MFK cast iron cutterHigh efficient cutter with 10 cutting edges per insert

2

MFK - high efficient multi-edge cutter for cast iron• The multi-edge cutter realizes high efficiency cast iron machining.• 10-cornered pentagonal inserts for stable and economical machining.

MFK reduces cutting force by good balanced design and creates an excellent surface finish by controlling chattering

MFK Competitor A

Poor surface by chattering

Surface finish comparison Burr comparison

Cutting direction

Cutting Conditions

Workpiece: GGG60, Dry, VC = 180 m/min, fz = 0.3 mm/t, ap × ae = 3 × 78 mm» Sharp cutting prevents

burr formation «

Cutting conditions

Workpiece: GGG60, Dry, Ø 125 mmVC = 180 m/min, fz = 0.3 mm/t, ap × ae = 3.0 × 62 mm

Cutting conditions

Workpiece: Nodular Cast Iron (with 4 bores), WetVC = 300 m/min, fz = 0.5 mm/t, ap = 2.0 mm

Reduced cutting force and improved edge strength

1 Low cutting force due to large rake angle 2 Dual cutting edge design suppresses fracture

Cutting force comparison

A.R. Max. + 15°

3000

2500

2000

1500

1000

500

0MFK Competitor C

[N]

Cutt

ing

Forc

e

7 % DOWN1000

800

600

400

200

0MFK Competitor D

[N]

Cutt

ing

Forc

e

16% DOWN

PR15

10CV

DCV

DCA

420M

MFK

Competitor E

Competitor F

0 5 10 15 20 25Cutting Time (min)

» Reducing impact load when approaching workpiece «

Primarycutting edge

Secondary cutting edge

Fracture resistance comparison

Burr

3

Toolholder lineup for various applicationsFine pitch type and extra fine pitch type are available.

Fine Pitch (Example : Ø 125, 12 inserts)

• Recommended for low rigidity workpiece

• For wide application range

Extra Fine Pitch (Example : Ø125, 18 inserts)

• Recommended for high rigidity workpiece

• For high efficiency machining

New CVD grade for milling CA420M realizes long tool life and stable machiningInsert grade lineup Wear resistance comparison

CA420MLong tool life

(1st recommendation)

PR1510Stable machining

PR1525Fracture resistance

0.10 10 20 30 40 50

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Cutting Time (min)

Cutting Conditions

Workpiece: Nodular Cast Iron, DryVC = 200 m/min, fz = 0.3 mm/t, ap × ae = 2.0 × 80 mm

CA420MCompetitor G

Wea

r (m

m)

Fracture

Applicable to various applications with wide range lineup of chipbreakers

General use: GM Chipbreaker

Finishing: GL Chipbreaker

Strong edge: GH Chipbreaker

Wiper edge: W Chipbreaker

4

MFK Face Mill

#1 #2

#3 #4

øC øD1

øD

S

G

ød4

ød3b

aE

ød

H

øD1øD

S

ød1

ød

b

a

E

H

VD1øDød2

ød1

ød

øD2 øD2

b

aE

S

H

øD1

øDC1C

S

ød6

ød5

ød4

ød3

G

b

aE

ød

H

ød1

ød1

70°

70°

70°70°

øD2 øD2

Rake Angle ( ° )

Description A.R. R.R.

MFK080R-OO

(MAX.)+15°

-7°

MFK100R-OO -6°

MFK125R-OO…MFK315R-OO

-5°

Toolholder dimensions

DescriptionStan-dard

No. of inserts

Dimension (mm)Drawing Weight (kg)

