TQ Chipbreaker NEW. Increase Productivity with Improved Chip Control. Threading Insert with Molded Chipbreaker

Transcription

1 hreading with Molded Chipbreaker hreading with Molded Chipbreaker Increase Productivity with Improved Chip Control table Chip Control Low Cutting orce and uppressed Vibration Improved ool Life with New Grades NEW

2 hreading with Molded Chipbreaker Increase Productivity with Improved Chip Control Improved ool Life with New Grades 1 table Chip Control table Chip Control with symmetric Chipbreaker Design Chipbreaker Geometry table chip control regardless of cutting direction Chip Control Performance (Internal Evaluation) Radial Infeed Competitor lank Compound Infeed or Radial Infeed symmetric dot design controls chip-flow direction or lank Infeed / lank Compound Infeed Breaks chips easily with shallow breaker depth 3 ~ 5 Competitor Cutting Conditions: Vc = 150 m/min, ap = 0.12 mm (4th Pass), L = 25 mm, Wet, 16ER150IO ype M45 P1.5 Workpiece: CM415 2 Low Cutting orce and Resists Vibration trong Edge and Low Cutting orce Comparison of Cutting orce Radial Infeed (Internal Evaluation) 600 Cutting orce Comparison lank Compound Infeed (Internal Evaluation) 600 Cutting orce (N) % DOWN Cutting orce (N) % DOWN Conventional (Without Molded Chipbreaker) Cutting Conditions: Vc = 150 m/min, Wet, 16ER150IO ype Cutting orce hows the verage of 6 Passes, M35 P1.5 Workpiece: CM415 Competitor (With Molded Chipbreaker) 0 Conventional (Without Molded Chipbreaker) Competitor (With Molded Chipbreaker) Cutting Conditions: Vc= 150 m/min, djusted ngle: 5 Degrees, Wet, 16ER150IO ype Cutting orce hows the verage of 6 Passes, M35 P1.5 Workpiece: CM415 1

3 3 Improved ool Life with New Grades or teel Machining PR1215 or tainless teel Machining PR1515 (irst Recommendation) PR1535 (tability ocused) Wear Resistance Comparison (Internal Evaluation) Workpiece: CM435 Workpiece: U304 Wear mount (mm) (PR1215) Competitor B Competitor C Wear mount (mm) (PR1515) Competitor B Competitor D Machining ime (min) Cutting Conditions: Vc = 150 m/min, P = 1.5 mm, Number of Passes = 6, Wet, 16ER150IO ype Radial Infeed Machining ime (min) Cutting Conditions: Vc = 100 m/min, P = 1.5 mm, Number of Passes = 8, Wet, 16ER150IO ype Radial Infeed Case tudies Handle teel ube n = 1,000 min -1 (Vc = 130 m/min) Number of Passes: 7 P = 1.5 mm Wet (Water oluble) 16ER150IO-Q PR1215 Nut 45C n = 1,000 min -1 (Vc = 95 m/min) Number of Passes: 7 P = 1.5 mm Wet (Water oluble) 16IR150IO-Q PR1215 Piping Parts U304 M42 P1.5 M32 P1.5 M14 P1.0 n = 1,500 min -1 (Vc = 65 m/min) P = 1.0 mm Wet (Oil) 16ER100IO-Q PR1535 ool Life PR1215 ool Life 300 pcs/edge x 1.5 Competitor B 200 pcs/edge or Less (PR1215) maintains 1.5 times the tool life of Competitor B with good chip control (User Evaluation) ool Life PR1215 ool Life 500 pcs/edge x 1.6 Conventional B 300 pcs/edge or Less (PR1215) maintains 1.6 times the tool life of Competitor B without breakage (User Evaluation) ool Life (ixed Quantity 1,200 pcs/edge) PR1535 Competitor E Wear: Large mount gainst Competitor E, (PR1535) provided stable machining and a better edge condition in fixed a quantity without sudden cracking (User Evaluation) 2

