AEROSPACE APPLICATIONS INDEX AEROSPACE AIR FRAME Y CFRP Y CFRP/AI Y CFRP/Ti Tool Page
A614G AEROSPACE APPLICATIONS INDEX AEROSPACE AIR FRAME y CFRP y CFRP/AI y CFRP/Ti Tool Page
Drilling MCC Drill 5 Drilling MCA Drill 6
Trimming DFC End Mill 7
y Aluminium Alloy y Aluminium-lithium Alloy
Face Milling, Pocket Milling AXD Series 8
Face Milling, Pocket Milling AXD Series 9 Face Milling, Pocket Milling ALIMASTER 10 Exchangeable Head End Mills Face Milling, Pocket Milling iMX Series 11
y Titanium Alloy
Side Milling, Rough Pocket Milling VFX Series 12
Face Milling, Side Milling AJX Series 13
Side Milling, Pocket Milling ARP Series 14 VQT5MVRB Slotting Corner Radius End Mill for High Effi ciency Titanium Alloy Machining 15
Side Milling, Pocket Milling Coolstar Series 16
y Precipitation Hardening Stainless Steel
Rough Pocket Milling VPX Series 17
Drilling MMS Drill 18
2 ENGINE y Ni-based Superalloy Tool Page LS/MJ/MS/MA/RS External, Face and Internal Turning MP9005/MP9015/MP9025 20 External, Face and Internal Turning US905/VP05RT/VP10RT 21
Copy Turning GY Series 22
Machining of Upper Surface of Protuberance APX Series 23
Drilling (Helical), Profi le Milling ARX/ARP Series 24
Drilling (Helical), Profi le Milling CERAMIC End Mill 25 SMART MIRACLE Finish Profi le Milling Vibration Control Ball Nose End Mill 26 VQT6UR Finish Profi le Milling Barrel End Mill for Finish Cutting of Titanium Alloys 27
Drilling MMS Drill 28 y Titanium-aluminium Alloy SMART MIRACLE Finish Profi le Milling End Mill Series 29 y Titanium Alloy External, Face and Internal Turning LS/MS/RS MT9005/MT9015 30 y Maraging Steel External, Face and Internal Turning FJ/MJ/MS/GJ VP05RT/VP10RT/VP15TF 31 External, Face and Internal Turning JT Holder 32 LANDING GEAR y Titanium Alloy
Rough Milling VFX Series 34
Rough Pocket Milling APX Series 35 SMART MIRACLE Finish Profi le Milling Vibration Control Ball Nose End Mill 36 Exchangeable Head End Mills Finish Pocket Milling iMX Series 37 Exchangeable Head End Mills Finish Pocket Milling iMX Series 38 Drilling MNS Drill 39
3 Air Frame
4 AIR FRAME Work Materials [CFRP]
New CVD diamond coated drills
Optimized cutting geometry Drilling MCC Drill (Leafl et P713G) Key Point on Machining a A 90°point angle is used to reduce thrust when drilling, this prevents delamination and also improves hole tolerance.
Application Example
Drill ø 6.55 Cutting Speed vc120 m/min (n5840 min-1) Feed f0.10 mm/rev Machine Vertical type M/C Coolant Dry cutting Comparison of Tool Life and Hole (Entrance/Exit) *The tool life determination depends on the chipping After 820 holes machining MCC A 1.6 times MCC B longer tool life Can continue Conventional
0 200 400 600 800 1000 1200 1400 1600 (Holes)
306 holes 588 holes MCC MCC ConventionalMCC Conventional (1192 holes)
Entrance
Exit
5 AIR FRAME Work Materials [CFRP, CFRP/Al]
New CVD diamond coated drills
Unique groove design Drilling MCA Drill (Leafl et P713G) Key Point on Machining a A unique flute design is employed to prevent the aluminium chips from damaging the finish of the CFRP section thus reducing the gap in hole size between the aluminium and CFRP section. Application Example
Drill ø 6.38 Work Material CFRP + Aluminium Alloy Cutting Speed vc100 m/min (n5000 min-1) Feed f0.15 mm/rev Machine Vertical type M/C Coolant Internal air
Groove Shape Effect MCA Conventional (μm) (μm) *Enlarged view 100 100 X Entrance (CFRP) X Center (CFRP) X Exit (Al) X Entrance (CFRP) X Center (CFRP) X Exit (Al)
80 Y Entrance (CFRP) Y Center (CFRP) Y Exit (Al) 80 Y Entrance (CFRP) Y Center (CFRP) Y Exit (Al) Back Counter Occurrence 60 60 CFRP CFRP 40 40 Al
20 20 Al
0 0 *Hatching: Required hole precision
-20 -20 Outside the hole tolerance standards (5 holes)
-40 -40 1 50 100 150 200 250 15 (Holes) (Holes)
New CVD diamond coated end mills
Optimized cutting geometry Trimming
DFC End mill (TOOLS NEWS B189G) Key Point on Machining a Tool life is generally short due to the high strength of the carbon fibres, and also due to the fact that delamination and burrs develop easily. Therefore the DFC end mill range employs a CVD diamond coating and a cutting edge geometry that prevents these problems and prolongs tool life.
