For Titanium Alloy Milling

Outstanding metal removal rates up to400cm3/min(with ø63 cutter)

VFX for high efficiency milling of titanium alloys.

VFXSeries

B182E2011.4 Update

Series

Expansions

1

Unparalleled chip ejection overturns the basic assumptions for machining titanium alloys.

VFXSeries

e

Highly reliable clamping mechanism

High rigidity design

Changeable coolant nozzle

Long life insert grade

Improved chip removal with coolant

Low resistance convex curvecutting edge

The insert seat has a curved bearing face in the radial direction of the tool and a V-shaped bearing face on the axis of rotation that can securely handle cutting forces from any direction.

Arranging the inserts vertically absorbs the principal cutting force through the thickness of the insert and achieves extremely high rigidity.

A replaceable nozzle is used for the internal coolant (hole diameter of the standard nozzle supplied: φ0.8). The coolant pressure can be adjusted up and down by using a nozzle with a smaller or larger diameter. Nozzles with different diameters are available as options.

The new insert grade MP9030 is a perfect combination of tough cemented carbide and titanium compound-based accumulated coating. It offers outstanding wear and fracture resistance for milling titanium alloys.

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.

The curved cutting edge resembling a solid end mill achieves low cutting resistance and enables high quality machining.

V formation of theclamping face

Coolant disoharge position

Convex curveCutting edge

Cutting force

Coolant nozzle

2

*1 *2

R D1 L1 D9 L7 D8 D7 W1 L8 ap XNMU160708R-MS

XNMU160708R-MS

VFX5-040A03A026R a 3 6 40 50 16 21 8.5 38.2 8.4 5.6 26 0.3 TS352 W8-S1 TKY10D HSD04004H08 MK1KS 3 3

-040A03A038R a 3 9 40 60 16 21 8.5 38.2 8.4 5.6 38 0.4 TS352 W8-S1 TKY10D HSD04004H08 MK1KS 3 6

-050A04A026R a 4 8 50 50 22 21 10.5 48.2 10.4 6.3 26 0.5 TS352 W10-S1 TKY10D HSD04004H08 MK1KS 4 4

-050A04A038R a 4 12 50 60 22 21 10.5 48.2 10.4 6.3 38 0.6 TS352 W10-S1 TKY10D HSD04004H08 MK1KS 4 8

-050X04A038R a 4 12 50 60 27 23 12.5 48.2 12.4 7.0 38 0.6 TS352 W12-S1 TKY10D HSD04004H08 MK1KS 4 8

-050A04A050R a 4 16 50 70 22 21 10.5 48.2 10.4 6.3 50 0.7 TS352 W10-S1 TKY10D HSD04004H08 MK1KS 4 12

-063A05A026R a 5 10 63 60 27 28 12.5 61 12.4 7.0 26 1.0 TS352 W12-S1 TKY10D HSD04004H08 MK1KS 5 5

-063A05A063R a 5 25 63 85 27 28 12.5 61 12.4 7.0 63 1.4 TS352 W12-S1 TKY10D HSD04004H08 MK1KS 5 20

-080A06A075R a 6 36 80 100 32 28 16.5 77.3 14.4 8.0 75 2.8 TS352 W16-S1 TKY10D HSD04004H08 MK1KS 6 30

L1 L2 L3 S1 F1 Re

MP9

030

XNMU160708R-MS a 16.0 7.0 11.1 6.5 1.0 0.8

VFX5-040A03A026R HSC08040 -040A03A038R HSC08050 -050A04A026R HSC10035 -050A04A038R HSC10045 -050X04A038R HSC12045 -050A04A050R HSC10055 -063A05A026R HSC12045 -063A05A063R HSC12070 -080A06A075R HSC16080

ø0.6mm ø0.8mm ø1.2mm ø1.6mmHSD04004H06 HSD04004H08 HSD04004H12 HSD04004H16

y

L2

L1

L3

Re

S1F1

L7L8

øD9

øD7

W1

øD1

øD8

apL1

SHELL TYPE

(Max. Depth of Cut)

Right hand tool holder only.

