Heavy Roughning Milling Cutter MSR Series Improving machine efficinecy Square Insert MSR Facemill MonSteR M S R Square S Mill Double the productivity MonSteR M S R Mill Insert lineup expanded
Heavy Milling Cutter MSR MSRType Heavy Milling Cutter MSR PR830 (For Steel) BT50 Integral rbor type PR905 (For Cast Iron) Low cutting force design Efficient Heavy Milling Double the metal removal rate; double the productivity. Notched inserts promote larger depth of cut and excellent chip control. Heavy machining with low cutting forces, and also drastically improves machining efficiency. (Reduction of machining time) Notched Insert Size Comparison (Full Size) Notch Notch Cutting Resistance(N) Comparison of cutting resistance 5000 000 3000 2000 000 0 Kyocera Comp. 2% 5028N 066N Combined Force Combined Force *The exclusive notched chipbreaker provides low resistance and good chip evacuation. Type 7 Type PMT25 Type (Internal evaluation)
Face Mill for Heavy Milling MSRSType Significantly Improved Metal Removal Rate.R. +9 R.R. 9 (ø80) 5 (more than ø00) Face Mill for Heavy Milling Lead angle: 75 degrees MSRStype MSRS Revolutionizes Heavy Milling (maximum depth of cut is 2mm) Large depth of cut and high feed rate achieve high efficiency machining. Recommended depth of cut: 5 to 0mm. Wide lands strengthen edges. Square Insert MSR Facemill Conventional tools Unique design allows suppressed chattering and low cutting force Comparison of cutting force (radial force) The MSRS suppresses chattering since less up force is created reducing potential to lift the work piece into the cutter. Notched 2mm Large wiper edges achieve high feed rate. (Max.D.O.C. ) 5mm CornerR=.2mm 8mm 6.35mm Inserts are strengthened with 6.35mm width. Notched insert reduces cutting force, chattering and enables efficient machining. Economical square inserts with four edges Three types added to lineup to suit the applications NB3 (With 3 notches) Direction to lift up workpiece (N) 200 00 0 00 200 300 00 200 00 0 00 200 300 00 Direction to press down workpiece (MSRS type) (Comp.) Possible to machine thinplate workpieces (low rigidity material such as can manufacturing equipment) NB2 (With 2 notches) NEW General Purpose 9mm Overhang 20mm NB2P (With notches) Standard type NB3P (With 5 notches) NB2T (With 2 notches) NB3T (With 3 notches) Tougher edge type MSRS5R8T Workpiece Material :S50C Vc=200m/min(n=398min ) fz=0.5mm/t(vf=77mm/min), ap x ae=6x00mm (Machining of overhang from 5mm to 9mm) 2
MP MSR Type MSR Type Rake ngle( ) ø63~ø80 ø00~.r. : +9.R. : +9 R.R. : 8 R.R. : 5 Spare Part (Bore : common inch/mm ) Spare Part Clamp Screw Wrench Shim Clamp Screw Wrench ntiseize Compound Fig. Fig.2 Fig.3 Fig. MSR 063R SB MSR 080R TT25L 20TR MP SB DT5 2506 00TR ~ MP 35R for Insert Clamp for Shim Clamp Fig.5 Fig.6 Fig.7 Fig.8 Fig.9 MP Coat seizing inhibitor (MP) thinly on clamp screw when insert is fixed. Toolholder Dimension (Bore : inch ) Stock No. of Insert No. of Line No. of Stage Dimension (mm) ød 2 H E a b S 3 5 6 øc øc G Shape Weight (kg) MSR 063R 65 23.5 Fig. 0.8 63 25. 