VFX for High Efficiency Milling of Titanium Alloys

Transcription

1 TOOL NEW Update B182A For Milling VFX eries Insert Expansion VFX for High Efficiency Milling of s Outstanding metal removal rates up to 24 inch 3 /min (with ø2.5" cutter)

2 Unparalleled Chip Ejection Properties Helps Re-define the Parameters for Machining VFX eries High Rigidity Design Arranging the inserts vertically absorbs the principal cutting force through the thickness of the insert and achieves extremely high rigidity. Highly Reliable Clamping Mechanism The insert seat has a curved seating face in the radial direction of the tool and a V-shaped seating face on the axis of rotation that can securely handle cutting forces from any direction. Low Resistance Convex Curve Cutting Edge The curved cutting edge resembles the geometry of a solid end mill and achieves low cutting resistance and enables high quality machining. V Formation of the Clamping Face Convex Curve Cutting Edge Cutting Force Improved Chip Removal with Coolant Coolant Nozzle The internal coolant is directed slightly above the rake face of the cutting edge so that it is aimed directly at the chip. Forcibly ejecting the chips prevents them from welding to the cutting edge, enabling higher efficiency machining. Coolant Discharge Position Replaceable Coolant Nozzle A replaceable nozzle is used for the internal coolant (hole diameter of the standard nozzle supplied: ø0.8 mm or.031 inch). The coolant pressure can be adjusted by using a nozzle with a smaller or larger diameter. Nozzles with different diameters are available as options. 1

3 electing Inserts L M H Produces compact chips without increasing cutting resistance. Excellent performance at large widths of cut and during slotting. Covers a wide range of cutting conditions and applications. Excellent chip separation and strong cutting edge. Highly efficient machining is possible at small widths of cut. Chip Breaker L M H First Recommended MP9130 A new and enhanced super fine cemented carbide substrate has increased toughness while maintaining hardness. The Al-Ti-Cr-N accumulated type coating ensures optimum heat and wear resistance. The combination of these properties gives excellent fracture resistance and a very low coefficient of friction for class leading welding resistance when machining titanium alloy. VFX5 Width of Cut : ae General Purpose Grade Combination of Holder and Insert Corner R uses an accumulated type coating based on a Ti compound that demonstrates excellent abrasion and fracture resistance during titanium alloy machining. VFX6 Grade:MP9130 Insert Type:M R.031" R.047" R.063" R.094" R.125" R.157" Grade:MP9130 Insert Type:H R.031" Grade:MP9130 Insert Type:L Grade:MP9130 Insert Type:M R.047" R.063" R.094" R.125" R.157" R.197" Grade:MP9130 Insert Type:H R.047" Grade:MP9130 Insert Type:L R.031" R.047" Only the end cutting edge can be changed. On the peripheral cutting edges please use R.047" for VFX6 and R.031" for VFX5. Newly Developed 3-flute Holder (VFX5 Only) During high chip volume applications such as slotting, chip evacuation performance is important and if insufficient can lead to chipping of the insert. To solve this problem a 3 flute cutter with maximized main flutes and chip pockets has been developed. Use of the new L breaker in conjunction with the 3 flute cutter will maximize the performance benefits. ub Pocket 2

