EPDBE. High-Precision Ball End Mills for Deep Machining FEATURES. Improved compound neck design for reduced chatter and increased strength
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1 High-Precisio Ball Ed Mills for Deep Machiig FEATURES Improved compoud eck desig for reduced chatter ad icreased stregth New flute shape icreases resistace to breakage Stroger R flute helix agle improves cuttig performace ATH ad PN Coatigs for maximum efficiecy ad tool life
2 Itroductio The Epoch Series Ball Ed Mills have bee desiged for cuttig deep ribs ad slots i molds, as well as machiig deep corers ad precisio features that were previously possible oly by EDM (electrical discharge machiig). Featurig a improved compoud eck desig, these ed mills exhibit greater breakage resistace ad less vibratio durig high speed machiig tha competitors tools. New cuttig geometries as well as the advaced ATH ad PN Coatigs help to maximize machiig performace as well as tool life. FeatureS 1. Iovative Ball Nose Geometry High-stregth flute shape with high chip removal characteristics. Stroger R flute helix agle improves cuttig performace. Tool ATH (R0.5 Uder eck 10mm) Fiishig surface New shape Iclie agle:1 Competitor Chippig occurred 2. Improved Compoud Neck Shape Further improves the covetioal compoud shape of R ad taper to both resist breakage ad suppress deflectio. New shape Smaller eck R rage Suppresses deflectio. Covetioal Deep series Large eck R rage Cautio: The iterferece regio has chaged due to chages i the eck shape. Be sure to check for iterferece before startig machiig. Load (N) Static load test results Testig tool size: 64 Covetioal 63 eck shape 62 New eck shape Deflectio amout (mm) Deflectio suppressio effect is high eve uder the same load. Eables machiig with eve higher accuracy Mitsubishi Hitachi Tool Egieerig, Ltd.
3 3. New PVD Coatig Techology Advaced TH (ATH) Coatig: With a hardess of 3800Hv ad oxidatio temperature of 1200, our ew ATH Coatig eables loger life ad higher efficiecy whe cuttig high-hardess materials (55HRC or higher). Compared with our previous geeratio coatig, double the tool life ad more tha double the machiig efficiecy ca be achieved. The ATH Coatig is ideal for both dry cuttig ad wet cuttig i a variety of materials icludig cold-worked die, HSS, tool, composite materials, carbide alloys ad more. Cross-sectio photograph of ATH coatig layer structure High hardess membrae 5m High heat resistace membrae Covetioal Coatig ATH Coatig for hard material Eve fier particle size is ao order. Pat.No. PN Coatig: By optimizig the AI cotet, the multi-layer PN Coatig exhibits both excellet heat-resistace ad adhesio to the tool substrate. Combiig of the AlCr coatig layer with Si produces high hardess (3000HV) as well as good wear resistace. PN Coatig provides exteded cuttig tool life i both wet ad dry machiig of materials icludig prehardeed, carbo, alloy, stailess, H13, D2 ad more Mitsubishi Hitachi Tool Egieerig, Ltd. 175
4 Helix agle:30 R θκ Neck R φ D1 Tolerace o shak : h5 Iclie agle Actual effective legth φ Dc Tolerace o R : Right table l L φ Ds BALL NOSE SEMI-FINISHING FINISHING HRC 2 FLUTES PN COATING ATH COATING Helix Agle 30 φds h5 R (R 0.25) ±0.003 R (0.25<R) ±0.005 Stock Size (mm) Actual Effective Legth i Iclie Agles Part No.* PN ATH R D c l D 1 L D s Neck R Ѳk *For the last 3 digits of the part o. eter the coatig type (PN, ATH) = Stocked items i Japa Mitsubishi Hitachi Tool Egieerig, Ltd.