20 26 6 9.5 063R2 8 2 85 5 Fig.3.0 080R 50 23.5 Fig.. 25. 20 26 6 9.5 080R2 Fig.3.6 8 2 70 5 080R23.75 80 3.75 27 8 32 8 2.7 Fig.3.7 080R 25. 20 26 6 9.5 Fig.5 2.6 6 5 90 080R3.75 3.75 27 8 32 8 2.7 Fig.5 2.7 00R 6 50 00R2 2 6 2 00 3.75 2 70 32 8 2.7 5 Fig. 2.2 23.5 Fig.2.6 00R 2 5 90 Fig.6 3.6 25R 6 25R2 2 6 2 25 38. 5 70 38 0 5.9 5 Fig. 3.8 23.5 Fig.2 3.5 25R 2 5 90 Fig.6 6. R 8 R2 6 8 2 50.8 68 70 38 9.0 5 Fig. 6. 23.5 Fig.2 5.8 R 32 5 90 Fig.6 0.7 200R 0 0 200 7.625 38 25. 23.5 Fig.7 7.5 8 26 0.6 32 200R2 20 2 80 5 Fig.8 0. 250R 2 2 250 7.625 38 25. 23.5 Fig.7 0.9 8 26 0.6 32 250R2 2 2 80 5 Fig.8.7 35R 35 7.625 35 25. 23.5 7 27 22 32 0.6 77.8 25 Fig.9 6.0 Shim is not available for MSR063R (Dia. D=63). :Standard Stock :Check vailability rbor attachment bolt(hh2x0) is included for MSR063R/MSR080R. rbor attachment bolt(hh6x5) is included for MSR080R 3.75. :Made to order It is not recommended using only top edge part (D.O.C 30mm) for stages type.if D.O.C is small, use stage or 2 stages type. Deep grooving is not recommended for this cutter. Toolholder Dimension (Bore : mm ) Stock No. of Insert No. of Line No. of Stage Dimension (mm) ød 2 H E a b S 3 5 6 øc øc G Shape Weight (kg) 3 MSR 063RM 65 63 27 20 22 7.2 2. 23.5 Fig. 0.7 063R2M 8 2 85 5 Fig.3 0.9 080RM 50 23.5 Fig..0 080R2M 8 2 80 27 20 70 22 7.2 2. 5 Fig.3.5 080RM 6 5 90 Fig.5 2.5 00RM 6 50 23.5 Fig.2.5 00R2M 2 6 2 00 32 2 70 28 8. 5 Fig. 2.0 00RM 2 5 90 Fig.6 3.2 25RM 6 23.5 Fig.2 3. 25R2M 2 6 2 25 0 58 70 30 9 6. 5 Fig. 3.7 25RM 2 5 90 Fig.6 6.0 RM 8 8 0 68 30 9 6. 23.5 Fig.7 6. 20 66.7 28 R2M 6 2 70 5 Fig.8 6.8 200RM 0 0 200 38 5 25.7 23.5 Fig.7 7.0 8 26 0.6 32 200R2M 20 2 80 5 Fig.8 9.9 250RM 2 2 250 38 5 25.7 23.5 Fig.7 0.3 8 26 0.6 32 250R2M 2 2 80 5 Fig.8.2 Shim is not available for MSR063R (Dia. D=63). rbor attachment bolt(hh2x0) is included for MSR063R/MSR080R. It is not recommended using only top edge part (D.O.C 30mm) for stages type.if D.O.C is small, use stage or 2 stages type. Deep grooving is not recommended for this cutter. :Standard Stock :Check vailability
3 3 3 3 MSR Type MSR Type 0 ød ø00 ød ø00 S 38 L BT50shank 0 BT50shank S 38 0.8 L 0.8 Holder Dimension (BT50 Integral rbor Type) Dimension(mm) Rake ngle( ) Spare Part Stock No. of Insert No. of Line No. of Stage ød L S.R. R.R. Shape Weight(kg) Clamp Screw Wrench Shim Clamp Screw Wrench ntiseize Compound MP MSR 063RBT50 063RBT505 6 20 63 5 80 90 Fig. Fig.2 5.7 6.2 080RBT50 6 90 +9 8 Fig. 6.9 080RBT505 20 80 5 80 Fig.2 7. 00RBT50 2 90 Fig. 9.6 6 00 +9 5 00RBT505 30 5 80 Fig.2 0.5 20TR TT25L for Insert Clamp MP2506 Shim is not available for MSR063R (Dia. D=63). It is not recommended using only top edge part (D.O.C 30mm) for stages/5 stages type. If D.O.C is small, use previous page's stage type or 2 stages type. Deep grooving is not recommended for this cutter. SB SB 00TR for Shim Clamp DT5 MP :Standard Stock MP Coat seizing inhibitor (MP) thinly on clamp screw when insert is fixed. pplicable Insert 3Notched Notched Shape Righthand shown rε rε PMT 2508ERNB3 Dimension (mm) ngle( ) PVD Coated T W rε α β γ PR6 PR830 