mfpn face mill - cobotec
TRANSCRIPT
MFPN Face MillHigh e�cient milling cutter with double sided inserts
2
Double Sided Pentagonal InsertsO�ering 10 edges per insert makes the MFPN a cost e�ective solution for your machining process. The insert pocket with two contact faces provides high accuracy and spreads the cutting force evenly.
Low Cutting ForceGood shearing e�ect, which is promoted by the high axial rake angle (Max.+10°), provides a better bite into the work-piece which lowers the cutting force signi�cantly.
Dual Cutting Edge Design (High Toughness)Primary Edge makes chips thinner and reduces impact force.
47.5° cutting edge angle
Two-face holding
fz ( mm/ t) Feed per tooth
ap (m
m) D
epth
of c
ut
0.5
0.06 0.1 0.2 0.3 0.4 0.5 0.6
32
456
8
10
12
0.7
MSRS
MFPNConv entional
+10°(A.R.)
Competitor C( PV D neg ativ e ins ert)
N o. of impacts
Competitor D( PV D neg ativ e ins ert)
PNMU1205ANER-GM(PR1225)
0.5mm/t
0.6mm/t
0.7mm/t
0 5 10 15 20
×
×○
×××
×××
fz=0.5mm/t fz=0.6mm/t fz=0.7mm/t
I ns ert cracks
N o cracks : :○×
Cutting conditions: Workpiece: 1.7223 (38~42HS) (workpiece with 20mm width slot) Machine: BT50 M/C, Vc=100m/min, fz=0.5~0.7mm/t, apxae=2x100mm
Comparison of fracture resistance
2000
1600
1200
800
Competitor A Competitor B
Principal force
Feed force
Back force
400
0GM SM
(1) - 16% reduction in comparison to competitor A(2) - 14% reduction in comparison with GM
(1)
(2)
Cutting conditions: Workpiece: C50, Vc=150m/min, fz=0.1mm/t, apxae=5x105 mm, Machine: M/C (BT50)
Comparison of cutting force
Wiper edgeSecondary cutting edge
Primary cutting edge
The down arrow symbol (↓) indicates wiper cutting edge. When attaching inserts, make sure that the arrow symbol points downward.
Combination with wiper insert
Chipbreaker Combination with Wiper
GM Yes
SM Yes
GH No
GL No
3
Long tool life with MEGACOATKYOCERA’s PVD coated carbide for milling improves tool life and high speed capability due to its superior heat resistance and hardness. The high thermal stability and surface smoothness provides excellent surface �nish.
Excellent Chip EvacuationSmooth chip evacuation reduces chip-biting.
* To improve surface �nish, please attach one wiper insert to cutter.
Har
dnes
s(G
Pa)
O x idation temperatu re
40
30
20
10
0 200 400 600 800 1000 1200
TiCN
TiC
TiN
MEGACOAT
TiAlNInsert Grades Workpiece Material
PR1535 Stainless Steel/TiNPR1525 SteelPR1510 Cast IronCA6535 Heat resistant Alloy
1
0.06 0.12 0.25
2
3
4
0.2
ap (m
m)
fz ( mm/ t)
W ( T N 1 0 0 M)
W ( P R 1 5 2 5 / P R 1 5 1 0 )
Chipbreaker Applications Shape
GM General
SM Low cutting force
GH Heavy milling
GL Surface �nish oriented
W Wiper Insertfor �nishing
1
0.06 0.1 0.2 0.3 0.4 0.5 0.6 0.7
3
6SM
ap (m
m)
fz ( mm/ t)
GHGM
GL
MEGACOAT
HS
b
Ød
Ød2
Ød1
ØDØD1
b
Ød
a
HS
ØD
ØD1
E
E
aØd1
HS
ØD
ØD1
b
Ød
Ød3
Ø26
Ød2
Ød1
E
a
S
ØD
ØD1
H
Ø22Ø18
Ø32
b
Ød
Ø177.8
Ød1
E
Ø101.6
a
Ød4
Fig.1 Fig.2 Fig.3 Fig.4
■ MFPN45 Face Mill
HS
b
Ød
Ød2
Ød1
ØDØD1
E
a
Fig.1
Rake Angle(°)
A.R. R.R.
