Xtra-tec High Performance Cutter F4030
Table of Content Product description Results from lab and customer Program range Application areas & Target groups Benefits for the customer Typical work pieces 2
01 Product description General points D C = 25 63 MM HARD NICKELIZED SURFACE 6 CUTTING EDGES 3
01 Product description Basic body High performance milling cutter for high feed rates Kappa 0-21 Ø 25-63 mm a pmax = 1 mm f z up to 3,5 mm Insert with negative basic shape 6 Cutting edges per insert 1 Insert size for complete program 2 different pitches 4
01 Product description The Insert R1,2 SUPPORT FACE SINTERED SLOPING CUTTING EDGE R14 NEGATIVE BASIC SHAPE 5
01 Product description The Insert Negative basic shape Trigon basic shape with 6 cutting edges Designation P23696-1.0 Insert completely sintered 6
01 Product description Insert geometries P23696 The universal one: For medium an unfavourable machining conditions Universal application for most materials 20 rake angle 7
02 Results from Lab (P23696-1.0) Face milling (Roughing) At a cutting speed of 250 m / min have we reached a max. feed rate f z = 1.5mm (V f = 9.2 m / min ). More was limited by the capacity of the machine. Face milling (Grooving) By grooving we increased the feed rate up to f z =2.5mm (V f = 15.3 m / min ), until the machine were at the end of capacity. Tool: F4030, Ø52mm, Z=4 Insert: P23696-1.0 a p max. = 1mm Material: 42CrMo4 Machine: Deckel-Maho DMU80 P mot = 20 kw M mot = 121 Nm 8
02 Results from Lab (P23696-1.0) Face milling (Roughing) The F4030 with Ø63 (Z=4) was milled at a V c of 250 m / min and a maximum feed rate f z = 3mm (V f = 15.1 m / min ) to the upper limit of the machine. The Ø50 (Z=3) was tested at the same cutting speed and a f z of max. 2 mm (V f = 9.5 m / min ). Face milling (Grooving) Both the Ø63 and the Ø50 (ScrewFit => Big Xs-Dimension) have reached with a feed rate f z of 2.5mm (V f = 12.6 m / min respectively V f = 11.9 m / min ) the end of the machining capacity. Tool: F4030, Ø63mm and Ø50mm Insert: P23696-2.0 a p max. = 2mm Material: 42CrMo4 Machine: Starrag Heckert HEC630 P mot = 67 kw M mot = 1200 Nm 9
02 Results from Lab (P23696-1.0) Circular interpolation Created diameter was 83mm. With a feed rate f z = 0.5mm (V f = 3.7 m / min ) was half of the available torque of the machine already consumed. When milling with f z = 1mm the machine has reached the torque limit. D 0 min = 82mm D 0 max = 104mm Tool: F4030, Ø52mm, Z=4 Insert: P23696-1.0 a p max. = 1mm Material: 42CrMo4 Machine: Deckel-Maho DMU80 P mot = 20 kw M mot = 121 Nm 10
02 Results from Lab (P23696-1.0) Circular interpolation With the Ø63 and a borehole diameter of 120mm, we have reached a feed rate f z of 2mm (V f = 12.6 m / min ). For this operation already 60% of the available torque of the machine were used. The maximum diameter which can be created with this tool is 126mm (respectively 100mm for the tool with Ø50). The F4030 with Ø50 (Z=3) was used with the same cutting speed V c = 250 m / min for producing a borhole with diameter 90mm. In this case we reached a feed rate of 2.5 mm (V f = 11.9 m / min ) for which 35% of max. torque were used. Tool: F4030, Ø63mm and Ø50mm Insert: P23696-2.0 a p max. = 2mm Material: 42CrMo4 Machine: Starrag Heckert HEC630 P mot = 67 kw M mot = 1200 Nm 11
02 Results from Lab (P23696-1.0) Ramping The Ø63 tool was tested starting with a f z = 0.15mm (V f = 0.6 m/min) and increased in steps of 0.05mm up to the maximum f z = 0.3mm (V f = 1.5 m/min) while the cutting speed was always V c = 250 m / min. The power consumption was not more then 35% of the machine capacity. When using the Ø50 we have a improvement of the process starting at a feed rate of f z = 0.2mm (V f = 0.8 m/min). The test was started also with f z = 0.15mm. At the max. feed reate f z of 0.25mm (V f = 1 m/min) were only 20% of the machine power used. Tool: F4030, Ø63mm and Ø50mm Insert: P23696-2.0 a p max. = 2mm Material: 42CrMo4 Machine: Starrag Heckert HEC630 P mot = 67 kw M mot = 1200 Nm 12
02 Results from Lab Ramping: Maximum Ramping angle E [ ] Insert Diameter Da Ø25 Ø32 Ø35 Ø40 Ø42 Ø50 Ø52 Ø63 Ø66 Ø80 Ø85 Ø100 P23696-1.0 10,5 8,0 7,0 5,5 5,0 3,8 3,5 2,5 P23696-2.0 8,5 7,0 6,5 4,5 4,0 3,0 2,5 2,0 13