Application Example a The combination of the CVD coating and the cutting edge prevents problems relating to burrs and delamination.
Trimming Hole Expansion End mill DFC4JCD1000 (ø10) End mill DFC4JCD1200 (ø12) Work Material CFRP Work Material CFRP n6000min-1 n2390min-1 Revolution (vc188m/min) Revolution (vc90m/min) vf750mm/min vf382mm/min Feed (fz0.03mm/tooth) Feed (fz0.04mm/tooth) Depth of Cut ap5mm Depth of Cut ap18mm, ae2.0mm & 0.5mm Coolant Air blow Coolant Air blow
DFC4JCD1000 96 Holes
No burr formation
Tool
Cutting direction
Conventional Machining path ø25.4 mm→ø30.4 mm 30.31 mm Burr formation
Flank wear after 96 holes machining Cutting direction Can continue 7 AIR FRAME [ ] Work Materials Aluminium Alloy Convex cutting edge
Helical fl ank
Low cutting resistance
Face Milling, Pocket Milling AXD Series (TOOLS NEWS B116G) Key Point on Machining a Machining of these kinds of components means machining from block, whereas much as 90% of the material needs to be removed. As such it is necessary to carry this out as fast and efficiently as possible. The AXD series uses inserts that have a suitable relief that results in lower cutting resistance. Also a convex cutting edge is used to improve the overall chip disposal. The combination of which result in the tool to be able to be used for high speed and high efficiency machining. Application Example a Metal removal rate of 10,000cm3/min can be achieved when using the AXD7000-HSK.
Holder AXD7000R05003A-H63A Insert (Grade) XDGX227030PDFR-GL (TF15) Work Material A7075 Cutting Speed vc2830 m/min (n18000 min-1) Feed fz0.21 mm/tooth (vf11340 mm/min) Depth of Cut ap18 mm, ae50 mm Coolant Emulsion
Point Avoids poor wall surface finishes because the tool is designed to interpolate corners of the pocket, thereby also preventing vibration.
ap18mm
ae50mm
8 AIR FRAME [ ] Work Materials Aluminium-lithium Alloy Convex cutting edge
Helical fl ank
Low cutting resistance
Face Milling, Pocket Milling AXD Series (TOOLS NEWS B116G) Key Point on Machining a For higher cutting speed ranges the use of the MP9120 is recommended.
Application Example a For the machining of Aluminium-lithium alloys the GM breaker in combination with the tool grade MP9120 is recommended. This results in reduced chipping and stable machining.
Holder AXD4000-050A04RA Insert (Grade) XDGX175024PDER-GM (MP9120) Work Material Aluminium-lithium Alloy Cutting Speed vc4712 m/min (n30000 min-1) Feed fz0.1 mm/tooth (vf12000 mm/min) Depth of Cut ap6 mm, ae50 mm Coolant Emulsion GM Breaker
Tool life (Number of work pieces) 0 1 2 3
GM breaker (MP9120)
Conventional 3 times
9 AIR FRAME Work Materials [Aluminium Alloy]
Instability in chip Smooth chip separation separation
Chip fl ow Chip fl ow
Competitor Mitsubishi
Face Milling, Pocket Milling Improved chip removal ALIMASTER (TOOLS NEWS B118G) Key Point on Machining a The ALIMASTER series employs a unique cross section geometry that enables effective chip removal properties. The overall result of which is that it can be used to machine with higher speeds and increased efficiency.
Application Example a Metal removal rate of 5,000cm3/min can be achieved when used on machines with sufficient power.
End mill CSRARBD2500R300 (ø 25/R3) Work Material A7075 Cutting Speed vc1178 m/min (n15000 min-1) Feed fz0.22 mm/tooth (vf10000 mm/min) Depth of Cut ap25 mm, ae20 mm Coolant Emulsion
Point Avoids poor wall surface finishes because the tool is designed to interpolate corners of the pocket, thereby also preventing vibration.
ae20mm
10 AIR FRAME Work Materials [Aluminium Alloy]
High Precision
High Rigidity Face Milling, Pocket Milling Low Cost Exchangeable Head End Mills iMX Series (TOOLS NEWS B200G) Key Point on Machining a The iMX exchangeable heads specific for machining aluminium alloys employs a large rake angle and polished cutting edges to result in a sharper cutting edge to reduce cutting resistance and to prevent problems relating to welding. Application Example a When the iMX head is used with a carbide arbor this results is high rigidity and prevents vibration even when carrying out slotting applications. Head (Grade) IMX10S3A10008 (ET2020) Holder IMX10-U10N014L070C Overhang length 35 mm Work Material A7075 Cutting Speed vc408 m/min (n13000 min-1) Feed fz0.12 mm/tooth (vf4680 mm/min) Depth of Cut ap5 mm, ae10 mm Coolant Emulsion
Effi ciency (%) 050100150
Wall surface iMX Bottom face
Wall surface Conventional 1.5 times Bottom face
11 AIR FRAME Work Materials [Titanium Alloy] Arranging the inserts vertically
Cutting force
V formation of the clamping face
Side Milling, Convex curve Rough Pocket Milling cutting edge VFX Series Key Point on Machining (TOOLS NEWS B182G) a When rough machining of titanium alloys problems such as chipping and abnormal damage can occur if using tools with low rigidity. The VFX series offers a design that has high rigidity and also insert geometry that employs a convex cutting edge to improve cutting edge stability.