4 For Milling DEEP HOULDER MILLING VFX5 Roughing CBDP L8 a Vertical inserts with high strength cutting edge. a crew-on type clamping. a High efficiency milling of titanium alloys. DAH KWW ON FM 90 APMX LF Right hand tool holder only. y hell Type =Inch, ON =Inch R No.F Total LF ON CBDP DAH FM KWW L8 APMX WT (lbs) VFX5UR0203CA10 a VFX5UR0203CA15 a VFX5UR0204AA10 a VFX5UR0204AA15 a VFX5UR0204CA15 a VFX5UR0204AA20 a VFX5UR0204CA20 a VFX5UR2505CA10 a VFX5UR2505CA24 a VFX5UR0306DA29 a No. F = Number of Flutes pare Parts tock 2 3 Number of Insert 1 Clamp crew Number eal Washer Wrench Coolant Nozzle Number Anti-seize Lubricant et Bolt End Cutting Edge XNMU1607 oor-oo Peripheral Cutting Edge XNMU R-oo VFX5UR0203CA10 T352 6 WU500-1 TKY10D HD04004H08 9 MK1K HCUF VFX5UR0203CA15 T352 9 WU500-1 TKY10D HD04004H08 12 MK1K HCUF VFX5UR0204AA10 T352 8 WU375-1 TKY10D HD04004H08 12 MK1K HCUF VFX5UR0204AA15 T WU375-1 TKY10D HD04004H08 16 MK1K HCUF VFX5UR0204CA15 T WU500-1 TKY10D HD04004H08 16 MK1K HCUF VFX5UR0204AA20 T WU375-1 TKY10D HD04004H08 20 MK1K HCUF VFX5UR0204CA20 T WU500-1 TKY10D HD04004H08 20 MK1K HCUF VFX5UR2505CA10 T WU500-1 TKY10D HD04004H08 15 MK1K HCUF VFX5UR2505CA24 T WU500-1 TKY10D HD04004H08 30 MK1K HCUF VFX5UR0306DA29 T WU625-1 TKY10D HD04004H08 42 MK1K HCUF Only corner radius RE.031 can be used. 2. Clamp Torque (lbf-in) : T352=22 3. The.031" nozzels are installed in the standard. elect and use alternate nozzles from below list depending on coolant pressure. 3 <140PI ( <5.3gal/min) Nozzle Dia. ø.024" ø.031" ø.047" ø.063" HD04004H06 HD04004H08 HD04004H12 HD04004H16 Clamp Torque (lbf-in) : HD0400Hpp=13 The part number for a plug screw without a through nozzle is H Insert with a corner radius of.125" and above, as corner radius increases the LF dimension increases. Corner radius.125": LF+.028" Corner radius.157": LF+.059" a : Inventory maintained. tandard (140PI-720PI) >720PI (>7.9gal/min) s : Inventory maintained in Japan. >1000PI (>13.2gal/min)

5 CBDP L8 Metric tandard =mm, ON=Inch y hell Type a Vertical inserts with high strength cutting edge. a crew-on type clamping. a High efficiency milling of titanium alloys. DAH KWW ON FM 90 APMX LF Right hand tool holder only. (mm) tock No.F Total LF ON CBDP DAH FM KWW L8 APMX WT(kg) R VFX5-040A03A026R s VFX5-040A03A038R s VFX5-050X03A026R s VFX5-050X03A038R s VFX5-050A04A026R s VFX5-050A04A038R s VFX5-050X04A038R s VFX5-050A04A050R s VFX5-063A05A026R s VFX5-063A05A063R s VFX5-080A06A075R s No. F = Number of Flutes pare Parts 2 3 Number of Insert 1 Edge XNMU1607 oor-oo Cutting Edge XNMU R-oo VFX5-040A03A026R T352 6 W8-1 TKY10D HD04004H08 9 MK1K HC VFX5-040A03A038R T352 9 W8-1 TKY10D HD04004H08 12 MK1K HC VFX5-050X03A026R T352 6 W12-1 TKY10D HD04004H08 9 MK1K HC VFX5-050X03A038R T352 9 W12-1 TKY10D HD04004H08 12 MK1K HC VFX5-050A04A026R T352 8 W10-1 TKY10D HD04004H08 12 MK1K HC VFX5-050A04A038R T W10-1 TKY10D HD04004H08 16 MK1K HC VFX5-050X04A038R T W12-1 TKY10D HD04004H08 16 MK1K HC VFX5-050A04A050R T W10-1 TKY10D HD04004H08 20 MK1K HC VFX5-063A05A026R T W12-1 TKY10D HD04004H08 15 MK1K HC VFX5-063A05A063R T W12-1 TKY10D HD04004H08 30 MK1K HC VFX5-080A06A075R T W16-1 TKY10D HD04004H08 42 MK1K HC Only corner radius RE0.8 can be used for the peripheral cutting edges except the end cutting edge. 2 Clamp Torque (N m) : T352=2.5 3 Coolant nozzles are available with varying diameters for adjusting coolant pressure. elect nozzles as required by the specification. <1Mpa (<20 l/min.) Clamp crew Number eal Washer Wrench Coolant Nozzle Number Anti-seize Lubricant et Bolt tandard >5Mpa ( >30 l/min.) >7Mpa ( >50 l/min.) Nozzle Dia. ø0.6mm ø0.8mm ø1.2mm ø1.6mm HD04004H06 HD04004H08 HD04004H12 HD04004H16 Clamp Torque (N m) : HD0400Hpp=1.5 The part number for a plug screw without a through nozzle is H Insert with a corner radius of 3.2mm and above, as corner radius increases the LF dimension increases. Corner radius 3.2mm: LF+0.7mm Corner radius 4.0mm: LF+1.5mm End Cutting Peripheral 4

