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PRODUCT NEWS No. 301

NEW PRODUCT

AL- OCHE One-Cut Helical End Mill Helical Interpolation

Spot Facing

Drilling

High efficient hole making end mill for Aluminum

DIJET INDUSTRIAL CO., LTD.

Sholder Milling

Slotting


One-Cut Helical End Mill Feature of product

One-Cut Helical can achieved: ࡮Intensive tool management ࡮High efficient machining

1

For Aluminum

Helical through coolant holes

2

Wider pocket for better chip evacuation.

The helical coolant holes along the flute was adopted. Excellent chip evacuation by using coolant through the tool.

3

Helix

4

30° for better surface finishing on holes shoulder.

6

Pocket

Cutting edge

The high efficient machining was achieved by devising original geometry.

New developed coating

Adopted new developed coating ''JC 20015'' to prevent the chip welding problem.

5

Tool surface

Lapping surface finishing on the tool's cutting edges, substrate is K 10 carbide.

The high efficient hole making that equaled a drill processing was achieved by having enabled farther deep helical milling depth H per revolution so far.

Newly developed cooting "JC 20015" By improving the hardness and lubricating compared with conventional coating,achieved excellent chip evacuation and longer tool life on aluminum machining by high helical milling.

JC 20015

High hardness and lubricating

Hardness㧔Hv 㧕

New machining method

3000

TiAIN TiCN TiN

2000 Lapping surface on K10 carbide

H

0.1

0.5

0.9

Coefficient of friction 㧔Ǵ㧕

Chip removal productivity Chip evacuation comparison between One-Cut Helical and Conventional end mill on AC4B machining. ‫ ع‬Type of machining Conventional end mill

After 3 holes, chips are welded and jammed.

After 20 m, no chips are welded and jammed. Excellent chip ejection!

ǾDc

H

ǾD

1

‫ع‬Cutting conditon

One-Cut Helical

Material Dc D Hole depth Vc f H Helical interpolation depth/tool path rev Internal coolant

㧦AC4B 㧦ø 8 㧦ø 10 㧦30mm 㧦200m/min 㧦0,25mm/rev 㧦4,65mm :H


Improved machining method Comparison between helical milling vs drilling Improved method:by high efficient helical milling

Current method: by Drilling ٨ The tool reduction is a problem because the tool for the hole making is use of a small amount of many varieties. ٨ Time hangs in the tool exchange to make various holes.

Ô™

ø10

ø10

Tool exchange

Tool exchange

Ô˜

No tool exchange!

ø12.5

ø12.5

30হ

㧌ø10‍ޔ‏ø12.5‍ޔ‏ø15㧔3 drills㧕 㧌120m/min 㧌0.2mm/rev

ø8

ø15

ø15

30হ

Material Hole depth Internal coolant

ø8

ø10

30হ

ĚŞ1 each hole making

Cutting conditon by Current 3 drills Tool dia. Vc f

٨ This problem is solved by doing the original developed helical milling method by using One-Cut Helical.

ø8

ø12.5

30হ

30হ

ø15

30হ

ĚŞ1 each hole making

Cutting conditon by One-Cut Helical

㧌AC4B 㧌30mm

Tool dia.㧌ø8 AL-OCHES2080 H㧌Helical interpolation depth/tool path rev. Vc 㧌200m/min Hole dia. D㧊10mm ĎˆH㧊4.65mm Hole dia. D㧊12.5mmĎˆ H㧊8.81mm f 㧌0.25mm/rev Hole dia. D㧊15mm ĎˆH㧊10.99mm

Material 㧌AC4B Hole depth 㧌30mm Internal coolant

㧔Drilling by same cutting condition 㧕

Total machining time: 10.4 sec.

One-Cut Helical





Ô˜ Reduced total machining time 8.5 sec. 45% reduction. ‍ޓޓ‏ Ô™ Reduced the no. of use tools from 3 pcs to 1 pc. ‍ޓޓ‏



Total machining time: 18.9 sec.

