Transcript Special Milling Cutters
Power Milling With Greenleaf
®
Power Milling With Greenleaf
®
Milling 101 Heavy Milling Cutters – Powermill – Special Milling Cutters • Heavy Milling • Rail Milling • Crankshaft Milling • Camshaft Milling – Cutter Repair Carbide Milling Grades CVD GA-5023 GA-5036 GA-5040 GA-5125 G-910 G-915 G-935 G-955 PVD G-9120
Milling 101 The basics of Milling with Greenleaf
®
Milling cutters.
Milling 101
Hand of Cutters • Right Hand Cutters Rotate Clockwise • Left Hand Cutters Rotate Counter-Clockwise
Milling 101
Select Correct Cutter Diameter • 1.5 Times Work Piece Width • WOC = 2/3 Cutter Diameter • Watch Machine Horsepower
Milling 101
Lead Angle • Thins the Chip • Uses Less Horsepower • Improved Tool Life
Milling 101
Lead Angles and Cutting Forces • Less Force Into Part • More Force on Spindle • Less Force on Spindle • More Force Into Part
Milling 101
Lead Angle Effect on Chip Thickness • At 0 ° • At 45 ° B = A B = 70% of A
Milling 101
Cutter Pitch Coarse Pitch : • Better Chip Evacuation • Heavier IPT (MM/tooth) • Larger DOC Fine Pitch : • More Teeth Engaged • Heavier IPM (MM/min) • Lighter DOC A good guide is diameter (inches) + 2
Milling 101
Cutter Geometry Radial Rake • Impacts Edge strength • Affects Cutting Forces
Milling 101
Cutter Geometry Axial Rake • Directs Chip Flow • Caution with Fixturing
Milling 101
Cutter Geometry Negative vs. Positive • Strongest Geometry • Higher Feed Possible • Maximum Insert Usage • Higher Cutting Forces • Lower Cutting Forces • Better Chip Evacuation • Lower HP Consumption • Weaker Geometry
Milling 101
Cutter Geometry Double Negative Negative Axial & Negative Radial Advantages : • Strongest Shape • Cast Iron • Best Economy Disadvantages : • Part/Machine Rigidity • Highest Forces • Chip Flow into Part
Milling 101
Cutter Geometry Double Positive
Positive Axial & Positive Radial
Advantages : • Milling Aluminum • Work Hardening Materials • Low HP Disadvantages : • Fragile Cutting Edge • Pulling Forces • Not for Hardened Materials
Milling 101
Cutter Geometry Negative / Positive Negative Radial & Positive Axial Advantages : Disadvantages : • Best General Purpose • Most Materials • Excellent Chip Ejection • Balanced Cutting Forces • Fewer Cutting Edges than Negative
Milling 101
Negative / Positive Best of Both Worlds • Capable of Heavy Duty Milling • Works Best With Lead Angle Cutters • Powermill & High Shear Cutters
Milling 101
Depth of Cut Do Not Exceed 2/3 of Edge Length (L)
Milling 101
Milling Techniques Conventional (Up) Milling • Counteract Table Feed Backlash • Poor Chip Formation – Creates Heat • Work Hardening • Poor Insert Life - Flank Wear
Milling 101
Milling Techniques Climb (Down) Milling • Good Tool Life • Inserts must Survive Shock of Entry • Good Chip Formation • Watch Table Backlash!
Milling 101
Milling Techniques Cutter Positioning • Can Cause Vibration Cutter On Center
Milling 101
Milling Techniques Cutter Positioning Slightly Off Center • Helps Eliminate Vibration • Climb Mill If Possible • Keep 2 Teeth in Cut • 1/4 - 1/3 Cutter Overhang
E2 > 90
°
Milling 101
Milling Techniques Angle of Entry Positive Angle of Entry Contact at Weak Section of Insert Poor Impact Resistance
Milling 101
Milling Techniques Angle of Entry Negative Angle of Entry Contact at Strong Section of Insert Best Impact Resistance
E1 < 90
°
Milling 101
Milling Techniques Angle of Entry
Milling 101
Milling Through Interruptions
• Use a Lead Angle Cutter • Use a Strong Carbide Grade • Use Medium to Fine Pitch Cutter • Use Lighter Feed Rate
Milling 101
Milling Techniques Surface Finish • Radii Leave “Tracks” • Radius Size Determines Finish
Milling 101
Milling Techniques Surface Finish • Milling Inserts Have Flats • “Wiping Effect” Improves Finish
Milling 101 Common Terms
English Metric Surface Feet Per Min.