PR905 PMT 25066ERNB3.6 5.875 6.35 6.5 25 PMT 250ERNB3.0 0.8 PMT 25066ELNB3.6 PMT 2508ERNB PMT 25066ERNB.6 5.875 6.35 6.5 25 PMT 250ERNB.0 0.8 PMT 25066ELNB.6 pplicable Tool holder MSR MSR M For custommade cutter MSR MSR M For custommade cutter rε rε PMT 25066ERNB3P 5.875 6.35 6.5 25.6 MSR MSR M Low resistance 3 notches rε rε PMT 25066ERNBP 5.875 6.35 6.5 25.6 MSR MSR M Low resistance notches Caution when installing notched Insert It is important to install the appropriate notched insert into the correct position. Failure to do so may result in damage to the cutter body. The appropriate insert is marked on the pocket of the cutter body. When it is installed wrong, it may damage the tool holder body. The notched insert location indicator is marked on the Insert itself. Indication is marked near the Insert pocket for MSR type. ) If marked with a "3" in the pocket, use P ERNB3 2) If marked with a "" in the pocket, use P ERNB :Standard Stock (Example of No of necessary inserts) No. of Inserts No. of No. of Nicked Insert Line NB3 NB MSR 00R 6 3 3 00R2 2 6 6 6 00R 2 2 2
MSR Type Caution when installing the insert with cornerradius.0mm When installing the insert with cornerradius.0mm, additional processing to the body is needed. pply additional processing to the body corner according to the chart. Insert CornerR(rε) dditional Processing Dimension (mm) to Body Corner.0 R2.0 *Round shaped additional processing is recommended.when applying chamfershaped additional processing,do not cut away too much. Body Corner Preprocessing dditionally Processed Postprocessing Insert with Large CornerR(rε) Cutting Conditions )Shouldering In case of MSR00R Workpiece Material Cast Iron Carbon Steel (S C SS) Overhang Length (mm) Up to 00mm 00~200mm More than 20mm Up to 00mm 00~200mm More than 20mm Cutting Conditions Cutting Speed (n=570min ) (n=570min ) Vc=20m/min (n=380min ) (n=80min ) (n=80min ) Vc=00m/min (n=320min ) Feed rate (Vf=690mm/min) (Vf=690mm/min) (Vf=mm/min) (Vf=575mm/min) (Vf=575mm/min) Stainless Steel Not Recommended Nonferrous Material Not Recommended D.O.C.(mm) (ap ae) Chip Removal rate (cc/min) 20 80 00 20 0 550 20 30 276 20 80 920 20 0 20 30 228 Overhang Length (mm) 3 In case of MSR00R2 3 Workpiece Material Overhang Length (mm) Cutting Conditions Cutting Speed Feed rate D.O.C.(mm) (ap ae) Chip Removal rate (cc/min) Cast Iron Carbon Steel (S C SS) Up to 30mm 30~230mm More than 23mm Up to 30mm 30~230mm More than 23mm (n=570min ) (n=570min ) Vc=20m/min (n=380min ) (n=80min ) (n=80min ) Vc=00m/min (n=320min ) (Vf=690mm/min) (Vf=690mm/min) (Vf=mm/min) (Vf=575mm/min) (Vf=575mm/min) 0 0 00 0 20 550 0 20 368 0 0 920 0 20 0 20 30 Stainless Steel Not Recommended Nonferrous Material Not Recommended In case of MSR00R Workpiece Material Overhang Length (mm) Cutting Conditions Cutting Speed Feed rate D.O.C.(mm) (ap ae) Chip Removal rate (cc/min) Cast Iron Carbon Steel (S C SS) Up to 80mm 80~280mm More than 28mm Up to 80mm 80~280mm More than 28mm (n=570min ) (n=570min ) Vc=20m/min (n=380min ) (n=80min ) (n=80min ) Vc=00m/min (n=320min ) (Vf=690mm/min) (Vf=690mm/min) (Vf=mm/min) (Vf=575mm/min) (Vf=575mm/min) 75 20 035 75 0 58 75 0 35 75 20 863 75 0 3 75 0 285 Stainless Steel Not Recommended Nonferrous Material Not Recommended 5
