1 / 36

RF 100 Programme 2010

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

orea
Download Presentation

RF 100 Programme 2010

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. RF 100 Programme 2010 Customer PresentationDate: February 10, 2010

  2. 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

  3. 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

  4. 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

  5. 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

  6. 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

  7. RF 100 High Performance End Mills Geometry in detail (flat roughing profile) • optimized roughing profile with new 3 radii design • Advantages • 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 3-Radien-Design

  8. RF 100 High Performance End Mills Advantages (summarisation) • Reduced vibrations allow: • higher feed rates • longer tool life • better surface quality • roughing, finishing and • slotting with 1 tool “High quantities” = Large batch sizes “Low quantities” = Small batch sizes

  9. RF 100 High Performance End Mills deduction of tools in a milling application Standard RF 100 + + = + • Argument: roughing, slotting & finishing = 1 tool !

  10. 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)

  11. RF 100 High Performance End Mills Advantages / Disadvantages

  12. 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).

  13. 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.

  14. RF 100 High Performance End Mills RF 100 Application at “field” customer • Tool: RF 100 U 16 mm, # 5735 • Machine: SK40, 12 KW and max. 8.000 RPM • Application & Material: C45 - Roughing 1 x d (ap = 1 x d / ae = 0,5 x d) • Cutting data (see Cat.): 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

  15. 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.

  16. 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

  17. 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.

  18. 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)

  19. 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)

  20. 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

  21. 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

  22. 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 : Cold Air Jet (Franken-Emuge)End Mill : 3803     Dia. = 20 mm Vf = 1.400 mm/min  ( fz = 0,093 mm ) n = 3800 1/min ae = 9 mm ap = up to 30 mm tool life = ~  54m

  23. RF 100 Programme Customer Test RF 100 VA (source: stainless steel catalogue 09/2009)

  24. 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)

  25. 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

  26. 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.)

  27. 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

  28. RF 100 Programme Customer Test RF 100 H Machine :  Taimac MCFV 1060  HSK63  Max RPM 18.000 1/min Material : 1.2343 52 HRC Coolant : dry Tool : # 3896     Dia. = 16 mm Vf = 636 mm/min  ( fz = 0,08 mm ) n = 1990 1/min ( Vc = 100 m/min ) ae = 1 mm ap = 16,5 mm tool life = 60-70m

  29. 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

  30. RF 100 Programme Customer Test RF 100 Ti • No vibration = very high surface quality (Ra 0,2 – 0,4 µm) • No additional finishing operation necessary

  31. 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

  32. 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

  33. RF 100 Programme Customer Test RF 100 S/F

  34. 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

  35. RF 100 Programme Conclusion • 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 • Do we have a full offering of diameters, length and styles? •  Yes, RF 100 complete programme

  36. 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.

More Related