max +10°øD=63 -10°øD=80 -8°øD=100-315 -6°
● Toolholder Dimension
Description
Sta
ndar
d
No.
of
Inse
rt Dimension (mm)
Sha
pe
Weight(kg)
ShimøD øD1 ød ød1 ød2 H E a b ød3 ød4
Bor
e D
ia. m
m s
pec
Coa
rse
pitc
h
MFPN 45063R-4T-M ● 4 63 76 22 19 11 40 21 6.3 10.4
- -Fig.1
0.5
Yes
45080R-5T-M ● 5 80 93 27 22 1350
24 7 12.4 1.145100R-6T-M ● 6 100 113 32 48
-30 8 14.4
Fig.21.4
45125R-7T-M ● 7 125 13840
58
6332 9 16.4
2.645160R-8T-M ● 8 160 173 68 66.7 14 20
Fig.33.8
45200R-10T-M ● 10 200 21360 110
101.640 14 25.7
18 266.4
45250R-12T-M ● 12 250 263 9.145315R-14T-M □ 14 315 328 - 80 - - Fig.4 21.3
Fine
pitc
h
MFPN 45063R-5T-M ● 5 63 76 22 19 11 40 21 6.3 10.4Fig.1
0.5
-
45080R-6T-M ● 6 80 93 27 22 1350
24 7 12.4 1.0 45100R-8T-M ● 8 100 113 32 48
-30 8 14.4
Fig.21.4
45125R-10T-M ● 10 125 13840
58
6332 9 16.4
2.545160R-12T-M ● 12 160 173 68 66.7
Fig.33.8
45200R-14T-M ● 14 200 21360 110
101.640 14 25.7
18 266.5
45250R-16T-M ● 16 250 263 9.145315R-18T-M □ 18 315 328 - 80 - - Fig.4 21.7
Ext
ra fi
ne p
itch
MFPN 45063R-6T-M ● 6 63 76 22 19 11 40 21 6.3 10.4
- -Fig.1
0.5
-
45080R-8T-M ● 8 80 93 27 22 1350
24 7 12.4 1.145100R-10T-M ● 10 100 113 32 48 - 30 8 14.4
Fig.21.3
45125R-13T-M ● 13 125 13840
58 -
6332 9 16.4
2.645160R-16T-M ● 16 160 173 68 66.7 14 20
Fig.33.9
45200R-18T-M ● 18 200 21360 110 101.6 40 14 25.7 18 26
6.645250R-20T-M ● 20 250 263 9.3
Bor
e D
ia. I
nch
spec
Coa
rse
pitc
h
MFPN 45080R-5T O 5 80 93 25.4 22 1350
27 6 9.5
- -
Fig.1 1.1
Yes
45100R-6T O 6 100 113 31.75 48-
32 8 12.7Fig.2
1.445125R-7T O 7 125 138 38.1 58
63
36 10 15.9 2.645160R-8T O 8 160 173 50.8 72 38 11 19.1 4.045200R-10T O 10 200 213
47.625 110101.6
40 14 25.418 26 Fig.3
6.745250R-12T O 12 250 263 9.445315R-14T □ 14 315 328 - 80 - - Fig.4 21.2
Fine
pitc
h
MFPN 45080R-6T O 6 80 93 25.4 22 1350
27 6 9.5 Fig.1 1.1
-
45100R-8T O 8 100 113 31.75 48-
32 8 12.7Fig.2
1.445125R-10T O 10 125 138 38.1 58
63
36 10 15.9 2.745160R-12T O 12 160 173 50.8 72 38 11 19.1 4.045200R-14T O 14 200 213
47.625 110101.6
40 14 25.418 26 Fig.3
6.945250R-16T O 16 250 263 9.645315R-18T □ 18 315 328 - - - Fig.4 21.5
Ext
ra fi
ne p
itch
MFPN 45080R-8T O 8 80 93 25.4 22 1350
27 6 9.5 Fig.1 1.1
-
45100R-10T O 10 100 113 31.75 48-
32 8 12.7Fig.2
1.345125R-13T O 13 125 138 38.1 58
63
36 10 15.9 2.745160R-16T O 16 160 173 50.8 72 38 11 19.1 4.045200R-18T O 18 200 213
47.625 110 101.6 40 14 25.4 Fig.36.9
45250R-20T O 20 250 263 9.6●： Standard Item O： Check Availability □： Made to Order※�Dimension S: 6mm (GM, SM, GH Chipbreakers), 5mm (GL Chipbreaker), 3mm (W Chipbreaker: PR15 Series)
4
■ Spare PartsSpare parts from (mm/inch common spec)
Description
Spare Parts
Clamp ScrewWrench
Shim Shim Screw Wrench Anti-seize Compound