MSR Type 2)Slotting In case of MSR00R Workpiece Material Overhang Length (mm) Cutting Speed Cutting Conditions Feed rate D.O.C. (mm) (ap ae) Chip Removal rate (cc/min) Up to 00mm (n=570min ) (Vf=680mm/min) 00 966 Cast Iron 00~200mm (n=570min ) (Vf=680mm/min) 7 00 83 More than 20mm Vc=20m/min (n=380min ) (Vf=mm/min) 00 8 Up to 00mm (n=80min ) (Vf=580mm/min) 7 00 03 Carbon Steel (S C SS) 00~200mm (n=80min ) (Vf=580mm/min) 00 230 More than 20mm Vc=00m/min (n=320min ) 3 00 Stainless Steel Not Recommended Nonferrous Material Not Recommended In case of MSR00R2 Workpiece Material Overhang Length (mm) Cutting Speed Cutting Conditions Feed rate D.O.C. (mm) (ap ae) Chip Removal rate (cc/min) Up to 30mm (n=570min ) (Vf=680mm/min) 00 966 Cast Iron 30~230mm (n=80min ) (Vf=580mm/min) 7 00 03 More than 23mm Vc=20m/min (n=380min ) (Vf=mm/min) 00 8 Up to 30mm (n=80min ) (Vf=580mm/min) 7 00 03 Carbon Steel (S C SS) 30~230mm Vc=20m/min (n=380min ) (Vf=mm/min) 00 8 More than 23mm Vc=00m/min (n=320min ) 3 00 Stainless Steel Not Recommended Nonferrous Material Not Recommended MSR00R Slotting is not recommended 6
MSR Type 2)Slotting In case of MSRR Workpiece Material Overhang Length (mm) Cutting Speed Cutting Conditions Feed rate D.O.C. (mm) (ap ae) Chip Removal rate (cc/min) Up to 00mm (n=3min ) (Vf=580mm/min) 0 928 Cast Iron 00~200mm (n=3min ) (Vf=580mm/min) 5 6 More than 20mm Vc=20m/min (n=20min ) 23 Up to 00mm (n=300min ) (Vf=80mm/min) 5 38 Carbon Steel (S C SS) 00~200mm (n=300min ) (Vf=80mm/min) 3 230 More than 20mm Vc=00m/min (n=200min ) 2 02 Stainless Steel Not Recommended Nonferrous Material Not Recommended In case of MSRR2 Workpiece Material Overhang Length (mm) Cutting Speed Cutting Conditions Feed rate D.O.C. (mm) (ap ae) Chip Removal rate (cc/min) Up to 30mm (n=3min ) (Vf=580mm/min) 0 928 Cast Iron 30~230mm (n=300min ) (Vf=80mm/min) 5 38 More than 23mm Vc=20m/min (n=20min ) 23 Up to 30mm (n=300min ) (Vf=80mm/min) 5 38 Carbon Steel (S C SS) 30~230mm Vc=20m/min (n=20min ) 3 82 More than 23mm Vc=00m/min (n=200min ) (Vf=320mm/min) 2 02 Stainless Steel Not Recommended Nonferrous Material Not Recommended MSR00R Slotting is not recommended 7
MSR Type Case Studies SS00 Base (n=78min ) apxae=0x5mm fz=0.5mm/t (Vf=30mm/min) Dry(ir blow) MSR00R2 6 fulutes PMT25066ERNB3 PMT25066ERNB (PR6) 20 MSR Chip Removal rate=258cc/min Competitor Cutter Chip Removal rate=3cc/min Since MSR is able to machine a greater D.O.C than competitor Cutter [dia 00mm (6 edges) fz=0.2mm/t (Vf=3mm/min) apxae=5x25mm] Chip Removal rate=3cc/ min, the cutting time is drastically improved. (Evaluation from the user) S5C S35C Plate Vc=0m/min (n=6min ) apxae=3x5mm (Vf=535mm/min) Dry MSR00R2 6 fulutes PMT25066ERNB3 PMT25066ERNB (PR6) 70 300 700 Bracket (n=78min ) apxae=20x70mm fz=0.25mm/t (Vf=78mm/min) Dry(Mist) MSR00R2 6 fulutes PMT25066ERNB3 PMT25066ERNB (PR6) 000 MSR Chip Removal rate=35cc/min