= Revolutions Per Min.
= Number Of Teeth = Feed Per Tooth = Feed Per Revolution = Feed Per Minute = = SFM RPM T FPT (IPT) Surface Meters Per = Min.
= Revolutions Per Minute = Number Of Teeth = FPR (IPR) Feed Per Tooth M/Min RPM Z FPT = (MM/Tooth) IPM Feed Per Revolution = FPR (MM/Rev) 3.1416
Feed Per Minute = = MM/Min 3.1416
Milling 101
•Select a cutter that is 1.5 times work piece width where possible.
•Select a cutter with Negative radial/Positive axial geometry in most cases.
•Select a cutter with a fairly course pitch for most materials.
•Use a cutter with a lead angle to reduce cutting forces.
•Climb (down) mill where possible.
•Position the cutter with a negative angle of entry with 1/4 th 1/3 rd overhang condition.
•Do not exceed 2/3 rd cutting edge length on your depth of cut.
Questions?
Powermill
®
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Powermill
®
When should you consider a Powermill ® ?
When removing forging scale in heavy-duty cutting with severe interruptions and uneven surfaces is required. • When large DOC and high MRR are crucial for productivity.
• When versatility and durability is required.
• When cost is a consideration.
• When horsepower is a concern, the LNES sinusoidal insert can be used to reduce HP consumption by approximately 30%.
Powermill
®
M402LN-A: 2 ° Lead, Neg-Neg Diameter range: 4” (100MM)-12” (315 MM)” M400LNP-A: 0 ° Lead, Neg-Pos Diameter range: 4” (100MM)-12” (315 MM)” M430LNP-A: 30 ° Lead, Neg-Pos C430LNP-H: 30 ° Lead, Neg-Pos (Heavy Duty) C430LNP-W: 30 ° Lead, Neg-Pos (Finishing) Diameter range: 4” (100MM)-12” (315 MM)”
Powermill
®
M402LN-A: 2 ° Lead, Neg-Neg Negative Radial, Negative Axial Diameter Range: 4” (100MM) – 12” (315 MM) Max. DOC Range: .68” (17.3MM) - 1.06” (26.9MM) Advantages : • Strongest Shape • Cast Iron • Best Economy • LNES insert for lower HP machines.
Disadvantages : • Part/Machine Rigidity • Highest Forces • Chip Flow into Part
Note: Tune up kit available
Powermill
®
M400LNP-A: 0 ° Lead, Neg-Pos Negative Radial & Positive Axial Diameter Range: 4” (100MM) - 12” (315 MM) Max. DOC Range: .68” (17.3MM) – 1.06” (26.9MM) Advantages : • Best General Purpose • Most Materials • Excellent Chip Ejection • Balanced Cutting Forces Disadvantages : • Fewer Cutting Edges than Negative
Note: Tune up kit available
Powermill
®
M430LNP-A: 30 ° C430LNP-H: 30 ° Lead, Neg-Pos Lead, Neg-Pos (Heavy Duty) C430LNP-W: 30 ° Lead, Neg-Pos (Finishing) Diameter range: 4” (100MM)-12” (315 MM) Max. DOC Range: .50” (12.7MM) - .88” (22.3MM) Advantages : • Best General Purpose • Most Materials • Excellent Chip Ejection • Balanced Cutting Forces • Chip thinning Note: Tune up kit available Disadvantages : • Fewer Cutting Edges than Negative • Lower maximum depth of cut than 0 ° lead cutter
Powermill
® Hardened Anvils and Back-up Plates
• Protect Cutter Body • Maintain Accuracy 58-60 R/C
Front Wedge Design
• Maximum Security & Insert Rigidity • Hard Faced for Durability
Interchangeable Components
• Multiple Applications • 2 o & 30 o Anvils fit Left and Right Hand Cutters
Powermill
®
Powermill
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Inserts
• Approximately equal width and thickness adds strength needed to handle large depths of cut and heavy interrupted cuts.