Arbar Clamp ScrewTT DTM
MP-1
Coa
rse
pitc
h MFPN 45063R-4T-M
- MP-1
HH10x30MFPN 45080R-5T-M SB-50140TR TT-15 MFPN-45 SPW-7050 LW-5 HH12x35MFPN 45100R-6T-M
-~
45315R-14T-M
Fine
pitc
h
MFPN 45063R-5T-M
- - - - MP-1
HH10x30MFPN 45080R-6T-M SB-50140TR TT-15 HH12x35MFPN 45100R-8T-M
-~
45315R-18T-M
Ext
ra fi
ne p
itch MFPN 45063R-6T-M
- - - MP-1
HH10x30MFPN 45080R-8T-M SB-40140TRN - DTM-15 HH12x35MFPN 45100R-10T-M
-~
45250R-20T-M
MP-1
Coat Anti-seize Compound (MP-1) thinly on portion of taper and thread when insert is fixed.
for Insert ClampRecommended torque is 4.2 Nm.
for Insert ClampRecommended torque is 6.0 Nm.
for Insert ClampRecommended torque is 4.2 Nm.
for Insert ClampRecommended torque is 3.5 Nm.
■ MFPN45 with cylindrical shank
ødh6
S
ℓ
L
øDøD1
● Toolholder Dimension
Description
Sta
ndar
d
No.
of I
nser
t Dimension (mm) Rake Angle(°) Spare Parts
øD øD1 ød L ℓ S A.R. (MAX) R.R.
Clamp Screw Wrench Anti-seize Compound
MP-1
MFPN 45050R-S32-3T ● 3 50 6332 110 30 6
(5) +10°-12° SB-50140TR TT-15
MP-145063R-S32-4T ● 4 63 76 -10°45080R-S32-5T ● 5 80 93 -8°
※�Dimension S: 6mm (GM, SM, GH Chipbreakers), 5mm (GL Chipbreaker), 3mm (W Chipbreaker: PR15 Series)MP-1
Coat Anti-seize Compound (MP-1) thinly on portion of taper and thread when insert is fixed.
Recommended torque is 4.2 N •m.
■ How to mount an insert
S ide s u rface of ins ert
Cons traints u rface
T op s u rface of ins ert
I ns ert corneridentification nu mb er
1. Be sure to remove dust and chips from the insert mounting pocket.2. After applying anti-seize compound, while pressing the insert against the constraint surfaces, put the screw into the hole of the insert and tighten the screw with appropriate torque.
See Fig. 1 and Fig. 2.3. After tightening the screw, make sure that there is no clearance between the insert seat surface and the bearing surface of the holder and between the insert side surfaces
and the constraint surface of the holder. 4. To change the cutting edge of the insert, turn the insert counterclockwise (see Fig. 3). Insert corner identification number is stamped on the top surface of insert (Fig.
4). To protect the wiper edge, use the corners of insert in the sequence of corner numbers.
5
■ Improved Surface Finish by Wiper Insert
Workpiece: 1.0040Cutting Conditions: Vc = 200m/min (n=510min-1), fz = 0.2 mm/t (Vf=1,020mm/min), MFPN45125R-10T ap×ae = 3×100mm, DRY
Chipbreaker Combination Insert Surface Finish Workpiece Surface Surface Finish
Wiper Insert
PR1525(PNMU-GM…9)
(PNEU-W…1)
Ra = 0.48μmRz = 3.39μm
GL Chipbreaker
PR1225(PNEU-GL…10)
Ra = 2.50μmRz = 11.41μm
When the surface roughness is unstable, please set the cutting speed higher, the feed rate lower or use a wiper insert (TN100M).