Application Example a When used with a high pressure internal coolant system efficiency can be increased by up to 150%.
Holder VFX6-063A04A060R Insert (Grade) XNMU190912R-LS (MP9130) Work Material Ti-6Al-4V Cutting Speed vc55 m/min (n280 min-1) Feed fz0.12 mm/tooth (vf135 mm/min) Depth of Cut ap25-60 mm, ae10-45 mm Coolant Emulsion (10 MPa)
Effi ciency (%) 050100150
VFX
Conventional Over 1.5 times
12 AIR FRAME Work Materials [Titanium Alloy]
*Graphical representation Multi-layering of the coating prevents cracks penetrating through to the substrate.
New coated Face Milling, Side Milling grade with AJX Series superior fracture (TOOLS NEWS B028G) resistance Key Point on Machining a When machining materials such as titanium alloys cutting resistance varies and as such the chips generated are saw-tooth type. This can result in chipping of the cutting edge when high feed roughing applications. To prevent this kind of problem from occurring the JL breaker, that has a sharp cutting edge to reduce overall cutting resistance and a newly developed multi-layered coating, MP9130 is employed. This combination leads to the ability for stable high feed roughing applications. Application Example a Possible to achieve 1.5 times longer tool life due the reduced cutting edge chipping. Holder AJX12R322SA32S Insert (Grade) JDMT120423ZDER-JL (MP9130) Work Material Ti-6Al-4V Cutting Speed vc50 m/min (n500 min-1) Feed fz0.6 mm/tooth (vf600 mm/min) Depth of Cut ap1 mm, ae20-32 mm Coolant Emulsion
Tool life (Number of work pieces) 012 3
AJX (MP9130)
Conventional 1.5 times
13 AIR FRAME Work Materials [Titanium Alloy]
3 types of breakers
Coolant nozzle
Side Milling, Pocket Milling
ARP (TOOLS NEWS B222G) Key Point on Machining a When rough machining of titanium alloys due to the type of chips generated problems relating to chipping and fracturing are common. The ARP series inserts are available in 3 breaker geometries and with the new MP9130 tool grade. This combination results in stable machining when carrying out roughing and finishing application of titanium alloys.
Application Example a Due to the use of the MP9130 and the L breaker tool life was improved by 25%.
Holder ARP5PR3204SA32M Insert (Grade) RPHT1040M0E4-L (MP9130) Work Material Ti-6Al-4V Cutting Speed vc50 m/min Feed fz0.1 mm/tooth Hole Depth ap2.5 mm ae25 mm Coolant Emulsion
0.25 Cutting Time: After 53 Minutes ARP 0.20 Conventional
0.15 ARP : VB=0.110 mm 0.10 VB (mm) VB Tool life extended by 25% 0.05 Conventional : VB=0.231 mm 0.00 0 13.126.239.352.465.478.5 Cutting time (min)
14 AIR FRAME Work Materials [Titanium Alloy] Corner Radius (Emphasis on Sharpness)
5 Flutes
Center Through Coolant Hole
Slotting VQT5MVRB Corner Radius End Mill for High Effi ciency Titanium Alloy Machining (TOOLS NEWS B230G) Key Point on Machining a Center through coolant hole realized rough cutting of titanium alloys with high efficiency by excellent chip discharging property, control of chatter vibration with Irregular Helix and long tool life by five cutting teeth.
Application Example a MRR ( Material Removal Rate ) : 250cc/min Can be achieved. Workpiece Ti-6Al-4V Tool VQT5MVRB250R400N075C Revolution n636 min-1 Table Feed vf206 mm/min Depth of Cut ap50 mm (DC×2) Width of Cut ae25 mm (Slot) Overhang Length 75 mm (DC×3) Cutting Mode Slot Milling, Internal Coolant + External Coolant (Emulsion) Machine Vertical MC (BT50) Deep depths of cut can shorten machining time. Irregular helix fl utes allow surfaces to be fi nished with excellent quality.
