rf 100 programme 2010 customer presentation date: february 10, 2010

RF 100 Programme 2010

Customer PresentationDate: February 10, 2010

RF 100 Programm 2010 (C) M.Strasmann; Gühring OHG 2

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

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



Solution: RF 100

General Style / Geometry Basics:

• different Helix angles

• uneven pitch

• micro edge protection

• optimized flute profile

• materialspecific coatings


RF 100 High Performance End Mills

• 2 different helix angles create an un-even pitch

• Different pitch on all cutting- levels

Geometry in detail (un-even helix)


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


3-Radien-Design


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



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



deduction of tools in a milling application

+

=

Standard RF 100

+

+

• Argument: roughing, slotting & finishing = 1 tool !


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)



Advantages / Disadvantages


RF 100 (U, F, A, Ti, VA, H) RF100 (WF/HF/NF)

+ hight range of materials + / - limited range of materials

+ high feed rate - normal feed rate

+ hight tool life - normal tool life

+ Roughing & Finishing + / - Roughing & Semi-Finishing

+ / - Substitution of Carbide end mills + Substitution of PM-HSS-end mills

+ / - ap preferable 1 x d + ap up to 2,5 x d

- high power consumption + less power consumption

- good chip removal must be guaranteed + trouble-free chip removal

- Sable conditions required + normale conditions required



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).



„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 dRF 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.



RF 100 Application at “field” customer

Tool: RF 100 U 16 mm, # 5735Machine: SK40, 12 KW and max. 8.000 RPMApplication & 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



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.


RF 100 U (pages 10-13)

RF 100 Programme

• 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


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.


RF 100 3-fluted (pages 16-17)

RF 100 Programme

• 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)


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)

RF 100 Programme


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


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


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/minae = 9 mmap = up to 30 mmtool life = ~ 54m


RF 100 Programme

Customer Test RF 100 VA

(source: stainless steel catalogue 09/2009)


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



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


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


also working with lower Vc (cutting speed) (e.g. 300 m/min. compared to 900 m/min.)


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


RF 100 Programme

Customer Test RF 100 H

Machine : Taimac MCFV 1060 HSK63 Max RPM 18.000 1/min

Material : 1.2343 52 HRCCoolant : dry

Tool : # 3896 Dia. = 16 mm

Vf = 636 mm/min ( fz = 0,08 mm )n = 1990 1/min ( Vc = 100 m/min )ae = 1 mmap = 16,5 mmtool life = 60-70m


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


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

Series #Dia. (mm) 25 16 12 12Application Slotting Slotting Slotting SlottingVc (m/min.) 50 50 50 60

ap (mm) (one-pass!!) 50 25 24 12ae (mm) 25 16 12 12fz (mm/z) 0,08 0,04 0,025 0,03

Vf (mm/min.) 203 159 132 190Q (cm³/min.) 254 81 38 26tool-life (m) 92 76 54 68

3499


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


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


RF 100 Programme

Customer Test RF 100 S/FCutomer Datum 30.11.2008

Material TA6V4 Tool Type RF 100 S/F PWZ (Prototyp)

Mat. Group Titan Art.No. 3632 xxx

DIN/ANSI - Coating FIRE TIALN

Diameter 16 16

Machine MAZAK VTC 200C Vc (m/min.) 80 165

Typer - fz (mm/min.) 0,06 0,05

Clamping - tool-life (m) 72 27

Coolant Oil tool-life (min.)

Coolant preassure - tool-life criteria Wear Wear

Power (KW) -

Component Titan

Application Roughing

ae (mm) 5 and. 0,35 mm

ap (mm) 22 mm

Machine

Application

Material Tool

PWZ (Prototype) runs with a much higher Vc, but only with a width of ae =0,35 mm

(14 passes need to achieve Guhring ae = 5,0 mm)

Guhring with ae = 5 mm and 3 x longer tool life PWZ was not able to run at 5 mm width.

MECA - Laurent Hamel


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


RF 100 Programme

Conclusion

1. 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

3. Do we have a full offering of diameters, length and styles?

Yes, RF 100 complete programme



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.

rf 100 programme 2010 customer presentation date: february 10, 2010

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