next-generation high feed machining cutter - dijet …dijetusa.com/media/sks...

8
Max. ap=3mm fz=2mm Possible high feed machining with fz=2mm/t at Max. depth of cut (ap)=3mm. HIGH PERFORMANCE HIGH FEED MACHINING DIJET INCORPORATED www.dijetusa.com SKS DIE & MOLD SERIES CATALOG NO. 10021 ® 7.5mm Next-generation high feed machining cutter Improved insert strength of 1.5 times compared with conventional tool. • Double-sided insert (6 corners) • New PVD coated grade “JC7560” Insert Thickness

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Max. ap=3mm fz=2mmPossible high feed machining withfz=2mm/t at Max. depth of cut (ap)=3mm.

HIGH PERFORMANCEHIGH FEED MACHINING

DIJET INCORPORATEDwww.dijetusa.com

SKSDIE & MOLD SERIESCATALOG NO. 10021

®

7.5mm

Next-generation high feedmachining cutter

Improved insert strength of 1.5 timescompared with conventional tool.

• Double-sided insert (6 corners)• New PVD coated grade “JC7560”

Insert Thickness

Adopted GN surface-hardening treatment on thermal resistant high strength steel gives high hardness of over 65HRC and secures insert pocket and holder against thermal deformation which improves body durability and tool life by 30% or more.

®

SKS ExtremeCopy MillingPocket Milling Helical InterpolationFace Milling

Product Feature

“SKS EXTREME” EXSKS type, next-generation high feed maching cutter Possible high feed machining with fz=2mm/t at max. depth of cut (ap)=3mm.

Economical double-sided insert (6 corners).

Insert thickness of 7.5mm has improved strength of 1.5 times when compared to conventional tool.

Stable high feed machining possible with long reach over L/D=6.

Excellent ramping and helical interpolation, and high efficient pocket milling. *Max. ramping angle 3° is possible with 2 1/2” (63mm) diameter.

Insert adopting new PVD coated grade “JC7560” with improved fracture toughness and achieving longer tool life.

Double-sided

7.5mm Insert

New PVD coated grade “JC7560” against thermal shock

Ti-based nitride layer with excellent welding resistance & low frictionAl-Cr-based nitride layer improved oxidation & thermal resistanceTi-Al-based nitride layer improved wear & thermal resistanceLayer improved adhesionSubstrate improved thermal crack resistance & thermal shock resistance

In case of rough milling, JC7560 improved heat-fracture resistance & impact strength, and achieved longer tool lfe.Section

6,000

5,000

4,000

3,000

2,000

1,000

0

(N)

NEW

DOWN!!

強く高剛

Cutting Performance

Cutting force comparison

Tool Diameter: Φ63mmMaterial: S50CVc=150m/min, fz=1.5mm/t,ap=1.5mm, ae=40mm

18% reduction from conventional tool,10% reduction from competitor D

X Feed forceY Main forceZ Back forceResultant force

Conventional Competitor D EXSKS type

Due to wedge-shape binding on the face of insert, only single screw needed toprevent movement and indexing easy.

