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8/13/2019 Brosura Franken
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Milling Technology
Effective volume machining in steel
Process-safe chip evacuation in roughing
For conventional machining jobs
Roughing and finishing in one work process
Milling instead of polishing and grinding
Product extension:
w i t h c o r n e r r a d i u s
w i t h
b a l l - n o s e
Setting new standards for milling tools…
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3
High-performance tools for highest economic efficiency
FRANKEN, as a manufacturer of highly innovative HSS, solid carbide and insert milling tools, isprepared to meet the future demands of new machine and machining technologies. The primetarget in this development is always the best advantage of our customers.The product family MULTI-Jet-Cut line is the latest state of the art, and unites highest economicefficiency with a high degree of process safety.
The tool families HPC-Jet-Cut line and HSC-Jet-Cut line are subject to continuous improvementand optimization.
The MULTI-Jet-Cut line was designed for large-volume machining in a high variety of steelmaterials, all non-ferrous heavy metals, titanium and stainless materials. Its special geometrypermits the combination of highest process safety with extra high machining volumes.With the latest version with internal coolant-lubricant supply, the MULTI-Jet-Cut IKZ, availablein a diameter range from 3 to 20 mm, FRANKEN treads entirely new paths. Good chip evacuationis no longer a problem with the MULTI-Jet-Cut IKZ.The MULTI-Jet-Cut line exists in 3 different dimensional versions and is available in a diameterrange from 1 to 20 mm.
The Multi-Jet-Cut with ball-nose also opens up new possibilities in 2.5D and 3D machining. Thistool permits not only the production of dies and molds, but also line-by-line strategies.
The Multi-Jet-Cut IKZ with corner radius represents an alternative to the Multi-Jet-Cut IKZ.The corner radius serves for the production of radii for minimizing crack formation in mechanicallystressed components on one hand, on the other hand it stabilizes and protects the cutting edgecorner against chipping.
The HPC-Jet-Cut line has established itself firmly in the market already. Due to this success,the product properties could be further optimized and ascertained. With the HPC-Jet-Cut line,highly efficient machining in the form of roughing and finishing in one work process has becomepossible in almost all materials! Three different geometries are available in a diameter rangefrom 3 to 20 mm.
With the HSC-Jet-Cut line, FRANKEN is now the only precision tool manufacturer to offer acomprehensive stock programme of milling cutters for HSC finish milling. With multipleeffective cutting edges – up to 8 cutting edges on ball-nose and torus cutters and up to 16 onend mills – the dynamics of the machine tool can be put to the best use for achieving a highmachining volume. The application range starts with construction steels and reaches up tohardened steels with 66 HRC and more. This proves not only the high flexibility of theHSC-Jet-Cut line, but also its economic efficiency. The end mills, ball-nose cutters andtorus cutters from this line are available in a diameter range from 3 to 16 mm.
Table of contents
Page
MULTI-Jet-Cut line ..........................................................................................4 - 7MULTI-Jet-Cut with ball-nose ..........................................................................8 - 9MULTI-Jet-Cut IKZ ........................................................................................10 - 13MULTI-Jet-Cut IKZ with corner radius ............................................................12 - 13
MULTI-Jet-Cut Base ......................................................................................14 - 15
HPC-Jet-Cut line ...........................................................................................16 - 19
HSC-Jet-Cut line ...........................................................................................20 - 25
Cold-air nozzle ..................................................................................................... 11
Description of material groups ............................................................................. 27
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One tool, many applications,to be used in different materials with a high degree of flexibility.With three different constructional lengths, all of them designed for the highestpossible stability, these tools open a new degree of flexibility in roughing withsolid carbide milling tools. With one single cutting geometry, stainless materials,long- and short-chipping steels can be machined. Even hardened steels up to42 HRC, cast iron and other materials like copper or bronze can be machinedwith a high degree of process safety.
Short description
Advantages
• maximum machining volumes due to high-performance carbide substrate
• short, light-weight chips due to a special roughing profile
• high degree of process safety due to stabilized cutting edge
• dynamic spacing of cutting edges for smooth, low-vibration machining
• neutral rake angle for maximum application flexibility
• extra short chip contact due to chip former
• extra long tool life due to optimized geometry
• optimized cutting depth of tools due to relieved shank
What is the right application for the MULTI-Jet-Cut?
