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KYOCERA UNIMERCO

MFPN Face Mill

High efficient milling cutter with double sided inserts


Double Sided Pentagonal Inserts Offering 10 edges per insert makes the MFPN a cost effective solution for your machining process. The insert pocket with two contact faces provides high accuracy and spreads the cutting force evently. Two-face holding

12 ap (mm) Depth of cut

10

MSRS

8 6 5 4 3 2

MFPN

Conventional

47.5° cutting edge angle

0.5 0.06 0.1

0.2

0.3

0.4

0.5

0.7

0.6

fz (mm/t) Feed per tooth

Low Cutting Force Good shearing effect, which is promoted by the high axial rake angle (Max.+10°), provides a better bite into the workpiece which lowers the cutting force significantly.

Comparison of cutting force Cutting conditions: Workpiece: C50, Vc=150m/min, fz=0.1mm/t, apxae=5x105 mm, Machine: M/C (BT50)

2000

+10°

(1)

1600

(A.R.)

(2)

1200 Principal force

800

Feed force

400 Back force

0

GM

SM

Competitor A

Competitor B

(1) - 16% reduction in comparison to competitor A (2) - 14% reduction in comparison with GM

Dual Cutting Edge Design (High Toughness) Primary Edge makes chips thinner and reduces impact force. Comparison of fracture resistance No. of impacts 0

5

10

PNMU1205ANER-GM (PR1225)

Wiper edge

○ ×

Competitor C (PVD negative insert)

Primary cutting edge

20

×

Secondary cutting edge

Competitor D (PVD negative insert)

15

×

× × × × × fz=0.5mm/t

0.5mm/t 0.6mm/t 0.7mm/t ○ : No cracks ×: Insert cracks

fz=0.6mm/t

fz=0.7mm/t

Cutting conditions: Workpiece: 1.7223 (38~42HS) (workpiece with 20mm width slot) Machine: BT50 M/C, Vc=100m/min, fz=0.5~0.7mm/t, apxae=2x100mm

2


Long tool life with MEGACOAT

MEGACOAT

KYOCERA’s PVD coated carbide for milling improves tool life and high speed capability due to its superior heat resistance and hardness. The high thermal stability and surface smoothness provides excellent surface finish.

40

MEGACOAT

TiC

Insert Grades PR1535 PR1525 PR1510 CA6535

Hardness(GPa)

30

Workpiece Material Stainless Steel/TiN Steel Cast Iron Heat resistant Alloy

TiCN 20

TiAlN

TiN

10

0

200

400

600

800

1000

1200

Oxidation temperature

Excellent Chip Evacuation Smooth chip evacuation reduces chip-biting.

SM

6

3

GH

GL

1

0.06 0.1

0.2

0.3

0.4

0.5

0.6

Applications

GM

General

SM

Low cutting force

GH

Heavy milling

GL

Surface finish oriented

W

Wiper Insert for finishing

Shape

0.7

fz (mm/t)

4 3 ap (mm)

ap (mm)

GM

Chipbreaker

2

W(PR1525/PR1510)

1

W(TN100M) 0.06

0.12

0.2

0.25

fz (mm/t)

* To improve surface finish, please attach one wiper insert to cutter.

Combination with wiper insert Chipbreaker

Combination with Wiper

GM

Yes

SM

Yes

GH

No

GL

Yes The down arrow symbol (↓) indicates wiper cutting edge. When attaching inserts, make sure that the arrow symbol points downward.

3


MFPN45 Face Mill A.R. Rake Angle(°)

R.R. øD=63 -10° øD=80 -8° øD=100-315 -6°

max +10°

Ø177.8 Ø101.6 Ød2 Ød

b

b

Ø18

b

Ø22 a

Ød3

H S

S

S

S

H

H

H

E

E

E

E

a

a

b

Ød a

Ød

Ød

ØD

ØD ØD1

Fig.1

Ød1

Ød1

Ød1

ØD

ØD

Fig.2

ØD1

Ø32

Ø26

Ød4

Ød2 Ød1

Fig.3

ØD1

Fig.4

ØD1

MFPN 45063R-4T-M 45080R-5T-M 45100R-6T-M 45125R-7T-M 45160R-8T-M 45200R-10T-M 45250R-12T-M 45315R-14T-M MFPN 45063R-5T-M 45080R-6T-M 45100R-8T-M 45125R-10T-M 45160R-12T-M 45200R-14T-M 45250R-16T-M 45315R-18T-M MFPN 45063R-6T-M 45080R-8T-M 45100R-10T-M 45125R-13T-M 45160R-16T-M 45200R-18T-M 45250R-20T-M MFPN 45080R-5T 45100R-6T 45125R-7T 45160R-8T 45200R-10T 45250R-12T 45315R-14T MFPN 45080R-6T 45100R-8T 45125R-10T 45160R-12T 45200R-14T 45250R-16T 45315R-18T MFPN 45080R-8T 45100R-10T 45125R-13T 45160R-16T 45200R-18T 45250R-20T