Wedge-shaped

2

WNMU090720ZER-PM

WNMU090720ZER-PM

FACE MILLHigh Feed cutter with double sided insertEXSK type

Specifications - Inch

Specifications - Metric

2.00

2.50

3.00

3.00

4.00

5.00

6.00

50

50

52

63

63

63

66

60

80

100

100

125

125

160

160

2.25

2.00

2.00

2.50

2.25

2.25

2.25

55

55

50

50

50

50

50

70

55

70

55

63

55

63

55

.750

.750

1.00

1.25

1.50

1.50

1.50

22.225

22

22

22.225

22

27

27

31.75

27

31.75

32

37.1

40

50.8

40

1.77

2.36

2.85

2.85

3.78

3.34

3.93

40

40

40

48

48

48

48

65

65

70

85

100

100

100

100

.319

.319

.374

.500

.626

.626

.626

5

6.3

6.3

5

6.3

7

7

8

7

8

8

10

9

11

9

.750

.750

.750

1.25

1.50

1.50

1.50

19

19

20

20

20

22

22

32

22

32

32

35

35

43

35

.378

.630

.827

1.02

1.19

2.36

2.36

9.6

9.6

17

17

17

20

20

26

37

26

45

60

60

75

85

1

2

2

2

2

3

3

1

1

2

2

2

2

2

2

3

3

3

3

3

3

3

4

5

6

6

7

8

9

4

4

4

5

5

5

5

6

6

7

7

8

8

9

9

CATALOGNUMBER

CATALOGNUMBER

DIMENSIONS

DIMENSIONS

D

D

EXSKS-4200-75R

EXSKS-5250-75R

EXSKS-6300-100R

EXSKS-6300-125R

EXSKS-7400-150R

EXSKS-8500-150R

EXSKS-9600-150R

EXSKS-4050R

EXSKS-4050R-22

EXSKS-4052R-22

EXSKS-5063R

EXSKS-5063R-22

EXSKS-5063R-27

EXSKS-5066R-27

EXSKS-6080R

EXSKS-6080R-27

EXSKS-7100R

EXSKS-7100R-32

EXSKS-8125R

EXSKS-8125R-40

EXSKS-9160R

EXSKS-9160R-40

PARTS

PARTS

Screw

Screw

Wrench

Wrench

STK

STK

Q

Q

L

L

d

d

D1

D1

a

a

b

b

e

e

d1

d1

INSERT

INSERT

CSW-513H

CSW-513H

A-20

A-20

Note: All cutters are supplied without inserts.

Note: All cutters are supplied without inserts.

•••••••

•••••••••••••••

FIG.

FIG.

Fig. 1Through coolant hole

DD D

LLL

D1D1

D1

d1d1d1

aa

a

dd

db

b

b

.196

.196

.236

.315

.393

.393

.393

8.4

10.4

10.4

8.4

10.4

12.4

12.4

12.7

12.4

12.7

14.4

15.9

16.4

19

16.4

G-Body

Fig. 2Through coolant hole

Fig. 3Without coolant hole

ee

e

R2R2 R2

Set bolt built into the cutter body

®

SKS ExtremeMETRICINCH

Copy MillingPocket Milling Helical InterpolationFace Milling

3

CatalogNumber

Work

Work

Tolerance

WNMU090720ZER-PM

Cavity mold

Mold steel (heat-treated)

30-34HRC

EXSKS-7100R

WNMU090720ZER-PM (JC7560)

325 (min-1)

102 (m/min)

3,980 (mm/min)

1.75 (mm/t)

2.5 (mm)

76 (mm)

Dry

Vertical MC (24Kw)

Die structure part

FC350 GG35

-

EXSKS-6080R

WNMU090720ZER-PM (JC7560)

500 (min-1)

125 (m/min)

5,000 (mm/min)

1.66 (mm/t)

3 (mm)

47 (mm)

Dry

Double column type MC

M 14 7.66 1.94 2

Dimensions (mm)JC7560 JC5118 A T B

PVD Coated

Test Cutting Data1. High feed machining on mold steel

Surface roughing

2. High feed machining on die structure part

Face roughing

Part Name

Part Name

Material

Material

Hardness

Hardness

Tool No.

Tool No.

Insert No.

Insert No.

ap

ap

ae

ae

Coolant

Coolant

Machine

Machine

Cutting Speed

Cutting Speed

Feed Speed

Feed Speed

n

Vc

Vf

fz

n

Vc

Vf

fz

Tool

Tool

CuttingConditions

CuttingConditions

Achieved high metal removal rate (Q=756cm3/min) by 2.4 times compared with conventional tool. Showednormal wear after 80 min. (machining at Max. main spindle load)

No chatter, very smooth cutting. Achieved high metalremoval rate by 1.9 times and longer tool life by 1.5times compared with competitor D. Able to machine for 5 hours.

Result

Result

Overhung length: 220mm

Coming Soon

®

SKS Extreme METRICINCH

Copy MillingPocket Milling Helical InterpolationFace Milling

4

Definition of Corner Shape for Programming

Recommended Data for Profile Milling

• Helical interpolation

Tool

dia

.

ØDh

Ødc

• Ramping

L

Ap

• Calculation of tool pass dia.

ØDc = ØDh - ØDc Tool pass dia. Bore dia. Tool Dia.

• In case of ramping and helical interpolation, apply 70% or less feed speed from standard cutting table.

• In case of drilling, apply 50% or less Z axis feed from standard cutting condition table.

• Long consecutive chips may come out in case of drilling, confirm safe operating conditions.

