Issuu on Google+

KYOCERA UNIMERCO

MRW Face Mill

High efficient cutter with double sided round insert


The MRW Radius Cutter lowers cutting costs The new cutter lowers cutting costs and increases efficiency due to economical 8-edges per insert. Combining sharpness and cutting edge strength to this geometry makes it applicabale to a wide variety of applicaton by improving the milling performances. The double-sided inserts improve milling in a wide variety of materials.

sharp cutting edge

L w cu Low Lo cutt cutting ttin tt ing ing ng forc ffo force orrc rce e chipbreaker

Flat Lock Structure Holds the insert firmly and prevents rotation of the insert during machining and provides stable machining.

Wide flat binding face • Receives cutting forces evenly • Prevents insert rotation

g tin ut ce C or F

Wide flat contact face

Waved cutting edge design Maximum axial rake 12° lowers cutting forces equivalent to positive type inserts.

A. R. Max.+12°

Cutting Force [N]

800 700

Positive type

Anti chattering

Negative type

118%

600 500

140%

108% 100%

Cutting conditions: Workpiece: 1.4301, Vc=120m/min, fz=0.2mm/t, apxae=1x40 mm, Cutter 0 50

400 300 MRW(SM chipbreaker) Competitor A

2

Competitor B

Competitor C


NEW

Wide range of applications from steel to difficult-to-cut materials CA6535 for difficult-to-cut materials (CVD) PR1535 for stainless steel (PVD)

TiN

High efficient machining of Ni-base heat resistant alloy and martensitic stainless steel can be done easily offering high heat resistance and wear resistance by CVD coating and improved stability due to the thin film coating technology.

Smooth & less adhesion

Îą -Al2 O3 Oxidation and wear resistant

Special Interlayer Prevent peeling of coating layer

CA6535

TiCN Frictional wear resistant

Layer structure of

For titanium alloy and precipitation hardened stainless steel. Stabilized milling operation and long tool life with MEGACOAT NANO coating technology.

MEGACOAT

PR1535

Longer tool life

Longer tool life with a wide lineup including 4 grades and 3 chipbreakers! Available for steel, stainless steel, and heat resistant alloys Workpiece

Insert Grade

Applicable Chipbreaker

P Carbon Steel / Alloy Steel / Die Steel

PR1525

GM/SM/GH Chipbreaker

K Gray Cast Iron / Nodular Cast Iron

PR1510

GH/GM Chipbreaker

CA6535

SM/GM Chipbreaker

PR1535

SM/GM Chipbreaker

S Ni-base Heat Resistant Alloy

M Martensitic Stainless Steel M Austenitic Stainless Steel

S Titanium Alloy

M Precipitation Hardened Stainless Steel

For Chipbreaker Selection and Recommended Cutting Conditions

P7

Comparison of tool life Ni-base Heat Resistant Alloy

Martensitic Stainless Steel 0.40

Competitor B(CVD)

0.35

0.35

0.30

0.30

Fracture

Wear [mm]

Wear [mm]

0.40

0.25 0.20

KYOCERA CA6535 GM

Competitor A(CVD)

0.15

Competitor A(CVD) Competitor B(CVD)

0.25 0.20 0.15

0.10

0.10

0.05

0.05

KYOCERA CA6535 SM

0.00

0.00 0

5

10

15

20

25

Cutting Time [min] Cutting Conditions: Vc=50m/min, ap=1.0mm, fz=0.15mm/t, WET

1st recommendation GM chipbreaker

0

5

10

15

20

25

Cutting Time [min] Cutting Conditions: Vc=300m/min, ap=2.0mm, fz=0.2mm/t, WET

1st recommendation SM chipbreaker

3


MRW Face Mill (with coolant hole) ØD1 Ød

ØD1 Ød b

S

S

H

H

E

E

a

a

b

Ød2

Ød1

Ød1

ØD

ØD

Fig.1

Fig.2

Inch

Metric

MRW 050R-12-5T-M 050R-12-6T-M 063R-12-6T-M 063R-12-7T-M 080R-12-6T-M 080R-12-8T-M 100R-12-7T-M 100R-12-9T-M MRW 063R-16-5T-M 063R-16-6T-M 080R-16-6T-M 080R-16-7T-M 100R-16-6T-M 100R-16-8T-M 125R-16-8T-M 125R-16-10T-M MRW 080R-12-6T 080R-12-8T 100R-12-7T 100R-12-9T MRW 080R-16-6T 080R-16-7T 100R-16-6T 100R-16-8T 125R-16-8T 125R-16-10T

● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

Ød1 Ød2

50

18

48

11

22 63

60

H

40

E

21

a

b

S

A.R. R.R.