Machined Surface
15 AIR FRAME Work Materials [Titanium Alloy]
Multiple internal coolant holes
Unique fl ute geometry
Side Milling, Pocket Milling Excellent cooling effect Coolstar Series (TOOLS NEWS B247G) Key Point on Machining a When machining titanium alloys due to the fact that the thermal conductivity is low heat generated during machining localizes around the cutting edge. This results in welding problems and as such it is necessary to prevent heat generation and to remove the chips effectively. The Coolstar series is designed with multiple through coolant hole in the flutes of the tool. This ensures effective cooling and improves chip evacuation.
Application Example a Due to the use of coolant through the flutes welding is prevented and effective chip evacuation can be achieved.
Ti-6Al-4V Effi ciency Comparison in Trochoid Milling VQ6MHVCH achieves machine 120% more effi ciently compared to conventional.
120% Effi ciency VQ6MHVCH
Continue Milling
Conventional
0500 1000 1500 Corner Breakage Table Feed vf (mm/min)
High rigidity cutter body
Double-sided Rough Pocket Milling insert VPX Series (TOOLS NEWS B250G) Key Point on Machining a 15-5PH is often used for components in the aerospace industry. It has high strength and as such chipping and fracturing of the cutting edge can easily occur. The VPX series has a number of insert geometries and coated tool grades to enable stable machining to be achieved.
Application Example a When compared to a conventional product when using the VPX series with the newly developed MP9130 coated tool grade, efficiency was improved by 200%. Holder VPX200R3004SA25S Insert (Grade) LUGU0904080PNER-M (MP9130) Work Material 15-5PH Cutting Speed vc40 m/min (n425 min-1) Feed fz0.06 mm/tooth (vf102 mm/min) Depth of Cut ap1.8 mm, ae20 mm Coolant Emulsion
Tool life (%) 050 100 150 200 250
APX (MP9130)
Conventional 2 times
17 AIR FRAME Work Materials [Precipitation Hardening Stainless Steel]
Excellent cooling performance
MMS Drill (TOOLS NEWS B180G) Drilling “TRI-Cooling Technology” Key Point on Machining a It has high strength and as such chipping and fracturing of the cutting edge can easily occur. For drilling applications the MMS drill employs a suitable cutting edge geometry and coating to enable stable machining.
Application Example a The end users target was 200 holes, however using the MMS drill it was possible to drill up to 400 holes, double that of the original target. Drill (Grade) MMS0800X3DB (DP7020) Work Material 15-5PH (42HRC) Cutting Speed vc100 m/min (n3980 min-1) Feed f0.2 mm/rev Hole Depth 24 mm Coolant Emulsion
Tool life (hole) 0100 200 300 400
MMS
User's target (Conventional 2 times product)
18 Engine
19 ENGINE Work Materials [Ni-based Superalloy]
Good cutting performance
External and Face HSK-T Tools PSC Tools LS/MJ/MS/MA/RS and Internal Turning (TOOLS NEWS B134G) (Special support) MP9005/MP9015/MP9025 (TOOLS NEWS B214G)
Key Point on Machining a The MP9000 coated tool grade series is available for low speed and medium rough machining applications of Ni based alloys.
Application Example a Based on the examples below, by employing the MP9000 series for low speed medium rough applications tool life was doubled compared to current tool grades.
Holder DCLNL3225P12 Holder DCLNL3225P12 Insert (Grade) CNMG120408-MS (MP9015) Insert (Grade) CNMG120408-LS (MP9005) Work Material Inconel® 718 Work Material Inconel® 625 Cutting Speed vc40 m/min Cutting Speed vc50 m/min Feed f0.2 mm/rev Feed f0.15 mm/rev Depth of Cut ap2 mm Depth of Cut ap0.5 mm Coolant Emulsion Coolant Emulsion
Tool life (min) Tool life (min) 0210 0430 0 03570
MP9015 MP9005
Conventional 2 times Conventional 2 times
20 ENGINE Work Materials [Ni-based Superalloy]
Good cutting performance
External and Face HSK-T Tools US905/VP05RT/VP10RT and Copy Turning (TOOLS NEWS B134G) (TOOLS NEWS B036G)
Key Point on Machining a US905 coated tool grade is available for high speed and medium finish machining applications of Ni based alloys.
Application Example a Based on the example below, by employing the US905 tool grade for high speed finishing applications tool life was increased by up to 2.5 times.
Holder H63TH-PRDCN-H12 Insert (Grade) RCMX1204M0 (US905) Work Material Inconel® 718 Cutting Speed vc100 m/min Feed f0.15 mm/rev Depth of Cut ap0.5 mm Coolant Emulsion
Tool life (min) 042 68 10
US905
Conventional 2.5 times
21 ENGINE Work Materials [Ni-based Superalloy]
Breaker (MediumBM feeds)
Breaker (LowGS feeds)
Good cutting GY Series Copy Turning (TOOLS NEWS B140G) performance
Key Point on Machining a When machining of Ni based alloys it is necessary to use a sharp edge to reduce cutting resistance and overall heat generation. The GY series employs a number of geometries that offers a sharp edge to increase tool life.
