IASF/ASF. New Generation Face Mill Dramatically Reduces Roughing Time FEATURES

Size: px

Start display at page:

Download "IASF/ASF. New Generation Face Mill Dramatically Reduces Roughing Time FEATURES"

Bertram Gordon
6 years ago
Views:

interrupted cutting Extraordinary metal removal and feed rates Economical four

1 New Generation Face Mill Dramatically Reduces Time FEATURES 2-5 times better roughing efficiency than conventional face mills Very stable performace in interrupted cutting Extraordinary metal removal and feed rates Economical four edged insert 2013 Hitachi Tool Engineering, Ltd. ph

2 IntroductIon Hitachi Tool s ASF Face Mills achieve a level of performance that was previously unattainable. The special radius cutting edge allows for extraordinary metal removal rates and dramatically lower roughing times. The chart on the right demonstrates the difference between conventional face mills and the new ASF. In most cases we are able to increase the feed (fz) up to five times without the need to increase the cutting speed (Vc) thus stabilizing or even increasing tool life. ASF Features 1. Unique Radius Cutting Edge The shape of the special insert creates an advantage over round and traditional radius type inserts. The combination of the unique insert and large pockets that assist with chip evacuation allow the ASF Series Face Mills to achieve depths of cut of up to 3mm (0.118"). The inserts also feature four usable cutting edges, therefore increasing the cost efficiency of every insert. Ø 30 mm Ø 1.181" doc = 3.0 mm 0.118" f z 2. Field Data Extraordinary feed rates of up to 3.5mm (0.138") per tooth in steel and 4.0mm (0.158") per tooth in cast iron are achievable. In addition, metal removal rates of 1000cm 3 (61 in 3 ) to 2000cm 3 (122 in 3 ) are possible. This example demonstrates the increased productivity of a 250mm (9.84") ASF Face Mill compared to a conventional radius cutter in stainless steel. Conventional ASF5250R Ø 250 mm (9.84") Ø 250 mm (9.84") 12 teeth 12 teeth Cutting Conditions Cutting Conditions N = 255 rpm N = 115 rpm Vc = 200 m/min (656 sfm) Vc = 90 m/min (295 sfm) Vf = 612 mm/min (24.09 ipm) Vf = 1,380 mm/min (54.33 ipm) fz = 0.2 mm/tooth ( in/tooth) fz = 1.0 mm/tooth ( in/tooth) doc = 2 mm (0.079") doc = 2 mm (0.079") woc = 150 mm (5.906") woc = 150 mm (5.906") Q = 184 cm3/min (11.23 in 3 /min) Q = 414 cm3/min (25.26 in 3 /min) Metal Removal in /min 184 cm 3 /min Conventional in 3 /min 414 cm 3 /min ASF Conventional ASF (piece) Workpiece: AlSI304 Stainless Steel Hitachi Tool Engineering, Ltd. ph

3 3. Stable Performance Even in Interrupted Cuts The highly rigid design of the ASF Face Mills and inserts provide exceptional performance even in interrupted cuts. In the example below, stable machining of 30HRC prehardened mold steel populated with 8.0mm holes is achieved. Ø 125 mm (4.921") Material: AISI P20V c 150 m/min (492.1 sfm) N = 380 rpm f z = 1.5 mm/tooth ( in/tooth) Hole Ø 8 mm V f = 540 mm/min (21.26 ipm) (0.315") doc x woc = 1.0 x 90 mm (0.0394" x 3.543") dry cutting 15 min Conventional radius mill ASF (P40) 180~210 min (98.4 ft.) (295.3 ft.) (393.7 ft.) (787.4 ft.) (m) Cutting Length L Hitachi Tool Engineering, Ltd. ph

4 Face Mill Style 50 ROUGHING FINISHING HRC 50 ød2 1 2 ød1 A B ød2 ød1 A B E E H H ød2 R15 ød2 R15 ød1: (D-20) ød ap=3.0 ød1: (D-20) ød ap=3.0 D 0/-0.2 IASF - INCH Part No. Flutes ØD ØD 1 H Ød 1 Ød 2 ØD2 E A B Type Insert IASF5040R SDNW15, SDMT15, SDEW15 IASF5048R SDNW15, SDMT15, SDEW15 IASF5064R SDNW15, SDMT15, SDEW15 IASF5080R SDNW15, SDMT15, SDEW15 IASF5096R SDNW15, SDMT15, SDEW15 IASF5128R SDNW15, SDMT15, SDEW15 IASF5160R SDNW15, SDMT15, SDEW15 Inserts p. 12 Part No. Clamp Screw Locator Locator Screw Wedge Screw Wedge Wrench IASF5040R T20 IASF5048R T20 IASF5064R T20 IASF5080R T20 IASF5096R T20L IASF5128R T20L IASF5160R T20L Hitachi Tool Engineering, Ltd. ph

Face Mill Style IASF/ASF 50 ROUGHING FINISHING HRC 50 ød2 1 2 ød1 A B ød2 ød1 A B E E H H ød2 R15 ød2 R15 ød1: (D-20) ød ap=3.0 ød1: (D-20) ød ap=3.0 D 0/-0.2 ASF - METRIC Part No.

