hard material matters HSC-HPC Tools for High Speed / Performance Cutting

Transcription

1 hard material matters HSC-HPC Tools for High Speed / Performance Cutting

2 CERATIZIT USA and the parent companies Headquarters and parent company in MAMER / Luxembourg Parent company in REUTTE / Austria Direct sales and distribution partners Branch in Columbia SC / USA 2

3 HIGH SPEED CUTTING definition, advantages and challenges Aluminium and its alloys in the field of civil aviation The most common material to build aircraft structural components is aluminium and its alloys. Aluminium Titanium Composite materials Others Source: EADS Germany Others: super alloys and stainless steels with similar properties (undercarriage etc.) Time saving with HPC machining Prerequisites for HPC machining Machining time [h] Conventional Machine down times Roughing Finishing HPC machining HSC spindle ( 24,000 rpm) High feed rates (> 30 m/min) High acceleration (> m/sec) Machine tool power ( 40 KW) Balanced tools Dedicated cutting materials Source: EADS Germany Source: Heidelberger Druck 3

4 System advantages The system TOOLS The tool bodies have been optimised in every respect for the special stress factors which occur during high-speed milling. Particular attention has been attached to material election, heat treatment and manufacturing tolerances. The construction process is supported by an accompanying FEM analysis of each tool. Based on established burst tests the maximum values of permissible number of revolutions per minute were determined; in this way application safety has been maximised. Tools with cylindrical shank (C) For use in shrink, expansion and collet chucks Attachment of Weldon clamping faces Shank tolerance h6 Tool diameter 1 inch 11 2 inches Working length 2 4 inches Each tool diameter in minimum two different projection lengths Each tool diameter over one inch in two different numbers of flutes Tools with threaded shank (GHPC-11) For application with an extension in order to achieve large overhangs (e.g. for very deep cavities) Suitable for use in existing modular tool holder system Tool diameter 1 inch 11 2 inches Each tool diameter over one inch in two different numbers of flutes Metric thread connection 4

5 System advantages The system Tools in monobloc version (M) First choice for high speed / high performance cutting (HPC) HSK63A shank as standard, other on request Maximum system rigidity and precision Tool diameter 1 inch 2 inches Working length 2 4 inches as standard, other on request Each tool diameter in minimum two different projection lengths Each tool diameter over one inch in two different number of flutes Shell mill cutters (A) Mainly for face milling in the larger diameter range Application together with milling adapters according to CAT ANSI, DIN, MAS-BT, HSK etc. Tool diameter 2 6 inches Each tool diameter over two inches in two different number of flutes SEAT POCKET DESIGN Utilizing easy screw clamping, the precisely milled support face and 5 contact points ensure an extraordinarily precise and accurate repeatability of the insert position / /2 Radial contact points > Guarantee 90 corner angles and exact radial run-out 3 Axial contact point > Guarantees precise axial run-out 4/5 Contact points > Positive location, resisting machining and centrifugal forces 5

6 System advantages The system INSERTS The particularly sophisticated geometry represents a milestone in the manufacturing technology of carbide inserts. Only the application of state-of-the-art production methods ensures that the high quality standards in volume production are maintained. Precise repeatability, the position of the cutting edge in relation to the shank of the milling tool and the quality of the cutting edges are only some of the parameters which continuously need to be controlled during the process. Insert size inches / 19 mm / with usable length of cutting edge of inches / 18 mm / Tip radius r inches mm High positive rake angle Fine grain carbide ISO K10 / CERATZIT H216T Microfinish rake face in order to avoid built-up edges Integrated wiper facet for radius smaller then inches H216T (K15) Composition: Co 6%; WC rest Grain size: fine; 1 µm Hardness: HV 1630 Coating specification: uncoated Toughness: Wear resistance: Wet / dry:

7 Insert Shape XDHX XDHX FR-27P H216T Radius > inches: Modify basic body, 20! Uncoated Coated Recommended application Possible application Size Type description Chip groove H216T inches d l s l 1 r d 1 19 XDHX FR-27P -27P XDHX FR-27P -27P XDHX FR-27P -27P XDHX FR-27P -27P XDHX FR-27P -27P XDHX FR-27P -27P XDHX FR-27P -27P XDHX FR-27P -27P XDHX FR-27P -27P XDHX FR-27P -27P XDHX FR-27P -27P Steel Stainless Cast iron Non ferrous metals Heat resistant Hard materials = Main application = International CERATIZIT range, for present availability see price list Ordering example: 150 pieces XDHT FR-27P H216T C G A M

8 Designation of HPC cutting tools C M Projection length l 2 Diameter of d 1 tool in inches 1 1¼ 1½ d d d d d d 1 C.R -Bxxx HPC. d 1.xx -19 -Axxx M.L -H63A -l 2 Only FRONT of tool in inches -F -EF Toolbody shape Tool concept Diameter of d 1 tool [100 inches] Tool orientation right / left Number of fl utes Insert size [mm] Holder connection size [xxx inches] Projection length l 2 [100 inches] FRONT and END of tool in inches A.R HPC. d 1 G.L.xx -19 Height h is fi xed i.e. 2 inches Length l 2 is different for each diameter of tool A G 8

9 Tools HPC milling cutters C Drawing: CHPC.150.R A EF Type, description d 1 l 1 l 2 d A a CHPC.100.R A EF XDHX CHPC.100.R A EF XDHX CHPC.125.R A EF XDHX CHPC.125.R A EF XDHX CHPC.125.R A EF XDHX CHPC.125.R A EF XDHX CHPC.150.R A EF XDHX CHPC.150.R A EF XDHX CHPC.150.R A EF XDHX CHPC.150.R A EF XDHX CHPC.150.R B EF XDHX CHPC.150.R B EF XDHX CHPC.150.R B EF XDHX CHPC.150.R B EF XDHX z Insert radius inches: Modify basic body, 20! GHPC 10 / AHPC 11 / MHPC Supply details: Basic body fitted with clamping screws, without inserts Ordering example: 3 pieces CHPC.150.R B EF V C 20 Spare parts / accessories d 1 = Ø 1 inch /M4,0x7,0/T15 d 1 = Ø inches /M4,0x8,5/T15 Nm in.lbs /TORX/T15 DMSD1-6NM BIT-TORX15 XDHX

10 Tools HPC milling cutters G Drawing: GHPC.125.R F Type, description d 1 d A [mm] l 2 GHPC.100.R F M ,00 2 XDHT GHPC.125.R F M ,00 2 XDHT GHPC.125.R F M ,00 3 XDHT GHPC.150.R F M ,00 2 XDHT GHPC.150.R F M ,00 3 XDHT d G [mm] a SW [mm] z Insert radius inches: Modify basic body, 20! CHPC 9 / AHPC 11 / MHPC Supply details: Basic body fitted with clamping screws, without inserts Ordering example: 3 pieces GHPC.125.R F V C 20 Spare parts / accessories d 1 = Ø 1 inch d 1 = Ø 1¼ - 1½ inches /M4,0x7,0/T /M4,0x8,5/T15 Nm in.lbs /TORX/T15 DMSD1-6NM BIT-TORX15 XDHX

11 Tools HPC milling cutters A Drawing: AHPC.250.R A EF Type, description d 1 d A a d l A h AHPC.200.R A EF XDHT AHPC.250.R A EF XDHT AHPC.250.R A EF XDHT AHPC.300.R A EF XDHT AHPC.300.R A EF XDHT AHPC.400.R B EF XDHT AHPC.400.R B EF XDHT AHPC.500.R B EF XDHT AHPC.500.R B EF XDHT AHPC.600.R B EF XDHT AHPC.600.R B EF XDHT AHPC.600.R B EF XDHT AHPC.600.R B EF XDHT z Insert radius inches: Modify basic body, 20! CHPC 9 / GHPC 10 / MHPC Supply details: Basic body fitted with clamping screws, without inserts Ordering example: 3 pieces AHPC.250.R A EF V C 20 Spare parts / accessories d 1 = Ø 11 2 inches d 1 = Ø 2-6 inches /M4,0x7,0/T /M4,0x8,5/T15 Nm in.lbs /TORX/T15 DMSD1-6NM BIT-TORX15 XDHX