‍ؚ‏Hole size: ø10

Drilling by 3 Drills











‍ؚ‏Hole size: ø12.5 ‍ؚ‏Hole size: ø15





  Machining time㧔sec.㧕



‍ؚ‏Tool changing time

Applicable hole range by each end mills ‍ؚ‏Applicable hole range by each endmills

‍ؚ‏Helical milling by ‍ޓ‏Tool dia. 8mm.

ø12 ø11.5

ø13



ø13.5



ø14

ø11 ø14.5 ø10.5 ø10

ø15

Tool dia.㧔mm㧕

ø12.5

    











      Applicable hole range㧔mm㧕











Wide range with only one tool

22


One-Cut Helical End Mill Cutting performance

‫ޓ‬Ԙ Helical milling Cutting condition Material Dc D Hole depth

㧦AC4B 㧦8mm 㧦10mm 㧦30mm

Vc n f Vf

㧦201m/min 㧦8,000min-1 㧦0.25mm/rev 㧦2,000mm/min

ǾDc

Helical interpolation depth/ tool path rev H: 4.65 mm. Machining time by 1hole :

H

2.2 sec.

Machining time 2.2 sec.

Internal coolant

ǾD

Result: Cutting length and VBmax ‫ع‬After 22.4m

0.200

VBmax: 0.074mm Normal wear

VBmax㧔mm㧕

0.160

0.120

Able to continue

0.080 0.074 0.040

After 22.4 m cutting length with H㧩4.65mm tool wear was normal VB max: 0.074

0.000 0

5

10 15 Cutting length㧔m㧕

20

22.4

25

Result: Cutting length and Cylindricity ‫ع‬Cylindricity㧩㧔Dmax㧙Dmin㧕

0.050

max

Cylindricity㧔mm㧕

0.040 Cylindricity: 0.02mm Cutting length 22.4m

0.030

min

0.020

0.010

0.000

0

5

10 15 Cutting length㧔m㧕

20 22.4

25

After 22.4 m cutting length the hole cylindricity is 0.02 mm.

Result: Cutting length and Surface roughness 6.00

㧔mm㧕

Surface roughness Rz 㧔Ǵm㧕

10.0

Rz: 2.94Ǵm Cutting length 22.4m

5.00

5.0 0.0

4.00

-5.0 -10.0

3.00

0.5

1.0

1.5

2.0

2.5

3.0

2.00 1.00 0.00 0

3

0.0

5

10 15 Cutting length㧔m㧕

20 22.4

25

After 22.4 m cutting length surface roughness Rz㧩2.94Ǵm.

3.5

4.0 㧔mm㧕


‫ޓ‬ԙ Spot facing Machining process Starting from hole ø 31mm. tool ø 16 mm. enlarge hole ø 45 with first helical milling. Make Spot facing ø 67 mm. by second helical milling 33mm. deep. Flood coolant

Internal coolant

Helical milling

Water soluble㧦2㨪3% dilution

Coolant pressure㧦1.5MPa

Cast aluminum alloy

Enlarge hole

Spot facing

㧔AC4B㧕

㧔ø31ψø45߳㧕

㧔ø45ψø67߳㧕

Through hole

ø67 ø45 ø31

ø31 Through hole making by helical interpolation.

Tool dia. 㧔mm㧕

16

V㧔m㧛min㧕 c

200

㧔 n min -1㧕

4,000

㧔mm㧛rev㧕 f

0.25

V㧔mm㧛min㧕 f

1,000

Max. helical interpolation depth/ tool path rev:H 㧔mm㧕

13 㧔on Spot facing 10mm㧕

㧞 33

ø45

Enlarge the hole by helical interpolation.

Spot facing by helical & circular interpolations.