MSR Chip Removal rate=005cc/min Competitor Cutter B Chip Removal rate=33cc/min Competitor Cutter C Chip Removal rate=7cc/min Since MSR is able to evacuate more than 0 times as many chips as competitor Cutter B [dia 25mm (6 Edges) Vc=20m/ min fz=0.mm/t (Vf=8mm/min) apxae=6x30mm] Chip Removal rate= 33cc/min, the cutting time is improved. Since MSR is able to cut stably even by increasing feed rate 2. times compared competitor Cutter C [dia 00mm (6 edge lines) Vc=30m/min fz=0.2mm/t (Vf=298mm/min) apxae=20x70mm], cutting efficiency is improved. (Evaluation from the user) (Evaluation from the user) 8
MSR Type Case Studies SC50(Cast Steel) Construction machine part Vc=25m/min (n=00min ) apxae=5x5mm fz=0.5mm/t (Vf=3mm/min) Dry MSR00R2 6 fulutes PMT25066ERNB3 PMT25066ERNB (PR6) Ø300 MSR Chip Removal rate=2cc/min Competitor Cutter D Chip Removal rate=22cc/min Even with double the feed rate, stable machining was possible. and machining efficiency was improved compared with Competitor Cutter D[Dia. 00( edges) Vc=25m/min fz=0.08mm/t (Vf=80mm/min) apxae=5x5mm] (Evaluation from the user) SS00 FCD50 Plate Vc=200m/min (n=min ) apxae=80x0mm fz=0.06mm/t (Vf=230mm/min) Dry MSR00R( stage type) 6 fulutes PMT25066ERNB3 PMT25066ERNB (PR6) 80 2000 Weak workpiece clamp and easy cause of chattering 350mm(Over hang) Construction machine part Vc=73m/min (n=550min ) apxae=5x50mm (Vf=6mm/min) Dry MSR00R2 6 fulutes PMT25066ERNB3 PMT25066ERNB (PR905) 000 230mm (Over hang) MSR Chip Removal rate=8cc/min MSR Chip Removal rate=65cc/min Competitor Cutter E Chip Removal rate=78cc/min Competitor Cutter F Chip Removal rate=5cc/min Machining efficiency is improved by 2.3 times due to MSR less cutting force performance. Machining efficiency is 3.2 times better than competitor due to the greater chip evacuation. (Evaluation from the user) (Evaluation from the user) 9
MSR Type MSR Cutter Q & Q. What is the most recommended cutting condition for MSR? Q.5 Can be applied for cast iron machining?.,, Large larger cutting depth and smaller cutting width In case of MSR00R2 e.g)loadmeter 20% e.g)loadmeter 90% pass 2 pass 3 pass ap X ae: 5 X 75mm 3 pass 2 pass ap X ae: 5 X 25mm pass.5 YES There is a case of cast iron machining at 800cc/min removal rate. Basically machinability is better than steel and there is no problem. Recommended cutting condition fz=0.3mm/t * In case necessity of wear resistant grade, use PR905(PR830) Q.6 What is the tool life? Q.2.2 Q.3.3 Required equipments for MSR? Maximum spindle revolution should be lower than 000min. BT50 or larger *MSR is not only for Double column machining center The reason why not recommended for high RPM spindle machine is its less toruque. *lthough MSR works with BT0 shank, maximum available fz is about 0.mm/tooth. What is the points to remember in case of less power machine? Do not use large size cutter Dia.63 or Dia.80mm is recommended. Set up conditions to get the largest available torque by checking torque curve of the machine. Tried under condition of, enough torque was not gained because of high gear. In this case, it