Transcript Folie 1 - Guehring

RF 100 Programme 2010
Customer Presentation
Date: February 10, 2010
Difficulties in a milling process
Situation in a milling application
Vibration in a milling process cause:
• Bad work piece surface
• short tool life
• extreme high noise level
• high load on spindle
• bad cost / efficiency relationship
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Difficulties in a milling process
Target
• creating a tool which does not vibrate
 high process security
• usable in a very large RPM-range.
 less RPM- adjustment necessary
• usable in a much higher Feed-Rate-Range (high performance milling)
 Increased metal removal rate, reduced cycle times
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Difficulties in a milling process
Solution: RF 100
General Style / Geometry Basics:
• different Helix angles
• uneven pitch
• micro edge protection
• optimized flute profile
• materialspecific coatings
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RF 100 High Performance End Mills
Geometry in detail (un-even helix)
• 2 different helix angles create an un-even pitch
• Different pitch on all cutting- levels
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RF 100 High Performance End Mills
Geometry in detail (micro edge protection)
• Very stable cutting edge through chamfer and lip-correction
Advantages:
Increased tool-life
because of reduced wear
Increased feed-rates
because of more edge stability
Perfect suitable for
ramp-milling or plunging
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RF 100 High Performance End Mills
Geometry in detail (flat roughing profile)
• optimized roughing profile with new 3 radii design
Advantages
3-Radien-Design
Increased tool life
because of less wear
Increased Feed-rate
because of more corner stability
No additional finishing necessary;
Work piece quality is Ra = 2-3 µm
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RF 100 High Performance End Mills
Advantages (summarisation)
Reduced vibrations allow:
• higher feed rates
• longer tool life
“High quantities” =
Large batch sizes
• better surface quality
“Low quantities” =
Small batch sizes
• roughing, finishing and
slotting with 1 tool
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RF 100 High Performance End Mills
deduction of tools in a milling application
Standard
RF 100
+
+
=
+
• Argument: roughing, slotting & finishing = 1 tool !
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RF 100 High Performance End Mills
2 Basic Geometries
• with plain cutting edge
(Type U, A, F, A, Ti, VA, H)
• with flat roughing profile
(Type U/HF, VA/NF, A/WF)
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RF 100 High Performance End Mills
Advantages / Disadvantages
RF 100 (U, F, A, Ti, VA, H)
RF100 (WF/HF/NF)
+ hight range of materials
+ / - limited range of materials
+ high feed rate
- normal feed rate
+ hight tool life
- normal tool life
+ Roughing & Finishing
+ / - Roughing & Semi-Finishing
+ / - Substitution of Carbide end mills
+ Substitution of PM-HSS-end mills
+ / - ap preferable 1 x d
+ ap up to 2,5 x d
- high power consumption
+ less power consumption
- good chip removal must be guaranteed
+ trouble-free chip removal
- Sable conditions required
+ normale conditions required
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RF 100 High Performance End Mills
Performance in comparison
 RF 100 U (#3732) can run at
the highest possible feed rate.
 At the same feed-rate, the
Rougher RF 100 U/HF (#3508)
requires a much lower
power, stability, torque, etc.
 The RF 100 U/HF closes the gap
between the RF 100 U‘s (5535)
fine pitch Roughers (#5504).
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RF 100 High Performance End Mills
„U“ or „U/HF“ – Which is the “better” tool?
• Vc – Values for both tools are identical.
• Vf – Values of the Rougher are about 30% lower.
RF 100 U with ap =
1,0 x d
RF 100 U/HF with ap = 1,5 – 2,0 x d
 The Argument for the RF 100 U/HF the metal removal rate (Q).
This means RF 100 U/HF is running with a lower feed rate,
but with a much higher depth of cut (ae).
 Feed-Rate „U/HF“ is lower; metal-removal-rate (Q) is higher.
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RF 100 High Performance End Mills
RF 100 Application at “field” customer
Tool:
Machine:
Application & Material:
Cutting data (see Cat.):
RF 100 U 16 mm, # 5735
SK40, 12 KW and max. 8.000 RPM
C45 - Roughing 1 x d (ap = 1 x d / ae = 0,5 x d)
Vc = 230 m/min. – fz = 0,11 mm/z
Possible problems:
• Machine stops
• tool is pulled out of the tool holder
• chips cannot be removed
Possible Solution: (tool change)
• RF 100 U (#3732)  RF 100 U/HF (#3508) with roughing profile
• Reduction of fz (mm/z) and increasing ap from 1 x d on 2 x d
• Metal Removal Rate (Q) increases
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RF 100 High Performance End Mills
What to do on an existing process?
• in the first try (step) a RF 100 with plain cutting edges should
be tried (e.g. RF 100 U #5535)
• on “unstable” machines, bad coolant, long reach, etc. a RF 100
with roughing profile should be used. (e.g. RF 100 U/HF)
 on existing customers, who are using a RF 100 U
successfully, the new Rougher will not work “better”!
 the RF 100 U/HF is also interesting for all new customers,
also for those who are using HSS-PM Roughing End Mills.