6 B B B For Milling Inserts tock Coated hape MP9130 L LE W1 INL B RE D1 Geometry 1 1 XNMU160708R-M a a XNMU160712R-M a a XNMU160716R-M a a XNMU160724R-M a a XNMU160732R-M a a XNMU160740R-M a a XNMU160708R-H a a INL RE L LE L W1 D1 W1 RE LE D1 INL XNMU160708R-L a L W1 RE LE D1 INL 1 Note for insert with a corner radius of.125" and above, as corner radius increases the LF dimension increases. Corner radius.125": LF+.028" Corner radius.157": LF+.059" 5 a : Inventory maintained. (10 insert in one case)

7 Recommended Cutting Conditions y VFX5 Work Material (Ti6Al4V) (Ti-5553) &2.0 &2.5 &3.0 &2.0 &2.5 &3.0 y VFX5 (Metric tandard) Number of Flutes Chip Breaker vc (FM) n (min -1 ) apmax ae fz (IPT) vf (IPM) Chip Removal Estimated Rate Cutting Power Expected Tool Life Torque Ratio Q (inch 3 /min) PC (HP) (lbf-ft) (%) 3 L M M H L M M H L M M H L M M H L M M H L M M H Work Material (Ti6Al4V) (Ti-5553) &40 &50 &63 &80 &40 &50 &63 &80 Number of Flutes Chip Breaker vc (FM) n (min -1 ) apmax ae fz (IPT) vf (IPM) Chip Removal Estimated Rate Cutting Power Expected Tool Life Torque Ratio Q (inch 3 /min) PC (HP) (lbf-ft) (%) 3 L M M H L M M H L M M H L M M H L M M H L M M H L M M H L M M H (Note 1) Note that machining performance varies depending to the conditions such as machine rigidity, work clamping rigidity, coolant supply system, pressure and flow volume etc. (Note 2) Internal coolant is recommended. To allow coolant through the tool, use a FMH coolant through type arbor. Using external coolant in combination with through coolant is even more effective. (Note 3) The tool life ratio shows the standard when ae = tool diameter 20% is assumed to be 100 when shoulder cutting. (Note 4) The maximum depth of cut (apmax) varies according to the machine rigidity and power. 6

8 For Milling DEEP HOULDER MILLING VFX6 Roughing CBDP L8 a Vertical inserts with high strength cutting edge. a crew-on type clamping. a High efficiency milling of titanium alloys. DAH KWW ON FM 90 APMX LF Right hand tool holder only. y hell Type =Inch, ON =Inch tock R No.F Total LF ON CBDP DAH FM KWW L8 APMX WT (lbs) VFX6UR2504CA12 a VFX6UR2504CA23 a VFX6UR0305DA12 a VFX6UR0305DA29 a VFX6UR0406EA12 a VFX6UR0406EA35 a No. F = Number of Flutes pare Parts 2 3 Number of Insert 1 Clamp crew Number eal Washer Wrench Coolant Nozzle Number Anti-seize Lubricant et Bolt End Cutting Edge XNMU1909 oor-oo Peripheral Cutting Edge XNMU R-oo VFX6UR2504CA12 T450 8 WU500-1 TKY20T HD04004H08 12 MK1K HCUF VFX6UR2504CA23 T WU500-1 TKY20T HD04004H08 20 MK1K HCUF VFX6UR0305DA12 T WU625-1 TKY20T HD04004H08 15 MK1K HCUF VFX6UR0305DA29 T WU625-1 TKY20T HD04004H08 30 MK1K HCUF VFX6UR0406EA12 T WU750-1 TKY20T HD04004H08 18 MK1K HCUF VFX6UR0406EA35 T WU750-1 TKY20T HD04004H08 42 MK1K HCUF Only corner radius RE.047" can be used. 2. Clamp Torque (lbf-in) : T450=44 3. The.031" nozzels are installed in the standard. elect and use alternate nozzles from below list depending on coolant pressure. <140PI ( <5.3gal/min) tandard (140PI-720PI) >720PI (>7.9gal/min) >1000PI (>13.2gal/min) Nozzle Dia. ø.024" ø.031" ø.047" ø.063" HD04004H06 HD04004H08 HD04004H12 HD04004H16 Clamp Torque (lbf-in) : HD0400Hpp=13 The part number for a plug screw without a through nozzle is H Insert with a corner radius of.125" and above, as corner radius increases the LF dimension increases. Corner radius.125": LF+.028" Corner radius.157": LF+.059" Corner radius.197": LF+.059" 7 a : Inventory maintained. s : Inventory maintained in Japan.