1.5mm
25μ
m
Classification of usageP
Steel ★ ■
★： Roughing / 1st Choice ： Roughing / 2nd Choice
■： Finishing / 1st Choice ： Finishing / 2nd Choice
(Hardened material is applicable only under 45HRC)
Die Steel ★ ■
M Stainless Steel ★
KGray Cast Iron ★
Nodular Cast Iron ★
N Non-ferrous Material
SHeat-resistant Alloy ★
Titanium alloy ★
H Hardened material
ShapeHandled insert indicates Right-Hand Description
Dimension (mm) MEGACOAT NANOcarbide
MEGACOATcarbide
CVDcarbide Cermet
A T ød X Z PR1535 PR1525 PR1510 PR1225 PR1210 CA6535 TN100M
General
A
T
Ød
Ød
Z
X
PNMU 1205ANER-GM
17.88 5.56
6.2
2.0 2.0
● ● ● ● ● ●
Low cutting force
A Ød
TX
ZPNMU 1205ANER-SM ● ● ● ● ● ●
Tough Edge
A Ød
TX
Z PNMU 1205ANER-GH 17.98 6.17 ● ● ● ● ● ●
High Precision
A Ød
TX
ZPNEU 1205ANER-GL 17.51 5.56 2.7 2.7 ● ● ● ●
2-edge Wiper Insert
ØdA
T
rε600
X
Z
PNEU 1205ANER-W 17.51 5.56 2.3 8.1 ● ● ●
Milling PurposeFacemill-type Chipbreaker
Coarse pitch Fine pitch Extra
fine pitch GM SM GH GL W
General milling of steel and alloy steel
Steel and alloy steel (at chattering due to low rigidity machine or poor clamping power)
Productivity oriented (Running cost decrease)
General milling of stainless steel
Stainless steel (at chattering due to low rigidity machine or poor clamping power)
Cast iron (for processing efficiency improvement)
Cast iron (Over ap=4 mm, over fz=0.35 mm/t)
● Reference for selecting a facemill and insert suitable for each milling purpose
■ Inserts
6
■ Case studies
1.4301/ X5CrNi18-10• Case• Vc=90m/min• ap x ae = 0.4x50mm• fz=0.19mm/t• Vf= 410mm/min• without coolant• MFPN45080R-6T (6 edges)
• PNMU1205ANER-SM (PR1225)
500
600
800
MFPN（PR1225）
Competitor M
•Even when the cutting depth, cutting speed and feed rate cannot be raised due to the low rigidity of workpiece, MFPN facemill enables stable milling without chattering and also has an improved tool life of 1.5 times.
1.5 pcs/edge
1 pcs/edge
42CrMo4Constructionmachine part• Vc=250m/min• ap×ae=2~3 × 75mm• fz=0.15mm/t
(Vf=900mm/min)• DRY• MFPN4580R-6T
(6 edges)• PNMU1205ANER-SM
(PR1225)
face milling
MFPN（PR1225）
Competitor B
•MFPN cutter improved machining efficiency 2.1 times of the Competitor B without changing spindle load.
•MFPN cutter was very stable at the entrance and exit of the machining. It controls chatter and remains stable even with low rigid machine.