Power consumption and machining time UGE

Ǿ Ǿ ⽾ㅢⓣ 31 ⽾ㅢⓣടᎿᤨ Through ടᎿᤨhole Through 㧦3.03 hole㧦M9 M9 kW

Spot ࠩࠣ࡝ടᎿᤨ facing Spot 㧦1.77kW facing㧦M9 M9

M9

Ǿ Ǿ ➅ࠅᐢߍ 45 ➅ࠅᐢߍടᎿᤨ Enlarge ടᎿᤨ Enlarge hole hole

Tool ø16 make full operation bore ø 45mm. and spot facing in 135 seconds. Through hole ø 31mm. power require 3.03 Kw. enlarge the hole at ø 45 mm. total machining time 67 seconds. Spot facing with the same tool from ø 45 to Ø 67 machining time 68 seconds.

Through hole making time 67sec

Spot facing time 68sec

Total machining time㧦 135sec

Result Y

Tool dia.㧦16mm

X

Input dia. of spot facing (d)

67㧔X㧕

67㧔Y㧕

Actual diameter (A)

66.990

66.974

Actual diameter (B)

66.993

66.982

66.992

66.986

Actual diameter (C) ǾA

Inclination (max-min)

0.019 mm 㧔66.993㧙66.974㧩0.019㧕

ǾB ǾC

4


One-Cut Helical End Mill Line up ‫ޓ‬One-Cut Helical End Mill

ø Ds h6

‫ޓޓ‬0 ø Dc 㧙0.02

AL- OCHE type

N

R0.5

Cat. No.

L

Dimensions㧔㨙㨙㧕 øD c

l

L

øDs

AL-OCHES2040

4

16

60

4

AL-OCHES2060

6

22

74

6

AL-OCHES2080

8

31

90

8

AL-OCHES2100

10

37

105

10

AL-OCHES2120

12

43

113

12

AL-OCHES2160

16

55

130

16

Recommended cutting conditions ‫ޓ‬Helical milling Aluminum alloy 㧔A5052‫ޔ‬A7075㧕

Materials

øDc H

tool path dia. Helical interpolation depth/ tool path rev D㧔mm㧕 k H㧔mm㧕

Depth T㧔mm㧕

4

5㨪7

max 15

16,000

960

6

7㨪11

max 21

10,600

1,060

1

8

10㨪15

max 30

8,000

2,000

2

5

10

12㨪19

max 36

6,400

1,600

3

6.4

12

14㨪23

max 42

5,300

1,300

4

7.4

16

18㨪31

max 54

4,000

1,000

5

8.2

6

8.8

7

9.4

Cast aluminum alloy 㧔Up to 13% Si 㧕

Materials

2.6

8

9.8

9

10.2

860

10

10.6

950

11

11

7,200

1,800

12

11.3

5,700

1,400

13

11.5 11.8 12

Hole dia. D㧔mm㧕

Depth T㧔mm㧕

4

5㨪7

max 15

14,400

6

7㨪11

max 21

9,500

8

10㨪15

max 30

10

12㨪19

max 36

Tool dia. D㧔 c mm㧕

øD

Spindle speed Feed speed V f㧔mm/min㧕 n㧔min-1㧕

Hole dia. D㧔mm㧕

Tool dia. D㧔 c mm㧕

Spindle speed Feed speed n㧔min-1㧕 V f㧔mm/min㧕

12

14㨪23

max 42

4,800

1,200

14

16

18㨪31

max 54

3,600

900

15

NOTE 1㧚Tool path dia.: Dk㧩Hole dia. D࡯Tool dia. Dc. 2㧚In case of blind hole, last revolution of H reduce to 0.8-2.0mm. 3㧚In case of through hole, top of tool must come off by 1mm or more because tool has R0.5mm corner radius. 4㧚In case of requring the hole accuracy, after making a little small bore(a e=0.03mm) by helical interpolation, enlarged bore by full depth circular interpolation with 20% reduced speed and feed speed. 5㧚Use internal coolant. 6㧚Above data applys for from solid work.In case of enlarging hole from pre-hole, apply same conditions.In this case, a e should be 75% of Dc or less. also in case of machining from pre-hole and casting hole, recommend to use flood coolant,too. 7㧚 In case of lack of machine & work rigidity and also chattering, reduce speed and feed with same ratio or H.