9 CBDP L8 Metric tandard =mm, ON=Inch a Vertical inserts with high strength cutting edge. a crew-on type clamping. a High efficiency milling of titanium alloys. DAH KWW ON FM 90 APMX LF Right hand tool holder only. y hell Type (mm) tock No.F Total LF ON CBDP DAH FM KWW L8 APMX WT(kg) R VFX6-063A04A031R s VFX6-063A04A060R s VFX6-080A05A031R s VFX6-080A05A075R s VFX6-100A06A031R s VFX6-100A06A090R s No. F = Number of Flutes pare Parts 2 3 Number of Insert 1 ø0.6mm ø0.8mm ø1.2mm ø1.6mm HD04004H06 HD04004H08 HD04004H12 HD04004H16 Edge XNMU1909 oor-oo Cutting Edge XNMU R-oo VFX6-063A04A031R T450 8 W12-1 TKY20T HD04004H08 12 MK1K HC VFX6-063A04A060R T W12-1 TKY20T HD04004H08 20 MK1K HC VFX6-080A05A031R T W16-1 TKY20T HD04004H08 15 MK1K HC VFX6-080A05A075R T W16-1 TKY20T HD04004H08 30 MK1K HC VFX6-100A06A031R T W20-1 TKY20T HD04004H08 18 MK1K HC VFX6-100A06A090R T W20-1 TKY20T HD04004H08 42 MK1K HC Only corner radius RE1.2 can be used for the peripheral cutting edges except the end cutting edge. 2 Clamp Torque (N m) : T450=5.0 3 Coolant nozzles are available with varying diameters for adjusting coolant pressure. elect nozzles as required by the specification. Nozzle Dia. <1Mpa (<20 l/min.) tandard Clamp Torque (N m) : HD0400Hpp=1.5 Clamp crew Number eal Washer Wrench Coolant Nozzle Number Anti-seize Lubricant et Bolt >5Mpa ( >30 l/min.) >7Mpa ( >50 l/min.) The part number for a plug screw without a through nozzle is H Insert with a corner radius of 3.2mm and above, as corner radius increases the LF dimension increases. Corner radius 3.2mm: LF+0.7mm Corner radius 4.0mm: LF+1.5mm Corner radius 5.0mm: LF+1.5mm End Cutting Peripheral 8

10 B B B For Milling Inserts hape MP9130 tock Coated L LE W1 INL B RE D1 Geometry XNMU190912R-M a a L XNMU190916R-M a a XNMU190924R-M a a XNMU190932R-M a a RE LE XNMU190940R-M a a XNMU190950R-M a a XNMU190912R-H a a L INL W1 D1 W1 RE LE D1 INL XNMU190912R-L a L W1 RE LE D1 INL 1 Note for insert with a corner radius of.125" and above, as corner radius increases the LF dimension increases. Corner radius.125": LF+.028" Corner radius.157": LF+.059" Corner radius.197": LF+.059" 9 a : Inventory maintained. (10 insert in one case)