Application cases for the MULTI-Jet-Cut
• pocket milling jobs of any kind where there are no requirements as to surface quality or dimensional accuracy
• rectangular pocket milling jobs, circular pocket milling jobs, slot milling jobs
• relief milling jobs without dimensional or optical function
• milling jobs where time saving is essential (high machining volumes)
Application example 1:
Pocket milling: Length 80 mm x width 100 mm x depth 30 mmMaterial: Tool steel 1.1730 (850 N/mm2)
Tool: Insert milling cutter dia. 25 mm – vc 200 m/min – fz 0.6 mm – ap 1 mm – ae 18 mm (Q = 82 cm3)
Machining time: 14 minutes with cold-air nozzle 1)
Tool: MULTI-Jet-Cut dia. 10 mm (art. no. 2869A.010) – vc 160 m/min – fz 0.085 mm – ap 15 mm – ae 8 mm (Q = 208 cm3)Machining time: 5 minutes with cold-air nozzle 1)
Application example 2:
Slot milling: Length 200 mm x width 25 mm x depth 20 mmMaterial: Tool steel 1.2312 (1050 N/mm2)
Tool: Insert milling cutter dia. 25 mm – vc 200 m/min – fz 0.6 mm – ap 1 mm – ae 25 mm (Q = 115 cm3)
Machining time: 2 minutes ramp-type slot milling with cold-air nozzle 1)
Tool: MULTI-Jet-Cut dia. 10 (art. no. 2873A.010) – vc 180 m/min – fz 0.06 mm – ap 20 mm – ae 7 mm (Q = 192 cm3)
Machining time: 1 minute trochoidal slot milling with cold-air nozzle 1)
1) Cold-air nozzle, see page 11
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5
• maximum machining volume
• high degree of application flexibility
• three different dimensional designs• depth of cut up to 3.5 x d1• low machining forces
• no tendency to vibration
• highest degree of process safety
• high-performance roughing tool
MULTI-Jet-Cut line
End mills MULTI-Jet-Cut – short design, for the roughing of slots Internal standard
Shank acc.DIN 6535 HA
ø d1h11
Form l2 l3 l1 ø d3 l4 ø d2h6
l A Z Art. no.
1 A 1.5 3 38 0.9 9 3 – 3 2869A.001
Shank acc.DIN 6535 HB
ø d1h11
Form l2 l3 l1 ø d3 l4 ø d2h6
l A Z Art. no.
2 A 3 8 57 1.9 15 6 21 3 2869A.002
3 A 5 14 57 2.9 18 6 21 3 2869A.003
4 A 8 18 57 3.8 20 6 21 3 2869A.004
5 A 9 19 57 4.8 20 6 21 3 2869A.005
6 B 10 – 57 5.8 20 6 21 4 2869A.006
8 B 12 – 63 7.7 25 8 27 4 2869A.008
10 B 15 – 72 9.5 30 10 32 4 2869A.010
12 B 18 – 83 11.5 35 12 38 4 2869A.012
14 B 21 – 83 13.5 35 14 38 4 2869A.014
16 B 24 – 92 15.5 40 16 44 4 2869A.016
20 B 30 – 104 19.5 50 20 54 4 2869A.020
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
Conventional cutting data
• low speeds (rpm)
• no dynamics
• stable clamping
• conventional machine
11.1 - 1.3 100 - 120 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —1.4 - 1.5 80 - 100 0.004 x d1 1 x d1 1 x d1 Cold air / Pressurized air —1.10 50 - 70 0.004 x d1 1 x d1 1 x d1 — Emulsion1.13 40 - 60 0.004 x d1 1 x d1 1 x d1 — Emulsion22.1 - 2.2 100 - 120 0.006 x d1 1 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 80 - 100 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —3
3.1 - 3.3 100 - 120 0.004 x d1 1 x d1 1 x d1 — Emulsion3.4 - 3.5 80 - 100 0.004 x d1 1 x d1 1 x d1 — Emulsion
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HPC cutting data
• normal speeds (rpm)
• dynamic machine
• stable clamping
• CNC machine
