/ GENERAL INFORMATION INSERT SCREWS FOR CUTTERS Referece Old referece Sie Leght Screwdriver Isert Family 28349 - M 5.0 13.00 T20 5.0 N.m MP 2099 ZP 3200.. 416.1-833 VF 2394 M 3.5 9.40 10 IP 2.0 N.m PT-8007 ZP 2000.. CMW 11 T3.. 416.1-834 VF 2396 M 4.0 11.00 15 IP 3.0 N.m MP 3125 RT 16 04.. ZP 2500.. 5513 020-02 VF 3468 M 4.0 8.50 15 IP 3.0 N.m MP 3125 RT 16 06.. 5513 020-07 VF 3133 M 5.0 10.85 20 IP 5.0 N.m MP 3662 ZP 3000.. 5513 020-09 VF 0089 M 3.5 8.10 15 IP 3.0 N.m MP 3125 APMW 16 04.. TX 215PLUS AN 2391 (shim) 5513 020-10 VF 0088 M 3.5 10.10 15 IP 3.0 N.m TX 215PLUS PG 16 04.. PLUNG-SAF 5513 020-19 - M 2.2 6.40 7 IP 0.8 N.m PT-8001 WN.. 04 T3.. COMPACT 90 5513 020-27 VF 1642 M 2.0 4.95 6 IP 0.6 N.m PT-8000 EN.. 04 02.. COMPACT 90 5513 020-28 VF 2655 M 2.0 4.25 6 IP 0.6 N.m PT-8000 RT 07 02.. ZP.. 5513 020-31 VF 2193 M 6.0 15.25 25 IP 7.5 N.m MP 3139 RC.. 20 06.. R-SAF ZP 4000.. 5513 020-32 - M 3.5 10.00 15 IP 3.0 N.m MP 3125 RC.. 12 04.. R-SAF RT 10 03.. 5513 020-35 VF 3509 M 2.5 7.30 8 IP 1.2 N.m PT-8006 RT 10 03/T3.. ZP 1600.. 5513 020-36 VF 2564 M 2.5 5.95 8 IP 1.2 N.m TX 208PLUS PG 10 03.. PLUNG-SAF PT-8006 ZP 1200.. 5513 020-40 VF 2900 M 2.0 3.50 6 IP 0.6 N.m PT-8000 R.. 05 01.. TORO-SAF 5513 020-41 VF 2833 M 2.2 4.70 7 IP 0.9 N.m PT-8001 R.. 07 T1.. TORO-SAF 5513 020-55 - M 5.0 14.25 20 IP 5.0 N.m MP 3662 RC.. 16 06.. R-SAF 5513 020-56 - M 2.5 7.00 8 IP 1.2 N.m PT-8006 CC.. 06 02.. TE-SAF 5513 020-57 - M 3.0 8.20 9 IP 1.2 N.m PT-8003 WN.. 06 04.. COMPACT 90 RT 13 04.. PT-8003 VF 0943 - M 3.0 8.50 9 IP 1.2 N.m RT 13 04.. TX 209PLUS PG 13 04.. PLUNG-SAF VF 0981 - M 3.5 8.00 10 IP 2.0 N.m PT-8007 S.. 09 03 AE.. GR-SAF P.. 09 05 AE PENTA 45 P.. 09 05 E PENTA 60 VF 2097 - M 5.0 13.00 20 IP 5.0 N.m MP 3662 P.. 09 05 ZE PENTA High Feed S.. 12 05.. QUARI SP O/R/S.. 12 05.. QUARI-SAF O/R/S.. 15 06.. QUARI-SAF VF 2259 - M 4.0 10.00 15 IP 3.0 N.m TX 215PLUS AN 4585 (shim) PENTA Heavy uty VF 2447 - M 8.0 20.00 T30 18.0 N.m MP 2514 ZP 5000.. VF 2910 - M 2.5 5.80 8 IP 1.2 N.m PT-8006 R.. 08 T2.. TORO-SAF VF 3020 - M 5.0 10.40 20 IP 5.0 N.m MP 3662 R.. 16 04.. TORO-SAF VF 3228 - M 2.2 5.20 6 IP 0.6 N.m TX 206PLUS PPH..06.. ARAF VF 3429 - M 3.0 7.80 8 IP 1.2 N.m TX 208PLUS PPH..10.. ARAF VF 3430 - M 3.5 9.50 10 IP 2.0 N.m TX 210PLUS PPH..12.. ARAF VF 3431 - M 4.0 13.30 15 IP 3.0 N.m TX 215PLUS PPH..16.. ARAF VF 3432 - M 5.0 16.20 20 IP 5.0 N.m TX 220PLUS PPH..20.. ARAF VF 3433 - M 6.0 20.00 25 IP 7.5 N.m MP 3139 PPH..25.. ARAF VF 3434 - M 