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RF 100 Programme
RF 100 U (pages 10-13)
• Suitable for Slotting, Roughing and Finishing in
all materials from 850 N/mm² up to 48 HRC
• Recessed neck on all tools incl. SL-brand
(see footnote in our catalogue)
• new medium length 3 x d for HPC-milling
• new long reach tools for die & mould making
applications
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RF 100 Programme
RF 100 U with corner radius (pages 14-15)
• Suitable for Slotting, Roughing and Finishing in all
materials from 850 N/mm² up to 48 HRC
• Available in the most popular corner radius sizes
and fully corrected corner radius (NAS-style)
• recessed neck for best reach in die & mould
making applications
• with „margin“ to increase
tool-life and work piece quality.
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RF 100 Programme
RF 100 3-fluted (pages 16-17)
• larger flutes for applications with chip
removal problems
• especially on diameters smaller than 8 mm
in order to guarantee a secure process
• 7° Rake angle (4-Flute is 4°) for universal
applications in various materials
• Tolerance e8 (undersize) for milling key-slots
in one pass acc. to ISO (size P9)
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RF 100 Programme
RF 100 U/HF (pages 18-19)
 lower cutting forces and power consumption
because of new roughing profile
 RF 100 U/HF suitable for unstable conditions,
low horsepower machines, bad coolant, long
reach tools holders, etc.
 feed-rate 30% lower compared to RF 100 U
 in general usable with higher depth of cut (ap)
and a higher metal removal rate (Q)
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RF 100 Programme
RF 100 F (pages 20-21)
• suitable for AlSi and especially soft, gluey long
chipping steels and materials up to 850 N/mm²
because of high rake angle of 9°
• current name „INOX“ is deleted
• For stainless steel in future RF 100 VA
• chip-evacuation problems in Stainless steel
RF 100 F with internal coolant (#3366)
• RF 100 F with internal coolant (#3366) as an
alternative suitable in aluminium
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RF 100 Programme
RF 100 VA (pages 22-23)
• Suitable for Stainless steels 1.4301 - 1.4405 –
1.4571(ANSI or SUS 303, 304 and 316
• Suitable for Roughing, Finishing and Slotting
• nano A- coating
• New flute profile for optimized chip-removal
• Round profile lead to less bending of the chips
and consequently less heat in the process
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RF 100 Programme
Customer Test RF 100 VA
Machine :
Haas 22,5 KW Maximum RPM 7.500 1/min SK 50
Material :
X20Cr13(1.4028)
Turbine blade ( various sizes )
Coolant :
End Mill :
Cold Air Jet (Franken-Emuge)
3803 Dia. = 20 mm
Vf =
n=
ae =
ap =
tool life =
RF 100 Programm 2010 (C) M.Strasmann; Gühring OHG
1.400 mm/min ( fz = 0,093 mm )
3800 1/min
9 mm
up to 30 mm
~ 54m
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RF 100 Programme
Customer Test RF 100 VA
(source: stainless steel catalogue 09/2009)
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RF 100 Programme
RF 100 VA/NF (pages 24-25)
 lower cutting forces and power consumption
because of new roughing profile
 RF 100 VA/NF suitable for unstable
conditions, low horsepower machines,
bad coolant, long reach tools holders, etc.
 feed-rate 30% lower compared to RF 100 U, F
 in general usable with higher depth of cut (ap)
and a higher metal removal rate (Q)
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RF 100 Programme
RF 100 A (pages 26-27)
• for finishing operations in aluminium up to
0,25 x d width of cut (ae)
• wrought aluminium (aircraft industry) could
cause chip-removal problems
• high performance in AlSi > 3 % (automotive)
• For slotting high pressure coolant is required
to guarantee chip removal
• on chip-removal problems GA 200 A or
RF 100 A/WF should be used
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RF 100 Programme
RF 100 A/WF (pages 28-29)
 lower cutting forces and power consumption
 RF 100 A/WF suitable for unstable
conditions, low horsepower machines,
bad coolant, long reach tools holders, etc.
 feed-rate 30% lower compared to RF 100 U
 in general usable with higher depth of cut (ap)
and a higher metal removal rate (Q)
 also working with lower Vc (cutting speed)
(e.g. 300 m/min. compared to 900 m/min.)
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RF 100 Programme
RF 100 H (pages 30-31)
• Finishing in hardened steel (up to 60 HRC) and
roughing up to ap = 1 x d ( up to 54 HRC)
• Extra core stability suitable for slotting ap = 1 x d
and finishing up to 2,5 x d
• Negative rake angle for HPC-milling with
increased tool life.