INSERTS

a : Inventory maintained. s : Inventory maintained in Japan.

*1 Clamp Torque (N • m) : TS352=2.5

*2 Coolant nozzles are available with varying diameters for adjusting coolant pressure. Select nozzles as required by the specification.

* Clamp Torque (N • m) : HSD0400Hpp=1.5

VFX5For Titanium Alloy Milling

*3 The part number for a blank screw without a through nozzle is HSS04004.

Order Number Sto

ckNu

mbe

r of F

lutes

Tota

l Dimensions (mm)To

ol W

eight

(kg)

Number of Insert

End cuttingedge

Peripheralcutting edge

ClampScrew

SealWasher Wrench Coolant

NozzleAnti-seizeLubricant

Shape Order Number

Stock Dimensions (mm)

GeometryCoated

<1Mpa(<20 l/min.) ←Standard→ >5Mpa

(>30 l/min.)>7Mpa

(>50 l/min.)

Nozzle Dia.

Order Number

Order Number Set Bolt Geometry

3

*1 *2

R D1 L1 D9 L7 D8 D7 W1 L8 ap XNMU190912R-MS

XNMU190912R-MS

VFX6-063A04A031R a 4 8 63 60 27 28 13 61 12.4 7.0 31 0.9 TS450 W12-S1 TKY20T HSD04004H08 MK1KS 4 4 -063A04A060R a 4 16 63 85 27 28 13 61 12.4 7.0 60 1.3 TS450 W12-S1 TKY20T HSD04004H08 MK1KS 4 12 -080A05A031R a 5 10 80 60 32 28 17 77.3 14.4 8.0 31 1.5 TS450 W16-S1 TKY20T HSD04004H08 MK1KS 5 5 -080A05A075R a 5 25 80 100 32 28 17 77.3 14.4 8.0 75 2.6 TS450 W16-S1 TKY20T HSD04004H08 MK1KS 5 20 -100A06A031R s 6 12 100 65 40 30 21 96.6 16.4 9.0 31 2.7 TS450 W20-S1 TKY20T HSD04004H08 MK1KS 6 6 -100A06A090R s 6 36 100 115 40 30 21 96.6 16.4 9.0 90 4.8 TS450 W20-S1 TKY20T HSD04004H08 MK1KS 6 30

L1 L2 L3 S1 F1 Re

MP9

030

XNMU190912R-MS a 19.1 9.5 12.7 8.5 1.0 1.2

VFX6-063A04A031R HSC12045 -063A04A060R HSC12070 -080A05A031R HSC16040 -080A05A075R HSC16080 -100A06A031R HSC20040 -100A06A090R HSC20090

ø0.6mm ø0.8mm ø1.2mm ø1.6mmHSD04004H06 HSD04004H08 HSD04004H12 HSD04004H16

y

L2

L1

L3

Re

S1F1

L7L8

øD9

øD7

W1

øD1

øD8

apL1

SHELL TYPE

(Max. Depth of Cut)

Right hand tool holder only.

INSERTS

*1 Clamp Torque (N • m) : TS450=5.0

*2 Coolant nozzles are available with varying diameters for adjusting coolant pressure. Select nozzles as required by the specification.

* Clamp Torque (N • m) : HSD0400Hpp=1.5

VFX6For Titanium Alloy Milling

*3 The part number for a blank screw without a through nozzle is HSS04004.

Order Number Set Bolt Geometry

Order Number Sto

ckNu

mbe

r of F

lutes

Tota

l Dimensions (mm)

Tool

Weig

ht

(kg)

Number of Insert

End cuttingedge

Peripheralcutting edge

ClampScrew

SealWasher Wrench Coolant

NozzleAnti-seizeLubricant

<1Mpa(<20 l/min.) ←Standard→ >5Mpa

(>30 l/min.)>7Mpa

(>50 l/min.)

Nozzle Dia.