5


Recommended cutting conditions ‫ޓ‬Shoulder cutting and Slotting Ԙ Shoulder cutting Materials

ԙ Slotting

Aluminum alloy

Aluminum alloy

㧔A5052㧕

㧔A7075㧕

ae Type of machining

ae

ap a p =1.5D c a e =0.4D c

Cast aluminum alloy (Up to 13% Si)

Materials

ap

a p =1.5D c a e =0.4D c

Aluminum alloy

㧔A5052㧕

㧔A7075㧕

ae

ae

ap

Aluminum alloy

ae

Type of machining

a p =1.5D c a e =0.4D c

Cast aluminum alloy (Up to 13% Si)

ae

ap a p =D c a e =D c

ap a p =D c a e =D c

ap a p =D c a e =D c

Tool dia.

Spindle speed Feed speed Spindle speed Feed speed Spindle speed Feed speed

Tool dia.

Spindle speed Feed speed Spindle speed Feed speed Spindle speed Feed speed

Dc 㧔mm㧕

n Vf n Vf n Vf 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕

Dc 㧔mm㧕

n Vf n Vf n Vf 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕

4

16,000

1,800

16,000

1,800

14,000

1,700

4

14,000

1,000

14,000

1,000

12,000

850

6

10,000

1,800

10,000

1,800

9,500

1,700

6

9,500

1,000

9,500

1,000

8,500

850

8

8,000

1,600

8,000

1,600

7,000

1,500

8

7,000

1,000

7,000

1,000

6,400

850

10

6,000

1,300

6,000

1,300

5,700

1,200

10

5,700

1,000

5,700

1,000

5,000

850

12

5,000

1,300

5,000

1,300

4,700

1,200

12

4,700

1,000

4,700

1,000

4,200

850

16

4,000

1,200

4,000

1,200

3,500

1,100

16

3,500

1,000

3,500

1,000

3,200

850

H.S.C. Recommended cutting conditions ‫ ޓ‬Shoulder cutting and Slotting Ԙ Shoulder cutting Materials

ԙ Slotting

Aluminum alloy

Aluminum alloy

㧔A5052㧕

㧔A7075㧕

ae

ae

ap

Type of machining

a p D c a e D c

Cast aluminum alloy (Up to 13% Si)

ap

Aluminum alloy

Aluminum alloy

㧔A5052㧕

㧔A7075㧕

ae

ae

ap a p D c a e D c

Materials

ae

Type of machining

a p D c a e D c

Cast aluminum alloy (Up to 13% Si)

ae

ap a p D c a e D c

ap a p D c a e D c

ap a p D c a e D c

Tool dia.

Spindle speed Feed speed Spindle speed Feed speed Spindle speed Feed speed

Tool dia.

Spindle speed Feed speed Spindle speed Feed speed Spindle speed Feed speed

Dc 㧔mm㧕

n Vf n Vf n Vf 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕

Dc 㧔mm㧕

n Vf n Vf n Vf 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕

4

32,000

3,800

32,000

3,800

28,000

3,300

4

28,000

1,900

28,000

1,900

24,000

1,600

6

21,000

3,800

21,000

3,800

18,000

3,300

6

19,000

1,900

19,000

1,900

16,000

1,600

8

16,000

3,200

16,000

3,200

14,000

3,300

8

14,000

1,900

14,000

1,900

12,000

1,600

10

12,000

3,200

12,000

3,200

11,000

3,000

10

11,000

1,900

11,000

1,900

9,500

1,600

12

10,000

3,200

10,000

3,200

9,000

2,700

12

9,500

1,900

9,500

1,900

8,000

1,600

16

8,000

2,800

8,000

2,800

7,000

2,450

16

7,000

1,800

7,000

1,800

6,000

1,600

Note: 1. Use water soluble oil. 2. It is important for grasping the shank to defend and keep proper grasping length. The figures to be adjusted according to machining shape, rigidity of machine and work clamping. 3. If machine does not have enough spindle speed, recommend to reduce the feed speed to the same ratio. 4. Full slotting is not recommended. But in case of working, reduce depth of cut up to 0.2D and reduce the feed speed 30 to 60% above data.

6


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