● ● ● ● ● ● ● □

● ● ● ● ● ● ● □

● ● ● ● ● ● ●

øD

øD1

ød

ød1

ød2

H

E

a

b

4 5 6 7 8 10 12 14 5 6 8 10 12 14 16 18 6 8 10 13 16 18 20 5 6 7 8 10 12 14 6 8 10 12 14 16 18 8 10 13 16 18 20

63 80 100 125 160 200 250 315 63 80 100 125 160 200 250 315 63 80 100 125 160 200 250 80 100 125 160 200 250 315 80 100 125 160 200 250 315 80 100 125 160 200 250

76 93 113 138 173 213 263 328 76 93 113 138 173 213 263 328 76 93 113 138 173 213 263 93 113 138 173 213 263 328 93 113 138 173 213 263 328 93 113 138 173 213 263

22 27 32

19 22 48 58 68

11 13

40

21 24 30

6.3 7 8

10.4 12.4 14.4

32

9

16.4

40

14

25.7

21 24 30

6.3 7 8

10.4 12.4 14.4

32

9

16.4

40

14

25.7

21 24 30

6.3 7 8

10.4 12.4 14.4

32

9

16.4

40

14

25.7

27 32 36 38

6 8 10 11

9.5 12.7 15.9 19.1

40

14

25.4

27 32 36 38

6 8 10 11

9.5 12.7 15.9 19.1

40

14

25.4

27 32 36 38

6 8 10 11

9.5 12.7 15.9 19.1

40

14

25.4

40 60

110

22 27 32

19 22 48 58 68

40

66.7

11 13

66.7

19 22 48 58 68

11 13 66.7

60

110

101.6

25.4 31.75 38.1 50.8

22 48 58 72

13

47.625

110

25.4 31.75 38.1 50.8

22 48 58 72

25.4 31.75 38.1 50.8

22 48 58 72

47.625

110

50

80 40 50

63

50

63 101.6 13

80 50

101.6 13

63

50

63 101.6

※Dimension S: 6mm (GM, SM, GH Chipbreakers), 5mm (GL Chipbreaker), 3mm (W Chipbreaker: PR15 Series)

4

ød4

Fig.1 -

Fig.2

14

20

18

26

-

-

Fig.3 Fig.4 Fig.1 Fig.2

63

101.6

22 27 32

110

80 40

-

110

47.625

63

101.6

60

40

50

-

ød3

Shape

Dimension (mm)

No. of Insert

Fine pitch Fine pitch Extra fine pitch

Bore Dia. Inch spec

Coarse pitch

Extra fine pitch

Bore Dia. mm spec

Coarse pitch

Description

Standard

● Toolholder Dimension

18

26

-

-

-

-

Fig.3 Fig.4 Fig.1 Fig.2

14

20

18

26

Fig.3 Fig.1

-

-

Fig.2

18

26

Fig.3

-

-

Fig.4 Fig.1 Fig.2

18

26

Fig.3

-

-

Fig.4 Fig.1

●:Standard Item

Fig.2 Fig.3

Weight (kg)

0.5 1.1 1.4 2.6 3.8 6.4 9.1 21.3 0.5 1.0 1.4 2.5 3.8 6.5 9.1 21.7 0.5 1.1 1.3 2.6 3.9 6.6 9.3 1.1 1.4 2.6 4.0 6.7 9.4 21.2 1.1 1.4 2.7 4.0 6.9 9.6 21.5 1.1 1.3 2.7 4.0 6.9 9.6

Shim

Yes

-

-

Yes

-

-

:Check Availability □:Made to Order


Spare Parts

Spare parts from (mm/inch common spec) Spare Parts Wrench TT DTM

Clamp Screw Description

Shim

Shim Screw

Wrench

Anti-seize Compound

Arbar Clamp Screw

MP

-1

45063R-4T-M 45080R-5T-M 45100R-6T-M

SB-50140TR

SB-50140TR

SPW-7050

HH10x30 HH12x35

LW-5 MP-1

for Insert Clamp Recommended torque is 6.0 Nm.