11.1 - 1.3 120 - 140 0.0065 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —1.4 - 1.5 100 - 120 0.0055 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —1.10 60 - 80 0.005 x d1 1 x d1 1 x d1 — Emulsion1.13 50 - 70 0.005 x d1 1 x d1 1 x d1 — Emulsion22.1 - 2.2 120 - 140 0.008 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 100 - 120 0.006 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —33.1 - 3.3 120 - 140 0.006 x d1 1.5 x d1 1 x d1 — Emulsion3.4 - 3.5 100 - 120 0.005 x d1 1.5 x d1 1 x d1 — Emulsion
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HSC cutting data
• high speeds (rpm)• dynamic machine
• stable clamping
• HSC machine
11.1 - 1.3 180 - 220 0.005 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —1.4 - 1.5 140 - 160 0.004 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —1.10 60 - 80 0.004 x d1 1.5 x d1 0.5 x d1 — Emulsion1.13 50 - 70 0.004 x d1 1.5 x d1 0.5 x d1 — Emulsion22.1 - 2.2 180 - 220 0.006 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —2.3 - 2.4 140 - 180 0.005 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —33.1 - 3.3 140 - 160 0.004 x d1 1.5 x d1 0.5 x d1 — Emulsion3.4 - 3.5 120 - 140 0.004 x d1 1.5 x d1 0.5 x d1 — Emulsion
ø
d 2
l2l4
l1
ø
d 1
≈ l A
(DIN 6535 HB)
ø
d 3
(
≈ l A
DIN 6535 HB)
ø
d 1
ø
d 2
l2l3
l4l1
ø
d 3
Form A
Form B
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End mills MULTI-Jet-Cut – long design, for HPC roughing DIN 6527 BL
Shank acc.DIN 6535 HB
ø d1h11
Form l2 l3 l1 ø d3 l4 ø d2h6
l A Z Art. no.
3 A 8 14 57 2.9 18 6 21 3 2873A.003
4 A 11 18 57 3.8 20 6 21 3 2873A.004
5 A 13 19 57 4.8 20 6 21 3 2873A.005 6 B 13 – 57 5.8 20 6 21 4 2873A.006
8 B 19 – 63 7.7 25 8 27 4 2873A.008
10 B 22 – 72 9.5 30 10 32 4 2873A.010
12 B 26 – 83 11.5 35 12 38 4 2873A.012
14 B 26 – 83 13.5 35 14 38 4 2873A.014
16 B 32 – 92 15.5 40 16 44 4 2873A.016
20 B 38 – 104 19.5 50 20 54 4 2873A.020
Explanation of cutting data
Conventional cutting data
• machines on which high speeds are not possible• stability of the machine and/or the workpiece clamping bad to moderate• chip evacuation only moderate to bad (e.g. deep pocket machining with emulsion)
HPC cutting data
• machines which provide high speeds and high spindle torque, stability and proper dynamics (optimum conditions)• good to very good stability of machine and/or workpiece clamping• reliable chip evacuation, increase of axial depth of cut also possible
HSC cutting data
• machines with high speeds and proper dynamics, but low spindle torque and stability• stable workpiece clamping is necessary, otherwise the spindle may be damaged (HSC spindle)• chip evacuation good to very good
Additional technical information:
• ramping angle in short-chipping materials 5-10°; reduce feed speed (vf) by approx. 50%• ramping angle in long-chipping materials 3-5°; reduce feed speed (vf) by approx. 50%• in case of vibration, reduce speed (rpm) slightly until the tool runs smoothly; keep up feed speed (vf)• all tool shanks are provided with a driving flat and should be used in suitable holders• with high feed values, tools may be extracted from holders without axial locking device
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
Conventional cutting data
• low speeds (rpm)• no dynamics
• stable clamping
• conventional machine
11.1 - 1.3 100 - 120 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —1.4 - 1.5 80 - 100 0.004 x d
11 x d
11 x d
1Cold air / Pressurized air —