202cc/minChip evacuation rate
94cc/min Chip evacuation rate
■ Recommended cutting condition
★: 1st Recommendation ✩: 2nd Recommendation
Chi
pbre
aker
Workpiece Material fz (mm/t)
Vc (m/min) Recommended Insert Grade
MEGACOAT NANO CVD
PR1535 PR1525 (PR1225) PR1510 (PR1210) CA6535
GM
Carbon Steel 0.1～0.2～0.4 - ★�120～180～250 - -
Alloy Steel 0.1～0.2～0.4 - ★�100～160～220 - -
Mold Steel 0.1～0.2～0.35 - ★�80～140～180 - -
Austenitic Stainless Steel 0.1～0.2～0.4 ☆�100～150～200 - - -
Martensitic Stainless Steel 0.1～0.2～0.4 - - - ☆�180～240～300
Precipitation Hardened Stainless Steel 0.1～0.2～0.3 ★�90～120～150 - - -
Gray Cast Iron 0.1～0.2～0.4 - - ★�120～180～250 -
Nodular Cast Iron 0.1～0.2～0.35 - - ★�100～150～200 -
Ni-base Heat resistant Alloy 0.1～0.12～0.2 - - - ★�20～30～50
SM
Carbon Steel 0.06～0.12～0.25 - ☆�120～180～250 - -
Alloy Steel 0.06～0.12～0.25 - ☆�100～160～220 - -
Mold Steel 0.06～0.1～0.2 - ☆�80～140～180 - -
Austenitic Stainless Steel 0.06～0.12～0.25 ★�100～150～200 - -
Martensitic Stainless Steel 0.06～0.12～0.25 - - ★�180～240～300
Precipitation Hardened Stainless Steel 0.06～0.12～0.25 ☆�90～120～150 - - -
Gray Cast Iron 0.06～0.12～0.25 - - 120～180～250 -
Nodular Cast Iron 0.06～0.1～0.2 - - 100～150～200 -
Ni-base Heat resistant Alloy 0.06～0.1～0.15 - - - ☆�20～30～50
Titanium Alloy 0.06～0.08～0.15 ★�40～60～80 - - -
GL
Carbon Steel 0.06～0.12～0.25 - 120～180～250 - -
Alloy Steel 0.06～0.12～0.25 - 100～160～220 - -
Mold Steel 0.06～0.1～0.2 - 80～140～180 - -
Austenitic Stainless Steel 0.06～0.12～0.25 100～150～200 - - -
Martensitic Stainless Steel 0.06～0.12～0.25 - - 180～240～300
Precipitation Hardened Stainless Steel 0.06～0.12～0.25 90～120～150 - - -
Gray Cast Iron 0.06～0.12～0.25 - - 120～180～250 -
Nodular Cast Iron 0.06～0.1～0.2 - - 100～150～200 -
Ni-base Heat resistant Alloy 0.06～0.1～0.15 - - - 20～30～50
Titanium Alloy 0.06～0.08～0.15 40～60～80 - - -
GH
Carbon Steel 0.2～0.4～0.7 - 120～180～250 - -
Alloy Steel 0.2～0.4～0.6 - ☆�100～160～220 - -
Mold Steel 0.2～0.35～0.5 - ☆80～140～180 - -
Gray Cast Iron 0.2～0.4～0.7 - - ☆120～180～250 -
Nodular Cast Iron 0.2～0.35～0.5 - - ☆100～150～200 -
Machining with coolant is recommended for Ni-base Heat Resistant Alloy and Titanium Alloy.
120
75
7
TZE00054
www.kyocera-unimerco.com
GERMANYKYOCERA UNIMERCO Tooling GmbHHammfelddamm 6 · 41460 NeussPhone +49 (0)2131 1637 115Fax +49 (0)2131 1637 [email protected]
ITALYKYOCERA UNIMERCO Tooling GmbH, Italy BranchVia Torino 51 · 20123 Milan Phone +39-02 00620 845Fax +39-02 00620 [email protected]
SPAINKYOCERA UNIMERCO Tooling GmbH, Spain BranchAvenida Manacor 4 · 28290 Las Matas, MadridPhone +34-91-631-83-92-802Fax [email protected]
POLANDKYOCERA UNIMERCO Tooling Sp. z o.o.ul. Gwiaździsta 66, 53-413 WrocławPhone (+48) 71 381 12 15Fax (+48) 71 381 12 [email protected]
FRANCEKYOCERA Fineceramics S.A.S.21 Rue de Villeneuve · 94583 RungisPhone +33 (0) 1 41 73 73 40Fax +33 (0) 1 56 72 18 [email protected]
UNITED KINGDOMKYOCERA UNIMERCO Tooling Ltd.101 Attercli�e Road · She�eld S4 7WWPhone +44 (0)1142 788787Fax +44 (0)1142 [email protected]
SWEDENKYOCERA UNIMERCO Tooling ABSagaholmsvägen 9 · 553 02 JönköpingPhone +46 036-34 46 00Fax +46 036-31 32 [email protected]
NORWAYKYOCERA UNIMERCO Tooling A/SKarihaugveien 89 · 1086 OsloPhone +47 22 72 06 02Fax +47 22 30 92 [email protected]
DENMARKKYOCERA UNIMERCO Tooling A/SDrejervej 2 · DK-7451 SundsPhone +45 97 14 14 11Fax +45 97 14 14 [email protected]