Application Example a Stable tool life was achieved when machining WASPALOY®. Holder GYHL2525M00-M25L Insert (Grade) GY2M0600J030N-GS (VP10RT) Work Material WASPALOY® Cutting Speed vc35 m/min Feed f0.05 mm/rev Depth of Cut ap10 mm Coolant Emulsion
MIRACLE ® coating
Carbide substrate (HRA92.0)
VB: 0.122mm VP10RT Further use is possible because of small wear. (after 25 min. machining)
22 ENGINE Work Materials [Ni-based Superalloy]
Double-phased helical rake angles
Tough cutting edge (Convex curve)
High rigidity cutter bodies
Low cutting Machining of upper surface resistance insert of protuberance APX Series (TOOLS NEWS B055G) Key Point on Machining a When machining exotic materials, like Ni-based alloys, due to the fact that the thermal conductivity is low heat generated during machining localizes around the cutting edge that results in work hardening leading to premature tool failure. The APX series offers suitable insert geometries and tool grades to achieve stable machining and increase tool life.
Application Example a Compared to a conventional product tool life was doubled.
Holder APX3000-050A07RA Insert (Grade) AOMT123620PEER-M (MP9130) Work Material Inconel® 718 Cutting Speed vc30 m/min (n190 min-1) Feed fz0.03 mm/tooth (vf40 mm/min) Depth of Cut ap1 mm, ae40 mm Coolant Emulsion
Tool life (min) 06030
APX
Conventional Over 2 times
23 ENGINE Work Materials [Ni-based Superalloy] Multifunctional
Drilling (Helical), Profile Milling ARX ARP (TOOLS NEWS B066G) (TOOLS NEWS B222G)
Key Point on Machining a For the engine casing there are applications that require hole making on the outside of the casing it is possible to use helical drilling to machine these holes. Additionally application may include profile milling.
Application Example a By using a small diameter radius end mill it is possible to machine large diameter holes via helical machining. Holder ARX35R142SA12S Insert (Grade) RDMW0724M0E (VP15TF) Work Material Inconel® 718 Cutting Speed vc30 m/min Feed f0.2 mm/rev (Helical Cutting) Hole Depth 20 mm (1 mm/rev), Hole dia. 25 mm Coolant Emulsion
y Helical Cutting a Setting a tool's centre excursion ødc = øDH - øD1
1 Tool's center Required bore Tool's cutting excursion diameter diameter øD
ødc øDH VB: 0.08mm Further use is possible because of small wear. (after 7 min. machining) 24 ENGINE Work Materials [Ni-based Superalloy]
Strong, negative flute and special rake edge withstands high temperatures and loads.
CERAMIC End mill (TOOLS NEWS B228G) Ultra-high-effi ciency performance Drilling (Helical), Profile Milling Key Point on Machining Ni based difficult-to-cut heat resistant alloys Tensile strength such as Inconel® 718 soften at temperatures exceeding 800ºC. At these temperatures, difficult-to-cut materials become easier to machine because their bearing and tensile Proof strength strengths are lowered. Ceramic end mills can work effectively at these high temperatures and self generate the heat required to soften the machined material through ultra-high feeds and speeds. Tensile Strength, Tensile Proof strength [MPa] 800°C Application Example Temperature Tool life comparison with Inconel®718 (HRC45) Ceramic end mill After cutting (12 m) Before cutting Edge Corner radius Revolution : 19,098 min-1 CE6SRB Feed rate : 6,875 mm/min
CE6SRB Broken after 42 m machining 2.8 times 30 m
$° Variable curve
SMART MIRACLE Coating
Variable pitch Finish Profile Milling SMART MIRACLE Vibration Control Newly designed ball nose end mill radius cutting edges (TOOLS NEWS B197G) reduce vibration Key Point on Machining a When machining Ni-based alloys which have low thermal conductivity and are subjected to work hardening, well-balanced cutting edge and superior coating grade are required. The latest SMART MIRACLE vibration control ball nose end mills have variable pitch geometry with newly designed radius-cutting-edges to reduce vibration.
Application Example a Achieved 1.5 times longer tool life in stable machining without vibration. End mill (ø 6/R3) 4 flute Smart Miracle taper ball nose end mill (Non-stocked item) Work Material Inconel® 718 Cutting Speed vc113 m/min (n6000 min-1) Feed fz0.06 mm/tooth (vf1440 mm/min) Depth of Cut ap0.4 mm, ae 0.5mm Coolant Emulsion
Tool life (Number of work pieces) 0 0.5 1
SMART MIRACLE
Conventional 1.5 times
26 ENGINE Work Materials [Titanium Alloy]
Radial Accuracy
Optimum Cutting Edge Design
6-fl ute Peripheral Cutting Edge Finish Profile Milling VQT6UR 3-fl ute End Barrel End Mill for Cutting Edge Finish Cutting of Titanium Alloys (TOOLS NEWS B232G) Key Point on Machining a Nose radius suitable for fillet milling, also tangential form radius fit composite blade surface machining. 3-flute end cutting edge improves chip evacuation and irregular pitch designed 6-flute peripheral cutting edge prevents from chattering. Tangential form radius makes highly efficient machining with larger pick feed.