1.10 50 - 70 0.004 x d1 1 x d1 1 x d1 — Emulsion1.13 40 - 60 0.004 x d1 1 x d1 1 x d1 — Emulsion22.1 - 2.2 100 - 120 0.006 x d1 1 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 80 - 100 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —33.1 - 3.3 100 - 120 0.004 x d1 1 x d1 1 x d1 — Emulsion3.4 - 3.5 80 - 100 0.004 x d1 1 x d1 1 x d1 — Emulsion
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HPC cutting data
• normal speeds (rpm)
• dynamic machine
• stable clamping
• CNC machine
11.1 - 1.3 120 - 140 0.0055 x d1 1.5 x d1 0.8 x d1 Cold air / Pressurized air —1.4 - 1.5 100 - 120 0.005 x d1 1.5 x d1 0.8 x d1 Cold air / Pressurized air —1.10 60 - 80 0.005 x d1 1.5 x d1 0.6 x d1 — Emulsion1.13 50 - 70 0.005 x d1 1.5 x d1 0.6 x d1 — Emulsion22.1 - 2.2 120 - 140 0.007 x d1 1.5 x d1 0.8 x d1 Cold air / Pressurized air —2.3 - 2.4 100 - 120 0.0055 x d1 1.5 x d1 0.8 x d1 Cold air / Pressurized air —33.1 - 3.3 120 - 140 0.005 x d1 1.5 x d1 0.8 x d1 — Emulsion
3.4 - 3.5 100 - 120 0.0045 x d1 1.5 x d1 0.8 x d1 — Emulsionvc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HSC cutting data
• high speeds (rpm)
• dynamic machine
• stable clamping
• HSC machine
11.1 - 1.3 180 - 220 0.005 x d1 2 x d1 0.5 x d1 Cold air / Pressurized air —1.4 - 1.5 140 - 160 0.004 x d1 2 x d1 0.5 x d1 Cold air / Pressurized air —1.10 60 - 80 0.004 x d1 2 x d1 0.4 x d1 — Emulsion1.13 50 - 70 0.004 x d1 2 x d1 0.3 x d1 — Emulsion22.1 - 2.2 180 - 220 0.006 x d1 2 x d1 0.5 x d1 Cold air / Pressurized air —2.3 - 2.4 140 - 180 0.005 x d1 2 x d1 0.5 x d1 Cold air / Pressurized air —33.1 - 3.3 140 - 160 0.004 x d1 2 x d1 0.5 x d1 — Emulsion3.4 - 3.5 120 - 140 0.004 x d1 2 x d1 0.5 x d1 — Emulsion
ø
d 2
l2l4
l1
ø
d 1
≈ l A
(DIN 6535 HB)
ø
d 3
(
≈ l A
DIN 6535 HB)
ø d
1
ø d
2
l2l3
l4l1
ø d
3
Form A
Form B
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7
End mills MULTI-Jet-Cut – extra long design, for HPC roughing Internal standard
Explanation of cutting data
Conventional cutting data
• machines on which high speeds are not possible• stability of the machine and/or the workpiece clamping bad to moderate• chip evacuation only moderate to bad (e.g. deep pocket machining with emulsion)
HPC cutting data
• machines which provide high speeds and high spindle torque, stability and proper dynamics (optimum conditions)• good to very good stability of machine and/or workpiece clamping• reliable chip evacuation, increase of axial depth of cut also possible
HSC cutting data
• machines with high speeds and proper dynamics, but low spindle torque and stability• stable workpiece clamping is necessary, otherwise the spindle may be damaged (HSC spindle)• chip evacuation good to very good
Additional technical information:
• ramping angle in short-chipping materials 5-10°; reduce feed speed (vf) by approx. 50%• ramping angle in long-chipping materials 3-5°; reduce feed speed (vf) by approx. 50%• in case of vibration, reduce speed (rpm) slightly until the tool runs smoothly; keep up feed speed (vf)• all tool shanks are provided with a driving flat and should be used in suitable holders• with high feed values, tools may be extracted from holders without axial locking device
Shank acc.DIN 6535 HB
ø d1h11
Form l2 l3 l1 ø d3 l4 ø d2h6
l A Z Art. no.
