead Angle edium Feed ate 2-edge GD PQ-15D GDG N-005PG 2.0 ± ±0.02 GDG 25N-005PG 2.5 ± ow Cutting Force 2-edge GDG 30N-005PG ± GDG -005PG-15D 2.0 ± ±0.02 GDG PG-15D 2.5 ± ead Angle ow Cutting Force 2-edge Corner () of PQ chipbreakers are small enough for automatic lathe. PF chipbreaker has a large corner (). For cutting conditions, see back cover. GDG PG-15D ± Inserts Sold in 10 Piece Boxes : Std. Item : Std. Item (ight-hand Only) Note: hen grooving, PF/P chipbreaker (for cut-off) cannot create a flat bottom (see right figure). Bottom Cutting Shape of PF/P Chipbreaker 3

5 NE Usage Classification : Continuous to ight Interruption / 1st Choice : Continuous to ight Interruption / 2nd Choice : Continuous / 1st Choice : Continuous / 2nd Choice Description Edge idth () Corner Stainless Steel N Non-ferrous etals Angle Cermet EGACOAT ( ) NANO P P1225 GD 30N-025P 5 GD 40N-030P 0.3 GD -0P-6D GD 25-0P-6D GD P-6D 5 GDS N-0P GDS 30N-025P 5 P1535 GDS 40N-030P 0.3 GDS -0P-6D GDS P-6D 5 1-edge TN lead angle 2-edge GDS P-6D 0.3 GD 24N-0G GD N-080G 0.8 GDS 22N-0G GDS 30N-040G 0.4 GDS 40N-040G N-0G 40N-040G GD 30N-0G 30N-040G lead angle 1-edge N-0P 2 2 For general purpose 2-edge For general purpose 1-edge N-0P 2-edge () GD Tolerance EGACOAT GD ight-handed Insert Shown Cut-off Carbon Steel / Alloy Steel Dimensions (mm) Shape Grooving and cut-off P : Std. Item Inserts Sold in 10 Piece Boxes : Std. Item (ight-hand Only) Insert Identification System idth Accuracy 13: 1.3 mm 15: 1.5 mm : 2 mm G: Class G : Class GD S 25: 2.5 mm 30: 3 mm 40: 4 mm 30 and of Tool Chipbreaker Symbol : ight-hand : eft-hand N: Neutral P: Cut-off PF: Cut-off (ow Feed) G: Grooving PQ: Cut-off (edium Feed) PG: Cut-off (ow Cutting Force) P - 6D Series No. of Edges Insert length Corner- () ead angle Cut-off GD series No Indication: 2-edge S: 1-edge 16: 16 mm : mm 003: 0.03 mm 0: mm 005: 0.05 mm 025: 5 mm 010: 0.1 mm 030: 0.3 mm 015: 0.15 mm No Indication: 0 6D: Applicable range Cutting Force igh PF P/G PQ PF PG PQ ow ow 0.1 Feed ate (mm/rev) igh 4

6 KGD (for Automatic athe) Edge idth: 1.3~ mm Insert Seat Angle 3 1 Insert Seat Angle h 3 4 F 2 1 B ight-hand Insert Shown A ø Dmax 2 1 Description Stock Cutting Dia. Dimensions (mm) Edge idth (mm) ø Dmax 1 = h B 1 2 F A IN. AX. Screw Spare Parts rench KGD / 1010JX SB-401T T-15S 1212JX SB-401T T-15S KGD / 1010JX SB-401T T-15S 1212JX SB-401T T-15S KGD / 1212F SB-401T T-15S KGD / 1212F SB-401T T-15S KGD / 1010JX SB-401T T-15S 1212JX SB-401T T-15S 1616JX SB-401T T-15S KGD / 1010JX SB-401T T-15S 1212JX SB-401T T-15S 1616JX SB-401T T-15S KGD / 1212JX SB-401T T-15S 1616JX SB-401T T-15S KGD / 1212F SB-401T T-15S KGD / 1212F SB-401T T-15S KGD / 1616JX- 3D SE-50125T T- KGD / 12JX-3D SE-50125T T- JX-3D SE-50125T T- Although mm-width insert can be installed in KGD /1212JX-3, it is not recommended due to the toolholder s rigidity. Note : hen machining large cutting dia. (over 36 mm) with KGD /...-3D38 or KGD /...-3D42, please follow the instructions below Use 1-edge inserts. aximum workpiece diameter for 2-edge inserts is ø 36 mm. : Std. Item Toolholder Identification System KGD KGDS 1616 JX - Toolholder and : ight-hand : eft-hand Shank Size mm Toolholder Overhang ength JX: 1 mm Applicable Inserts GD/GDS Edge width 3 4 mm Applicable Inserts GD/GDS Edge idth 1.3 mm Others D38: ø Dmax 38 mm D38 B Others B: for Sub Spindle Tooling 5