4 External hreading s Metric (M) 6 Right-handed hown 16ER 100IO-Q pplicable hread hread ngle mm PI ød IO-Q IO-Q IO-Q M IO-Q IO-Q IO-Q MEG CO MEGCO NNO : tandard tock Unified (UN) 6 Right-handed hown 16ER 24UN-Q pplicable hread hread ngle mm PI ød UN-Q UN-Q UN-Q UN-Q UN,UN UN-Q UN-Q UN-Q UN-Q MEG CO MEGCO NNO : tandard tock Parallel Pipe [G (P)], Whitworth (W) 55 Right-handed hown 16ER 19W-Q pplicable hread hread ngle MEG CO MEGCO NNO PI ød G (P) W W-Q G (P) W-Q W W-Q : tandard tock apered Pipe [R(P), (BP)] 55 Right-handed hown 16ER 28BP-Q pplicable hread hread ngle mm PI ød BP-Q R (P) BP-Q (BP) BP-Q MEG CO MEGCO NNO : tandard tock 3

5 External hreading s Metric (M), Unified (UN) 6 Partial Profile Partial Profile Right-handed hown 16ER 60-Q pplicable hread hread ngle mm PI ød G60-Q M UN UN G60-Q MEG CO MEGCO NNO : tandard tock Parallel Pipe [G (P)], apered Pipe [R(P), (BP)], Whitworth (W) 55 Partial Profile Partial Profile Right-handed hown pplicable hread PI G (P) R (P) hread ngle MEG CO MEGCO NNO ød W 16ER 55-Q 28, G55-Q G (P) 14, R (P) W G55-Q : tandard tock 4

6 Internal hreading s Metric (M) 6 Right-handed hown 11IR 100IO-Q pplicable hread hread ngle mm PI ød IO-Q IO-Q M MEG CO MEGCO NNO 175IO-Q IR 100IO-Q Unified (UN) 6 Parallel Pipe [G (P)], Whitworth (W) 55 Right-handed hown IO-Q IO-Q IO-Q M IO-Q IO-Q IO-Q IR 19W-Q Right-handed hown Right-handed hown apered Pipe [Rc(P), (BP)] 55 pplicable hread 6 hread ngle : tandard tock MEG CO MEGCO NNO PI ød G (P) W W-Q G (P) W-Q W W-Q IR 28BP-Q pplicable hread pplicable hread 55 hread ngle mm PI ød BP-Q BP-Q Rc (P) IR 14BP-Q (BP) BP-Q hread ngle mm PI ød 16IR 24UN-Q UN-Q UN-Q UN-Q UN-Q UN,UN UN-Q UN-Q UN-Q UN-Q MEG CO MEG CO MEGCO NNO : tandard tock : tandard tock MEGCO NNO : tandard tock 5

7 Recommended Cutting Conditions : 1st Recommendation : 2nd Recommendation Recommended Grade (Vc m/min) Workpiece Material MEGCO MEGCO NNO Carbon teel Initial D.O.C. (Radial) 0.3mm or Less lloy teel Initial D.O.C. (Radial) 0.3mm or Less tainless teel Initial D.O.C. (Radial) 0.25mm or Less 0.25mm or Less Coolant is Recommended or stainless steel threading, please set a smaller initial D.O.C. and take two or three more passes than threading for carbon steel. (ee Page 7-8) Infeed Methods Infeed Methods Radial Infeed eatures General method he cutting edge moves towards the center of the workpiece with each pass uitable for small pitch size threading V-shape chips are generated and chip control may be difficult depending on the workpiece material Used for large pitch size threading No D. O. C. on right side of the figure causes insert wear Chips flow to one side lank Infeed djusted variation of flank infeed above No D. O. C. is reduced Chips flow to one side 3 ~ 5 lank Compound Infeed 6