3 A 5 19 62 2.9 23 6 26 3 2875A.003
4 A 8 23 62 3.8 25 6 26 3 2875A.004
5 A 9 24 62 4.8 25 6 26 3 2875A.005 6 B 10 – 62 5.8 25 6 26 4 2875A.006
8 B 12 – 68 7.7 30 8 32 4 2875A.008
10 B 15 – 80 9.5 35 10 40 4 2875A.010
12 B 18 – 93 11.5 45 12 47 4 2875A.012
14 B 21 – 99 13.5 50 14 54 4 2875A.014
16 B 24 – 108 15.5 55 16 60 4 2875A.016
20 B 30 – 126 19.5 70 20 76 4 2875A.020
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
Conventional cutting data
• low speeds (rpm)• no dynamics
• stable clamping
• conventional machine
11.1 - 1.3 100 - 120 0.005 x d1 0.5 x d1 1 x d1 Cold air / Pressurized air —1.4 - 1.5 80 - 100 0.004 x d
10.5 x d
11 x d
1Cold air / Pressurized air —
1.10 50 - 70 0.0035 x d1 0.5 x d1 1 x d1 — Emulsion1.13 40 - 60 0.0035 x d1 0.5 x d1 1 x d1 — Emulsion22.1 - 2.2 100 - 120 0.006 x d1 0.5 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 80 - 100 0.005 x d1 0.5 x d1 1 x d1 Cold air / Pressurized air —33.1 - 3.3 100 - 120 0.004 x d1 0.5 x d1 1 x d1 — Emulsion3.4 - 3.5 80 - 100 0.004 x d1 0.5 x d1 1 x d1 — Emulsion
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HPC cutting data
• normal speeds (rpm)
• dynamic machine
• stable clamping
• CNC machine
11.1 - 1.3 120 - 140 0.0055 x d1 1 x d1 1 x d1 Cold air / Pressurized air —1.4 - 1.5 100 - 120 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —1.10 50 - 70 0.005 x d1 1 x d1 1 x d1 — Emulsion1.13 40 - 60 0.005 x d1 1 x d1 1 x d1 — Emulsion22.1 - 2.2 120 - 140 0.007 x d1 1 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 100 - 120 0.0055 x d1 1 x d1 1 x d1 Cold air / Pressurized air —33.1 - 3.3 120 - 140 0.005 x d1 1 x d1 1 x d1 — Emulsion
3.4 - 3.5 100 - 120 0.0045 x d1 1 x d1 1 x d1 — Emulsionvc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HSC cutting data
• high speeds (rpm)
• dynamic machine
• stable clamping
• HSC machine
11.1 - 1.3 160 - 200 0.005 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —1.4 - 1.5 120 - 140 0.004 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —1.10 60 - 80 0.004 x d1 1.5 x d1 0.5 x d1 — Emulsion1.13 50 - 70 0.004 x d1 1.5 x d1 0.5 x d1 — Emulsion22.1 - 2.2 180 - 220 0.006 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —2.3 - 2.4 140 - 180 0.005 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —33.1 - 3.3 140 - 160 0.004 x d1 1.5 x d1 0.5 x d1 — Emulsion3.4 - 3.5 120 - 140 0.004 x d1 1.5 x d1 0.5 x d1 — Emulsion
ø
d 2
l2l4
l1
ø
d 1
≈ l A
(DIN 6535 HB)
ø
d 3
(
≈ l A
DIN 6535 HB)
ø d
1
ø d
2
l2l3
l4l1
ø d
3
Form A
Form B
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8
MULTI-Jet-Cut line
• from cutting dia. 3 mm available ex stock
• stabilized ball-nose
• open chip-space geometry for optimum chip evacuation• high machining volumes
• suitable also for the machining of slots
• highest application flexibility
• special diameters and lengths available upon request
What is the right application for the Multi-Jet-Cut with ball-nose?
Application cases for the MULTI-Jet-Cut with ball-nose
• pocket milling jobs of any kind where there are no requirements as to surface quality
• pocket milling jobs with radius in the pocket bottom for minimizing crack formation in mechanically stressed components
• slots with radius in the slot bottom, sealing slots
• relief milling jobs of any kind
• 3D machining applications in die-and-mold making – preroughing of 3D contours
• machining of components exposed to vibrations due to unstable tool clamping
Application example 1:
Pocket milling: Length 50 mm x width 70 mm x depth 15 mmMaterial: Construction steel St 52 (500 N/mm2) – cooling with cold-air nozzle 1)
Tool: MULTI-Jet-Cut dia. 10 mm with ball-nose (art. no. 2667A.010) – fvc 200 m/min – fz 0.04 mm – ap 15 mm – ae 5 mm
Application example 2:
Slot milling: Length 140 mm x width 10 mm x depth 10 mmMaterial: Tool steel 1.2085 (1100 N/mm2) – cooling with cold-air nozzle 1)
Tool: MULTI-Jet-Cut dia. 10 mm with ball-nose (art. no. 2667A.010) – vc 160 m/min – fz 0.04 mm – ap 15 mm – ae 10 mm
Application example 3:
3D machining: Length 150 mm x width 60 mm x depth 30 mm (component size)
Material: Tool steel 1.2312 (1000 N/mm2) – cooling with cold-air nozzle 1)
Tool: MULTI-Jet-Cut dia. 10 mm with ball-nose (art. no. 2667A.010) – vc 160 m/min – fz 0.05 mm – ap 20 mm – ae 5 mm
Additional technical information:
• ramping angle in short-chipping materials 5-10°; reduce feed speed (vf) by approx. 50%
• ramping angle in long-chipping materials 3-5°; reduce feed speed (vf) by approx. 50%
• always provide good concentricity and tool holders with high holding force
• down-milling will lead to better tool life
1) Cold-air nozzle, see page 11
For videos about the application examples, see our homepage www.emuge-franken.de under Media/downloads
with ball-nose
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10
• from cutting dia. 3 mm available with internal coolant-lubricant supply
• high machining volumes
• very high degree of application flexibility• reliable chip evacuation
• increased process safety
• low machining forces
• no tendency to vibration
• longer tool life
MULTI-Jet-Cut IKZ
End mills MULTI-Jet-Cut IKZ – short design, for the roughing of slots Internal standard
Shank acc.DIN 6535 HB
ø d1h11 Form l2 l1 ø d3 l3 l4 ø d2
h6 l A Z Art. no.