7 KGDS (for Cut-Off Operation Near Sub Spindle Side) ight-hand 3 2 ø Dmax Description Stock Cutting Dia. Dimensions (mm) Edge idth (mm) ø Dmax = h 2 3 B F A ( ) IN. AX. Spare Parts Screw rench KGDS /1616JX-1.3B SB-401T T-15S KGDS /1616JX-1.5B SB-401T T-15S KGDS /1616JX-2B SB-401T T-15S : Std. Item KGD Standard Type Both ight-hand and eft-hand types are applicable to gang tool post. efthand type is recommended for cut-off operations when using a sub-spindle. KGDS Sub Spindle Type The KGDS can be used to reduce overhang distance from the main spindle when cutting off small diameter workpieces. KGD (ight-hand) KGD (eft-hand) KGDS (ight-hand) KGDS (eft-hand) ain Spindle ain Spindle Sub Spindle ain Spindle Sub Spindle ain Spindle Sub Spindle h F B 2 3 A 1 eft-hand ø Dmax h 3 B F A 1 KGD / KGDS Selection eference ecommendations (ight-hand) Use insert with lead angle to remove boss No sub-spindle Cut-off close to main spindle ecommendations (eft-hand) Insert without lead angle Sub-spindle use Cut-off close to sub-spindle ecommendations (ight-hand) ong workpiece Good rigidity Cut-off near main spindle ecommendations (eft-hand) Short workpiece Poor rigidity Cut-off near sub-spindle 6

8 inimum Overhand ength (2) of the Toolholder achining Tips Advantage Advantage Compatible with any machine setups regardless of overhang length specifications inimum and optimal overhang length helps to control chattering 2 Product ineup with a aximum Cutting Diameter of 42 mm Note : hen machining large cutting dia. (over 36 mm) with KGD /...-3D38 or KGD /...-3D42, please follow the instructions below Use 1-edge inserts aximum workpiece diameter for 2-edge inserts is ø 36 mm ø Dmax ecommended Cutting Conditions of PF / PQ / PG Chipbreaker 1st ecommendation 2nd ecommendation orkpiece EGACOAT NANO Cutting Conditions (Vc: m/min) Feed ate (f: mm/rev) ecommended Insert Grade PF (Corner 0.03) PF (Corner 0.15) PQ PG EGACOAT Carbide Edge idth (mm) Edge idth (mm) Edge idth (mm) Edge idth (mm) P1535 P1225 P1215 G15 1.3/ / 1.3/ / / / Notes Carbon Steel Alloy Steel Stainless Steel Cast Iron Aluminum Brass et ecommended Cutting Conditions of P / G Chipbreaker 1st ecommendation 2nd ecommendation orkpiece EGACOAT NANO Cutting Conditions (Vc: m/min) Feed ate (f: mm/rev) ecommended Insert Grade P G EGACOAT Edge idth (mm) Edge idth (mm) P1535 P1225 P /2.4 / Notes Carbon Steel Alloy Steel Stainless Steel Cast Iron et 15 KYOCEA Corporation CP353