0,8. R a. Masterfinish - Turning

Transcription

1 N6 0,8 R a Masterfinish - Turning

2 CERATIZIT the parent companies Headquarters and main site Mamer / Luxembourg Main site Reutte / Austria Hard material matters it is the core of our business. Through profound knowledge and highly flexible production facilities we strive to provide our business partners with direct competitive advantages in the field of hard materials for tooling solutions and wear parts. Our dedication to hard material matters creates intelligent solutions for tomorrow and time to come. Production plants in the three main economic areas and a worldwide sales network of subsidiaries and distribution partners ensure a quick response to customer needs. In-house trainings and seminars guarantee that both business partners and employees share the latest information on our product range. We promote intensive dialogue with our customers and strive for long-term business relations on a partnership basis. The CERATIZIT corporate value The focus and point of view of our business partners matters is a guiding principle for all CERATIZIT employees worldwide. Europe Austria Bulgaria Czech Republic France Germany Hungary Italy Luxembourg Netherlands Poland Switzerland Spain United Kingdom North America USA Asia China India Japan South America Brasil Direct sales and distribution partners 2

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4 Masterfinish Function principle / benefit Improved surface finish With the same feed rate an insert with Masterfi nish cutting edge reaches a roughness value R a which is many times lower than the one of a conventional insert. Conventional Masterfi nish Shorter machining time If you want to reach the same R a -value as with a standard insert, a twice as high feed rate can be applied for the insert with Masterfi nish cutting edge (= shorter production time per component!) Conventional Masterfi nish Insert: Insert: WNMG EN-TMR v c : 200 m/min a p : 1,0 mm f: 0,4 mm WNMG EN-TFQ v c : 200 m/min a p : 1,0 mm f: 0,4 mm 4

5 Surface quality Theoretical surface finish The maximum theoretical surface roughness with turning, Rt theor. is the combination of feed rate and corner radius. or approximately Theoretical surface roughness Rt (mm) Feed rate f (mm) Cutting data for feed rate Roughness range R z in µm R t max corresponds to R a -value Roughness index ISO 1302 Corner radius rε (mm) and feed rate f (mm/rev.) rε = 0,4 rε = 0,8 rε = 1,2 rε = 1, Rt ,5-25 N ,51 0,69 0, Rt 63 6,3-25 N 10 12,5 0,27 0,43 0,56 0,68 31, ,5 Rt 40 Rt 31,5 4,9-6,3 4,0-4,9 N 9 6,3 0,25 0,22 0,37 0,32 0,49 0,41 0,57 0, Rt 25 Rt 16 2,5-4,0 1,6-2,5 N 8 3,2 0,20 0,15 0,28 0,22 0,36 0,29 0,39 0,31 6,3-10 Rt 10 1,0-1,6 N 7 1,6 0,10 0,13 0,18 0,20 5

6 Surface quality ISO-DIN measured surface roughness Average roughness value R a (DIN 4768) This is defi ned as the arithmetical mean of the absolute sums of the roughness profi le R within the entire measured length l m. Average roughness depth R z (DIN 4768) This is defi ned as the average value resulting from the single roughness depths of fi ve successive single measured lengths l e. Single surface roughness depth Z 1... Z 5 This is the vertical distance between the highest and the lowest point of the roughness profi le R within a single measured length l e. Maximum surface roughness depth R t (DIN 4768/1) This is the distance between the elevation and depression of the line within the measured length (reference distance) of profi le fi ltered according to DIN 4768 sheet 1. Surface quality according to manufacturing method Surface symbol according to ISO 1302 new Surface symbol according to DIN 3141 until now Roughness index Arithmetic mean value R a [µm] Surface roughness depth R z [µm] Longitudinal turning Face turning Longitudinal turning Face turning Longitudinal grinding Surface grinding with CERATIZIT Masterfinish Surface roughness (produced through special methods) Surface roughness (produced through normal workshop methods) Surface roughness (produced through rough machining methods) 6