3 A 5 57 2.9 14 16 6 21 3 2869AZ.003
4 A 8 57 3.8 18 20 6 21 3 2869AZ.004
5 A 9 57 4.8 19 20 6 21 3 2869AZ.005
6 B 10 57 5.8 – 20 6 21 4 2869AZ.006
8 B 12 63 7.7 – 25 8 27 4 2869AZ.008
10 B 15 72 9.5 – 30 10 32 4 2869AZ.010
12 B 18 83 11.5 – 35 12 38 4 2869AZ.012
14 B 21 83 13.5 – 35 14 38 4 2869AZ.014
16 B 24 92 15.5 – 40 16 44 4 2869AZ.016
20 B 30 104 19.5 – 50 20 54 4 2869AZ.020
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HPC cutting data
• normal speeds (rpm)
• dynamic machine
• stable clamping
• CNC machine
11.1 - 1.3 200 - 240 0.0065 x d1 1.5 x d1 1 x d1 ILZ / IMMS IKZ1.4 - 1.5 160 - 200 0.0055 x d1 1.5 x d1 1 x d1 ILZ / IMMS IKZ1.10 60 - 90 0.005 x d1 1 x d1 1 x d1 — IKZ1.13 50 - 80 0.005 x d1 1 x d1 1 x d1 — IKZ22.1 - 2.2 100 - 160 0.008 x d1 1.5 x d1 1 x d1 ILZ / IMMS IKZ2.3 - 2.4 80 - 120 0.006 x d1 1.5 x d1 1 x d1 ILZ / IMMS IKZ33.1 - 3.3 140 - 160 0.006 x d1 1.5 x d1 1 x d1 — IKZ3.4 - 3.5 120 - 140 0.005 x d1 1.5 x d1 1 x d1 — IKZ55.1 350 - 400 0.007 x d1 1.5 x d1 1 x d1 — IKZ5.2 - 5.3 250 - 300 0.007 x d1 1.5 x d1 1 x d1 — IKZ77.1 50 - 70 0.0045 x d1 1.5 x d1 1 x d1 — IKZ
ILZ = internal air supply
IMMS = internal MMS supply (minimum-quantity lubrication)IKZ = internal coolant-lubricant supply (with emulsion)
7.2 40 - 60 0.0045 x d1 1 x d1 1 x d1 — IKZ8
8.1 140 - 160 0.007 x d1 1.5 x d1 1 x d1 — IKZ99.2 80 - 100 0.005 x d1 1 x d1 1 x d1 — IKZ
Tool life can be increased by up to 100% by the use of IKZ, ILZ or IMMS, especially in the machining of particularly difficult and tough
materials. This will extend the application range of the MULTI-Jet-Cut IKZ dramatically.
The application of our MULTI-Jet-Cut IKZ can increase process safety in roughing considerably, due to the optimized chip evacuation. Forthis, however, sufficient coolant or air pressure through the spindle is essential. Modern machines are equipped with optional fine filters, these
are necessary for the use of tool diameters 3 to 5 mm. The filter particle size should not exceed 0.01 mm, because otherwise there is dangerof the coolant hole of the tools becoming clogged; this in turn might impede chip evacuation which is essential for the machining process.