has to be prioritized using Vc which can exert enough torque as Vc=20m/min. Please increase cutting speed and decrease feed ratio. *Machine torque curve will be prioritized..6 Q.7.7 Chip weight: 700kg/Corner (Result by PR6) Machining time: 90min (calculated value) Machining distance: 65m (calculated value) How great 000cc/min? bout 7.8kg chips removed per minute Tool life time = 700kg (Chip weight) 7.8kg (Chip evacuation amount per min) = 90min Machining distance= 90min (Time by the end of tool life) x 77mm/min (Table feed ratio per min)=65m * In case of, ap x tae: 20x70mm, Vf=77mm/min * Tool: MSR00R2 (6 flutes) How to reduce chattering. If chattering is caused under machining environment, following condition is recommended. In case of chattering Reduce cutting speed and increase feed rate Q.. In case of unstable workpiece Decrease feed ratio at start cutting workpiece In case of general steel Vc=80m/min fz=0.25mm/t In case of cat iron Vc=80m/min fz=0.35mm/t * lmost all cases f moving workpiece happens when start machining Effective for increasing cutting speed and decrease feed ratio, Vc=200m/min,fz=0.5mm/t 0
MSRS Type Face Mill MSRS Type E a b a b H H b 2 ød ød 3 S Fig. E Rake ngle( ).R. R.R. MSRS5080R +9 9 ød ød b 3 S 5 Fig.2 MSRS500R ~ MSRS535R +9 5 øc ød ød S H E a G 6 S Fig.3 H E a G G (The photograph shows the standard type.) øc øc ød ød Fig. Holder dimension (Bore : inch) Stock No. of Insert Dimension (mm) ød ød 2 H E a b S 3 5 6 øc øc G Fig. Weight (kg) Coarse pitch type MSRS 5080RT 80 87 25. 20 3 26 6 9.5 Fig..3 50 500RT 00 07 3.75 2 32 8 2.7 2.0 525R6T 6 25 32 38. 5 0 5.9 Fig.2 3.6 5R8T 8 67 50.8 68 9.0 2 5.0 5200R0T 0 200 207 38 7.7 32 Fig.3 5250R2T 2 250 257 7.625 25. 8 26 0.6 2.0 535RT 35 322 22 32 77.8 25 Fig. 7.0 Close pitch type MSRS 5080R6T 6 80 87 25. 20 3 26 6 9.5 Fig..3 50 500R6T 6 00 07 3.75 2 32 8 2.7.9 525R8T 8 25 32 38. 5 0 5.9 Fig.2 3.5 5R0T 0 67 50.8 68 9.0 2.9 5200R2T 2 200 207 38 7.6 32 Fig.3 5250RT 250 257 7.625 25. 8 26 0.6.9 535R6T 6 35 322 22 32 77.8 25 Fig. 7.0 rbor mounting bolts (HH2X35) are included in MSRS5080R T Type. :Standard Stock :Check vailability :Made to order Cartridge is included in the standard type, but no Cartridge in the multiedges type. Holder dimension (Bore : mm) Stock No. of Insert Dimension (mm) ød ød 2 H E a b S 3 5 6 øc øc G Fig. Weight (kg) Coarse pitch type MSRS 5080RTM 80 87 27 20 3 2 7 2. Fig..3 50 500RTM 00 07 32 5 29 8. 2.0 Fig.2 525R6TM 6 25 32 55 3.6 0 33 9 6. 5R8TM 8 67 68 2 20 66.7 28 5.0 5200R0TM 0 200 207 Fig.3 7.7 5250R2TM 2 250 257 38 5 25.7 8 26 0.6 32 2.0 535RTM 35 322 22 32 77.8 Fig. 7.0 Close pitch type MSRS 5080R6TM 6 80 87 27 20 3 2 7 2. Fig..3 50 500R6TM 6 00 07 32 5 29 8..9 Fig.2 525R8TM 8 25 32 55 3.5 0 33 9 6. 5R0TM 0 67 68 2 20 66.7 28.9 5200R2TM 2 200 207 Fig.3 7.6 5250RTM 250 257 38 5 25.7 8 26 0.6 32.9 535R6TM 6 35 322 22 32 77.8 Fig. 7.0 rbor mounting bolts (HH2X35) are included in MSRS5080R TM Type. :Standard Stock :Check vailability :Made to order Cartridge is included in the standard type, but no Cartridge in the multiedges type.