HH10x30 HH12x35

TT-15 -

-

-

-

MP-1

for Insert Clamp Recommended torque is 4.2 Nm.

SB-40140TRN

-

HH10x30 HH12x35

DTM-15 -

-

-

MP-1

for Insert Clamp Recommended torque is 3.5 Nm.

~

Extra fine pitch

MFPN MFPN MFPN

45315R-18T-M 45063R-6T-M 45080R-8T-M 45100R-10T-M

MFPN-45 -

~

Fine pitch

MFPN MFPN MFPN

45315R-14T-M 45063R-5T-M 45080R-6T-M 45100R-8T-M

TT-15

for Insert Clamp Recommended torque is 4.2 Nm.

~

Coarse pitch

MFPN MFPN MFPN

-

45250R-20T-M -1

MP

Coat Anti-seize Compound (MP-1) thinly on portion of taper and thread when insert is fixed.

øD

øD1

ødh6

MFPN45 with cylindrical shank

S ℓ L

MFPN 45050R-S32-3T 45063R-S32-4T 45080R-S32-5T

No. of Insert

Description

Standard

● Toolholder Dimension

● ● ●

3 4 5

Dimension (mm)

Spare Parts

Rake Angle(°) Clamp Screw

øD

øD1

ød

L

S

A.R. R.R. (MAX)

50 63 80

63 76 93

32

110

30

6 (5)

-12° +10° -10° -8°

Wrench

Anti-seize Compound MP

-1

SB-50140TR

TT-15

Recommended torque is 4.2 N • m.

MP-1

※Dimension S: 6mm (GM, SM, GH Chipbreakers), 5mm (GL Chipbreaker), 3mm (W Chipbreaker: PR15 Series) -1

MP

Coat Anti-seize Compound (MP-1) thinly on portion of taper and thread when insert is fixed.

How to mount an insert

1. Be sure to remove dust and chips from the insert mounting pocket. 2. After applying anti-seize compound, while pressing the insert against the constraint surfaces, put the screw into the hole of the insert and tighten the screw with appropriate torque. See Fig. 1 and Fig. 2. 3. After tightening the screw, make sure that there is no clearance between the insert seat surface and the bearing surface of the holder and between the insert side surfaces and the constraint surface of the holder. 4. To change the cutting edge of the insert, turn the insert counterclockwise (see Fig. 3). Insert corner identification number is stamped on the top surface of insert (Fig. 4). To protect the wiper edge, use the corners of insert in the sequence of corner numbers.

Side surface of insert

Top surface of insert

Constraint surface

Insert corner identification number

5


Inserts Classification of usage

Steel

P

★:Roughing / 1st Choice

Die Steel

★:Roughing / 2nd Choice

M

■:Finishing / 1st Choice ■:Finishing / 2nd Choice

Ød

A

Z

X

Titanium alloy

★ ★

Hardened material

Heat-resistant Alloy

H

A

★ ★ ★

★ ★

T

ød

X

★ ★

MEGACOAT NANO carbide

Dimension (mm)

Description

Non-ferrous Material

S

Handled insert indicates Right-Hand

Nodular Cast Iron

N

Shape

Gray Cast Iron

K

(Hardened material is applicable only under 45HRC)

Stainless Steel

Z

MEGACOAT carbide

CVD Cermet carbide

PR1535 PR1525 PR1510 PR1225 PR1210 CA6535 TN100M

PNMU 1205ANER-GM

T

17.88 5.56 Ød

PNMU 1205ANER-GH 17.98 6.17 6.2

Z

X

2.0

PNMU 1205ANER-SM

Ød

A

General

2.0

T

A

Low cutting force

Z

X

T

Ød

PNEU 1205ANER-GL 17.51 5.56

2.7

2.7

Ød

A

Tough Edge

PNEU 1205ANER-W

17.51 5.56

2.3

8.1

Z X

High Precision

T 0

60

A

Z

X

T

2-edge Wiper Insert

● Reference for selecting a facemill and insert suitable for each milling purpose Facemill-type Milling Purpose

Coarse pitch

Fine pitch

Extra fine pitch

General milling of steel and alloy steel Steel and alloy steel (at chattering due to low rigidity machine or poor clamping power)