5 Helix agle:30 R θκ Neck R φ D1 Tolerace o shak : h5 Iclie agle Actual effective legth φ Dc Tolerace o R : Right table l L φ Ds BALL NOSE SEMI-FINISHING FINISHING HRC 2 FLUTES PN COATING ATH COATING Helix Agle 30 φds h5 R (R 0.25) ±0.003 R (0.25<R) ±0.005 Stock Size (mm) Actual Effective Legth i Iclie Agles Part No.* PN ATH R D c l D 1 L D s Neck R Ѳk *For the last 3 digits of the part o. eter the coatig type (PN, ATH) = Stocked items i Japa 2015 Mitsubishi Hitachi Tool Egieerig, Ltd. 177
6 Helix agle:30 R θκ Neck R φ D1 Tolerace o shak : h5 Iclie agle Actual effective legth φ Dc Tolerace o R : Right table l L φ Ds BALL NOSE SEMI-FINISHING FINISHING HRC 2 FLUTES PN COATING ATH COATING Helix Agle 30 φds h5 R (R 0.25) ±0.003 R (0.25<R) ±0.005 Stock Size (mm) Actual Effective Legth i Iclie Agles Part No.* PN ATH R D c l D 1 L D s Neck R Ѳk *For the last 3 digits of the part o. eter the coatig type (PN, ATH) = Stocked items i Japa Mitsubishi Hitachi Tool Egieerig, Ltd.
7 Helix agle:30 R θκ Neck R φ D1 Tolerace o shak : h5 Iclie agle Actual effective legth φ Dc Tolerace o R : Right table l L φ Ds BALL NOSE SEMI-FINISHING FINISHING HRC 2 FLUTES PN COATING ATH COATING Helix Agle 30 φds h5 R (R 0.25) ±0.003 R (0.25<R) ±0.005 Stock Size (mm) Actual Effective Legth i Iclie Agles Part No.* PN ATH R D c l D 1 L D s Neck R Ѳk *For the last 3 digits of the part o. eter the coatig type (PN, ATH) = Stocked items i Japa 2015 Mitsubishi Hitachi Tool Egieerig, Ltd. 179
8 Helix agle:30 R θκ Neck R φ D1 Tolerace o shak : h5 Iclie agle Actual effective legth φ Dc Tolerace o R : Right table l φ Ds L BALL NOSE SEMI-FINISHING FINISHING HRC 2 FLUTES PN COATING ATH COATING Helix Agle 30 φds h5 R (R 0.25) ±0.003 R (0.25<R) ±0.005 Stock Size (mm) Actual Effective Legth i Iclie Agles Neck Part No.* PN ATH R D c l D 1 L D s R Ѳk *For the last 3 digits of the part o. eter the coatig type (PN, ATH) Mitsubishi Hitachi Tool Egieerig, Ltd.
9 Helix agle:30 R θκ Neck R φ D1 Tolerace o shak : h5 Iclie agle Actual effective legth φ Dc Tolerace o R : Right table l L φ Ds BALL NOSE SEMI-FINISHING FINISHING HRC 2 FLUTES PN COATING ATH COATING Helix Agle 30 φds h5 R (R 0.25) ±0.003 R (0.25<R) ±0.005 Stock Size (mm) Actual Effective Legth i Iclie Agles Neck Part No.* PN ATH R D c l D 1 L D s R Ѳk *For the last 3 digits of the part o. eter the coatig type (PN, ATH) 2015 Mitsubishi Hitachi Tool Egieerig, Ltd. 181
10 Cuttig Coditios High Efficiecy (Metric) Copper (Cu) Carbo Alloy ( HB) PN Coatig Stailess Tool (25-35HRC) Pre-harde (35-45HRC) ATH Coatig (45-55HRC) (55 - HRC) Ratio to stadard depth of cut 120% 100% 90% 80% % 60% R Mill dia. Uder eck legth a p mi) mi) mi) mi) mi) , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,000 1,500 50,000 1,500 46,800 1,404 44,200 1,193 39,000 1,053 36, ,000 1,500 50,000 1,500 46,800 1,404 44,200 1,193 39,000 1,053 36, ,000 1,200 50,000 1,200 46,800 1,123 44, , , ,000 1,081 50,000 1,000 42, , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,000 2,250 50,000 2,250 50,000 2,250 50,000 1,950 48,000 1,728 44,800 1, ,000 2,250 50,000 2,250 50,000 2,250 50,000 1,950 48,000 1,728 44,800 1, ,000 1,800 50,000 1,800 50,000 1,800 50,000 1,560 48,000 1,382 44, mi) Mitsubishi Hitachi Tool Egieerig, Ltd.