•Insert design allows for high strength while using minimal carbide to reduce cost.
• Performance with high metal removal rates.
• Productive Greenleaf carbide grades.
Powermill
®
LNE-335
Inserts
Insert LNE-335F LNE-34.57
LNE-34.57F
Cutter 2 ° Neg lead Neg LNES-335 LNES-34.57
2 ° Neg lead Neg LNP-335R/L LNP-335-90R/L LNP-34.57R/L LNP-34.57-90R/L LNP-34.57 RW/LW YCE-434 01 30 ° lead Neg-Pos Finishing 0 ° Pos lead Neg 30 ° Pos lead Neg-
Powermill
® Test Data
Powermill
® Test Data
Powermill ® Milling Cutter - M430LNP12A Material - 350 BHN Steel Forging Cutter dia. - 12.0 (301.1 mm) Grade – G-955 Speed - 400 SFM (122 M/Min) Feed - .013 (0.33 mm) per Tooth WOC - 8.0 (203.2 mm) DOC - .40 (10.2 mm) MRR - 122 Cu In / Min (2000 cu cm/min) Required HP - 153
Resulted in an order for (4) 12” cutters and a blanket order for 23,000 inserts
Powermill
® Test Data
Prior – Competitor Button Cutter Material – Alloy Steel unknown hardness Cutter dia. – 8.0 (203 mm) Insert/Grade – RNMA-84 SF30 Speed - 367 SFM (112 M/Min) Feed - .018 (0.45 mm) per Insert .0134 (.34 mm) ACT WOC – 5.25 (134.1 mm) DOC - .30 (7.62 mm) Maximum MRR - 40 Cu In / Min (655 cu cm/min) Required HP - 50 Powermill Milling Cutter - C430LNP10H Material – Alloy Steel unknown hardness Cutter dia. - 10.0 (254 mm) Insert/Grade – LNP-44.57R GA-5036 Speed - 540 SFM (165 M/Min) Feed - .011 (0.28 mm) per Insert WOC – 6.5 (165.1 mm) DOC - .60 (15.2 mm) MRR - 90 Cu In / Min (1475 cu cm/min) Required HP - 112
3X increase in speed and 2X increase in DOC with 225% increase in MRR resulted in order
Powermill
® Test Data
Powermill
® Beware of Required Horsepower
Powermill ® Milling Cutter - M430LNP04A Material – P20 350 BHN Cutter dia. – 4.0” (102 mm) Speed – 400 SFM (122 M/Min) Feed .020” (0.51 mm)/Insert WOC – 3” (203.2 mm) DOC .50” (12.7 mm) MRR – 46.5 Cu In / Min (762 Cu Cm/Min) Powermill ® Milling Cutter - M430LNP12A Material – P20 350 BHN Cutter dia. – 12” (305 mm) Speed – 400 SFM (122 M/Min) Feed .020” (0.51 mm)/Insert WOC – 9” (203.2 mm) DOC .50” (12.7 mm) MRR – 140 Cu In / Min (2285 Cu Cm/Min) Required HP - 93 Required HP - 279
Powermill
®
•Powermill ® cutters have the versatility to get the job done.
•Powermill ® cutters are standard and most are in stock.
•Productive carbide grades available for many materials.
•Capable of very high metal removal rates.
•DOC range from .50 max to 1.06 max depending on cutter and hardware.
•Be sure to calculate horsepower and ensure the machine has the capability to run the cutter.
•Consider the Powermill ® before going to a special cutter.
Questions?
Special Milling Cutters
Special Milling Cutters
Advantages • • Custom built milling cutters optimized for the application at hand.
• If the application permits, most cutters can be designed for high speed milling and high metal removal rates.
Most cutters are designed with replaceable hardened components.
• • Productive carbide grades available for most applications.
• Tune up kits available In event of a major crash, we can re-work Greenleaf ® special cutters to as new condition.
