Expansion of the HELIIQMILL 390 Line with New 15 mm Insert Geometries

Transcription

1 MILLING JANUARY Page 1 / 6 Expansion of the HELIIQMILL 390 Line with New 15 mm Insert Geometries

2 JANUARY Page 2 / 6 Highlights ISCAR is expanding the range of the HELIIQMILL 390 Line inserts with additional geometries to meet more application requirements. Following market demand, ISCAR is expanding the HELIIQMILL HM triangular inserts family to meet the growing requirements of efficient milling in various industrial sectors and applications, by adding three new geometries, one in a cermet grade. HM390 TDKT 1505PDR-GW IC30N Generally, cermet features excellent wear resistance at high temperatures and reduced built-up edge formation (BUE) with respect to tungsten carbide. These properties contribute greatly to successfully applying cermet tools to high speed machining (HSM) and achieving superior finish cutting. ISCAR s cermet grade IC30N was designed for long tool life and excellent surface quality. The new insert is intended mostly for semi-finish and finish milling operations, providing a fine machined surface for general use applications. Features Cermet grade for longer tool life and superior surface finish Good choice for HSM due to high resistance to abrasion and oxidation wear Wide and sharp-edge wiper for improved quality of machined surface 0.8 mm corner radius Covers a wide milling application range on steel, stainless steel, cast iron and sintered materials, including finish operations with high accuracy and roughness requirements

3 JANUARY Page 3 / 6 Cutting Data for HELIIQMILL Tools Carrying Inserts Made From Cermet IC30N ISO Material Condition P M H Non-alloy steel and cast steel, free cutting steel Low alloy steel and cast steel (less than 5% of alloying elements) High alloyed steel, cast steel, and tool steel Stainless steel and cast steel Hardened steel Tensile Strength [N/mm2] Hardness HB Material No. IC30N Cutting Speed (m/min) < 0.25 %C Annealed >= 0.25 %C Annealed < 0.55 %C Quenched and tempered >= 0.55 %C Annealed Quenched and tempered Annealed Quenched and tempered Annealed Quenched and tempered Ferritic/martensitic Martensitic Austenitic Hardened 55 HRC Hardened 60 HRC Chilled cast iron Cast Cast iron Hardened 55 HRC Applying inserts made from cermet prevents BUE and thus increases productivity when milling materials that cause high adhesion wear. The insert cutting edge continues to be sharp over a long period of time, maintaining low cutting forces and excellent surface quality - hence, the cermet inserts are a good choice for precise finish milling.

4 JANUARY Page 4 / 6 HM390 TDCT 1505PDR The peripherally ground TDCT 1505PDR insert with its special chipformer produces excellent surface finish, accurate machined dimensions and precise 90 shoulders. The insert enables smooth machining with low cutting forces, especially for milling the various high temperature alloys widely used in the aerospace and power generation industries. The above features lead to a smooth and light cut, minimize burrs and provide extremely long tool life in either wet or dry machining. Features Sharp ground cutting edge with special edge preparation All-around ground periphery, including contact areas for accurate clamping in the insert pocket of a milling cutter Wide and sharp-edge wiper for high surface finish High accuracy of produced 90 profile 0.8 mm corner radius Available in SUMO TEC carbide grades IC830, IC808 and IC380 Grade IC380 is a first priority grade for machining titanium, high temperature alloys and heat resistant alloys. In addition, it can be used successfully for milling austenitic stainless steel, carbon steel and hard steel at medium to high cutting speeds, even under unfavorable machining conditions or interrupted cuts. Moreover, its high resistance to thermal cracking makes it suitable for machining with wet cooling, in applications where reduction of generated heat is critical. The following field reports show the advantage of the new HM390 TDCT 1505PDR geometry. Machining Examples Shoulder Milling Workpiece: SAE HRc/DIN Tool description HM390 FTD D Diameter (mm) 50 No of teeth 5 Insert type HM390 TDCT 1505PDR Grade IC830 No of corners 3 Cutting speed (m/min) 180 Feed per tooth (mm/t) 0.15 Depth of cut (mm) 5 Width of cut (mm) 32 Coolant Air Tool life (min) 80 Metal removal rate (cm 3 /min) 138 Shoulder Milling Workpiece: AISI 316L / DIN Tool description HM390 FTD D Diameter (mm) 50 No of teeth 4 Insert type HM390 TDCT 1505PDR Grade IC808 No of corners 3 Cutting speed (m/min) 150 Feed per tooth (mm/t) 0.15 Depth of cut (mm) 5 Width of cut (mm) 30 Coolant Air Tool life (min) 50 Metal removal rate (cm 3 /min) 86

5 JANUARY Page 5 / 6 Shoulder Milling Workpiece: Titanium TiAl6V4 Tool description HM390 FTD D Diameter (mm) 50 No of teeth 3 Insert type HM390 TDCT 1505PDR Grade IC380 No of corners 3 Cutting speed (m/min) 60 Feed per tooth (mm/t) 0.08 Depth of cut (mm) 5 Width of cut (mm) 27 Coolant Wet Tool life (min) 50 Metal removal rate (cm 3 /min) 12 HM390 TDCR 1505PDFR-P IC28 The TDCR insert features a peripherally ground flank and polished rake surface. The insert s super positive cutting geometry and sharp edges ensure high efficiency milling of aluminum alloys, titanium and magnesium. Features Sharp cutting edge with a special chipformer for soft materials All-around ground periphery, including contact clamping surfaces in the pocket of the milling cutter Polished rake face Wide and sharp-edge wiper for high surface finish 0.8 mm corner radius The polished rake surface of the insert ensures excellent chip flow, preventing chips from sticking to the surface when milling soft workpiece materials such as aluminum and magnesium. The high-positive cutting geometry results in a soft cutting action and prevents BUE. All the new inserts can be mounted on any standard HELIIQMILL HM cutter. ISCAR s HELIIQMILL 390 family - New levels of productivity and cost reduction per edge in square shoulder milling

6 JANUARY Page 6 / 6 HM390 TDKT/CT 1505 Triangular Inserts with 3 Helical Cutting Edges, for 90 Shoulder Accuracy di ap l S F r -FW Dimensions Tough Ö Hard Recommended Machining Data NEW NEW NEW ap fz Designation l di S r F (mm) (mm/t) HM390 TDCT 1505PDR l l l HM390 TDCR 1505PDFR-P (1) l HM390 TDKT 1505PDR-GW l HM390 TDKT 1505PDR l l l l l l l HM390 TDKT PDR l l l HM390 TDKT PDR l l l HM390 TDKT PDR (2) l l l HM390 TDKT PDR (3) l l HM390 TDKT 1505PDR-FW (4) l (1) Peripherally ground flank and super positive polished rake surface for milling of aluminum, titanium and magnesium. (2) Tools should be modified by rounding the insert pocket corners to R=2.0 mm (3) Tools should be modified by rounding the insert pocket corners to R=4.0 mm (4) Chip splitting cutting edge. IC28 IC330 IC845 IC830 IC5400 IC380 IC808 IC30N IC810