7 Surface quality Surface and roughness Table for the comparison of the measuring systems (metric compared to inch) of surface roughness R tmax [µm] CLA/R a [µm] CLA [µ ] RMS [µm] RMS [µ ] 0,06 0,02 0,75 0,02 0,8 0,1 0,03 1,2 0,04 1,3 0,2 0,06 2,5 0,08 2,8 0,3 0,09 3,7 0,1 4,2 0,4 0,13 5,0 0,14 5,6 0,5 0,16 6,7 0,18 6,9 0,6 0,19 7,5 0,21 8,3 0,7 0,22 8,7 0,25 9,7 0,8 0,25 10,0 0,28 11,1 0,9 0,28 11,2 0,32 12,5 1,0 0,31 12,5 0,35 14,0 1,2 0,38 15,8 0,42 16,7 1,5 0,47 18,8 0,53 20,9 1,8 0,57 22,6 0,64 25,5 2,0 0,64 25,1 0,78 27,9 2,4 0,73 30,1 0,85 33,4 2,8 0,89 35,2 0,99 39,0 3,0 0,95 37,6 1,06 41,9 3,5 1,11 43,9 1,24 48,8 4,0 1,27 50,2 1,41 55,8 5,0 1,59 62,7 1,77 69,7 6,0 1,91 75,5 2,12 83,6 7,0 2,22 87,5 2,48 92,6 8,0 2,54 100,0 2,83 111,7 10,0 3,18 125,5 3,54 140,0 20,0 6,64 251,0 7,8 279,0 40,0 12,7 502,0 14,1 558,0 60,0 19,1 755,0 21,2 836,0 125,0 39,5 1560,0 43,5 1750,0 200,0 64,0 2510,0 78,0 2790,0 1 µm = 0,001 mm = 39,37 µ 1 µ = 0, = 0, mm CLA (centre line average) RMS (root mean square) 7

8 Depth of cut - feed rate Application range a p [mm] f [mm] CNMG EN-TFQ 0,3-3,0 0,1-0,35 CNMG EN-TFQ 0,5-4,0 0,1-0,5 CNMG EN-TFQ 0,8-5,0 0,15-0,7 CNMG EN-TMQ 0,8-6,0 0,2-0,7 CNMG EN-TMQ 1,0-6,0 0,25-0,85 DNMG EN-TFQ 0,3-3,0 0,1-0,35 DNMG EN-TFQ 0,5-3,5 0,1-0,5 DNMG EN-TFQ 0,8-4,0 0,15-0,55 DNMG EN-TMQ 0,8-4,5 0,2-0,55 DNMG EN-TMQ 1,0-6,0 0,25-0,65 WNMG EN-TFQ 0,3-3,0 0,05-0,3 WNMG 06408EN-TFQ 0,5-3,0 0,1-0,5 WNMG EN-TFQ 0,3-3,0 0,1-0,35 WNMG EN-TFQ 0,5-4,0 0,1-0,5 WNMG EN-TFQ 0,8-5,0 0,15-0,7 WNMG EN-TMQ 0,8-6,0 0,2-0,7 WNMG EN-TMQ 1,0-6,0 0,25-0,85 Attention: for cermet inserts the maximum values have to be reduced by 30%! 8

9 Inserts Maxilock N -TFQ -TMQ Corner radius L N R Cermet Carbide [mm] Type, description TCC410 CTC1110 CTC1125 l Ø d s Ø d 1 0,4 CNMG EN-TFQ N 12,9 12,7 4,76 5,16 0,8 CNMG EN-TFQ N 12,9 12,7 4,76 5,16 0,8 CNMG EN-TMQ N 12,9 12,7 4,76 5,16 1,2 CNMG EN-TFQ N 12,9 12,7 4,76 5,16 1,2 CNMG EN-TMQ N 12,9 12,7 4,76 5,16 0,4 DNMG EN-TFQ N 15,5 12,7 6,35 5,16 0,8 DNMG EN-TFQ N 15,5 12,7 6,35 5,16 0,8 DNMG EN-TMQ N 15,5 12,7 6,35 5,16 1,2 DNMG EN-TFQ N 15,5 12,7 6,35 5,16 1,2 DNMG EN-TMQ N 15,5 12,7 6,35 5,16 0,4 WNMG EN-TFQ N 6,5 9,52 4,76 3,81 0,8 WNMG EN-TFQ N 6,5 9,52 4,76 3,81 0,4 WNMG EN-TFQ N 8,5 12,7 4,76 5,16 0,8 WNMG EN-TFQ N 8,5 12,7 4,76 5,16 0,8 WNMG EN-TMQ N 8,5 12,7 4,76 5,16 1,2 WNMG EN-TFQ N 8,5 12,7 4,76 5,16 1,2 WNMG EN-TMQ N 8,5 12,7 4,76 5,16 Steel Stainless Cast iron Non ferrous metals Heat resistant Hard materials Main application Extended application R= international CERATIZIT range, for present availability see price list Ordering example: 10 pieces CNMG EN-TFQ CTC1110 9