8.0 25.00 40 IP 26.0 N.m MP 3441 PPH..32.. ARAF VF 3503 - M 3.5 6.70 15 IP 3.0 N.m MP 3125 R.. 10 03.. TORO-SAF VF 3504 - M 3.5 8.00 15 IP 3.0 N.m MP 3125 R.. 12 T3.. TORO-SAF VF 3658 - M 2.5 5.00 8 IP 1.2 N.m PT-8006 R.. 07 02.. TORO-SAF VF 3992 - M 3.5 12.50 15 IP 3.0 N.m TX 215PLUS XPB 20.. SM-SAF VF 3993 - M 4.0 14.00 15 IP 3.0 N.m TX 215PLUS XPB 25.. SM-SAF VF 3994 - M 5.0 17.00 20 IP 5.0 N.m TX 220PLUS XPB 32.. SM-SAF VF 4207 - M 4.0 16.00 15 IP 3.0 N.m TX 215PLUS HN.. 09 05.. FORCE-SAF VF 6240 - M 2.5 6.25 7 IP 1.0 N.m TX 207PLUS PPH..08.. ARAF VF 6243 - M 4.0 11.30 T15 3.0 N.m TX 215 PPH..14.. ARAF VZ 3642 - M 8.0 26.00 30 IP 18.0 N.m MP 3460 PN.. 13 08.. PENTA Heavy uty TORX-P-M3X8/9 M3 X 8/9 M 3.0 8.20 9 IP 1.2 N.m PT-8003 CC.. 08 03.. TE-SAF TORX-P-M4X10/15A M4 X 10/15 M 4.0 10.00 15 IP 3.0 N.m TX 215PLUS CC.. 09 T3.. TE-SAF TORX-P-M5X10/25 M5 X 10/25 M 5.0 10.00 25 IP 6.5 N.m TX 225PLUS CC.. 12 04.. TE-SAF 496 Geeral Catalog
/ GENERAL INFORMATION FORMULAE Required parameters Kow parameters Fmulae Cuttig speed (m/mi) v c Millig cutter diameter Revolutios per miute v c =.. Revolutios per miute (rpm) Cuttig speed Millig cutter diameter v c =.v c. Feed per revolutio Revolutios per miute = =. (mm/mi) Feed per revolutio Revolutios per miute =.. =. Revolutios per miute =. Feed per revolutio = Metal removal rate (cm 3 /mi) Q Cuttig width (ifeed) Cuttig depth Q =.. Millig cutter pitch u Millig cutter diameter u =. Customer Service - Tel.: +33 (0)1 46 10 54 00 Fax: +33 (0)1 46 10 54 54 497
/ GENERAL INFORMATION CHIP THICKNESS = Remider of symbols used Chip productio rate Cutter isert diameter Q Chip productio rate (cm 3 /mi) Radial cuttig depth (ifeed) (mm/mi) Axial cuttig depth Cuttig depth Maximum chip thickess h m Mea chip thickess Feed per revolutio Cuttig width.. Q = Note : epedig o the type of cutter, cosider Chip thickess to program F a 1 2 sie cutter F a 3 sie cutter Ø f Ø vf ae Ø = 60 Ø = 120 = 5 = 10 required = 0.12 required = 0.12 / = 0.08 / = 0.08 F a ball ose millig cutter F a roud cutter Actual tooth feed (f) A Isert Ø ap Chip thickess obtaied Ø = 12 = 1 ap Ø Ø = 15 = 1.2 required = 0.12 required = 0.12 / = 0.08 Feed to be programmed based o the table o ext page / = 0.08 498 Geeral Catalog