8 DEPH O CU ND NUMBER O PE 11 / 16 () hread ype Metric Unified Parallel Pipe Whitworth apered Pipe External hread Internal hread External hread Internal hread External hread Internal hread External hread Internal hread External hread Internal hread mm & PI C (mm) otal D.O.C. (mm) No. of Passes mm 16ER 100IO-Q mm 125IO-Q mm 150IO-Q mm 175IO-Q mm 200IO-Q mm 250IO-Q mm 300IO-Q mm 11IR 100IO-Q mm 125IO-Q mm 150IO-Q mm 175IO-Q mm 16IR 100IO-Q mm 125IO-Q mm 150IO-Q mm 175IO-Q mm 200IO-Q mm 250IO-Q mm 300IO-Q PI 16ER 24UN-Q PI 20UN-Q PI 18UN-Q PI 16UN-Q PI 14UN-Q PI 13UN-Q PI 12UN-Q PI 10UN-Q PI 08UN-Q PI 16IR 24UN-Q PI 20UN-Q PI 18UN-Q PI 16UN-Q PI 14UN-Q PI 13UN-Q PI 12UN-Q PI 10UN-Q PI 08UN-Q PI 16ER 19W-Q PI 14W-Q PI 11W-Q PI 16IR 19W-Q PI 14W-Q PI 11W-Q PI 16ER 16W-Q PI 14W-Q PI 11W-Q PI 16IR 16W-Q PI 14W-Q PI 11W-Q PI 16ER 28BP-Q PI 19BP-Q PI 14BP-Q PI 11BP-Q PI 11IR 28BP-Q PI 19BP-Q PI 14BP-Q PI 16IR 14BP-Q PI 11BP-Q (D.O.C. shows the value of radial D.O.C.) Caution for 1) When using full profile insert, pre machining with finishing allowance by thread diameter mm 2) inal D.O.C. for finishing should be mm 3) Prepare chamfering for C0.3 - C0.5 to prevent cracking the insert in the 1st pass 4) Coolant is recommended Corner-R ( r ε) election for Partial Profiling s Metric Unified Parallel Pipe (Whitworth) apered Pipe : Corner-R P: (Metric) (= 25.4 n ) n: PI External hread Internal hread P P (or Both External and Internal hread) P Metric, Unified hread Corner-R ( r ε) of internal threading is almost half of that of external Parallel Pipe, apered Pipe, Whitworth hread ame Corner-R ( r ε ) for both external and internal threading Corner-R (r ) C (D.O.C. shows the value of radial D.O.C.) 7

9 DEPH O CU ND NUMBER O PE 6/55 (Partial Profile) (D.O.C. shows the value of radial D.O.C.) hread ype Metric Unified Parallel Pipe apered Pipe Whitworth External hread External hread External hread External hread mm & PI 0.5mm 0.75mm 1.00mm 1.25mm 1.50mm 1.75mm 2.00mm 2.50mm 3.00mm 48 PI 24 PI 20 PI 18 PI 16 PI 14 PI 13 PI 12 PI 10 PI 9 PI 8 PI 28 PI 19 PI 14 PI 11 PI 48 PI 24 PI 20 PI 18 PI 16 PI 14 PI 12 PI 11 PI 10 PI 9 PI 8 PI Corner-R () otal D.O.C. (mm) No. of Passes ER 60-Q G60-Q ER 60-Q G60-Q ER 60-Q G60-Q ER 60-Q G60-Q ER 60-Q G60-Q ER G60-Q G60-Q ER G60-Q G60-Q ER G60-Q G60-Q ER G60-Q G60-Q ER 60-Q G60-Q ER 60-Q G60-Q ER 60-Q G60-Q ER 60-Q G60-Q ER 60-Q G60-Q ER G60-Q G60-Q ER G60-Q G60-Q ER G60-Q G60-Q ER G60-Q G60-Q ER G60-Q G60-Q ER G60-Q G60-Q ER 55-Q G55-Q ER 55-Q G55-Q ER G55-Q G55-Q ER G55-Q G55-Q ER 55-Q G55-Q ER 55-Q G55-Q ER 55-Q G55-Q ER 55-Q G55-Q ER 55-Q G55-Q ER G55-Q G55-Q ER G55-Q G55-Q ER G55-Q G55-Q ER G55-Q G55-Q ER G55-Q G55-Q ER G55-Q G55-Q

