High Productivity with Newly Designed Wiper Edge Geometry

Transcription

1 Positive Wiper Insert High Productivity with Newly Designed Wiper Edge Geometry Excellent Surface Roughness and Smooth Chip Control During High Feed Machining High Quality Surface Finish with No Galling High Machining Accuracy with Low Cutting Forces

2 Positive Wiper Insert High Productivity with Newly Designed Wiper Edge Geometry 1 Excellent Surface Roughness During High Feed Machining Dual-dot Structure One dot offers stabilized chip control at low feed rates, while a second dot controls chips at higher feeds. Wiper Edge Comparison (Internal Evaluation) 2 2 Sharp Wiper Edge Design Excellent surface finish and low cutting forces with sharp wiper edge design. Surface Roughness Rz (μm) 1 1 Non-wiper Edge Cutting Conditions: Vc = 66 sfm, ap =.12" Toolholder: A2R-SCLCR9-22AE Insert: CCMT321 Wiper Edge 2 Stable Chip Control in a Wide Range of Feed Rates Smooth chip control from low feed to high feed rates. Chip Control Comparison (Internal Evaluation) Competitor A Cutting Conditions: Vc = 66 sfm, D.O.C. =.12", Wet Toolholder: A2R-SCLCR9-22AE Insert: CCMT321 Workpiece: 4118 Steel 2

3 3 Excellent Surface Finish WP chipbreaker offers excellent surface roughness across a wide range of cutting conditions. Surface Finish Comparison (Internal Evaluation) 2 f =.4 ipr f =.16 ipr Surface Roughness Rz (μm) 1 1 Competitor B Competitor C Rz = 2.7 μm Competitor B Rz = 1.4 μm Competitor C Rz = 6.7 μm Competitor B Rz = 1. μm Competitor C Rz = 1.6 μm Rz = 13.2 μm Cutting Conditions: Vc = 49 sfm, D.O.C. =.2", Wet Toolholder: A2R-SCLCR9-22AE Insert: CCMT321 Workpiece: 4118 Steel 4 Reduces Surface Finish Galling WP chipbreaker reduces tearing of the finished surface by controlling adhesion with the newly designed wiper edge. (Internal Evaluation) Competitor D (Wiper Edge) Cutting Conditions: Vc = 26 sfm, D.O.C. =.29", f =.6 ipr, Wet Insert: CCMT321 Workpiece: Steel High Machining Accuracy with Low Radial Forces Prevents tool deflection by reducing radial forces. Cutting Force Comparison (Internal Evaluation) Cutting Force (N) f =.4 ipr Radial Force 14% DOWN Cutting Force (N) Radial Force 14% DOWN f =.16 ipr Principal Force Radial Force Feed Force Competitor E Cutting Conditions: Vc = 66 sfm, D.O.C. =.13", Wet Toolholder: A2R-SCLCR9-22AE Insert: CCMT321 Workpiece: 4118 Steel Competitor E 3

4 Case Studies Hub 14 Vc = 2 sfm D.O.C. =.6" (1 pass) f =.3 ipr Wet A16Q-SCLCR9-18AE CCMT9T34WP TN62 Sleeve 14 Vc = 9 sfm D.O.C. =.8" f =.11 ipr Wet S16-SCLCR9 type CCMT9T34WP PV72 Ø1.12 Competitor G (Wiper Edge) TN62 Competitor F (No Wiper) 2.3 sec. % and more Cutting Time.6 sec. WP chipbreaker reduced the cutting time by more than % by increasing feed rate and reducing number of cuts (2 passes to 1 pass) Wiper edge also improved surface roughness. (User Evaluation) WP chipbreaker improved chip control compared to Competitor G Machining efficiency was improved by increasing feed rate. Tool life extended to 1. times that of Competitor G. (User Evaluation) Corresponding Toolholders / Lead Angles Applicable Cutting Edge Angle Insert Cutting Edge Angle CCMT21.. / CCMT DCMX211 / DCMX TCMX1811 / TCMX211 9 Cutting Edge Angle TPMX1811 / TPMX221 9 Applicable Toolholder Insert Application Description Applicable A-SCLC-AE Insert Application Description Applicable ADJC-FF Boring S-SCLC-A E-SCLC-A SDJC-FF SDJC CCMT21.. CCMT32.. DCMX211 DCMX321 External Turning Boring HA-SCLC9 ACLC-FF SCLC-FF SCLC S-SCLC A-SDUC-AE S-SDUC-A E-SDUC-A HA-SDUC11 A-SDZC-AE S-SDZC-A E-SDZC-A A-SDQC-AE DCMX211 DCMX321 TCMX1811 TCMX211 TPMX1811 TPMX221 S-SDUC External Turning SDLC-FF See Caution S-SDLC SDXC SDNC-F No SDNC A-STLC-AE Boring S-STLC-A External Turning STGC No A-STLP-AE S-STLP-A E-STLP-A Boring S-STWP-E S-STWP No S-SDQC-A No C-STXP E-SDQC-A External Turning STGP No 4 Caution: The SDLC-FF and S-SDLC toolholders have a lead angle. While the DCMX...WP can offer surface finish improvements over non-wiper inserts in those toolholders, optimum performance will be obtained by using a 3 lead angle, such as ADJC-FF, SDJC-FF, SDJC, S-SDUC, etc.