22222222

.08”

.08”

.08”

.08”

.08”

.08”

71.671.657.363.774.7

101.1132.2171.92.82”2.26”2.94”3.98”5.20”6.77”

687294

100128168218288

2.74”3.74”4.74”6.74”8.74”

10.74”

96100122128156196246316

3.84”4.84”5.84”7.84”9.84”11.84”

33333333

.12”

.12”

.12”

.12”

.12”

.12”

2°24’2°24’

3°2°42’2°18’1°42’1°18’

1°2°24’

3°2°18’1°42’1°18’

33.735.746.749.763.683.6108.5143.51.36”1.86”2.36”3.35”4.35”5.35”

EXSKS-*050EXSKS-*052EXSKS-*063EXSKS-*066EXSKS-*080EXSKS-*100EXSKS-*125EXSKS-*160EXSKS-*200EXSKS-*250EXSKS-*400EXSKS-*400EXSKS-*500EXSKS-*600

CATALOGNUMBER

TOOLDIA.

EFFECTIVECUTTING

DIA.

MAX.DEPTH OF

CUT: AP

RAMPING HELICALINTERPOLATION

MAX.ANGLE

TOTAL CUTTING

LENGTH AT MAX. AP:

L

MIN BOREDIA.: Dh

MAX BOREDIA.: Dh

MAX.DRILLINGDEPTH: Z

50526366801001251602”

2.5”3”4”5”6”

θ°

INC

HM

ETR

IC

• Depth of cut per one circuit should not exceed max. depth of cut Ap

• Down cutting is recommended, so tool pass rotation should be counterclockwise

ØD

c

Corner R for Programming

8.2 mm

Overcut

Remains

Corner R forProgramming (mm)

Over cut(mm)

Remains(mm)

R3.0R3.5R4.0

00

0.025

1.411.301.19

®

SKS ExtremeMETRICINCH

Copy MillingPocket Milling Helical InterpolationFace Milling

5

6810121416681012141668101214166810121416

6810121416681012141668101214166810121416

AP(inch)

AP(inch)

AP(inch)

AP(inch)

AP(inch)

AP(inch)

No. of Teeth 4N

No. of Teeth 7N

Vf(i.p.m.)

Vf(i.p.m.)

Vf(i.p.m.)

Vf(i.p.m.)

Vf(i.p.m.)

Vf(i.p.m.)

M.R.R.Q(inch3/min)

M.R.R.Q(inch3/min)

M.R.R.Q(inch3/min)

M.R.R.Q(inch3/min)

M.R.R.Q(inch3/min)

M.R.R.Q(inch3/min)

N(r.p.m.)

N(r.p.m.)

N(r.p.m.)

N(r.p.m.)

N(r.p.m.)

N(r.p.m.)

2

4

950800650650

--

830700570570

--

950800650650

--

950800650650

--

480430380350350350410370330280280280480430380350350350480430380350350350

750680600550550550650580520460460460750680600550550550750680600550550550

380340300280280280330300260230230230380340300280280280380340300280280280

600540480440440440520470420360360360600540480440440440600540480440440440

300270240220220220260230210180180180300270240220220220300270240220220220

300189133102

--

26016511790--

300189133102

--

300189133102

--

265237209193193193226204182154154154265237209193193193265237209193193193

300267236217217217256228205181181181295268236216216216295268236216216216

239214189176176176208189164145145145239214189176176176239214189176176176

283255227208208208246222198170170170283255227208208208284255227208208208

213191170156156156184163149128128128213191170156156156213191170156156156

32.815.67.33.4--

28.413.66.43.0--

32.815.67.33.4--

41.220.611.05.6--

57.951.845.631.931.921.149.444.639.725.425.416.857.951.845.631.931.921.172.765.045.642.231.921.1

41.033.224.414.89.16.134.928.321.212.47.65.140.333.324.414.79.16.050.636.624.414.79.16.0

65.258.451.648.036.336.356.851.644.839.629.929.965.258.451.648.036.336.382.073.464.848.036.336.3

46.438.033.825.817.010.540.333.129.521.113.98.646.438.033.825.817.010.558.441.837.225.817.010.5

69.862.655.751.151.138.760.353.448.841.941.931.769.862.655.751.151.138.787.778.670.064.251.138.7

Recommended Cutting Conditions - Inch

Carbon Steel(C50, C55)

Below 250HB

Mold Steel(1.2311, P20)

30-36HRC

Die Steel(1.2344, 1.2379)Below 255HB

Gray & NodularCast Iron

(GG, GGG)Below 300HB

Carbon Steel(C50, C55)

Below 250HB

Mold Steel(1.2311, P20)