6.3 10.4

19

Fig.1

6.0 +12° -15.5°

6 80

70

27

20

13

24

7

12.4

30

8

14.4

50 100

78

32

46

-

63

60

22

19

11

40

21

Fig.2

6.3 10.4 Fig.1

80

70

27

20

13

24

7

12.4

50

8 100

78

32

46

8.0 +11° -16.5° 30

8

Yes

14.4

125

89

40

55

80

70

25.4

20

Fig.2

63 13

33

9

16.4

27

6

9.5

50

6 100

78 31.75 46

80

70

25.4

20

13

Fig.1

6.0 +12° -15.5° 34

8

12.7

Fig.2

27

6

9.5

Fig.1

34

8

12.7 8.0 +11° -16.5°

50 8

100

78 31.75 46 -

125

89

38.1

55

Fig.2

63

38

10

15.9

Weight(kg)

ØD ØD1 Ød

Drawing

rε 5 6 6 7 6 8 7 9 5 6 6 7 6 8 8 10 6 8 7 9 6 7 6 8 8 10

Rake Angle (° )

Dimension (mm)

Coolant Hole

Description

No. of Inserts

Standard

● Toolholder Dimension Max. Revolution (min-1)

0.3 0.3 0.6 0.6 1.1 1.1 1.5 1.4 0.5 0.5 1.1 1.0 1.4 1.3 2.6 2.5 1.2 1.1 1.5 1.4 1.1 1.1 1.4 1.4 2.6 2.6

16,000 14,000 12,000 10,600 12,800 11,000 9,600 8,560 12,000 10,600 11,000 9,600 8,560 ●:Standard Item

● Spare Parts and Applicable Inserts ●

Clamp Screw

Wrench

Anti-seize Compound

Mounting Bolt

Description DTPM-15

TTP-20

MRW 050R-12... SB-4085TRP DTPM-15 063R-12... Recommended Torque 080R-12... for Insert Clamp 3.5Nm 100R-12... MRW 063R-16... SB-50140TRP TTP-20 080R-16... Recommended Torque 100R-16... for Insert Clamp 4.5Nm 125R-16...

Applicable Inserts

MP-1

HH12x35 HH10x30 HH12x35

ROMU12…

ROMU16…

Recommended Cutting Conditions

4

When running an endmill or a cutter at the maximum revolution, the insert or cutter may be damaged by centrifugal force.

HH10x30 MP-1

Caution with Max. Revolution

P7

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

S is Maxmum ap. For more details, see page 7.


Ød

ØD

Ød

ØD

h6

MRW End Mill (with coolant hole) h6

S

S

Fig.3

Ød

ØD

Ød

ØD

h6

L

Fig.1

h6

L

S

S

ℓ L

L

Fig.2

Fig.4

Standard (Weldon)

Long Shank (Cylindrical)

3

ØD 32

6

Ød 32

Rake Angle (° )

L

140

40

S

A.R. (MAX)

6.0

+12°

R.R. -20°

40-S32-12-4T

4

160

40

50-S42-12-5T

5

50

42

170

40

-15.5°

MRW 40-S32-16-3T

3

40

32

160

40

-18°

50-S42-16-4T

4

63-S42-16-5T

5

63

MRW 32-S32-12-2T-200

2

32

40-S32-12-3T-200

40

Coolant Hole

Dimension (mm)

-16.5°

Drawing

MRW 32-S32-12-3T

No. of Inserts

Standard (Cylindrical)

Description

Standard

● Toolholder Dimension Max. Revolution (min-1)