øD øD1 øD2 ød ød1 ød2 H E a b s ød3 ød4 ød5 ød6 øC øC1 G

Met

ric

Fine p

itch

MFK 080R-11-8T-M N 8 80 89 76 27 20 13

63

24 7 12.4

6.0

– –

– –

–

–

– #1 1.87100R-11-10T-M N 10 100 109 96 32 26 17 28 8 14.4 2.99125R-11-12T-M N 12 125 134 100 40 55

–

33 9 16.4 #2 3.56160R-11-16T-M N 16 160 169 70 14 20 66.7 28

#34.51

200R-11-20T-M N 20 200 209 142 60 110 40 14 25.7 18 26 101.6 327.35

250R-11-24T-M N 24 250 259 10.43315R-11-28T-M MTO 28 315 324 220 22 32 177.8 #4 19.41

Extra

Fine

pitch

MFK 080R-11-10T-M N 10 80 89 76 27 20 13

63

24 7 12.4

6.0

– –

– –

–

–

– #1 1.81100R-11-14T-M N 14 100 109 96 32 26 17 28 8 14.4 2.86125R-11-18T-M N 18 125 134 100 40 55

–

33 9 16.4 #2 3.38160R-11-22T-M N 22 160 169 70 14 20 66.7 28

#34.32

200R-11-28T-M N 28 200 209 142 60 110 40 14 25.7 18 26 101.6 327.10

250R-11-36T-M N 36 250 259 10.07315R-11-44T-M MTO 44 315 324 220 22 32 177.8 #4 18.92

Inch

Fine p

itch

MFK 080R-11-8T O 8 80 89 76 31.75 26 17

63

32 8 12.7

6.0

– –– –

––

–#1 1.76

100R-11-10T O 10 100 109 96 2.98125R-11-12T O 12 125 134 100 38.1 55

–

38 10 15.9 #2 3.65160R-11-16T O 16 160 169 50.8 70 11 19.1 4.62200R-11-20T O 20 200 209 142 47.625 110 40 14 25.4 18 26 101.6 32 #3 7.65250R-11-24T O 24 250 259 10.73315R-11-28T MTO 28 315 324 220 22 32 177.8 #4 19.71

Extra

Fine

pitch

MFK 080R-11-10T O 10 80 89 76 31.75 26 17

63

32 8 12.7

6.0

– –– –

––

–#1 1.70

100R-11-14T O 14 100 109 96 2.85125R-11-18T O 18 125 134 100 38.1 55

–

38 10 15.9 #2 3.44160R-11-22T O 22 160 169 50.8 70 11 19.1 4.44200R-11-28T O 28 200 209 142 47.625 110 40 14 25.4 18 26 101.6 32 #3 7.40250R-11-36T O 36 250 259 10.36315R-11-44T MTO 44 315 324 220 22 32 177.8 #4 19.21

Spare parts and applicable inserts

Description(Metric)

Wedge Wedge screw Wrench Mounting Bolt

Applicable InsertsDescription

(Inch)

Wedge Wedge screw Wrench Mounting Bolt

Applicable Inserts

MFK 080R-11-8T-M

C09N W6X18N TT-15

HH12X35PNMG1106XNEN-GMPNMG1106XNEN-GHPNEG1106XNEN-GLPNEG1106XNER-W

MFK 080R-11-8T

C09N W6X18N TT-15

HH16X40PNMG1106XNEN-GMPNMG1106XNEN-GHPNEG1106XNEN-GLPNEG1106XNER-W

100R-11-10T-M HH16X40 100R-11-10T125R-11-12T-M

–

125R-11-12T

–160R-11-16T-M 160R-11-16T200R-11-20T-M 200R-11-20T250R-11-24T-M 250R-11-24T315R-11-28T-M 315R-11-28T

MFK 080R-11-10T-M

C09N W6X18N TT-15

HH12X35PNMG1106XNEN-GMPNMG1106XNEN-GHPNEG1106XNEN-GLPNEG1106XNER-W

MFK 080R-11-10T

C09N W6X18N TT-15

HH16X40PNMG1106XNEN-GMPNMG1106XNEN-GHPNEG1106XNEN-GLPNEG1106XNER-W

100R-11-14T-M HH16X40 100R-11-14T125R-11-18T-M

–

125R-11-18T

–160R-11-22T-M 160R-11-22T200R-11-28T-M 200R-11-28T250R-11-36T-M 250R-11-36T315R-11-44T-M 315R-11-44T

● : Std. Item ○ : Check availability MTO : Made to order

5

Insert DescriptionDimension (mm)

CVD Coated Carbide

Megacoat Nano

A T X Z CA420M PR1510 PR1525

General

A

X

Z

T

PNMG1106XNEN-GM

17.23

6.35

2.0 2.0

N N N

Tough edge

A

X

Z

T

PNMG1106XNEN-GH N N N

Surface-finish Oriented

T

A

X

Z PNEG1106XNEN-GL 17.18 2.6 2.6 N N N

Wiper insert (2-edge)

X

Z

A

T

PNEG1106XNER-W 18.02 2.0 10.0 N N N

Applicable inserts

Recommended cutting conditions

Recommended application range

Workpiece material Insert grade Cuting speed (m/min) Chipbreakersfz (mm/t) feed per tooth

0.06 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Gray Cast Iron

CA420M 170 ~ 230 ~ 300 GM★

PR1510120 ~ 180 ~ 250

GH✩

PR1525 GL

Nodular Cast Iron

CA420M 150 ~ 200 ~ 250 GM★

PR1510100 ~ 150 ~ 200

GH✩

PR1525 GL

GL GM

W

GH

fz (mm/t)

ap (m

m)

6.0

4.0

2.0

0.1 0.2 0.3 0.4fz (mm/t)

ap (m

m)

GL

GM

W

GH6.0

4.0

2.0

0.1 0.2 0.3 0.4

Workpiece: Gray Cast Iron Workpiece: Nodular Cast Iron

NotesWhen using W type, please use together with GM or GH. If machining over fz = 0.2, insert corner will be damaged. The main cutting edge of W type insert is receding from that of GM and GH. Therefore, the feed rate for the insert next to W type is double of the other inserts.