5 Face Mill Style IASF/ASF 50 ROUGHING FINISHING HRC 50 ød2 1 2 ød1 A B ød2 ød1 A B E E H H ød2 R15 ød2 R15 ød1: (D-20) ød ap=3.0 ød1: (D-20) ød ap=3.0 D 0/-0.2 ASF - METRIC Part No. Flutes ØD ØD 1 H Ød 1 Ød 2 ØD 2 E A B Type Insert ASF5063RM SDNW15, SDMT15, SDEW15 ASF5080RM SDNW15, SDMT15, SDEW15 ASF5100RM SDNW15, SDMT15, SDEW15 ASF5125RM SDNW15, SDMT15, SDEW15 ASF5160R SDNW15, SDMT15, SDEW15 ASF5200R SDNW15, SDMT15, SDEW15 Inserts p. 12 Part No. Clamp Screw Locator Locator Screw Wedge Screw Wedge Wrench ASF5063RM T20 ASF5080RM T20 ASF5100RM T20 ASF5125RM T20 ASF5160R T20L ASF5200R T20L 2013 Hitachi Tool Engineering, Ltd. ph

6 Inserts T W W W R SDNW R SDMT with breaker R SDMT with breaker and wiper Part No. R T W Type SDNW1505ZDTN-R A SDMT1505ZDTN-C C SDMT1505ZDTN-R B All inserts have four effective cutting edges COATING MATERIALS FOR INSERTS Material Name Coating Name Coating Type Application Features (P10-M10-K10) (P30-M30-K30) (P30-M30-K30) (P40-M40-K40) (P40-M40) JP Coating PVD JX Coating PVD CY Coating (TiAlN) PVD JS Coating PVD JM coating PVD For cutting of pre-hardened steel (40-50 HRC) General purpose for steel General purpose for steel General purpose for steel For cutting stainless-steel materials Uses coating with excellent shock resistance, making it superior for cutting pre-hardened steel Uses moderate substrate, Multi purpose grade Uses TiAlN coating, has wide cutting range Uses coating with excellent heat resistance and librication characteristics / Has wide cutting range Uses coating with adhesion of membranes to reduce peeling of membranes due to welding Hitachi Tool Engineering, Ltd. ph

7 Cutting Conditions Inch Material Mild Steel (200HB) (<30HRC) (30-40HRC) (40-45HRC) (45-50HRC) Ø 2.5" or 63mm (4 Flutes) 3" or 80mm (4 Flutes) 4" or 100mm (5 Flutes) 2013 Hitachi Tool Engineering, Ltd. ph N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) Stainless Steel N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) Cast Iron N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in)

8 Cutting Conditions Inch Material Mild Steel (200HB) (<30HRC) (30-40HRC) (40-45HRC) (45-50HRC) 6" or 160mm (8 Flutes) 8" or 200mm (10 Flutes) N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) Stainless Steel N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) Cast Iron N(rpm) Vc(sfm) Vf(in/min) fz(in/t) doc(in) " or 250mm (12 Flutes) Hitachi Tool Engineering, Ltd. ph

9 Cutting Conditions Metric Material Mild Steel (200HB) (<30HRC) (30-40HRC) (40-45HRC) (45-50HRC) Ø 2.5" or 63mm (4 Flutes) 3" or 80mm (4 Flutes) 4" or 100mm (5 Flutes) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) Stainless Steel N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) Cast Iron N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) Hitachi Tool Engineering, Ltd. ph

10 Cutting Conditions Metric Material Mild Steel (200HB) (<30HRC) (30-40HRC) (40-45HRC) (45-50HRC) 6" or 160mm (8 Flutes) 8" or 200mm (10 Flutes) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) Stainless Steel N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) Cast Iron N(rpm) Vc(m/min) Vf(mm/min) fz(mm/t) doc(mm) " or 250mm (12 Flutes) Hitachi Tool Engineering, Ltd. ph

AEROSPACE DIE & MOLD MACHINE TOOL INDUSTRY MEDICAL END MILLS HIGH-PERFORMANCE CARBIDE DRILLS A PRODUCT OF KENNAMETAL INC.

AEROSPACE DIE & MOLD MACHINE TOOL INDUSTRY MEDICAL END MILLS HIGH-PERFORMANCE DRILLS A PRODUCT OF KENNAMETAL INC. INCH VERSION TOOLS Hanita Cutting Tools is recognized as one of the world's leading manufacturers