10 Depth of cut - feed rate Application range a p [mm] f [mm] CCMT 09T304EN-SMQ 0,5-4,0 0,1-0,4 CCMT 09T308EN-SMQ 0,8-4,0 0,15-0,5 CCMT EN-SMQ 0,5-4,0 0,1-0,4 CCMT EN-SMQ 0,8-4,0 0,15-0,5 DCMT EN-SMQ 0,5-3,0 0,1-0,3 DCMT 11T304EN-SMQ 0,5-4,0 0,1-0,4 DCMT 11T304EL-SMQ 0,5-4,0 0,1-0,4 DCMT 11T304ER-SMQ 0,5-4,0 0,1-0,4 DCMT 11T308EN-SMQ 0,8-4,0 0,15-0,5 10

11 Inserts Maxilock S -SMQ...EN -SMQ...EN -SMQ...ER Corner radius Type, description L N R Carbide [mm] CTC1110 CTC1125 l Ø d s Ø d 1 0,4 CCMT 09T304EN-SMQ N 9,7 9,52 3,97 4,4 0,8 CCMT 09T308EN-SMQ N 9,7 9,52 3,97 4,4 0,4 CCMT EN-SMQ N 12,9 12,7 4,76 5,5 0,8 CCMT EN-SMQ N 12,9 12,7 4,76 5,5 0,4 DCMT EN-SMQ N 7,75 6,35 2,38 2,9 0,4 DCMT 11T304EN-SMQ N 11,6 9,52 3,97 4,4 0,4 DCMT 11T304EL-SMQ L 11,6 9,52 3,97 4,4 0,4 DCMT 11T304ER-SMQ R 11,6 9,52 3,97 4,4 0,8 DCMT 11T308EN-SMQ N 11,6 9,52 3,97 4,4 Steel Stainless Cast iron Non ferrous metals Heat resistant Hard materials Main application Extended application R= international CERATIZIT range, for present availability see price list Ordering example: 10 pieces DCMT 11T304EL-SMQ CTC

12 Masterfinish advantages Masterfinish because... -TFQ Surface Conventional Manufacturing cost factor... applying Masterfi nish inserts, top quality surfaces can be produced at low costs... optimum swarf control can be obtained by means of the new chip groove geometry... in many cases grinding is no longer necessary... the cutting forces are not higher than with a standard insert... inserts CNMG EN-TFQ can be used at both the acute and the obtuse corners Masterfinish because... 12

13 Application Excellent surfaces - simple and fast production Usage in ISO tool holders. Please note approach angle! x Masterfinish cutting edge x x applies to Maxilock N only PCLNL/R PCBNL/R PCKNL/R PDJNL/R PWLNL/R DNMG insert Due to the Masterfi nish edge with the -...Q geometry a certain profi le deviation on the workpiece results compared to standard inserts (see picture 1). The Masterfi nish effect occurs only when longitudinal or face turning parallel or at a 90 angle to the axis. Picture 1 ATTENTION: the above mentioned information must be observed when programming! e.g.: = corner profi le of a standard insert PDJNL/R 13

14 Application Support measures for optimisation a) Ensure condition of the tool holder with reference to: deformation of insert seat shim clamping lever... b) Check for minimised tool overhang c) Ensure correct alignment of tool Attention! b + c not necessary when using the CERATIZIT UTS tooling system - see catalogue CERATIZIT Maxifl ex UTS - the universal tooling system, no

15 Application Optimisation of cutting parameters Type of problem Workpiece problems Type of wear Swarf control Surface quality (deviation of measured value) Chatter marks, vibrations Surface quality (optical) Profi le deviation Formation of burrs Cratering Built-up edge Flank wear Plastic deformation Chip too long (continuous chip) Chip too short (fragmented chip) Corrective measures Cutting speed Feed rate Cutting depth Cutting values Corner radius Type of insert Approach angle <90 >90 Selection of insert Clamping of tool Overhang length Alignment of Masterfi nish edge in mounted position Cooling lubricant General criteria Clamping of workpiece Programming (tool correction) raise, increase control avoid, reduce use 15

16 329/ Headquarters: CERATIZIT S.A. Main site Luxembourg CERATIZIT Luxembourg Sarl Route de Holzem, B.P. 51 L-8201 Mamer Tel.: Fax: info@ceratizit.com Main site Austria CERATIZIT Austria Gesellschaft m.b.h. A-6600 Reutte/Tyrol Tel.: +43 (5672) Fax: +43 (5672) info.austria@ceratizit.com 329 EN We reserve the right to make technical changes for improvement of the product.