11 Recommended Cutting Conditions y VFX6 Work Material (Ti6Al4V) (Ti-5553) &2.5 &3.0 &4.0 &2.5 &3.0 &4.0 y VFX6 (Metric tandard) Work Material (Ti6Al4V) (Ti-5553) &63 &80 &100 &63 &80 &100 Number of Flutes Chip Breaker vc (FM) n (min -1 ) apmax ae fz (IPT) vf (IPM) Chip Removal Estimated Rate Cutting Power Expected Tool Life Torque Ratio Q (inch 3 /min) PC (HP) (lbf-ft) (%) 4 L M M H L M M H L M M H L M M H L M M H L M M H Number of Flutes Chip Breaker vc (FM) n (min -1 ) apmax ae fz (IPT) vf (IPM) Chip Removal Estimated Rate Cutting Power Expected Tool Life Torque Ratio Q (inch 3 /min) PC (HP) (lbf-ft) (%) 4 L M M H L M M H L M M H L M M H L M M H L M M H (Note 1) Note that machining performance varies depending to the conditions such as machine rigidity, work clamping rigidity, coolant supply system, pressure and flow volume etc. (Note 2) Internal coolant is recommended. To allow coolant through the tool, use a FMH coolant through type arbor. Using external coolant in combination with through coolant is even more effective. (Note 3) The tool life ratio shows the standard when ae = tool diameter 20% is assumed to be 100 when shoulder cutting. (Note 4) The maximum depth of cut (apmax) varies according to the machine rigidity and power. 10

12 Application Examples Tool VFX5-050A04A050R VFX5-050A04A050R VFX5-050A04A050R (Ti6Al4V) (Ti6Al4V) (Ti6Al4V) Workpiece Cutting Conditions Component Aerospace Parts Aerospace Parts Aerospace Parts Cutting peed (FM) Table Feed (IPM) Feed per Tooth (IPT) Width of Cut ae Depth of Cut ap Cutting Mode Wet Cutting (Internal:435PI) Wet Cutting (External:220PI) Wet Cutting (External:435PI) Results Efficiency was increased by a factor of 1.3. Efficiency increased by a factor of 1.5 and was also possible to achieve stable machining of thin walled parts. It was possible to use 2 times increased cutting conditions for greater cost reduction. Tool VFX6-080A05A075R VFX6-063A04A060R VFX6-063A04A060R (Ti-5553) (Ti6Al4V) (Ti6Al4V) Workpiece Cutting Conditions Component Aerospace Parts Aerospace Parts Aerospace Parts Cutting peed (FM) Table Feed (IPM) Feed per Tooth (IPT) Width of Cut ae Depth of Cut ap Cutting Mode Wet Cutting (Internal:1015PI) Wet Cutting (Internal:1450PI) Wet Cutting (External:220PI) Results With the same tool life (190 mins) as conventional tools, it was possible to use 1.2 times increased cutting conditions for greater efficiency. At a metal removal rate of 4.7inch 3 /min, tool life was constant at 60mins and efficiency increased x 1.5. VFX was stable in tests at a max. metal removal rate of 24inch 3 /min. Three times tool life at cutting conditions improved by a factor of 2.7. Total cost reductions of 62%. awith reference to the above examples, adjust the cutting conditions according to the machine specifications, workpiece geometry and clamping method used. For your safety adon't touch breakers and chips without gloves. aplease machine within recommended application range, and exchange expired tools with new parts in advance. aplease use safety cover and wear safety glasses. awhen using compounded cutting oils, please take fire prevention. awhen attaching inserts or spare parts, please use the attached wrench or driver. awhen using tools in revolution machining, please make a trial run to check run-out, vibration, abnormal sounds etc. Customer ervice : Technical ervice : LO ANGELE HEAD OFFICE later Avenue, Fountain Valley, CA TEL : FAX : CHICAGO OFFICE 1314B North Plum Grove Road, chaumburg, IL TEL : FAX : MMC METAL DE MEXICO,.A. DE C.V. Av. La Cañada No.16, Parque Industrial Bernardo Quintana, El Marques, Queretaro, CP76246, Mexico TEL : FAX : TORONTO OFFICE 3535 Laird Road, Units 15 & 16, Mississauga, Ontario, L5L 5Y7, Canada TEL : FAX : URL : (Tools specifications subject to change without notice.) EXP-10-E016 Printed in U..A. 5/17