11 Cuttig Coditios High Efficiecy (Metric) Copper (Cu) Carbo Alloy ( HB) PN Coatig Stailess Tool (25-35HRC) Pre-harde (35-45HRC) ATH Coatig (45-55HRC) (55 - HRC) Ratio to stadard depth of cut 120% 100% 90% 80% % 60% R Mill dia. Uder eck legth a p mi) mi) mi) mi) mi) ,000 1,800 50,000 1,800 50,000 1,800 50,000 1,560 48,000 1,382 44, ,000 1,710 50,000 1,710 50,000 1,709 48,960 1,452 43,200 1,183 40, ,000 1,710 50,000 1,710 50,000 1,709 48,960 1,452 43,200 1,183 40, ,000 1,350 50,000 1,350 48,600 1,313 45,900 1,074 40, , ,000 1,350 46,800 1,264 42,120 1,138 39, , , ,000 1,350 46,800 1,264 42,120 1,138 39, , , ,000 1,350 46,800 1,264 42,120 1,138 39, , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,000 2,700 50,000 2,700 50,000 2,700 50,000 2,400 48,000 2,592 44,800 1, ,000 2,700 50,000 2,700 50,000 2,700 50,000 2,400 48,000 2,592 44,800 1, ,000 2,431 50,000 2,429 50,000 2,431 48,960 2,114 43,200 2,123 40,320 1, ,000 2,269 50,000 2,267 45,360 2,058 42,840 1,727 37,800 1,429 35,280 1, ,920 1,617 41,600 1,348 37,440 1,213 35,360 1,018 31, , ,400 1,175 32, , , , , ,000 3,197 50,000 3,197 50,000 3,197 50,000 2,821 45,600 2,411 42,560 2, ,000 2,771 50,000 2,771 50,000 2,771 48,450 2,369 42,750 1,959 39,900 1, ,000 2,302 47,880 2,020 43,092 1,818 40,698 1,515 35,910 1,253 33,516 1, ,776 1,679 36,480 1,399 32,832 1,259 31,008 1,049 27, , ,000 3,750 50,000 3,750 48,600 3,645 45,900 3,098 43,200 2,722 37,800 2, ,000 3,750 50,000 3,750 48,600 3,645 45,900 3,098 43,200 2,722 37,800 2, ,000 3,750 50,000 3,750 48,600 3,645 45,900 3,098 43,200 2,722 37,800 2, ,000 3,500 46,800 3,276 42,120 2,948 39,780 2,596 43,200 2,540 32,760 1, ,000 3,151 42,120 2,4 40,824 2,558 38,556 2,319 38,880 2,353 29,484 1, ,6 2,100 38,880 1,750 34,992 1,574 33,048 1,338 31,590 1,323 27,216 1, ,6 2,100 38,880 1,750 34,992 1,574 33,048 1,338 31,590 1,323 27, ,6 2,100 38,880 1,750 34,992 1,574 33,048 1,338 31,590 1,323 27, ,6 2,100 38,880 1,750 34,992 1,574 33,048 1,338 31,590 1,323 27, ,560 1,469 28,800 1,224 25,920 1,102 24, , , ,560 1,469 28,800 1,224 25,920 1,102 24, , , ,560 1,469 28,800 1,224 25,920 1,102 24, , , ,560 1,469 28,800 1,224 25,920 1,102 24, , , ,240 1,210 25,200 1,008 22, , , , ,920 1,037 21, , , , , ,000 3,924 50,000 3,924 45,360 3,560 42,840 2,927 37,800 2,452 35,280 2, ,000 3,924 50,000 3,924 45,360 3,560 42,840 2,927 37,800 2,452 35,280 2, ,736 2,767 39,780 2,306 35,802 2,075 33,813 1,706 29,835 1,430 27,846 1, ,736 2,306 39,780 2,306 35,802 1,729 31,212 1,312 27,540 1,100 25, ,736 2,306 39,780 1,774 35,802 1,729 31,212 1,312 27,540 1,100 25, mi) 2015 Mitsubishi Hitachi Tool Egieerig, Ltd. 183