5 Setting Conditions for Wiper Inserts Theoretical Surface Roughness Theoretical Surface Roughness Rz (μm) Insert without Wiper Corner-R (rε) = 1/64 CC type Corner-R (rε) =.8 CC type Corner-R (rε) = 1/64 CC type Corner-R (rε) = 1/32 DC/TC/TP type Corner-R (rε) = 1/64 The theoretical surface roughness of a wiper insert is lower than inserts without a wiper. When selecting a feed rate, see left chart for theoretical surface roughness Edge Position Offset Adjustment For D type and T type, cutting edge offsets are required. Amount (in) D type T type.4.8 Standard Insert Edge Line Wiper Insert Edge Line X-direction Correction Amount (in) D type T type.4.3 For D type and T type, program corrections are required for ramping and profiling. Amount θ Z-direction Correction Amount θ Ramping Angle θ Amount (in) D type Profiling Angle θ Amount (in) D type Amount (in) T type Profiling Angle θ Amount (in) D type Amount (in) T type

6 Stock Items Usage Classification : Interruption / 1st Choice : Interruption / 2nd Choice : Continuous - Light Interruption / 1st Choice : Continuous - Light Interruption / 2nd Choice : Continuous / 1st Choice : Continuous / 2nd Choice P Carbon Steel / Alloy Steel M Stainless Steel Shape Description Dimensions (in) Cermet MEGACOAT NANO Cermet CVD Coated Carbide MEGACOAT NANO MEGACOAT I.C. Thickness Hole Corner-R (rε) Relief Angle TN62 PV72 CA1 CA1 CA2 CA3 PR142 PR122 CCMT 21WP 1/4 3/ ß ß ß Þ Þ ß Þ Þ 211WP 1/4 3/ /64 7 ß ß ß Þ Þ ß Þ Þ CCMT 321WP 3/8 / /64 7 ß ß ß Þ Þ ß Þ Þ 322WP 3/8 / /32 7 ß ß ß Þ Þ ß Þ Þ DCMX 211WP 1/4 3/ /64 7 ß ß ß Þ Þ ß Þ Þ DCMX 321WP 3/8 / /64 7 ß ß ß Þ Þ ß Þ Þ TCMX 1811WP 7/32 3/ /64 7 ß ß ß ß ß ß ß ß TCMX 211WP 1/4 3/ /64 7 ß ß ß ß ß ß ß ß TPMX 1811WP 7/32 3/ /64 11 ß ß ß ß ß ß ß ß TPMX 221WP 1/4 1/8.13 1/64 11 ß ß ß ß ß ß ß ß Þ : U.S. Stock ß : World Express (Shipping: 7-1 Business Days) 6

7 Recommended Cutting Conditions Workpiece Insert Grade Cutting Speed Vc (sfm) TN PV CA Min. - Recommendation - Max. D.O.C. (in) Feed f (ipr) D.O.C. (in) WP Carbon Steel / Alloy Steel CA CA CA PR Insert: CCMT32 type Material: Steel PR Recommended Insert Grade Carbon Steel / Alloy Steel Applications Target Base Material Coating Recommended Grade Surface Quality Non-coated TN62 Continuous Cermet Wear Resistance MEGACOAT NANO PV72 Wear Resistance (High Speed) CVD CA1 / CA1 / CA2 / CA3 Light Interrupted Carbide Fracture Resistance (Small Parts) MEGACOAT NANO MEGACOAT PR142 / PR122 7

8 KYOCERA Precision Tools, Inc. 12 Industrial Park Road Hendersonville, NC Customer Service Option 1 Technical Support Option 2 Official Website Distributor Website mykpti.kyocera.com cuttingtools@kyocera.com KYOCERA Precision Tools, Inc. 2/16, K Printed in U.S.A.