Special Milling Cutters
Test Data
Special Milling Cutters
30 o 24” (610mm) Dia. Lead High Shear Mill
High Speed Milling with grades
GA-5125, G-9120
Special Milling Cutters
30 o 24” (610mm) Dia. Lead High Shear Mill
Special Milling Cutter Material - 350 BHN Steel Forging Cutter dia. 24” (301.1 mm) Insert – 428522 GA-5125 Speed - 415 SFM (127 M/Min) Feed .0075” (0.19 mm) per Insert WOC 18” (203.2 mm) DOC .50” (12.7 mm)
MRR –107 Cu In/Min (1180 Cu Cm/ Min Required HP - 133
Special Milling Cutters
24” (610mm) Dia. 30 o Lead High Shear Mill
Special Milling Cutter Material - 350 BHN Steel Forging Cutter dia. 24” (301.1 mm) Insert – 428522 G-9120 Speed - 415 SFM (127 M/Min) Feed .0101” (0.26 mm) per Insert WOC DOC 18” (457.2 mm) .50” (12.7 mm)
MRR-144 Cu In/Min (2360 Cu Cm/Min) Required HP - 180 35% increase in feed equated to a 35% increase in MRR over GA-5125 with 30 minute time savings per block!
Special Milling Cutters
30 o 12” (305MM) Dia. Lead High Shear Mill
High Speed Milling with grade
G-955
Special Milling Cutters
12” (305MM) Dia. 30 o Lead High Shear Mill
High Speed Milling with grade
G-955
Special Milling Cutter Material - 350 BHN Steel Forging Cutter dia. - 12.0 (301.1 mm) Insert - 436034 G-955 Speed - 400 SFM (122 M/Min) Feed - .013 (0.33 mm) per Insert WOC - 8.0 (203.2 mm) DOC - .40 (10.2 mm)
MRR - 122 Cu In / Min (2000 Cu Cm/Min) Required HP - 153
Special Milling Cutters
6” (152.4MM) Dia. 90 o Lead High Shear Mill
High Speed Milling with grade
G-935
Special Milling Cutters
6” (152.4MM) Dia. 90 o Lead High Shear Mill
High Speed Milling with grade
G-935
Special Milling Cutter Material - 4140 Steel 350 BHN Cutter dia. 6” (301.1 mm) Insert – TPEN-53P12R G-935 Speed - 474 SFM (145 M/Min) Feed .004” (0.10 mm) per Insert WOC DOC 4.5” (114 mm) .50” (12.7 mm)
MRR - 29 Cu In / Min (475 Cu Cm/Min) Required HP - 36
Special Milling Cutters
9.0” (228 MM) Dia. Special Switch Point Rail Milling Cutter
High Speed Milling with grade
GA-5125
Special Milling Cutters
9.0” (228 MM) Dia. Special Switch Point Rail Milling Cutter
High Speed Milling with grade
GA-5125
Special Milling Cutter Material - Manganese Steel 400 BHN Cutter dia. – 9.0” (229 mm) Insert – RPGN-84 GA-5125 SPGN-643 GA-5125 Speed - 500 SFM (152.5 M/Min) Feed .0126” (0.32 mm) per Insert WOC – .75” (19 mm) DOC - Varies LOC – 39 Feet (11.9 Meter)
See customer testimonial
Special Milling Cutters
A page from the customers justification report Several grades of carbide from three different manufacturers, Ingersoll, AGI / VR Wesson and Greenleaf ® have been run in these tools trying to improve performance. The best performance achieved was from Greenleaf with their GA-5125 grade carbide inserts In almost every case where a catastrophic Insert failure has occurred, we were able to replace the wedges, wedge screws and or back-up plates, and have the tool back in service in less than a couple of hours.
Special Milling Cutters
Another page from the customers justification report.
Special Milling Cutters
9.5” (241 MM) Dia. Special Rail Milling Cutter
High Speed Milling with grade
GA-5125
Special Milling Cutters
9.5” (241 MM) Dia. Special Rail Milling Cutter
High Speed Milling with grade
GA-5125
Special Milling Cutter Material - Manganese Steel 375 BHN Cutter dia. – 9.5” (301.1 mm) Insert – SNGN-643 GA-5125 431884 GA-5125 431885 GA-5125 Speed - 500 SFM (152.5 M/Min) Feed .0298” (0.76 mm) per Insert to obtain .018 (0.46 mm) ACT WOC – 3.5” (89 mm) DOC .08” (2 mm)
Required HP - 48
Special Milling Cutters
25 degree Special Flair Rail Milling Cutter Cutter uses 72 inserts!