Application Example a Achieved 5 times longer tool life in stable machining by variable pitch geometry.
Workpiece Ti-6Al-4V Tool VQT6URR020R085S10 Revolution n2546 min-1 Feed per Tooth fz0.03 mm/tooth Depth of Cut ap4.0 mm, ae0.3 mm Tilt Angle 8° Overhang Length 40 mm Cutting Mode External Coolant (Emulsion) Machine 5-axis MC (HSK63)
Comparison of Tool Life in Titanium Alloy
VQT6UR VQT6UR
Conventional Fractures Fractures
0 204060 Conventional Cutting Length (m) 27 ENGINE Work Materials [Ni-based Superalloy]
Excellent cooling effect
MMS Drill (TOOLS NEWS B180G) Drilling “TRI-Cooling Technology”
Key Point on Machining a The key is how to cool the cutting edge when drilling Ni-based alloys. It is possible to extend tool life greatly by using a solid carbide drill that employs TRI-Cooling through coolant technology with a high-pressure coolant supply.
Application Example a 15 times longer tool life is achieved when applying high- pressure internal coolant and TRI-cooling technology. Drill (Grade) MMS0610X3DB (DP7020) Work Material Inconel® 718 Cutting Speed vc14 m/min Feed f0.06 mm/rev Hole Depth 15 mm Coolant Emulsion
Tool life (hole) 010155
MMS: Internal coolant (7 MPa) 15
MWS: Internal coolant 1 VB: 0.21mm (1.5 MPa) 15 times MWE: External coolant 1
28 ENGINE Work Materials [Titanium-aluminium Alloy]
SMART MIRACLE Coating
ZERO- μ SURFACE
Superior vibration Finish Profile SMART MIRACLE resistance ENDMILL SERIES Milling （TOOL NEWS B197J） Key Point on Machining a Titanium-aluminium alloy has low thermal conductivity and tends to concentrate heat on the cutting edge and moreover scratches can occur easily on the cutting surface when cutting Titanium-aluminium alloy. Therefore, it is important to remove heat on the cutting edge efficiently and to evacuate chips smoothly. The Smart Miracle end mills series with an optimum balance of sharpness and smoothness of the coating layer due to Mitsubishi original smoothening treatment enables stable cutting.
Application Example a Smoothening treatment of the coating layer reduces cutting resistance and improves tool life.
End mill VQMHVRBD1200R100 Work Material Titanium-aluminium Alloy Cutting Speed vc60 m/min (n1592 min-1) Feed fz0.08 mm/tooth (vf509 mm/min) Depth of Cut ap 2 mm, ae 1 mm Coolant Emulsion
Tool life (min) 015304560
SMART MIRACLE
Conventional 2 times
29 ENGINE Work Materials [Titanium Alloy]
Good cutting performance
External and Face and Internal Turning HSK-T Tools LS/MS/RS (TOOLS NEWS B134G) MT9005/MT9015 (TOOLS NEWS B214G)
Key Point on Machining a Rough estimate of the tool life is 120 minutes at 80m/min, 60 minutes at 120m/ min, when finish-machining titanium-alloy. Non-coated grades are the first recommendation.
Application Example a By setting the correct cutting speed longer tool life can be achieved. Holder H63TH-DCLNR-DX12 Insert (Grade) CNMG120408-LS (MT9015) Work Material Ti-6Al-4V Cutting Speed vc80, 120 m/min Feed f0.15mm/rev Depth of Cut ap0.25 mm Coolant Emulsion LS Breaker Tool life (min) 0609012015018021030
Cutting Speed vc80 m/min
Cutting Speed vc120 m/min
30 ENGINE Work Materials [Maraging Steel]
Good cutting performance
External and Face HSK-T Tools FJ/MJ/MS/GJ and Internal Turning (TOOLS NEWS B134G) VP05RT/VP10RT/VP15TF (TOOLS NEWS B036G)
Key Point on Machining a For rough machining of maraging steel shafts, generally cBN tool grades are used. However for hard material ranges it is possible to use the VP05RT coated tool grade. Application Example a Compared to the conventional tool grade double the tool life was achieved when using the VP05RT coated tool grade. Holder PSC63-DDJNR Insert (Grade) DNMG150412-MS (VP05RT) Work Material Maraging Steel (48-50HRC) Cutting Speed vc90 m/min Feed f0.23 mm/rev Depth of Cut ap2 mm Coolant Emulsion MS Breaker Tool life (min) 0105
VP05RT
Conventional 2 times
31 ENGINE Work Materials [Ni-based Superalloy]
JT Holder External and Face Tool wear Turning minimization Key Point on Machining a When machining heat resistance materials if heat generation can be prevented then tool life can be achieved. Application Example a The example below shows the tool life increase when using the external coolant system JT series. An increase of over 1.5 time and more can be obtained when compared to conventional external cooling. Holder PSC50-DCJNR Insert (Grade) CNMG120408-MJ (US905) Work Material Inconel® 718 Cutting Speed vc150 m/min Feed f0.1 mm/rev Depth of Cut ap0.3 mm Coolant Emulsion Discharge Pressure and Tool Life Changes : Machined Length (m) 0 200 400 600 800 1000 1200
JT discharge pressure: 20MPa
JT discharge pressure: 10MPa
JT discharge pressure: 5MPa
JT discharge pressure: 1MPa
JT discharge pressure: 0.3MPa
External Coolant
Wear standard = 0.2mm 32 Landing Gear
33 LANDING GEAR Work Materials [Titanium Alloy] Arranging the inserts vertically
Cutting force
V formation of the clamping face Rough Milling Convex curve cutting edge VFX Series Key Point on Machining (TOOLS NEWS B182G) a When rough machining of titanium alloys problems such as chipping and abnormal damage can occur if using tools with low rigidity. The VFX series offers a design that has high rigidity and also insert geometry that employs a convex cutting edge to improve cutting edge stability.