/ GENERAL INFORMATION CHIP THICKNESS Feed multiplicat fact 0.70 0.60 0.50. 0.50 0.40 0.35 0.30 0.25 0.22 0.20 0.40 0.35 0.30 0.25 0.20 0.15 0.15 0.12 0.10 0.09 0.08 0.12 0.10 0.08 0.01 0.02 0.03 0.04 0.05 0.06 0.08 0.10 0.16 0.25 0.40 ae/ 0.07 0.09 0.12 0.20 0.32 0.50 Cutter Ø = 120 mm Z = 4 = 10 mm v c = 130 m/mi = 0.22 mm / = 0.08 Chip thickess required : = 0.12 mm to be programmed : = 0.22 / = 0.08 : Example f hemispherical cutter with roud iserts Number of revolutios per miute : = x v c x = 344 rpm : = x x = 303 mm/mi Chip thickess calculatio Maximum chip thickess = 2 ( 1 ) = 2 ( 1 ) Average chip thickess h m = f = h m Profilig with a hemispherical cutter Roughess Value of Rt as a fuctio of the sweepig pitch Pitch = ae Rt Pitch2 Rt = 8R R = Cutter radius Customer Service - Tel.: +33 (0)1 46 10 54 00 Fax: +33 (0)1 46 10 54 54 499
/ GENERAL INFORMATION INSERT WEAR MECHANISM Flak wear Flak wear gives a idicatio of the isert life. Whe it becomes too high, cuttig fces icrease ad the surface fiish deteriates. - Cuttig speed too high - Feed too low - Isert wear hardess too low Solutios : - Reduce cuttig speed - Icrease feed Crater wear Crater wear is rare i millig. - Cuttig speed too high - Isert wear hardess too low Solutios : - Reduce cuttig speed Cracks Mechaical shocks whe the isert comes ito cotact with the material ad variatios i cuttig fces ca cause cracks parallel to the cuttig edge. Thermal shocks cause cracks perpedicular to the cuttig edge. - Crack wear caused by temperature variatios - Cracks caused by variatio i cuttig fces Solutios : - Select a tougher grade offerig better resistace to thermal shocks - Select a tougher grade offerig better resistace to mechaical shocks Cuttig edges chippig Small carbide particle separate from the isert, the result is po surface fiish ad excessive flak wear. - Grade too hard - Isert geometry too sharp - Built-up edge Solutios : - Select a tougher grade - Select a geometry with a tougher reifced cuttig edge - Icrease cuttig speed - Check f vibratios Built-up edge If the cuttig temperature is too low material builds up o the cuttig edge. This results i po surface fiish ad separatio of the material may cause cuttig edge chippig. - Cuttig speed too low - Negative cuttig geometry - Material too sticky Example: Stailess steel, alumium. Solutios : - Icrease cuttig speed - Select ositive cuttig geometry - Icrease cuttig speed Plastic defmatio Collapse idetatio of the cuttig edge (due to excessive edge temperature) causig po surface fiish. Flak wear exteds fially causig the isert to break. - Cuttig temperature too high - Cuttig speed too high - Cuttig fces too high Solutios : - Reduce cuttig speed. - Reduce feed 500 Geeral Catalog