MSRS Type Face Mill Spare parts Spare Part Clamp Screw Wrench Cartridge Clamp Screw Wrench ntiseize Compound rbar Clamp Screw MP MSRS 5080R (M) MSRS 500R HH2 35 SB20TR (M) TT25L MP806 SB00TR DT5 MP ~ for Insert Clamp Tightening Torque 7.5Nm 535R (M) MSRS 5080R (M) MSRS 500R (M) for Shim Clamp Tightening Torque 3.5Nm SB20TR TT25L for Insert Clamp Tightening Torque 7.5Nm 535R HH2 35 ~ Close pitch type Coarse pitch type MP (M) MP Coat ntiseize Compound (MP) thinly on clamp screw when insert is fixed. pplicable Insert Dimension (mm) Shape T X Z α β γ PR905 PVD Coated PR830 ngle( ) PR6 SPMT 806EDERNB2 8 6.35 6.8 R.2 3. SPMT 806EDERNB3 8 6.35 6.8 R.2 3. SPMT 806EDS$NB2T 8 6.35 6.8 R.2 3. R SPMT 806EDS$NB3T 8 6.35 6.8 R.2 3. R SPMT 806EDERNB2P 8 6.35 6.8 R.2 3. SPMT 806EDERNB3P 8 6.35 6.8 R.2 3. SPMT 806EDERV 8 6.35 6.8 R.2 3. Righthand shown pplicable Toolholder β Z X α γ 2 notches General Purpose T Z β X α γ 3 notches General Purpose T β Z X α γ 2 notches Tough edge type T β Z X α γ 3 notches Tough edge type β Z X γ notches Low resistance type NEW T α β Z X γ 5 notches Low resistance type MSRS M T NEW MSRS Z T α β X γ Without notch T α :Standard Stock 2
MSRS Type Face Mill Insert Grades Workpiece Material Good wear resistance Good fracture resistance Recommended Cutting Condition Workpiece Material Feed Rate (mm/t) Recommended Insert Grades (Speed Vc:m/min) PVD Coated Steel (Carbon Steel/lloy Steel) Cast Iron (FC/FCD) PR830 PR905 PR6 PR830 NB2P+NB3P NB2+NB3 NB2T+NB3T PR6 PR830 PR905 Carbon Steel(SxxC) 0.5 0.2 0.3 50~200 80~220 lloy Steel(SCM) 0.5 0.2 0.3 50~200 80~220 Die Steel(SKD/NK) 0. 0.5 0.2 20~80 50~200 Gray Cast Iron(FC) 0.2 0.25 0.35 80~220 50~250 Nodular Cast Iron(FCD) 0.5 0.2 0.3 80~220 80~220 Stainless Steel(SUS30) Not Recommended Nonferrous Material Not Recommended :st Recommendation :2nd Recommendation Selection of chipbreaker Emphasis on low cutting force General Purpose Emphasis on edge strength type + + + NB2P( notches) NB3P(5 notches) NB2(2 notches) NB3(3 notches) NB2T(2 notches) NB3T(3 notches) pplication Ideal when using long arbor type or for machining of thinplate workpieces General purpose type with balance of strength and resistance Ideal for interrupted cutting and high load cutting. Ideal when feed rate is increased or workpiece material is FC/FCD s many as four (or five) notches help to alleviate the shock when biting into the workpiece Strength, edge and chip control are all well balanced Strength is increased by the edge shape and moderate rake angle of the chamfer edge Edge preparation second land first land Large rake angle Smooth rake angle wide land with Corner Chamfering C0.2x +R0.05 supplemental chipbreaker is used when it is necessary to increase strength and bite while focusing on resistance, as when machining welded areas. NB2 OR NB3 Insert Replacement Identification + V bout marked numbers of NB2P(notches) and NB3P(5notches) Inserts In order to adjust applicable inserts on marked numbers on tool holders,"2 + " is marked for NB2P ( notches) and "3 + " is marked on NB3P(5 notches). Notch effect The effects of the notch can be seen at more than 5mm of vertical depth of cut. (effects for NB3 appears from at least 2mm or more) 5mm Insert number is transcribed as a result of the cutting tool load. 3 * Depending on the cutting conditions,marks are not transcribed. 2mm With two notchs NB2 With three notchs NB3