12 Cuttig Coditios High Efficiecy (Metric) Copper (Cu) Carbo Alloy ( HB) PN Coatig Stailess Tool (25-35HRC) Pre-harde (35-45HRC) ATH Coatig (45-55HRC) (55 - HRC) Ratio to stadard depth of cut 120% 100% 90% 80% % 60% R Mill dia. Uder eck legth a p mi) mi) mi) mi) mi) ,000 3,924 46,154 3,743 41,538 3,260 39,230 2,717 36,923 2,555 32,307 1, ,928 2,570 37,440 2,142 33,696 2,103 31,824 2,069 30,240 2,062 26,208 1, ,472 1,940 34,560 1,708 31,104 1,456 29,376 1,322 27,000 1,069 24, ,472 1,940 34,560 1,618 31,104 1,456 29,376 1,322 25,920 1,026 24, ,312 2,830 32,760 2,359 29,484 2,123 27,846 1,805 24,570 1,533 22,932 1, ,288 1,960 30,240 1,633 27,216 1,470 25,704 1,249 22,680 1,062 21, ,880 1,371 22,400 1,142 20,160 1,028 19, , , ,000 4,951 42,000 4,158 37,800 3,742 35,700 3,213 31,500 2,552 29,400 2, ,000 4,951 42,000 4,158 37,800 3,742 35,700 3,213 31,500 2,552 29,400 2, ,312 2,802 32,760 2,627 29,484 2,101 27,846 1,805 24,570 1,434 22,932 1, ,288 2,586 30,240 2,156 27,216 1,940 25,704 1,666 22,680 1,323 21,168 1, ,288 2,155 30,240 1,796 27,216 1,616 25,704 1,388 22,680 1,103 21, ,256 1,810 30,240 1,796 24,192 1,357 22,848 1,1 20, , ,880 1,508 22,400 1,257 20,160 1,131 19, , , ,880 1,508 22,400 1,257 20,160 1,131 19, , , ,880 1,508 22,400 1,257 20,160 1,131 19, , , ,680 3,669 36,400 3,058 32,760 2,752 30,940 2,493 27,300 2,129 23,660 1, ,312 3,467 32,760 2,889 29,484 2,601 27,846 2,176 24,570 1,858 21,294 1, ,696 2,123 28,080 1,769 25,272 1,592 23,868 1,332 21,060 1,138 19, ,960 1,485 20,800 1,238 18,720 1,114 17, , , ,560 3,894 33,800 3,245 30,420 2,920 28,730 2,413 25,350 2,008 23,660 1, ,696 2,426 28,080 2,022 25,272 1,819 23,868 1,504 21,060 1,250 19,6 1, ,696 2,426 28,080 2,022 25,272 1,819 23,868 1,504 21,060 1,250 19,6 1, ,960 1,697 20,800 1,414 18,720 1,273 17,680 1,052 15, , ,800 5,670 31,500 4,725 28,350 4,253 26,775 3,616 23,625 3,049 22,050 2, ,800 5,670 31,500 4,725 28,350 4,253 26,775 3,616 23,625 3,049 22,050 2, ,800 5,103 31,500 4,253 28,350 3,827 26,775 3,213 23,625 2,693 22,050 2, ,800 5,103 31,500 4,253 28,350 3,827 26,775 3,213 23,625 2,693 22,050 2, ,280 4,234 29,400 3,528 26,460 3,175 24,990 2,699 22,050 2,249 19,110 1, ,752 3,809 26,460 3,175 23,814 2,858 22,491 2,430 19,845 2,051 17,199 1, ,752 3,809 26,460 3,175 23,814 2,858 22,491 2,430 19,845 2,024 15,876 1, ,752 3,301 26,460 2,752 23,814 2,477 22,491 2,106 18,428 1,629 15,876 1, ,484 2,123 24,570 1,769 22,113 1,593 20,885 1,353 18,428 1,467 15, ,216 1,960 22,680 1,633 20,412 1,470 19,278 1,249 18,428 1,354 15, ,216 1,960 22,680 1,633 20,412 1,470 19,278 1,249 18,428 1,128 15, ,420 1,457 17,850 1,214 16,0 1,092 15, , , ,160 1,371 16,800 1,142 15,120 1,028 14, , , ,160 1,371 16,800 1,142 15,120 1,028 14, , , ,640 1,129 14, , , , , , , , , , , mi) Mitsubishi Hitachi Tool Egieerig, Ltd.