Productivity oriented (Running cost decrease)

GM

Stainless steel (at chattering due to low rigidity machine or poor clamping power)

GH

○ ○ ○

○ ○

Cast iron (for processing efficiency improvement)

Cast iron (Over ap=4 mm, over fz=0.35 mm/t)

SM

General milling of stainless steel

■ Improved

Chipbreaker

Surface Finish by Wiper Insert

Workpiece: 1.0040 Cutting Conditions: Vc = 200m/min (n=510min-1), fz = 0.2 mm/t (Vf=1,020mm/min), MFPN45125R-10T ap×ae = 3×100mm, DRY Chipbreaker Combination

Insert

Surface Finish

Workpiece Surface

Surface Finish

PR1525 (PNMU-GM…9) (PNEU-W…1)

Ra = 0.48μm Rz = 3.39μm

25μm

Wiper Insert

GL Chipbreaker

PR1225 (PNEU-GL…10)

Ra = 2.50μm Rz = 11.41μm

When the surface roughness is unstable, please set the cutting speed higher, the feed rate lower or use a wiper insert (TN100M).

6

1.5mm

GL

W


Recommended cutting condition

Chipbreaker

Vc (m/min) Recommended Insert Grade Workpiece Material

MEGACOAT NANO

fz (mm/t) PR1535

Alloy Steel

0.1∼0.2∼0.4

-

Mold Steel

0.1∼0.2∼0.35

-

Austenitic Stainless Steel

0.1∼0.2∼0.4

☆ 100∼150∼200

-

Martensitic Stainless Steel

0.1∼0.2∼0.4

-

-

-

☆ 180∼240∼300

Precipitation Hardened Stainless Steel

0.1∼0.2∼0.3

★ 90∼120∼150

-

-

-

0.1∼0.2∼0.4

-

-

-

-

-

-

-

0.1∼0.2∼0.4

-

-

Nodular Cast Iron

0.1∼0.2∼0.35

-

-

Ni-base Heat resistant Alloy

0.1∼0.12∼0.2

-

-

-

★ 20∼30∼50

Carbon Steel

0.06∼0.12∼0.25

-

-

0.06∼0.12∼0.25

-

☆ 120∼180∼250 ☆ 100∼160∼220 ☆ 80∼140∼180

-

Alloy Steel

-

-

0.06∼0.1∼0.2

-

Austenitic Stainless Steel

0.06∼0.12∼0.25

★ 100∼150∼200

Martensitic Stainless Steel

0.06∼0.12∼0.25

-

-

-

-

-

-

-

★ 180∼240∼300

Precipitation Hardened Stainless Steel

0.06∼0.12∼0.25

☆ 90∼120∼150

-

-

-

Gray Cast Iron

0.06∼0.12∼0.25

-

-

120∼180∼250

-

0.06∼0.1∼0.2

-

-

100∼150∼200

☆ 20∼30∼50

Ni-base Heat resistant Alloy

0.06∼0.1∼0.15

-

-

-

Titanium Alloy

0.06∼0.08∼0.15

★ 40∼60∼80

-

-

-

Carbon Steel

0.06∼0.12∼0.25

-

120∼180∼250

-

-

Alloy Steel

0.06∼0.12∼0.25

-

100∼160∼220

-

-

Mold Steel

0.06∼0.1∼0.2

-

80∼140∼180

-

-

Austenitic Stainless Steel

0.06∼0.12∼0.25

100∼150∼200

-

-

-

Martensitic Stainless Steel

0.06∼0.12∼0.25

-

-

180∼240∼300

Precipitation Hardened Stainless Steel

0.06∼0.12∼0.25

90∼120∼150

-

-

-

Gray Cast Iron

0.06∼0.12∼0.25

-

-

120∼180∼250

-

0.06∼0.1∼0.2

-

-

100∼150∼200

-

Nodular Cast Iron Ni-base Heat resistant Alloy

GH

-

Gray Cast Iron

Nodular Cast Iron

GL

-

★ 120∼180∼250 ★ 100∼150∼200

Mold Steel

SM

CA6535

★ 120∼180∼250 ★ 100∼160∼220 ★ 80∼140∼180

Carbon Steel

GM

CVD

PR1525 (PR1225) PR1510 (PR1210)