Application Example a When used with a high pressure internal coolant system tool life can be increased by up to 7 times compared to a conventional tool. Holder VFX6-080A05A075R Insert (Grade) XNMU190912R-LS (MP9130) Work Material Ti-5Al-5Mo-5V-3Cr Cutting Speed vc40 m/min (n160 min-1) Feed fz0.1 mm/tooth (vf80 mm/min) Depth of Cut ap65 mm, ae5 mm Coolant Emulsion (8 MPa)
Tool life (min) 0609012015018021030
VFX
Conventional Over 7 times
34 LANDING GEAR Work Materials [Titanium Alloy]
Double-phased helical rake angles
Tough cutting edge (Convex curve)
High rigidity cutter body
Rough Pocket Milling Low cutting resistance insert APX Series (TOOLS NEWS B055G) Key Point on Machining a When rough machining of titanium alloys due to the type of chips generated problems relating to chipping and fracturing are common. The APX series inserts employ a curved cutting edge to reduce cutting resistance and rigid tool body with through coolant to achieve stable machining.
Application Example a Even when used with long overhang applications the combination of the screw-in head with a carbide shank stable machining was achieved. Holder (Screw-in type) APX3000R254M12A35 SC25M12S125SW Insert (Grade) AOMT123620PEER-M (MP9120) Depth 80mm Work Material Ti-6Al-4V Cutting Speed vc40 m/min (n510 min-1) Feed fz0.08 mm/tooth (vf160 mm/min) Depth of Cut ap6 mm, ae25 mm Coolant Emulsion
Edge condition (85min.)
Screw-in head
Carbide shank
35 LANDING GEAR [ ] Work Materials Titanium Alloy %° Wider chip pocket %° $° Variable pitch
$° Variable curve
SMART MIRACLE Coating
Finish Profile Variable pitch Milling
SMART MIRACLE Newly designed Vibration Control radius cutting edges ball nose end mill reduce vibration Key Point on Machining (TOOLS NEWS B197G) a When rough machining of titanium alloys due to the type of chips generated problems relating to vibration can easily occur. To prevent these problem the SMART MIRACLE vibration control end mill was developed. The series has irregular pitch and a newly developed radius geometry to overcome the problems related to vibration.
Application Example a Stable machining was achieved, and tool life was increased by 3 times due to the increase in the number of flutes. End mill VQ4SVBR0600 Work Material Ti-10V-2Fe-3Al Cutting Speed vc200 m/min (n5300 min-1) Feed vf1590 mm/min Depth of Cut ap1.0 mm, ae0.5 mm Coolant Emulsion
Tool life (min) 0609030
VQ4SVB 3 times
VQ6SVB (increased number of teeth)
36 LANDING GEAR Work Materials [Titanium Alloy]
High Precision
High Rigidity
Finish Pocket Milling
Low Cost Exchangeable Head End Mills iMX Series (TOOLS NEWS B200G) Key Point on Machining a When rough machining of titanium alloys due to the type of chips generated problems relating to vibration can easily occur. To prevent these problem the iMX series also has a range of exchangeable heads that offer vibration resistance properties. Additionally chip evacuation can also be improved leading to stable machining.