30-36HRC

Die Steel(1.2344, 1.2379)Below 255HB

Gray & NodularCast Iron

(GG, GGG)Below 300HB

WorkMaterials

WorkMaterials

InsertGrade

InsertGrade

OverhungLength (inch)

OverhungLength (inch)

JC7560

JC7560

JC7560

JC7560

JC7560

JC7560

JC7560

JC7560

Tool Diameter (inch)

Tool Diameter (inch)

AP: Depth of cut, N: Spindle speed, Vf: Speed feed, Pc: Net power consumption

AP: Depth of cut, N: Spindle speed, Vf: Speed feed, Pc: Net power consumption

No. of Teeth 5N

No. of Teeth 8N

2.5

5

No. of Teeth 6N

No. of Teeth 9N

3

6

.078

.059

.039

.024--

.078

.059

.039

.024--

.078

.059

.039

.024--

.098

.078

.059

.039--

.078

.078

.078

.059

.059

.039

.078

.078

.078

.059

.059

.039

.078

.078

.078

.059

.059

.039

.098

.098

.078

.078

.059

.039

.078

.071

.059

.039

.024

.016

.078

.071

.059

.039

.024

.016

.078

.071

.059

.039

.024

.016

.098

.078

.059

.039

.024

.016

.078

.078

.078

.078

.059

.059

.078

.078

.078

.078

.059

.059

.078

.078

.078

.078

.059

.059

.098

.098

.098

.078

.059

.059

.078

.071

.071

.059

.039

.024

.078

.071

.071

.059

.039

.024

.078

.071

.071

.059

.039

.024

.098

.078

.078

.059

.039

.024

.078

.078

.078

.078

.078

.059

.078

.078

.078

.078

.078

.059

.078

.078

.078

.078

.078

.059

.098

.098

.098

.098

.078

.059

Notes:1. The figures should be adjusted according to the machine and work rigidity.2. If chattering occurs, reduce the DOC (AP) or RPM by 30% and keep the feed per tooth the same.3. If machine does not have enough power, the DOC (AP) or spindle speed should be reduced by 30%.4. Use air instead of coolant.

®

SKS ExtremeCopy MillingPocket Milling Helical InterpolationFace Milling

6

INCH

(mm) (mm) (mm)AP

(mm)AP

(mm)AP

(mm)

No. of Teeth 4NN

(min1)N

(min1)N

(min1)Vf

(mm/min)Vf

(mm/min)Vf

(mm/min)Pc

(kW)Pc

(kW)Pc

(kW)

50/52

21.51

0.6--2

1.51

0.6--2

1.51

0.6--

2.52

1.51--

222

1.51.51222

1.51.51222

1.51.51

2.52.522

1.51

21.81.51

0.60.42

1.81.51

0.60.42

1.81.51

0.60.42.52

1.51

0.60.4

2222

1.51.52222

1.51.52222

1.51.52.52.52.52

1.51.5

21.81.81.51

0.62

1.81.81.51

0.62

1.81.81.51

0.62.522

1.51

0.6

22222

1.522222

1.522222

1.52.52.52.52.52

1.5

950800650650

--

830700570570

--

950800650650

--

950800650650

--

480430380350350350410370330280280280480430380350350350480430380350350350

750680600550550550650580520460460460750680600550550550750680600550550550

380340300280280280330300260230230230380340300280280280380340300280280280

600540480440440440520470420360360360600540480440440440600540480440440440

300270240220220220260230210180180180300270240220220220300270240220220220

7,6004,8003,3802,600

--

6,6404,2002,9602,280

--

7,6004,8003,3802,600

--

7,6004,8003,3802,600

--

6,7206,0205,3204,9004,9004,9005,7405,1804,6203,9203,9203,9206,7206,0205,3204,9004,9004,9006,7206,0205,3204,9004,9004,900

7,5006,8006,0005,5005,5005,5006,5005,8005,2004,6004,6004,6007,5006,8006,0005,5005,5005,5007,5006,8006,0005,5005,5005,500

6,0805,4404,8004,4804,4804,4805,2804,8004,1603,6803,6803,6806,0805,4404,8004,4804,4804,4806,0805,4404,8004,4804,4804,480

7,2006,4805,7605,2805,2805,2806,2405,6405,0404,3204,3204,3207,2006,4805,7605,2805,2805,2807,2006,4805,7605,2805,2805,280

5,4004,8604,3203,9603,9603,9604,6804,1403,7803,2403,2403,2405,4004,8604,3203,9603,9603,9605,4004,8604,3203,9603,9603,960