0.06∼0.1∼0.15

-

-

-

20∼30∼50

Titanium Alloy

0.06∼0.08∼0.15

40∼60∼80

-

-

-

Carbon Steel

0.2∼0.4∼0.7

-

120∼180∼250

-

-

Alloy Steel

0.2∼0.4∼0.6

-

-

-

Mold Steel

0.2∼0.35∼0.5

-

☆ 100∼160∼220 ☆ 80∼140∼180

-

-

0.2∼0.4∼0.7

-

-

0.2∼0.35∼0.5

-

-

Gray Cast Iron Nodular Cast Iron

☆ 120∼180∼250 ☆ 100∼150∼200 ★: 1st Recommendation ✩: 2nd Recommendation

Machining with coolant is recommended for Ni-base Heat Resistant Alloy and Titanium Alloy.

Case studies 42CrMo4

MFPN (PR1225)

Competitor B

1.4301/ X5CrNi18-10

120

202cc/min Chip evacuation rate

94cc/min Chip evacuation rate

•MFPN cutter improved machining efficiency 2.1 times of the Competitor B without changing spindle load. •MFPN cutter was very stable at the entrance and exit of the machining. It controls chatter and remains stable even with low rigid machine.

• Case • Vc=90m/min • ap x ae = 0.4x50mm • fz=0.19mm/t • Vf= 410mm/min • without coolant • MFPN45080R-6T (6 edges) • PNMU1205ANER-SM (PR1225)

MFPN (PR1225)

Competitor M

600

80 0

face milling

75

Construction machine part • Vc=250m/min • ap×ae=2~3 × 75mm • fz=0.15mm/t (Vf=900mm/min) • DRY • MFPN4580R-6T (6 edges) • PNMU1205ANER-SM (PR1225)

500

1.5 pcs/edge

1 pcs/edge

•Even when the cutting depth, cutting speed and feed rate cannot be raised due to the low rigidity of workpiece, MFPN facemill enables stable milling without chattering and also has an improved tool life of 1.5 times.

7


www.kyocera-unimerco.com

GERMANY KYOCERA UNIMERCO Tooling GmbH Hammfelddamm 6 · 41460 Neuss Phone +49 (0)2131 1637 115 Fax +49 (0)2131 1637 152 kutde@kyocera-unimerco.com ITALY KYOCERA UNIMERCO Tooling GmbH, Italy Branch Via Torino 51 · 20123 Milan Phone +39-02 00620 845 Fax +39-02 00620 848 kutde@kyocera-unimerco.com

DENMARK KYOCERA UNIMERCO Tooling A/S Drejervej 2 · DK-7451 Sunds Phone +45 97 14 14 11 Fax +45 97 14 14 86 umdk@unimerco.com

SPAIN KYOCERA UNIMERCO Tooling GmbH, Spain Branch Avenida Manacor 4 · 28290 Las Matas, Madrid Phone +34-91-631-83-92-802 Fax +34-91-631-82-19 kutde@kyocera-unimerco.com

NORWAY KYOCERA UNIMERCO Tooling A/S Karihaugveien 89 · 1086 Oslo Phone +47 22 72 06 02 Fax +47 22 30 92 20 umno@unimerco.com

POLAND KYOCERA UNIMERCO Tooling Sp. z o.o. ul. Gwiaździsta 66, 53-413 Wrocław Phone (+48) 71 381 12 15 Fax (+48) 71 381 12 16 kutde@kyocera-unimerco.com

SWEDEN KYOCERA UNIMERCO Tooling AB Sagaholmsvägen 9 · 553 02 Jönköping Phone +46 036-34 46 00 Fax +46 036-31 32 00 umse@unimerco.com

FRANCE KYOCERA Fineceramics S.A.S. 21 Rue de Villeneuve · 94583 Rungis Phone +33 (0) 1 41 73 73 40 Fax +33 (0) 1 56 72 18 94 kutde@kyocera-unimerco.com

UNITED KINGDOM KYOCERA UNIMERCO Tooling Ltd. 101 Attercliffe Road · Sheffield S4 7WW Phone +44 (0)1142 788787 Fax +44 (0)1142 757155 uksales@unimerco.com

DISTRIBUYE:

HERCOIN RIBERA DE AXPE 11 - D1 48950 ERANDIO (VIZCAYA) Tlf.: 94 463 4761, FAX: 94 463 2399 www.hercoin.com, hercoin@hercoin.com

TZE00054

KYOCERA MFPN Face Mill  

High efficient milling cutter with double sided inserts

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