12 Tools HPC milling cutters M * metric dimension mm Drawing: MHPC.125.R H63A-325-F Type, description d 1 d A * l 1 l 2 l 3 a MHPC.100.R H63A-200-F XDHX MHPC.100.R H63A-250-F XDHX MHPC.100.R H63A-325-F XDHX MHPC.100.R H63A-400-F XDHX MHPC.125.R H63A-250-F XDHX MHPC.125.R H63A-325-F XDHX MHPC.125.R H63A-400-F XDHX MHPC.125.R H63A-250-F XDHX MHPC.125.R H63A-325-F XDHX MHPC.125.R H63A-400-F XDHX MHPC.150.R H63A-250-F XDHX MHPC.150.R H63A-325-F XDHX MHPC.150.R H63A-400-F XDHX MHPC.150.R H63A-250-F XDHX MHPC.150.R H63A-325-F XDHX MHPC.150.R H63A-400-F XDHX Insert radius inches: Modify basic body, 20! z CHPC 9 / GHPC 10 / AHPC 11 Supply details: Basic body fitted with clamping screws, without inserts Ordering example: 1 piece MHPC.150.R H63A-250-F V C 20 Spare parts / accessories d 1 = Ø 1 inch d 1 = Ø inhes /M4,0x7,0/T /M4,0x8,5/T15 Nm in.lbs /TORX/T15 DMSD1-6NM BIT-TORX15 KMS-HSK63 SS-KMS-HSK63 XDHX

13 Tools HPC milling cutters M * metric dimension mm Drawing: MHPC.200.R H63A-400-F Type, description d 1 d A * l 1 l 2 l 3 a z MHPC.200.R H63A-250-F XDHX MHPC.200.R H63A-325-F XDHX MHPC.200.R H63A-400-F XDHX MHPC.200.R H63A-250-F XDHX MHPC.200.R H63A-325-F XDHX MHPC.200.R H63A-400-F XDHX MHPC.200.R H63A-250-F XDHX MHPC.200.R H63A-325-F XDHX MHPC.200.R H63A-400-F XDHX Insert radius inches: Modify basic body, 20! CHPC 9 / GHPC 10 / AHPC 11 Supply details: Basic body fitted with clamping screws, without inserts Ordering example: 1 piece MHPC.200.R H63A-250-F V C 20 Spare parts / accessories d 1 = Ø 2 inches /M4,0x11,0/T /TORX/T15 DMSD1-6NM BIT-TORX15 KMS-HSK63 SS-KMS-HSK63 XDHX Nm in.lbs 7 13

14 Packaging Packaging and designation of tool Characteristic: Example: Tool description/identifi cation MHPC.125.R H63A-250-F Serial-Ident number / 01 Maximum permissible number of revolutions per minute n max = Specifi cation of screw Clamping torque for insert 53.1 in.lbs. Tip radius limitation XDHX R<=0.160 inches All evidence of protection must be removed prior to use. Accompany safety instruction and balance certificate Note the HPC safety data sheet that is supplied with the HPC tool. Balance certifi cate is supplied with each monobloc tools only. See details page

15 Permissible number of revolutions per minute Burst test Each high speed cutting tool has limitation of permissible rotational speed. This limitation is a result of the allowed centrifugal force carried out both by the seat pocket design and the clamping screw. To establish this limit, tools are subjected to a burst test. This test runs tools to destruction. The allowed number of revolutions is defined as half of the number of revolutions reacjed by this executed burst test. Number of revolutions per minute [rpm] Ø l 2 = Projection length of the tool Tool Ø Permissible number of revolutions as function of tool projection length [rpm] (l 2 = 1-2 x Ø) (l 2 = 2,5 x Ø) (l 2 = 3 x Ø) (l 2 = 4 x Ø) (l 2 = 5 x Ø) 1, , , , , , , , ,