12.45.92.71.3--

12.35.92.71.3--

12.45.92.71.3--

12.46.23.31.7--

21.819.617.311.911.98.021.319.217.210.910.97.321.819.617.311.911.98.021.819.613.812.79.66.4

15.412.59.25.63.42.315.212.29.15.43.22.215.412.59.25.63.42.315.411.17.44.52.71.8

24.722.119.518.213.713.724.522.319.317.112.812.824.722.119.518.213.713.724.722.119.514.610.910.9

18.715.213.510.36.94.118.515.113.59.66.43.918.715.213.510.36.94.118.713.512.08.25.53.3

28.125.322.520.620.615.427.824.622.519.319.314.428.125.322.520.620.615.428.125.322.520.616.512.4

Recommended Cutting Conditions - Metric

Carbon Steel(C50, C55)

(S50C, S55C0Below 250HB

Mold Steel(1.2311, P20)

(HPM7, PX5, P20)30-36HRC

Die Steel(1.2344, 1.2379)(SKD61, SKD11)

Below 255HB

Gray & NodularCast Iron

(GG, GGG)(FC, FCD)

Below 300HB

WorkMaterials

InsertGrade

JC7560

JC7560

JC7560

JC7560

Tool Diameter

: Overhung length, AP: Depth of cut, N: Spindle speed, Vf: Speed feed, Pc: Net power consumption

No. of Teeth 5N63/66

No. of Teeth 6N80

150200250300350400150200250300350400150200250300350400150200250300350400

150200250300350400150200250300350400150200250300350400150200250300350400

150200250300350400150200250300350400150200250300350400150200250300350400

150200250300350400150200250300350400150200250300350400150200250300350400

150200250300350400150200250300350400150200250300350400150200250300350400

150200250300350400150200250300350400150200250300350400150200250300350400

Notes:1. The figures should be adjusted according to the machine and work rigidity.2. If chattering occurs, reduce the DOC (AP) or RPM by 30% and keep the feed per tooth the same.3. If machine does not have enough power, the DOC (AP) or spindle speed should be reduced by 30%.4. Use air instead of coolant.

(mm) (mm) (mm)AP

(mm)AP

(mm)AP

(mm)

No. of Teeth 7NN

(min1)N

(min1)N

(min1)Vf

(mm/min)Vf

(mm/min)Vf

(mm/min)Pc

(kW)Pc

(kW)Pc

(kW)

100

Carbon Steel(C50, C55)

(S50C, S55C0Below 250HB

Mold Steel(1.2311, P20)

(HPM7, PX5, P20)30-36HRC

Die Steel(1.2344, 1.2379)(SKD61, SKD11)

Below 255HB

Gray & NodularCast Iron

(GG, GGG)(FC, FCD)

Below 300HB

WorkMaterials

InsertGrade

JC7560

JC7560

JC7560

JC7560

Tool Diameter

: Overhung length, AP: Depth of cut, N: Spindle speed, Vf: Speed feed, Pc: Net power consumption

No. of Teeth 8N125

No. of Teeth 9N160

®

SKS ExtremeMETRIC

Copy MillingPocket Milling Helical InterpolationFace Milling

7

DIJET INDUSTRIAL CO., LTD.2-1-18, Kami-Higashi, Hirano-ku,Osaka 547-0002, JapanPhone: +81-6-6794-0167Fax: +81-6-6793-3930www.dijet.co.jp

DIJET INDUSTRIAL CO., LTD.Immarmannstr 940210 Düsseldorf, GermanyPhone: +49 (0) 211-50088820Fax: +49 (0) 211-50088823

DIJET, INC.45807 Helm Street, Plymouth, MI 48170Phone: 1-800-743-4538 Fax: 1-734-454-9395www.dijetusa.com

®

North America:

CanadaMexicoU.S.A.

South America:

Brazil

Africa:

South Africa

Asia:

ChinaIndonesiaJapanKoreaMalaysiaPhilippinesSingaporeTaiwanThailandVietnam

North East:

Russia

Europe:

Austria Germany NetherlandsBelgium Greece NorwayDenmark Holland PolandEngland Hungary PortugalFinland Italy SpainFrance Ireland Sweden Switzerland

WORLDWIDE DISTRIBUTION

No part of this catalog may be printed, copied or reproduced without the expressed written permission of DIJET, Inc.

Middle East:

IndiaIsraelPakistanTurkey