02 Results from Lab (P23696-1.0) Plunging The tool was modular extended with NCT up to a length of Xs=260mm. The smaller the enlacement is, the smoother runs the tool. The tests was made at a cutting speed of V c = 250 m / min and with a feed rate f z =0.2mm (v f = 1 m/min). With a length Xs=180mm (Master+Combi-Arbor) there was a improvement of the complete process. When using big enlacement and a feed rate of f z =0.25mm (v f = 1.3 m/min) we have reached the best result. Tool: F4030, Ø63mm, Z=4 Insert: P23696-2.0 a p max. = 2mm Material: 42CrMo4 Machine: Starrag Heckert HEC630 P mot = 67 kw M mot = 1200 Nm 14
02 Results from Lab (P23696-1.0) Plunging Small Enlacement (Offset) Medium Enlacement (Offset) Big Enlacement (Offset) 15
02 Results from Customer Component: Tool housing Workpiece Material: 1.2312 Machine: Anayak VH Plus 2000-MG 50 KW SK50 Operation: Pocket milling with continuous cut Coolant: Air 16
02 Results from Customer Current situation Tool/Insert SR66-55 D27 9588.A.12520 PE6 Cutting parameter V c = 155 m/min f z = 1,6 mm a p = 1,0 mm V f = 5980 m/min Competitor 01 Competitor 02 17
02 Results from Customer Walter solution Tool/insert F4030.B22.063.Z06.01 P23696-1.0 WSP45 Cutting parameter v c = 120 m/min f z = 2,0 mm a p = 1,0 mm v f = 7275 m/min Cutting speed : 20% Feed/tooth : 20% Feed/min : 18% 18
02 Results from Customer Wear 19
02 Results from Customer Savings/Productivity Words of the customer : we have never seen and hear a milling cutter running so smooth with the another tools we tried, we couldn t use a feed rate like this because the over last of the machine the tool and the insert looks stable and reliable, we want to use it!!! Saving: R70 000 20 200 hours free machine capacity
03 Product Program Bodies metric Bezeichnung Name Da Dc d1 X1 X2 Lc ae Anz. Type Type Metrische Inch Baureihe Range mm mm mm mm mm mm mm Z kg WSP WSP Schraube Screw F4030.B22.050.Z04.01 50 38,4 22 40 1 10 4 0,4 4 F4030.B22.050.Z05.01 50 38,4 22 40 1 10 5 0,3 5 F4030.B22.052.Z04.01 52 40,4 22 40 1 10 4 0,4 4 F4030.B22.063.Z05.01 63 51,4 22 50 1 10 5 0,7 5 F4030.B22.063.Z06.01 63 51,4 22 50 1 10 6 0,7 6 F4030.T22.025.Z02.01 25 13,4 22 35 1 10 2 0,1 2 F4030.T28.032.Z03.01 32 20,4 28 40 1 10 3 0,2 3 F4030.T28.035.Z03.01 35 23,4 28 40 1 10 3 0,2 3 F4030.T36.040.Z03.01 40 28,4 36 40 1 10 3 0,3 3 F4030.T36.040.Z04.01 40 28,4 36 40 1 10 4 0,3 4 F4030.T36.042.Z03.01 42 30,4 36 40 1 10 3 0,4 3 F4030.Z25.025.Z02.01* 25 13,4 25 35 200 1 10 2 0,1 2 F4030.Z32.032.Z03.01* 32 20,4 32 40 250 1 10 3 0,2 3 P23696-1.0 FS2081 *not *nicht included im Highlightflyer in the highest vorhanden flyer 21
03 Product Program Bodies metric Bezeichnung Name Da Dc d1 X1 X2 Lc ae Anz. Type Type Inch Baureihe Inch Range mm mm mm mm mm mm mm Z kg WSP WSP Schraube Screw F4030.UT22.026.Z02.01 25,4 13,8 22 35 1 10 2 0,1 2 F4030.UT28.031.Z03.01 31,75 20,15 28 40 1 10 3 0,2 3 F4030.UT36.038.Z03.01 38,1 26,5 36 40 1 10 3 0,3 3 F4030.UW19.026.Z02.01 25,4 13,8 19,05 104,7 1 10 2 0,2 2 F4030.UW26.031.Z03.01 31,75 20,15 25,4 111 1 10 3 0,4 3 F4030.UW31.038.Z03.01 38,1 26,5 31,75 111 1 10 3 0,6 3 F4030.UZ19.026.Z02.01 25,4 13,8 19,05 203,2 1 10 2 0,4 2 F4030.UZ26.031.Z03.01 31,75 20,15 25,4 254 1 10 3 1,0 3 F4030.UZ31.038.Z03.01 38,1 26,5 31,75 254 1 10 3 1,5 3 F4030.UB19.051.Z05.01 50,8 39,2 19,05 40 1 10 5 0,4 5 F4030.UB26.064.Z05.01 63,5 51,9 25,4 50 1 10 5 0,7 5 F4030.UB26.064.Z06.01 63,5 51,9 25,4 50 1 10 6 0,7 6 P23696-1.0 FS2081 22
WKP25 WKP35S WSP45 WSM35 WSP45 WAK15 WKK25 WKP25 WKP35 WKP35S WXN15 WK10 WSM35 WSP45 WHH15 03 Product Program Inserts NEW 2010 P23696 Name Radius mm Width mm P M K N S H HC HC HC HC HW HC HC P23696-1.0 14 J K L K L K L L K L No WKP35 (mistake in the Highlight flyer) 23
04 Application Areas & Target Groups For machining of steel, stainless steel, cast iron and difficult to cut materials Applications Face milling with high feed rates, Ramping, Circular interpolation, pocketing and plunging Main target groups Useful in nearly all industrial sectors e.g. Energy industry and mould and die 24
05 Benefits for the customer Low cutting tool costs Due to 6 cutting edges per insert High chip removal rate Due to high feed rates Low power consumption due to the positive geometry High process reliability Due to stable indexable inserts (negative basic shape) Large support of insert on the body High flexibility Due to large application area 25
06 Typical workpieces Form plate Turbine blades Injection Mold 26
The End Thank you. FOR MORE DETAILS Tel: 0860 23 23 23 Fax: 0860 33 22 33 Website: www.spectra-sa.co.za E-mail: spectra@spectra-sa.co.za SPECTRA CARBIDE TOOLING TECHNOLOGY (PTY) LTD