Special Milling Cutters
25 degree Special Flair Rail Milling Cutter 50% increase in speed, 90% increase in feed. Resulted in order of more geometries! Required HP - 143
Special Milling Cutters
Examples of Tools for the Rail industry
Special Milling Cutters
Camshaft and Crankshaft Milling
Special Milling Cutters
Camshaft and Crankshaft Milling Design OD Segments
64” (1625 MM) diameter cutter
Special Milling Cutters
Camshaft and Crankshaft Milling Design (48) Inserts RNGN-84 12 segments per cutter 168 total inserts/load (120) Inserts SNGN-643
Special Milling Cutters
Crankshaft Milling Cutter supplied by Greenleaf ® • Locomotive and Marine Diesel Engines • Power Generation • Automotive
(120) Inserts SNGN-643 (48) Inserts RNGN-84
Special Milling Cutters
Camshaft and Crankshaft Milling
Customers' existing Cutter
Special Milling Cutters
Crankshaft Milling Cutter supplied by Greenleaf ® Segments allow inexpensive repairs Qualified mounting allows you to replace one segment or all
3.425 (87 MM) Width of Cut 22.44” (570 MM) I.D.
Special Milling Cutters
Camshaft and Crankshaft Milling Design ID Segments 8 Segments per cutter 64 inserts total/cutter load
Special Milling Cutters
Crankshaft Milling Cutter supplied by Greenleaf ®
Cam Shaft Mill Cutter Dia: 16.0” (406.4 mm) Cutting width: .81” (20.6 mm) 72 Total Inserts, (24) Effective
Special Milling Cutters
Cam Shaft, 4140 Steel Forging
Insert Grade GA 5036 Original Tool Life: Slotting Cutter: 18 parts per index New Tool Life: Slotting Cutter:
85
parts per index
Cutter Repair
We refurbish and repair damaged Greenleaf ® special Tooling.
•
Special Milling Cutters
Advantages
Custom built milling cutters optimized for the application at hand.
• If the application permits, most cutters can be designed for high speed milling and high metal removal rates.
• Most cutters are designed with replaceable hardened components.
• Productive carbide grades available for most applications.
• Tune up kits available • In event of a major crash, we can re-work
Greenleaf ®
cutters to as new condition.
special
Questions?
Greenleaf ® Carbide Grades for Milling
Greenleaf ® Corporation is an industry pioneer in coated carbide technology. Selecting the best carbide grade for the application is critical to the success and productivity of any milling operation.
Greenleaf ® Carbide Grades for Milling UNCOATED
General Purpose Milling Steel and Steel Alloys Good Toughness and Wear Resistance
High Shear,
Powermill Finish Milling Grade for Steels Finish Wiper Inserts Powermill
Greenleaf ® Carbide Grades for Milling MT-CVD COATED
GA-5036
High Performance Steel Milling Heavy or Light Duty at High Speed
Hushcut, High Shear,
Powermill, Screw-on, Excelerator
GA-5125
High Performance Manganese Steel Milling Grade High Speeds and Moderate Feeds
Special Applications
Greenleaf ® Carbide Grades for Milling MT-CVD COATED
GA-5040
Tough Grade for Milling most Materials Severe Applications, Low Speeds
Hushcut, High Shear,
Powermill, Screw-on, Excelerator
GA-5023
High Performance Cast Iron Milling
Special Applications
Greenleaf ® Carbide Grades for Milling PVD COATED
G-910
High Temp Alloys, Primarily Titanium at Moderate Speeds
G-915
High Shear
High Temps, Stainless & Carbon Steels at Moderate Speeds Tough, Abrasion Resistant
G-935
Hushcut, High Shear, Screw-on, Excelerator Tough, Higher Speed Steel Milling
Screw-on
Greenleaf ® Carbide Grades for Milling PVD COATED
G-955
Rough Steel Forgings, tool steels.
Tough, High speed steel Milling
Special Applications
G-9120
Tough, Higher Speed Steel Milling Rough Steel Forgings, tool steels Improvement over G955 in most apps
Special Applications