16 Balancing Forces in the tooling system Reasons for unsymmetric mass distribution regarding the rotational axis Driving slots or dogs at HSK A, B, C, D / BT / CAT ANSI etc. Position of radial clamping screw (Weldon, Whistle notch) Collet chuck (radial position of slots) Collet and nut Shank detail with Weldon and Whistle notch Differential pitch of milling cutter Manufacturing tolerances (tool and adapter) F a = Axial force F r = Radial force F t = Tangential force Insert clamping screw F c Insert F i Note HPC safety data sheet supplied with tool F c = Centrifugal force (tool body) F r F t F i = Centrifugal force (insert) F a F a Forces present in the HPC milling cutter during machining. With HPC machining, the centrifugal forces produce considerably more stress on the tool than the cutting forces. Centrifugal forces generated are dependant upon tool diameter and rotational speed (rpm), example: indexable insert of lbs / 12g / Doubling of cutting speed (e.g. number of revolutions) causes increases of centrifuged force by a factor of four. Note: Centrifuged force is product of mass and square of rotational speed of centre of gravity. 1 N = lbs 1 lbs = 4.45 N 16

17 Balancing m s m 1 + s = Imbalance s m 1 Static imbalance Imbalance Moment imbalance Dynamic imbalance is the sum of static imbalance and moment imbalance is the state of a rotating part in which the mass axis does not coincide with the rotational axis. U = m e [gmm] Rotational axis Mass axis U e S m r m k m = Mass [g] e = Radius of gravity centre [mm] S = Mass axis = Rotational axis m k = Counter weight U = Imbalance ω = Angular velocity [s -1 ] Imbalance is produced by a centrifugal force F: F = u ω 2 = m e ω 2 = m e (2 π n) [N] m k = m e r [g] Balancing by design CERATIZIT Monoblock tools are produced with the intention to have zero imbalance in the body. Towards this solution all bodies have two additional surfaces within HSK cone (designated as with yellow color) to compensate imbalance of notches and slots. After production remind unbalance is result of production tolerances. Note: all dimensions in mm 17

18 Balancing What is a quality class? Permissible residual imbalance Quality class (G) means the permissible speed of the gravity centre Note: Quality of ballancing is internationaly measured and defined in metric system. It is the reason why this brochure presents all dimensions and explanations metric. Permissible residual unbalance / body mass in gmm/kg i.e. e in µm , , , ,15 2,5 2 1,6 1,25 1 0,8 0,63 0,5 0,4 0,315 0,25 0,2 0, G 40 G 16 G 6,3 G 2, DIN/ISO G = e ω [mm/s] Quality class means the permissible speed of the gravity centre G = Speed of gravity centre [mm/s] e = Radius of gravity centre [mm] ω = Angular velocity [s -1 ] The specific residual imbalance e in μm results from the operating speed and the desired quality class. For example: m = 2 kg n = min -1 G = 2.5 results in e = 1.6 μm U tol = 1.6 μm 2 kg = 3.2 gmm As a standard, monobloc tools with HSK connection are precision balanced corresponding to quality class G 6.3 at maximum allowed numbers of revolutions. 18

19 Balancing All monobloc tools with direct HSK connection are delivered with a balancing report. 19

20 Application data Modification to basic body from insert radius r inches onwards Modification to front profile For indexable inserts with a corner radius larger than inches the basic body of the tool must be modified according to the drawing above (can be done by CERATIZIT upon request). Clamping screws The XDHT-19 insert is mounted onto the insert pocket with the specified screw and a torque moment of 53.1 in.lbs. (6.0 Nm). Failure to observe correct insert mounting procedure can result in insert breakage, machine damage and personal injury of the operator. For safety reasons it is recommended to use a new screw after every insert change in.lbs 6.0 Nm Cutting data tool/material Frame of suggested cutting conditions for machining aluminium alloys in aerospace industry. v c (fpm) f z (inches) a p (inches) v c (fpm) f z (inches) a p (mm) v c (fpm) f z (inches) a p (inches) Requested surface quality depends on used tip radius and chip load. Combined cutting condition and radial depth of cut (a e) must fit to continuous power of machine tools. For more detailed information regarding appropriate cutting data and their comparison with existing continuous power of machine tool please consult our CD catalogue and Power estimation chapter. 20