● : Std. Item ○ : Check availability MTO : Made to order

● 0.25

● 0.3

● 0.12

● 0.2

● 0.25

● 0.1

6

Case studies

GG25 (Gray Cast Iron)

720 1.000

• Machine base• Vc = 160 m/min• fz = 0.16 mm/t(Vf = 782 mm/min)

• ap × ae = 3 × 100 mm• Dry• MFK125R-11-12T (12 inserts)• PNMG1106XNEN-GM (PR1510)

PR1510 Chip removal rate = 235 cc/min

Competitor H (12 inserts) Chip removal rate = 125 cc/min

Light noise and small vibration even increasing cutting speed and feed rate.

GG25 (Gray Cast Iron)

800 800

• Base• Vc = 160 m/min• fz = 0.18 mm/t

(Vf = 917mm/min)

• ap × ae = 3 × 140 mm• Dry• MFK200R-11-20T (20 inserts)• PNMG1106XNEN-GM (CA420M)

CA420M Chip removal rate = 385 cc/min

Competitor I (12 inserts)

Chip removal rate = 167 cc/min

CA420M improved the efficiency by 2.3 times. Small noise and stable machining.

Efficiency

2.3 times

GG30 (Gray Cast Iron)

2.2 m

10 m

• Bed• Vc = 150 m/min• fz = 0.26 mm/t

(Vf = 1,242 mm/min)

• ap × ae = 3 × 100 mm• Dry• MFK160R-11-16T (16 inserts)• PNMG1106XNEN-GM (CA420M)

CA420M Chip removal rate = 372 cc/min

Conventional K (8 inserts)

Chip removal rate = 93 cc/min

CA420M improved the efficiency by 4 times compared to Conventional K.

GGG60 (Nodular Cast Iron)

• Mold part• Vc = 90 m/min• fz = 0.34 mm/t

(Vf = 974 mm/min)

• ap × ae = 2 × 60 mm• Dry• MFK080R-11-8T (8 inserts)• PNMG1106XNEN-GM (PR1525)

PR1525 Machining efficiency: 3 pcs/edge

Competitor J (8 inserts)

Machining efficiency: 1 pcs/edge

Competitor J had chipping after machining 1pc. PR1525 kept good edge condition and stable machining after machining 3 pcs.

Efficiency

4 timesTool life

3 times

Efficiency

2 times

7

TZE00066

www.kyocera-unimerco.com

GERMANYKYOCERA UNIMERCO Tooling GmbHHammfelddamm 6 · 41460 NeussPhone +49 (0)2131 1637 115Fax +49 (0)2131 1637 152kutde@kyocera-unimerco.com

ITALYKYOCERA UNIMERCO Tooling GmbH, Italy BranchVia Torino 51 · 20123 Milan Phone +39-02 00620 845Fax +39-02 00620 848kutde@kyocera-unimerco.com

SPAINKYOCERA UNIMERCO Tooling GmbH, Spain BranchAvenida Manacor 4 · 28290 Las Matas, MadridPhone +34-91-631-83-92-802Fax +34-91-631-82-19kutde@kyocera-unimerco.com

POLANDKYOCERA UNIMERCO Tooling Sp. z o.o.ul. Gwiaździsta 66, 53-413 WrocławPhone (+48) 71 381 12 15Fax (+48) 71 381 12 16kutde@kyocera-unimerco.com

FRANCEKYOCERA Fineceramics S.A.S.21 Rue de Villeneuve · 94583 RungisPhone +33 (0) 1 41 73 73 40Fax +33 (0) 1 56 72 18 94kutde@kyocera-unimerco.com

TURKEYKYOCERA UNIMERCO Tooling GmbH, Turkey Liaison O�ceBuyukdere Caddesi 195 · Levent, IstanbulPhone +90 (0) 212 703 3165Fax +90 (0) 212 324 7618kutde@kyocera-unimerco.com

UNITED KINGDOMKYOCERA UNIMERCO Tooling Ltd.101 Attercli�e Road · She�eld S4 7WWPhone +44 (0)1142 788787Fax +44 (0)1142 757155uksales@unimerco.com

SWEDENKYOCERA UNIMERCO Tooling ABSagaholmsvägen 9 · 553 02 JönköpingPhone +46 036-34 46 00Fax +46 036-31 32 00umse@unimerco.com

NORWAYKYOCERA UNIMERCO Tooling A/SKarihaugveien 89 · 1086 OsloPhone +47 22 72 06 02Fax +47 22 30 92 20umno@unimerco.com

DENMARKKYOCERA UNIMERCO Tooling A/SDrejervej 2 · DK-7451 SundsPhone +45 97 14 14 11Fax +45 97 14 14 86umdk@unimerco.com

RUSSIAKYOCERA Fineceramics GmbH, Russia Representative O�ceProspekt Andropova 18, Bldg. 6, O�ce No. 4-03 · 115432 MoscowPhone +7 (495) 258 70 27Fax +7 (495) 258 70 27kutde@kyocera-unimerco.com