MSRS Type Face Mill Case studies chievement of productivity improvement and machining time reduction SS00 S50C Plate Rail (n=382min ) apxae=0 25mm (Vf=58mm/min) Dry 6edges MSRS525R6T SPMT806EDERNB2 SPMT806EDERNB3 (PR830) 500 dvancing Productivity. times! (n=300min ) apxae=6 0mm (Vf=80mm/min) Dry 8edges MSRS5R8T SPMT806EDERNB2 SPMT806EDERNB3 (PR830) Upper side 0 Lower side dvancing Productivity.7 times! MSRS Chip removal 572cc/min. MSRS Chip removal 03cc/min. Competitor Cutter G 29cc/min. Competitor Cutter H 8cc/min. (Competitor Cutter G) (User comment) (Competitor Cutter H) (User comment) ø25, 6edges (n=382min ) ap ae=3 25mm Improvement of the condition to a large extent results in time reduction. Productivity has improved. times. 2mmx3pass (n=300min ) ap ae=2 0mm MSRS enabled one pass cutting, while it formerly took three pass. Still, the MSRS has less cutting noise. Productivity has improved.7 times. fz=0.5mm/t fz=0.25mm/t (Vf=3mm/min) (Vf=300mm/min) (Evaluation by the user) (Evaluation by the user) C2(Cast steel) S5C Industrial machinery components Gear Vc=00m/min (n=200min ) apxae=0 mm fz=0.mm/t (Vf=635mm/min) Dry 8edges MSRS5R8T SPMT806EDERNB2 SPMT806EDERNB3 (PR830) dvancing Productivity 2.5 times! Vc=200m/min (n=255min ) apxae=0 200mm fz=0.7mm/t (Vf=0mm/min) Dry edges MSRS5250RT SPMT806EDERNB2 SPMT806EDERNB3 (PR830) dvancing Productivity 2.6 times! MSRS Chip removal 72cc/min. MSRS Chip removal 200cc/min. Competitor Cutter I 290cc/min. Competitor Cutter J 59cc/min. (Competitor Cutter I ) (User comment) (Competitor Cutter J ) (User comment) 6inch Dia., 8edges Vc=250m/min (n=522min ) ap ae=2.5 mm fz=0.25mm/t lthough conventional type could not increase depth of cut due to high cutting force, MSRS has enabled to increase depth of cut without increasing spindle load. Productivity increased 2.5 times. ø250,2edges Vc=20m/min (n=53min ) ap ae=5 200mm fz=0.25mm/t Cutting noise is quiet even when cutting width is nearly 80% of cutter diameter. Productivity increased 2.6 times. (Vf=06mm/min) (Vf=59mm/min) (Evaluation by the user) (Evaluation by the user)
MSRS Type Face Mill Q& Q What is the recommended radial width of cut (ae)? Recommendation is 70 to 80% of cutter diameter. Q2 Why is the MSRS cutting edge inclination angle 75 degree? 2 Type with 5 degree cutting edge angle suppresses the impact of cutting into workpiece, but has bigger radial force. Meanwhile, type with 90 degree cutting edge angle has smaller radial force, but bigger impact on cutting into workpiece. The MSRS cutter with 75 degree cutting edge angle generates small radial force even on large depth of cut, as well as less impact on approaching, and, due to its wellbalanced design, enables smooth machining. The amount of chip evacuation of MSRS Type is increased much more than conventional tools. Features of Holder Coarse pitch type Design of large chip pocket Good chip evacuation Close pitch type doption of cartridge (standard type) Damage prevention of base body Display the applicable insert number (Notch number) Higher productivity due to close pitch design