Application Example a Stable machining without vibration was achieved resulting in an increase in tool life of up to 7 times. Head (Grade) IMX16C10HV160R10016 (EP7020) Holder IMX16-U16N056L110C Work Material Ti-6Al-4V ae 0.5mm Cutting Speed vc150 m/min (n3000 min-1) Feed fz0.05 mm/tooth (vf1500 mm/min) ap 12mm Depth of Cut ap12 mm, ae0.5 mm Coolant Emulsion
Tool life (min) 0609030
iMX No vibration
Conventional 7 times
Chatter mark
37 LANDING GEAR Work Materials [Titanium Alloy]
High Precision
High Rigidity Finish Pocket Milling
Low Cost Exchangeable Head End Mills iMX Series (TOOLS NEWS B200G) Key Point on Machining a When finish machining of titanium alloys due to the type of chips generated problems relating to vibration can easily occur. To prevent these problem the iMX series also has a range of exchangeable heads that offer vibration resistance properties. This ensures that even when using long overhang vibration can be minimized leading to stable machining. Application Example a Stable machining without vibration was achieve that resulted in double the tool life.
Head (Grade) IMX20C4HV200R10040 (EP7020) øD Holder IMX20-U20N070L130C Overhang length 125 mm Work Material Ti-5Al-5Mo-5V-3Cr Cutting Speed vc38 m/min (n600 min-1) 2D Feed fz0.04 mm/tooth (vf96 mm/min) Depth of Cut ap30 mm, ae5-20 mm Coolant Emulsion
Tool life (min) 0609030
ae5-20 mm iMX
ap30 mm
Conventional 2 times
38 LANDING GEAR Work Materials [Titanium Alloy]
Outstanding sharpness and high edge strength
Excellent cooling performance
Improved chip removal Drilling MNS Drill (TOOLS NEWS B135G)
Key Point on Machining a When machining titanium alloys due to the fact that the thermal conductivity is low heat generated during machining localizes around the cutting edge. This results in welding problems and as such it is necessary to prevent heat generation and to remove the chips effectively. The MNS drill range is designed to increase the cooling effect and to discharge the chips via a unique flute geometry resulting is stable machining of titanium alloys.
Application Example a Stable machining can be achieved due to effective cooling and chip evacuation.
Drill (Grade) MNS0600X20DB (TF15) Work Material Ti-6Al-4V Cutting Speed vc30 m/min Feed f0.06 mm/rev Hole Depth 120 mm Coolant Emulsion (3 MPa)
39 RESPONSIVE, ATTRACTIVE, PROACTIVE
Mitsubishi Materials Corporation, Metalworking Solutions Company, offers a “Comprehensive Craftsman Studio” which addresses the individual needs and requirements of our customers’ in order to make their business successful. Here the Machining Technology Center is the front-line base. It is fully equipped with advanced machines, measuring instruments, extensive cutting data, knowledge, technologies as well as having a team of highly-experienced technical staff members. All of which allows Mitsubishi Materials Corporation to offer the best solution and services for our valued customers.
We try answering questions and demands from customers around the world by providing detailed solutions to meet our customer's expectations. 応 RESPONSIVE
Training Technical Support Machining Technology Center 攻 Cutting Test 魅 PROACTIVE ATTRACTIVE
We identify the potential needs of Showing and demonstrating. customers and develop innovative tools to Attractive events and practical seminars cultivate markets to widen future business present the new possibilities in machining possibilities. which evoke a feeling of curiosity. 40 Central Japan Technical Center (MTEC Gifu)
Strengthening of total tooling solutions for our cutting tools
In order to provide our customers with a total tooling solution for our cutting tools Mitsubishi Materials has opened 2 technical centers within Japan. In addition to this there are also 4 other locations globally, Spain, North America, China and Thailand. Since establishing the Machining Technology Center (East Japan Technical Center - MTEC Saitama) in 2010, services to our valued customers are provided based on the know-how, that has been developed over the years, this in combination with the use of the latest cutting edge machine tools, measuring equipment and CAM/ CAE software, allows us to provide the most suitable solution to meet our customers’ needs. This experience enables effective use of the Central Japan Technical Center (MTEC Gifu) as our second technical support base in Japan. From the Central Japan Technical Center, we will strive to continue to provide various technical solutions especially for cutting tool customers in Central and West Japan. This particular region has a high density of automotive and aerospace customers.
Direction of Research & Development
Base for developing of New Products Base for providing Solutions
Responding to the common needs Responding to the needs of our customers. developing of new and standard tools. Research on advanced machining technology · Proposal for machining technology. and proposals for exclusively developed tools. · Support for setting up new machining process line. · Proposal for process improvement. · Direct proposal for process improvement. · Independent development. · Cooperated development with customers. · Tooling proposal in collaboration with machine tool builders.
y Machining Technology Center (Machining technology for next generation, education) Driving Force for the y R & D centers (at our 3 main manufacturing plants: Basic technology, Product development) Research & Development Base y Central Research Institute (Development base, Analysis and Evaluation, CAE) y Open Innovation y Human Resources Development (Globalization, Diversifi cation)
State of the Art Machine Tools Recently installed several of the latest machine tools, such as a high rigidity & high power horizontal machining center, a MQL function equipped machining center, a fully 5-axis controlled vertical machining center, an exclusive machining center for machining of CFRP materials, a multi-tasking machine with double head turning axis, a CNC automatic lathe with a frequency vibration cutting function. 41 *OREDO
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