Fig.1

22,000

Yes

18,800 Fig.2

8

50

6

3

42

32

40

8.0

+11°

170

40

170

50

-16.5°

200

40

-20°

200

40

6.0

+12°

-16.5°

-16.5°

16,000 17,200 Yes

Fig.2

14,800 12,800

Fig.1

Yes

22,000 18,800

Fig.2

50-S42-12-4T-300

4

50

42

300

40

-15.5°

16,000

MRW 40-S32-16-2T-200

2

40

32

200

40

-18°

17,200

50-S42-16-3T-300

3

63-S42-16-4T-300

4

63

3

32

MRW 32-W32-12-3T 40-W32-12-4T

4

50-W40-12-5T

5

MRW 40-W32-16-3T

3

50-W40-16-4T

4

63-W40-16-5T

8

50

6

42

32

40

8.0

+11°

300

40

300

50

-16.5°

102

40

-20°

100

40

50

40

110

40

40

32

100

40

110

40

120

50

6.0

+12°

-16.5°

-16.5°

Yes

Fig.2

14,800 12,800

Fig.3

Yes

22,000 18,800

Fig.4

8

50

5

63

40

-15.5°

16,000

-18° 8.0

+11°

-16.5° -16.5°

17,200 Yes

Fig.4

14,800 12,800 ●:Standard Item

● Spare Parts and Applicable Inserts ●

Clamp Screw

Anti-seize Compound

Wrench

Description DTPM-15

SB-4085TRP MRW ■■■ -12...

When running an endmill or a cutter at the maximum revolution, the insert or cutter may be damaged by centrifugal force.

Applicable Inserts

DTPM-15

Recommended Torque for Insert Clamp 3.5Nm

SB-50140TRP MRW ■■■ -16...

TTP-20

Caution with Max. Revolution

MP-1

ROMU12…

MP-1

ROMU16…

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

S is Maxmum ap. For more details, see page 7.

TTP-20

Recommended Torque for Insert Clamp 4.5Nm

Recommended Cutting Conditions

P7

5


Classification of Usage

Carbon Steel / Alloy Steel

P

Die Steel

★ ★ ★

Austenitic Stainless Steel

M

★: Roughing / 1st Choice ★: Roughing / 2nd Choice ■: Finishing / 1st Choice ■: Finishing / 2nd Choice (In case hardness is under 45 HRC)

Martensitic Stainless Steel Precipitation Hardened Stainless Steel

★ ★

Nodular Cast Iron

★ ★

Ni-base Heat Resistant Alloy

S

Titanium Alloy

H

General Purpose

Gray Cast Iron

K

Insert

★ ★ ★

★ ★ ★

Hard Materials

MEGACOAT NANO

Dimension (mm)

Description

CVD coated carbide

T

Ød

W

ROMU 1204M0ER-GM

12

4.75

4.6

11.8

6

1605M0ER-GM

16

5.48

6.2

15.8

8

ROMU 1204M0ER-SM

12

4.75

4.6

11.8

6

PR1535 PR1525 PR1510 CA6535

A

Ø

● P3 P4

Ød

W

ØA

Applicable Holder Reference Page

Inserts

1605M0ER-SM

16

5.48

6.2

15.8

8

ROMU 1204M0ER-GH

12

4.75

4.6

11.8

6

1605M0ER-GH

16

5.48

6.2

15.8

8

T

Low Cutting force

Tough Edge (Heavy Milling)

●:Standard Item

How to mount an insert

1.

Be sure to remove dust and chips from the insert mounting pocket.

2.

Apply anti-seize compound on portion of taper and thread of clamp screw. Attach the screw to the front end of the wrench. While lightly pressing the insert against the constraint surfaces, put the screw into the hole of the insert and tighten. (See Fig. 1)

3.

Wrench and clamp screws are "Torx Plus". Fig. 2 wrench is for MRW-12. Fig. 3 wrench is for MRW-16. For recommended torque, see page 4 and 5.

4.

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.

Wrench Clamp Screw

Fig.3

Fig.2

Fig.1

Fig.4

15IP

Torx Plus

15IP for MRW-12

T15

Torx Plus

20IP for MRW-16

Do NOT use T15 for MRW

Case studies

12Cr Steel

12Cr Steel Turbine Blade Vc=270m/min, fz=0.278mm/t ap=0.5~1.0mm, ae=max35mm, Dry MRW050R-12-6T-M (6 inserts), ROMU1204M0ER-SM (CA6535)

1.2 x increased machining efficiency

Turbine Blade Vc=250m/min fz=0.16mm/t ap=2.0mm ae=5x30mm, Wet MRW050R-12-5T-M (5 inserts) ROMU1204M0ER-SM (CA6535)

Same or longer tool life

CA6535

Stable Machining

CA6535

Stable Machining

Competitor A Positive Type

Unstable Machining

Competitor B Positive Type

Unstable Machining

MRW improved machining efficiency 1.2 times with same tool life compared to Competitor A. MRW has a cost advantage due to double sided inserts.