Order Number

Shape Order Number

Stock Dimensions (mm)

GeometryCoated

4

S

&40

3 40 318 24<ae<40 <38 0.10 6.5 40 3 25 199 24<ae<40 <38 0.08 3.4 30 3 50 398 16<ae<24 <38 0.10 4.5 60 3 25 199 16<ae<24 <38 0.08 1.9 50 3 60 477 8<ae<16 <38 0.10 3.5 80 3 30 239 8<ae<16 <38 0.10 1.8 70 3 60 477 ae<8 <38 0.12 2.3 100 3 30 239 ae<8 <38 0.10 1.0 90

&50

4 40 255 24<ae<40 <50 0.10 9.1 40 4 25 159 24<ae<40 <50 0.08 4.7 30 4 50 318 16<ae<24 <50 0.10 6.2 60 4 25 159 16<ae<24 <50 0.08 2.6 50 4 60 382 8<ae<16 <50 0.10 4.9 80 4 30 191 8<ae<16 <50 0.10 2.6 70 4 60 382 ae<8 <50 0.12 3.3 100 4 30 191 ae<8 <50 0.10 1.5 90

&63

5 40 202 24<ae<40 <60 0.10 10.3 40 5 25 126 24<ae<40 <60 0.08 5.4 30 5 50 253 16<ae<24 <60 0.10 7.3 60 5 25 126 16<ae<24 <60 0.08 3.1 50 5 60 303 8<ae<16 <60 0.10 6.0 80 5 30 152 8<ae<16 <60 0.10 3.2 70 5 60 303 ae<8 <60 0.12 4.1 100 5 30 152 ae<8 <60 0.10 1.9 90

&80

6 40 159 24<ae<40 <75 0.10 11.7 40 6 25 99 24<ae<40 <75 0.08 6.1 30 6 50 199 16<ae<24 <75 0.10 8.8 60 6 25 99 16<ae<24 <75 0.08 3.7 50 6 60 239 8<ae<16 <75 0.10 7.4 80 6 30 119 8<ae<16 <75 0.10 3.9 70 6 60 239 ae<8 <75 0.12 5.0 100 6 30 119 ae<8 <75 0.10 2.3 90

S

&60

4 40 202 38<ae<63 <60 0.10 13.4 40 4 25 126 38<ae<63 <60 0.08 7.0 30 4 50 253 25<ae<38 <60 0.10 9.5 60 4 25 126 25<ae<38 <60 0.08 4.0 50 4 60 303 13<ae<25 <60 0.10 7.2 80 4 30 152 13<ae<25 <60 0.10 3.8 70 4 60 303 ae<13 <60 0.12 4.7 100 4 30 152 ae<13 <60 0.10 2.1 80

&80

5 40 159 48<ae<80 <75 0.10 20.8 40 5 25 99 48<ae<80 <75 0.08 10.8 30 5 50 199 32<ae<48 <75 0.10 14.7 60 5 25 99 32<ae<48 <75 0.08 6.2 50 5 60 239 16<ae<32 <75 0.10 11.2 80 5 30 119 16<ae<32 <75 0.10 5.9 70 5 60 239 ae<16 <75 0.12 7.3 100 5 30 119 ae<16 <75 0.10 3.3 80

&100

6 40 127 60<ae<100 <90 0.10 29.6 40 6 25 80 60<ae<100 <90 0.08 15.3 30 6 50 159 40<ae<60 <90 0.10 20.9 60 6 25 80 40<ae<60 <90 0.08 8.8 50 6 60 191 20<ae<40 <90 0.10 16.0 80 6 30 95 20<ae<40 <90 0.10 8.4 70 6 60 191 ae<20 <90 0.12 10.3 100 6 30 95 ae<20 <90 0.10 4.7 80

ae

ae

ap

ap

y

y

RECOMMENDED CUTTING CONDITIONS

(Note 1) TL: Based on ae= outer diameter x 20%(Note 2) Maximum depth of cut, ap should be changed depending on machine rigidity and power.(Note 3) Please note that machining performance differs according to conditions such as the rigidity of the machinery used, workpiece clamping rigidity,

the coolant supply system pressure and flow.(Note 4) Internal coolant is recommended. For the tool holder, use an FMH arbor with a through coolant system. Use with external lubricating

coolant is also effective.

