Xtra-tec - Spectra...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...

High Performance Cutter F4030

Xtra-tec

| April 2010 | VM | Vötsch2

Product description

Results from lab and customer

Program range

Application areas & Target groups

Benefits for the customer

Typical work pieces

Table of Content


01 – Product descriptionGeneral points

DC = 25 – 63 MM

6 CUTTING EDGES

HARD NICKELIZED SURFACE


01 – Product descriptionBasic body

• High performance milling cutter for high feed rates

• Kappa 0° - 21°

• Ø 25 - 63 mm

• apmax = 1 mm

• fz up to 3,5 mm

• Insert with negative basic shape

• 6 Cutting edges per insert

• 1 Insert size for complete program

• 2 different pitches


NEGATIVE BASIC SHAPE

SLOPING CUTTING EDGE

SINTERED

SUPPORT FACE

R14

R1,2

01 – Product descriptionThe Insert


• Negative basic shape

• Trigon basic shape with 6 cutting edges

• Designation P23696-1.0

• Insert completely sintered

01 – Product descriptionThe Insert


• P23696 – The universal one:

– For medium an unfavourable machining conditions– Universal application for most materials– 20° rake angle

01 – Product descriptionInsert geometries


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 fz = 1.5mm(Vf = 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 fz =2.5mm (Vf = 15.3 m/min),until the machine were at the end of capacity.

Tool: F4030, Ø52mm, Z=4Insert: P23696-1.0 ap max.= 1mmMaterial: 42CrMo4Machine: Deckel-Maho DMU80

Pmot = 20 kWMmot = 121 Nm


• Face milling (Roughing)The F4030 with Ø63 (Z=4) was milled at a Vc of 250 m/min and a maximumfeed rate fz = 3mm (Vf = 15.1 m/min) to the upper limit of the machine.The Ø50 (Z=3) was tested at the same cutting speed and a fz of max. 2 mm(Vf = 9.5 m/min).

• Face milling (Grooving)Both the Ø63 and the Ø50 (ScrewFit => Big Xs-Dimension) have reached witha feed rate fz of 2.5mm (Vf = 12.6 m/min respectively Vf = 11.9 m/min) theend of the machining capacity.

Tool: F4030, Ø63mm and Ø50mmInsert: P23696-2.0 ap max.= 2mmMaterial: 42CrMo4Machine: Starrag Heckert HEC630




• Circular interpolationCreated diameter was 83mm. With a feed rate fz = 0.5mm (Vf = 3.7 m/min) washalf of the available torque of the machine already consumed.When milling with fz = 1mm the machine has reached the torque limit.

Tool: F4030, Ø52mm, Z=4Insert: P23696-1.0 ap max.= 1mmMaterial: 42CrMo4Machine: Deckel-Maho DMU80


D0 min = 82mm

D0 max = 104mm



• Circular interpolationWith the Ø63 and a borehole diameter of 120mm, we have reached a feed ratefz of 2mm (Vf = 12.6 m/min). For this operation already 60% of the availabletorque 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 Vc = 250 m/min

for producing a borhole with diameter 90mm. In this case we reached a feedrate of 2.5 mm (Vf = 11.9 m/min) for which 35% of max. torque were used.





• RampingThe Ø63 tool was tested starting with a fz = 0.15mm (Vf = 0.6 m/min) andincreased in steps of 0.05mm up to the maximum fz = 0.3mm (Vf = 1.5 m/min)while the cutting speed was always Vc = 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 fz = 0.2mm (Vf = 0.8 m/min). The test was started also with fz = 0.15mm.At the max. feed reate fz of 0.25mm (Vf = 1 m/min) were only 20% of themachine power used.





• 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

02 – Results from Lab


• PlungingThe tool was modular extended with NCT up to a length of Xs=260mm. Thesmaller the enlacement is, the smoother runs the tool. The tests was madeat a cutting speed of Vc = 250 m/min and with a feed rate fz=0.2mm (vf = 1 m/min).

With a length Xs=180mm (Master+Combi-Arbor) there was a improvement of thecomplete process. When using big enlacement and a feed rate of fz =0.25mm(vf = 1.3 m/min) we have reached the best result.

Tool: F4030, Ø63mm, Z=4Insert: P23696-2.0 ap max.= 2mmMaterial: 42CrMo4Machine: Starrag Heckert HEC630




• Plunging

Small Enlacement (Offset)

Medium Enlacement (Offset)

Big Enlacement (Offset)



• Component:– Tool housing

• Workpiece Material:– 1.2312

• Machine:– Anayak VH Plus 2000-MG– 50 KW– SK50

• Operation: – Pocket milling with continuous cut

Coolant: Air

02 – Results from Customer


• Tool/Insert– SR66-55 D27– 9588.A.12520 PE6

• Cutting parameter– Vc = 155 m/min– fz = 1,6 mm– ap = 1,0 mm

– Vf = 5980 m/min

Competitor 01 Competitor 02

02 – Results from Customer Current situation


• Tool/insert– F4030.B22.063.Z06.01– P23696-1.0 WSP45

• Cutting parameter– vc = 120 m/min– fz = 2,0 mm– ap = 1,0 mm

– vf = 7275 m/min

Cutting speed : 20%

Feed/tooth : 20%

Feed/min : 18%

02 – Results from Customer Walter solution


02 – Results from Customer Wear


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

200 hours free machine capacity

02 – Results from Customer Savings/Productivity


Bezeichnung Da Dc d1 X1 X2 Lc ae Anz. Typ Typ

Metrische Baureihe mm mm mm mm mm mm mm Z kg WSP WSP Schraube

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

*nicht im Highlightflyer vorhanden

FS2081P23696-1.0

Name Type

Inch Range

Type

WSP Screw

03 – Product Program Bodies metric

*not included in the highest flyer


Bezeichnung Da Dc d1 X1 X2 Lc ae Anz. Typ Typ

Inch Baureihe mm mm mm mm mm mm mm Z kg WSP WSP Schraube

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

Name Type

Inch Range

Type

WSP Screw

03 – Product Program Bodies metric


P23696

NameRadius

mmWidth

mm

P M K N S H

HC HC HC HC HW HC HC

WK

P2

5

|

WK

P3

5S

WSP

45

WSM

35

WSP

45

WA

K1

5

WK

K2

5

WK

P2

5

WK

P3

5

WK

P3

5S

WX

N1

5

WK

10

WSM

35

WSP

45

WH

H1

5

P23696-1.0 14 J K L K L K L L K L

NEW

2010

03 – Product Program Inserts

No WKP35 (mistake in the Highlight flyer)


• 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

04 – Application Areas & Target Groups


• 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

05 – Benefits for the customer


Form plate Turbine blades Injection Mold

06 – Typical workpieces

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: [email protected] |

SPECTRA CARBIDE TOOLING TECHNOLOGY (PTY) LTD

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Xtra-tec - Spectra...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...

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