21 Application data Shown value presents nett power at the cutting edge in HP 21

22 Application data Plunging into solid material d x max. x max. x max ,087 0,058 0, ,083 0,054 0, ,090 0,059 0, ,102 0,063 0, ,104 0,074 0, ,128 0,091 0, ,121 0,078 0, ,090 0,078 0, ,095 0,043 0,028 Linear angled ramping d α R [ ] α R [ ] α R [ ]

23 Application data Helical milling into solid material r α R [ ] = insert radius = maximum ramp angle (in relation to tool centre) a p = pitch è D x π x tan(α R) D = è D max - d 1 or D min - d 1 For flat bottom ground D max = maximum hole diameter D min = minimum hole diameter DN max = Maximum hole diameter for non flat bottom d 1 (DN max) (1.960) (2.460) (2.960) (3.960) (4.960) (5.960) (7.960) (9.960) (11.960) α R [ ] D max D min α R [ ] D max D min α R [ ] D max D min α R [ ] D max D min α R [ ] D max D min α R [ ] D max D min α R [ ] D max D min α R [ ] D max D min α R [ ] D max D min XDHT-19 () r = r = r = r = r = r = r = r = r = r = r =

24 Application data - chatter free noching Experimental method There are two empirical ways to establish stability charts for combination of installed high frequency spindle and cutting tool assembly. 1. Tap test using an acoustic hammer The diagramm below show frequency response chart as result of tap test. The established natural frequency (3984 Hz) is a basis for the calculation of the stability curve presented with a bold red line in the diagrams below. 2. Series of short cutting tests of each combination of number of revolutions (e.g. in 1000 rpm steps) and axial depth of cut (e.g. in 0,040 inches steps) staring from inches up to the occurrence of chatter. The shown diagram presents very reliable source of data but it is an extremely time and resource consuming process. Each combination of the axial depth of cut and the number of revolutions below points of significant chatter (or red stability curve) assumes stuble cutting process without appearence of chatter. Stability curve calculated with frequency response result shown above significat chatter small chatter no chatter possible combination of cutting condition without appear of chatter 24

25 Application data Simulation method To avoid tap testing or time consuming experimental way of establishing stability charts for each tool, computer calculation/simulation can be used instead. Once designed and proved software model of high frequency spindle of machine tool allows the user to establish frequency and stability charts of each SPINDLE-TOOL combination. Model of tool Model of spindel Calculation of the best number of revolutions. n=60*f/z where is: n - number of revolutions [rpm] f - frequency [Hz] z - number of flutes f = 1423 Hz n = 60 * 1423 / 2 = rpm Frequency chart of selected sindle and tool Stability curve (bold red line) presented togather with lines of different levels of deflection at the end of tool. Diagram and selected point presents one possible selection of cutting conditions: 1mm = 0.04 inch 1 inch = 25.4 mm 1μm = inch a p = 5.7 mm = inches V = 1993 cm 3 /min = 122 inch 3 /min td = 50 µm = inches 25

26 Application data Stability chart for MHPC.125.R H63A-400-F The case below presents the result of computer simulation made by SIMM-MILL software using one of high frequency spindle and CERATIZIT monobloc tool MHPC.125.R H63A-400-F. The result of the simulation suggests to use cutting conditions around rpm as the best one to achive stable machining without appear of chatter. Thin lines give additional information regarding expected deflection at the end of tool. Model of tool Frequency chart Important note: Presented cutting conditions are valid for selected spindle and tool ONLY. They can not be used as a rule for other machines and spindles. SIMM-MILL is registrated trade mark of E.L.P.S. company 26