(Note 1) TL: Based on ae= outer diameter x 20%(Note 2) Maximum depth of cut, ap should be changed depending on machine rigidity and power.(Note 3) Please note that machining performance differs according to conditions such as the rigidity of the machinery used, workpiece clamping rigidity,

the coolant supply system pressure and flow.(Note 4) Internal coolant is recommended. For the tool holder, use an FMH arbor with a through coolant system. Use with external lubricating

coolant is also effective.

Cutting Conditions

Cutting Conditions

Cutting SpeedRevolutionFeed per ToothEstimated cutting powerTool life ratio

Cutting SpeedRevolutionFeed per ToothEstimated cutting powerTool life ratio

Formula of max. metal removal rates ap x ae x n x fz x Number of flute MRR (cm3/min) = 1000

Formula of max. metal removal rates 　　ap x ae x n x fz x Number of flute MRR (cm3/min) = 1000

Material Titanium Alloy (Ti-Al-4V) Titanium Alloy (Ti-5Al-5V-5Mo-3Cr)

Cutting EdgeDiameter

Number of Flutes

vc(m/min)

n(min-1)

ae(mm)

ap(mm)

fz(mm/tooth)

Pc(kW)

TL(%)

Number of Flutes

vc(m/min)

n(min-1)

ae(mm)

ap(mm)

fz(mm/tooth)

Pc(kW)

TL(%)

Cutting Diameter(mm)

Material Titanium alloy (Ti-6Al-4V) Titanium alloy (Ti-5Al-5V-5Mo-3Cr)

Number ofEffective Flute

vc(m/min)

n(min-1)

ae(mm)

ap(mm)

fz(mm/tooth)

Pc(kW)

TL(%)

Number ofEffective Flute

vc(m/min)

n(min-1)

ae(mm)

ap(mm)

fz(mm/tooth)

Pc(kW)

TL(%)

VFX5

VFX6

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MMC METAL FRANCE S.A.R.L.6, rue Jacques Monod, 91400 Orsay, FranceTel. +33-1-69-35-53-53 Fax +33-1-69-35-53-50e-mail mmfsales@mmc-metal-france.fr

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www.mitsubishicarbide.com

VFX6-080A05A075R VFX6-063A04A060R VFX6-063A04A060R

32.5 55 4525 133 45

0.04 0.12 0.0510-30 10-45 12-3730-60 25-60 5-24

VFX5-050A04A050R VFX5-050A04A050R VFX5-050A04A050R

40 50 55102 127 1400.10 0.1 0.15-30 50 355-60 10 15

APPLICATION EXAMPLES

aWith reference to the above examples, adjust the cutting conditions according to the machine specifications, workpiece geometry and clamping method used.

Tool

Workpiece

Titanium alloy Titanium alloy Titanium alloy

Component Aerospace parts Aerospace parts Aerospace parts

Cuttin

g Con

dition

s Cutting Speed (m/min)Table Feed (mm/min)Feed per Tooth (mm/tooth)Radial Depth of cut ae (mm)Axial Depth of cut ap (mm)

Coolant Wet cutting (Internal:3MPa) Wet cutting (External:1.5MPa) Wet cutting (External:3MPa)

ResultsEfficiency 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 conditions for greater greater cost reduction.

Tool

Workpiece

Titanium alloy Titanium alloy Titanium alloy

Component Aerospace parts Aerospace parts Aerospace parts

Cuttin

g Con

dition

s Cutting Speed (m/min)Table Feed (mm/min)Feed per Tooth (mm/tooth)Radial Depth of cut ae (mm)Axial Depth of cut ap (mm)

Coolant Wet cutting (Internal:7MPa) Wet cutting (Internal:10MPa) Wet cutting (Internal:1.5MPa)

Results

With the same tool life (190 mins) as conventional tools, it was possible to use 1.2 times increased cutting cond i t ions , resu l t ing in g rea te r efficiency.

At a metal removal rate of 120cm3, tool life was constant at 60 mins duration and machining efficiency increased 1.5 fold. VFX is stable in cutting at a maximum metal removal rate of 400cm3.

Three times tool life at cutting conditions improved by a factor of 2.7. Total cost reductions of 62%.