• Suitable for HPC milling (“Trochoid”) of key slots
in materials up to 60 HRC and bigger.
• Extra core stability for less deflection
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RF 100 Programme
Customer Test RF 100 H
Machine :
Taimac MCFV 1060 HSK63 Max RPM 18.000 1/min
Material :
Coolant :
1.2343 52 HRC
dry
Tool :
# 3896
Vf =
n=
ae =
ap =
tool life =
RF 100 Programm 2010 (C) M.Strasmann; Gühring OHG
Dia. = 16 mm
636 mm/min ( fz = 0,08 mm )
1990 1/min ( Vc = 100 m/min )
1 mm
16,5 mm
60-70m
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RF 100 Programme
RF 100 Ti (pages 32-34)
• Suitable for Roughing, Slotting, Finishing in
Titanium Alloys (TiAl6v4 - 1.200 N/mm²)
• Especially designed for Slot Milling with
cutting depths of up to 2 x d in one pass.
• Available only with fully corrected corner radius
to aircraft industry’s demands (NAS style).
• new flute profile for best chip evacuation
• 3-facette + margin design for best tool-life
and highest surface qualities
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RF 100 Programme
Customer Test RF 100 Ti
Series #
Dia. (mm)
Application
Vc (m/min.)
ap (mm) (one-pass!!)
ae (mm)
fz (mm/z)
Vf (mm/min.)
Q (cm³/min.)
tool-life (m)
3499
25
Slotting
50
50
25
0,08
203
254
92
16
Slotting
50
25
16
0,04
159
81
76
12
Slotting
50
24
12
0,025
132
38
54
 No vibration = very high surface quality (Ra 0,2 – 0,4 µm)
 No additional finishing operation necessary
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12
Slotting
60
12
12
0,03
190
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RF 100 Programme
RF 100 S/F (pages 35-36)
• 6-Fluter with 3 different helix angles
• suitable for all materials up to 52 HRC
(incl. AlSi and CrNi- alloys)
• Finishing and Semi-Roughing with up to 0,3 x d
width of cut (ae)
• with HPC-strategy (“Trochoid”) also suitable for
slotting with full depth of cut
• Less bending and increased stability
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RF 100 Programme
RF 100 S/F (pages 35-36)
• 5-Fluter with un-even flute spacing
• suitable for all materials up to 52 HRC
(incl. AlSi and CrNi- alloys)
• Finishing and Semi-Roughing with up to
0,25 x d width of cut (ae)
• with HPC-strategy (“Trochoid”) also suitable for
slotting with full depth of cut (ap = 3 x d)
• Less bending and increased stability
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RF 100 Programme
Customer Test RF 100 S/F
Cutomer
MECA - Laurent Hamel
Datum
Material
30.11.2008
Tool
Material
TA6V4
Tool Type
RF 100 S/F
PWZ (Prototyp)
Mat. Group
Titan
Art.No.
3632
xxx
DIN/ANSI
-
Coating
FIRE
TIALN
Diameter
16
16
Machine
Machine
MAZAK VTC 200C
Vc (m/min.)
80
165
Typer
-
fz (mm/min.)
0,06
0,05
Clamping
-
tool-life (m)
72
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Coolant
Oil
tool-life (min.)
Coolant preassure
-
tool-life criteria
Wear
Wear
Power (KW)
-
Application
Component
Titan
Application
Roughing
ae (mm)
5 and. 0,35 mm
ap (mm)
22 mm
RF 100 Programm 2010 (C) M.Strasmann; Gühring OHG
PWZ (Prototype) runs with a much higher Vc, but
only with a width of ae =0,35 mm
(14 passes need to achieve Guhring ae = 5,0 mm)
Guhring with ae = 5 mm and 3 x longer tool life
PWZ was not able to run at 5 mm width.
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RF 100 Programme
Diameter and Length
Complete programme:
• Diameter-Range 3 – 25 mm
• With HA-shank (plain) and HB (flatted)
• With recessed neck on all RFs
• Short and long DIN- length
• Medium and extra long length
• Long and extra long reach style
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RF 100 Programme
Conclusion
1. Do we have a solution for all work-piece materials?
 Yes, RF 100 Types U, F, A, Ti, H, VA, S/F
2. Do we have a solution for unstable conditions and machines?
 Yes, RF 100 Types U/HF, VA/NF, A/WF
3. Do we have a full offering of diameters, length and styles?
 Yes, RF 100 complete programme
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RF 100 High Performance End Mills
RF 100 – the highest performance!
We deliver the prove:
“Request your free
trial end mill!*”
Please contact our sales-representative
or your Guhring-Partner
* Participation conditions:
We will provide each customer with one trial end mill. Type and dimensions from our standard
RF 100 program as requested by the customer. The trial end mill is delivered personally by our
representative. The test results are documented in a Guhring test report and remain available
to Guhring for further use without restriction. Offer valid until 31.0X.2010.
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