6

Torx Plus

MRW showed less damage on the cutting edge with reduced cutting noise. MRW has equal or longer tool life and cost advantage due to double sided inserts.


Recommended Cutting Conditions Recommended Insert Grade(Vc m/min)

Recommended Chipbreaker (fz mm/t)

Workpiece Material

Recommended feed rate (standard value) for ROMU12: ap=3mm, ROMU16: ap=4mm

CVD coated carbide

MEGACOAT NANO

GM

SM

GH

PR1525

PR1510

PR1535

CA6535

Carbon Steel

★ 0.1~0.2~0.3

★ 0.06~0.15~0.2

★ 0.15~0.3~0.35

★ 120~180~250

-

-

-

Alloy Steel

★ 0.1~0.2~0.3

★ 0.06~0.15~0.2

★ 0.15~0.3~0.35

★ 100~160~220

-

-

-

Die Steel

★ 0.1~0.15~0.25

★ 0.06~0.12~0.2

★ 0.15~0.2~0.3

★ 80~140~180

-

-

-

Austenitic Stainless Steel

★ 0.1~0.15~0.2

★ 0.06~0.12~0.2

-

★ 100~160~200

-

★ 100~160~200

-

Martensitic Stainless Steel

★ 0.1~0.15~0.2

★ 0.06~0.12~0.2

-

-

-

★ 150~200~250

★ 180~240~300

Precipitation Hardened Stainless Steel

★ 0.1~0.15~0.2

★ 0.06~0.12~0.2

-

-

-

★ 90~120~150

-

Gray Cast Iron

★ 0.1~0.2~0.3

-

★ 0.15~0.3~0.35

-

★ 120~180~250

-

-

Nodular Cast Iron

★ 0.1~0.15~0.25

-

★ 0.15~0.2~0.3

-

★ 100~150~200

-

-

Ni-base Heat Resistant Alloy

★ 0.1~0.12~0.15

★ 0.06~0.1~0.15

-

-

-

★ 20~30~50

★ 20~30~50

Titanium Alloy

★ 0.1~0.12~0.15

★ 0.06~0.1~0.15

-

-

★ 30~50~70

★ 40~60~80

-

★: 1st recommendation ★: 2nd recommendation * Machining with coolant is recommended for Ni-base Heat Resistant Alloy and Titanium Alloy. * Adjust the cutting speed and the feed rate within the above conditions according to the actual machining situation. * Recommended feed rate is the reference value when ap is rε/2 (3mm for ROMU12, 4mm for ROMU16). For lower feed rates than the above conditions, the conversion factor in the following table is recommended.

Conversion factor for feed per tooth by depth of cut (ap) ap (recommended)

Insert

ap (max)

Conversion factor for feed per tooth ap=1mm ap=2mm ap=3mm

ap=0.5mm

ROMU12 type

3mm or less

6mm

2.1

1.5

1.1

ROMU16 type

4mm or less

8mm

2.4

1.7

1.3

1.0 (Standard)

1.1

ap=4mm – 1.0 (Standard)

Example (ROMU12 type, Carbon Steel, GM chipbreaker, ap=1mm) Recommended feed/tooth: 0.2mm/t (standard value for Carbon Steel / GM chipbreaker) x 1.5 (Conversion factor for ROMU12 / ap=1mm)=0.3mm/t

* Recommended ap: 3mm or less for ROMU12, 4mm or less for ROMU16

Corner R shape during processing

Gap between insert corner R

Corner R shape during processing with MRW (see Fig.)

Insert

ap (max)

X

Y

ROMU12 type

6mm

3mm

0.1mm

ROMU16 type

8mm

4mm

0.1mm

Insert corner

Recommended ap

Maximum depth of cut

* When machining with larger ap than recommended ap (X), there is a gap (Y) between the workpiece corner and insert corner R (rε). * The above figure is an estimation. There is a ±0.2mm variation depending on the cutting conditions.

Application

Facing

Shouldering

Contouring

Plunging / Profiling

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

TZE00055


KYOCERA MRW Face Mill