10 hread Methods () External hread (L-hand hread / R-hand hread) External hread oolholder oolholder he direction of spindle revolution M04 he direction of spindle revolution M03 Left-Hand hread oolholder Right-Hand hread oolholder he direction of spindle revolution M03 he direction of spindle revolution M04 * hese tables are based on KN/KN oolholder Internal hread (L-hand hread / R-hand hread) Internal hreading oolholder oolholder Left-Hand hread he direction of spindle revolution M03 Right-Hand hread he direction of spindle revolution M03 * hese tables are based on IN/CIN oolholder 9

11 KN/ KN External hreading oolholder h Right-hand hown Right-hand for Right-hand oolholder, Left-hand for Left-hand oolholder h H3 L2 KNL External hreading leeve Holder H2 H1 ød2 2 1 ød1 B B H3 H1 ig. 1 h L2 H1 H3 ig. 2 h H3 L2 B B H1 H1 KNR1010H K-16 KNR1616K K-16 ig. 3 ig. 4 Right-hand hown Right-hand for Right-hand oolholder oolholder Dimensions tock R L H1=h H3 B L2 Drawing pare Parts Clamp et Clamp crew Wrench him him crew KNR/L 1216JX ig. 1 B-3.5R LW H ig. 2 CP-5-15 N-32 P3X JX ig. 1 B-3.5R LW H ig. 2 CP-5-15 N-32 P3X8 2020JX ig. 1 B-3.5R LW K M ig. 2 CP-5-15 N-32 P3X8 KNR 1010H ig. 3 B-3.5R 1212K K ig. 4 CP-5 N-32 P3X8 2020K KNR2020H-16 indicates short-shank type LW pplicable s 16ER/L 16ER : tandard tock ød Left-hand hown Right-hand for Left-hand oolholder oolholder Dimensions tock ød 1 2 ød1 ød2 H1=H2 pare Parts Clamp crew Wrench pplicable s 16-KN K-KN K-KN K-KN H-KN K-KN B-3.5R LW-15 16ER : tandard tock

12 IN/CIN Internal hreading Holder ø Min. Bore Dia. ø Min. Bore Dia. L2 ød L2 ød ø Min. Bore Dia. H ig. 1 ig. 3 ø Min. Bore Dia. H L2 ød L2 ød H ig. 2 ig. 4 H Right-hand hown Right-hand for Right-hand oolholder, Left-hand for Left-hand oolholder oolholder Dimensions tock Min. Bore Dia. R L ø ød H L2 Drawing pare Parts Clamp crew Clamp et Wrench him him crew pplicable s IN R/ L E ig. 1 B-2R -8 11I R/ L ig ig B-3.5R I R/ L CIN R/ L ig. 4 CP-5-15 N-32 P3X8 16I R/ L : tandard tock Guide for Internal hreading or internal threading, pay extra attention to "tabilizing Diameters of Pre-drilled Holes" and "Chip Evacuation" 1. tabilizing Diameters of Pre-drilled Holes Because small pitch internal threads have a small corner radius, any variation in the diameter of pre-drilled holes will greatly affect the tool life of the insert Please minimize any variation of pre-drilled holes and add an air pass to the first thread pass for safety Pre-drilled holes are finished to stabilize the first thread pass 2. Chip Evacuation If the threading cycle continues with chips tangled on the holder or the part, it may damage the insert Use the methods below to make sure chips do not become entangled < 1 When Running the irst Part of a etup> Run the program in single block tart each thread pass 50mm-100mm from the workpiece face to allow room for the coolant to remove chips from the tool on each pass < 2 When Running the econd Part of a etup> Run through the full threading cycle and again check that chips are removed from the tool before going into production mm he information contained in this brochure is current as of July Duplication or reproduction of any part of this brochure without approval is prohibited. CP KYOCER Corporation