13 Cuttig Coditios High Efficiecy (Metric) Copper (Cu) Carbo Alloy ( HB) PN Coatig Stailess Tool (25-35HRC) Pre-harde (35-45HRC) ATH Coatig (45-55HRC) (55 - HRC) Ratio to stadard depth of cut 120% 100% 90% 80% % 60% R Mill dia. Uder eck legth a p mi) mi) mi) mi) mi) ,300 6,075 27,750 5,063 24,975 4,556 23,588 3,797 20,813 3,088 19,425 2, ,300 6,075 27,750 5,063 24,975 4,556 23,588 3,797 20,813 3,088 19,425 2, ,974 3,411 21,645 2,842 19,481 2,558 18,398 2,132 16,234 2,023 15,152 1, ,976 2,624 19,980 2,186 17,982 1,968 16,983 1,640 16,234 1,445 13,986 1, ,976 2,360 19,980 1,967 17,982 1,770 16,983 1,475 14,985 1,200 13, ,760 1,836 14,800 1,530 13,320 1,377 12,580 1,148 11, , ,800 6,480 24,000 5,400 21,600 4,860 20,400 4,100 18,000 3,402 16,800 3, ,800 6,480 24,000 5,400 21,600 4,860 20,400 4,100 18,000 3,402 16,800 3, ,880 4,838 22,400 4,032 20,160 3,629 19,040 3,061 16,800 2,540 15,680 2, ,880 4,355 22,400 3,629 20,160 3,266 19,040 2,755 16,800 2,286 14,560 1, ,464 3,033 18,720 2,527 16,848 2,275 15,912 1,919 14,040 1,593 12,096 1, ,464 3,033 18,720 2,527 16,848 2,275 15,912 1,919 14,040 1,593 12,096 1, ,736 2,800 17,280 2,333 15,552 2,100 14,688 1,771 12,960 1,470 12,096 1, ,360 1,958 12,800 1,632 11,520 1,469 10,880 1,239 9,600 1,028 10,752 1, ,450 4,399 17,875 3,666 16,088 3,299 15,194 2,750 13,406 2,236 12,513 1, ,820 2,736 14,850 2,280 13,3 2,052 12,623 1,710 11,138 1,391 10,395 1, ,820 2,736 14,850 2,280 13,3 2,052 12,623 1,710 11,138 1,391 10,395 1, ,200 1,918 11,000 1,598 9,900 1,438 9,350 1,199 8, , ,700 6,210 17,250 5,175 15,525 4,8 14,663 3,960 12,938 3,299 12,075 2, ,700 6,210 17,250 5,175 15,525 4,8 14,663 3,960 12,938 3,299 12,075 2, ,700 6,210 17,250 5,175 15,525 4,8 14,663 3,960 12,938 3,299 12,075 2, ,940 4,306 14,950 3,588 13,455 3,229 12,708 2,746 11,213 2,287 10,4 2, ,146 3,488 13,455 2,906 12,110 2,616 11,437 2,223 10,092 2,162 9,419 1, ,904 2,683 12,420 2,236 11,178 2,012 10,558 1,710 9,316 1,426 8,694 1, ,904 2,683 12,420 2,236 11,178 2,012 10,558 1,710 9,316 1,426 8,694 1, ,904 2,683 12,420 2,236 11,178 2,012 10,558 1,710 9,316 1,426 8,694 1, ,040 1,877 9,200 1,564 8,280 1,408 7,820 1,196 6, , ,040 1,877 9,200 1,564 8,280 1,408 7,820 1,196 6, , ,120 5,443 12,600 4,536 11,340 4,082 10,710 3,213 9,450 2,835 8,820 2, ,040 5,054 11,700 3,0 10,530 3,791 9,945 2,984 8,775 2,633 8,190 2, ,636 4,549 10,530 2,780 9,477 3,413 8,951 2,685 7,898 2,369 7,371 1, ,664 2,520 9,720 2,100 8,748 1,890 8,262 1,487 7,290 1,313 6,804 1, ,200 6,804 13,500 5,670 12,150 5,103 11,475 4,253 10,125 3,459 9,450 2, ,300 5,967 12,750 4,973 11,475 4,475 10,838 3,729 9,563 3,033 8,925 2, ,480 3,594 10,400 2,995 9,360 2,696 8,840 2,122 7,800 2,028 7,280 1, ,368 2,687 8,640 2,239 7,776 2,016 7,344 1,587 6,480 1,400 6,048 1,175 mi) 2015 Mitsubishi Hitachi Tool Egieerig, Ltd. 185
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