27 Application data Stability chart for MHPC.125.R H63A-400-F The case below presents the result of computer simulation made by SIMM-MILL software using one of high frequency spindle and CERATIZIT monobloc tool MHPC.125.R H63A-400-F. The result of the simulation suggests to use cutting conditions around rpm as a best one to achive stable machining without appear of chatter. Thin lines give additional information regarding expected deflection at the end of tool. Model of tool Frequency chart Important note: Presented cutting conditions are valid for selected spindle and tool ONLY. They can not be used as a rule for other machines and spindles. SIMM-MILL is registrated trade mark of E.L.P.S. company 27

28 Application data Below shown diagrams present suggestion of tool selection with diameter of 11 2 inch having different projection length (X-axis of diagram) and 2 or 3 flutes used by different high frequency spindles. The selection takes into account the best number of revolutions calculated via natural frequency of specified spindle and tool. DISCLAIMER Company CERATIZIT can not be held responsible for any use of above shown data. Data shown on this page are calculated as suggestion values and upon the best knowledge and experience. Variation of spindles based on delivery time and version can play important role. All FISCHER... and STARRAG... names and models are registrated trademarks of respective companies: 28

29 Application data Below shown diagrams present suggestion of tool selection with diameter of 11 2 inch having different projection length (X-axis of diagram) and 2 or 3 flutes used by different high frequency spindles. The selection takes into account the best number of revolutions calculated via natural frequency of specified spindle and tool. DISCLAIMER Company CERATIZIT can not be held responsible for any use of above shown data. Data shown on this page are calculated as suggestion values and upon the best knowledge and experience. Variation of spindles based on delivery time and version can play important role. All MAKINO... and STEPTEC... names and models are registrated trademarks of respective companies: 29

30 Application data Application suggestion Some useful suggestions to reach chatter-free cutting conditions and good quality of machined surfaces Each combination of machine spindle and selected tool results with a specific natural frequency. Longer tools have for the same spindle lower frequencies then corresponding shorter tools. This results, in most cases with a lower best number of revolutions per minute. Tools with the same tool body shape and different number of flutes have near identical frequencies. To adjust the tool to the best possible number of revolutions it may be necessary to select the appropriate number of flutes. Generally, doubling the number of flutes will result with a lower risk of chatter for the same cutting conditions. Note: Available continues power must be taken into consideration. To reach certain chip removal rate [in 3 /min] it is suggested to increase chip load against axial depth of cut. Such a strategy always results with smaller risk of chatter. Full radial depth of cut (sometimes called width of cut - a e ) will also lead to a smaller risk of chatter. Consistency of radial depth of cut will results also with lower risk of chatter. Keeping this in mind an allowance for finishing should be selected in the way to reduce sudden change of required power while driving into pocket corners. This problem should be avoided by the appropriate combination of diameters for roughing and finishing tool, as well as, optimum value of the finishing allowance. 30

31 Application data CD Catalogue Attached CD CATALOGUE contains information similar to these one shown in tables and diagrams of this brochures plus some additional information regarding application engineering required and used in aerospace industry as: power estimation for all tools in CERATIZIT range and more ramping and plunging capabilities with some further explanation of process of plunging selected chatter-free tool catalogues (upon availability) Your distributor: 31

32 - just a click. Headquarters: CERATIZIT S.A. Main site Luxembourg CERATIZIT Luxembourg Sarl Route de Holzem L-8232 Mamer Tel.: Fax: info@ceratizit.com Main site Austria CERATIZIT Austria Gesellschaft m.b.h. A-6600 Reutte/Tyrol Tel.: +43 (5672) Fax: +43 (5672) info.austria@ceratizit.com USA CERATIZIT USA Inc. 777 Old Clemson Road Columbia South Carolina Toll free: +1 (800) Tel.: +1 (803) Fax: +1 (803) info.usa@ceratizit.com 151/ 0 USA We reserve the right to make technical changes for improvement of the product.