Additional technical information:
• ramping angle in short-chipping materials 5-10°; reduce feed speed (vf) by approx. 50%
• ramping angle in long-chipping materials 3-5°; reduce feed speed (vf) by approx. 50%• in case of vibration, reduce speed (rpm) slightly until the tool runs smoothly; keep up feed speed (vf)
• all tool shanks are provided with a driving flat and should be used in suitable holders
• with high feed values, tools may be extracted from holders without axial locking device
ø
d 2
l2l4
l1
ø
d 1
≈ l A
(DIN 6535 HB)
ø
d 3
(
≈ l A
DIN 6535 HB)
ø
d 1
ø
d 2
l2l3
l4l1
ø
d 3
Form A
Form B
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11
Principle of the cold-air nozzle
The application of cooled air can help to reduce temperatures in the cuttingarea, which in turn permits higher cutting speeds and longer tool life.This type of cooling is necessary to bring out all the advantages of moderncoatings, because the cutting edge can no longer be damaged by thermal
shock. In addition, the cold-air nozzle will help to remove the tiny chips whichare produced in copy milling even from deep recesses or cavities.The function of the cold-air nozzle is based on the principle of the vortex tube,in which two opposed, rotating air streams are generated (without using any
moving components).
The internal air stream exits from one end,in the form of useable cold air with atemperature down to -40 °C.
The only thing that is neededis a normal pressurizedair connection.
Cold-air nozzle – increasing efficiency
Spare hose
Length Art. no.
≈ 300 mm 6910.20
≈ 400 mm 6910.22
≈ 500 mm 6910.21
Fixture complete
Weight Art. no.
0.4 kg 6910.25
Magnetic shoe
Diameter Art. no.
80 mm 6910.26
Pressure of incoming air Temperature of usable air in °C, with a cold air percentage of
bar 25% 50% 75%
3 -31 -22 - 6
4 -35 -35 - 8
5 -39 -28 -10
6 -42 -31 -11
7 -46 -34 -13
Temperature, measured on the effective exitof the vortex tube (not the end of the nozzle!)
Input pressure Air consumption Capacitybar6.9 7.08 l/s; 25.5 m3 /h 226 kcal/h; 263 W
Air consumption, with anincoming air temperature of 21 °C
Available cold air
Pressurized air, approx. 6 bar
Adjustable valve
Hot exhaust air
Delivery:• length (without hose) 225 mm, weight: 0.7 kg
• with flexible hose (length approx. 300 mm) for cold air• muffler (SN14) for hot exhaust air
• ball-valve with fitting (1 / 4“) for inlet hose (6 mm)
with quick-change attachment (7.2 mm)
Art. no.
Cold-air nozzle 6910.15
Accessories for cold-air nozzle
Socket
Height Art. no.
≈ 75 mm 6910.27
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12
MULTI-Jet-Cut IKZ
• from cutting dia. 6 mm available ex stock with up to 4 radius variants
• axial IKZ bore – high process safety
• optimum chip evacuation with internal coolant-lubricant supply• high machining volumes
• highest application flexibility
• special radii available upon request
What is the right application for the Multi-Jet-Cut IKZ with corner radius?
Application cases for the MULTI-Jet-Cut IKZ with corner radius
• pocket milling jobs of any kind where there are no requirements as to surface quality
• pocket milling jobs with radius in the pocket bottom for minimizing crack formation in mechanically stressed components
• slots with radius in the slot bottom, sealing slots
• relief milling jobs of any kind
• milling jobs with tool life problems in the cutting edge corner area – this can be stabilized by the radius
• machining of components exposed to vibrations due to unstable tool clamping
Application example 1:
Pocket milling: Length 50 mm x width 70 mm x depth 12 mmMaterial: Construction steel St 52 (500 N/mm2) – cooling with ILZ and cold-air nozzle 1)
Tool: MULTI-Jet-Cut IKZ dia. 10 mm with corner radius 1 mm (art. no 2673AZ.010010) vc 200 m/min – fz 0.05 mm – ap 15 mm – ae 7 mm
Application example 2:
Slot milling: Length 140 mm x width 10 mm x depth 10 mmMaterial: Tool steel 1.2085 (1100 N/mm2) – cooling with ILZ and cold-air nozzle 1)
Tool: MULTI-Jet-Cut IKZ dia. 10 mm with corner radius 1.5 mm (art. no. 2673AZ.010015)
vc 160 m/min – fz 0.05 mm – ap 15 mm – ae 10 mm
Application example 3:
Circular slot milling: Length 150 mm x width 25 mm x depth 20 mm
Material: Tool steel 1.2312 (1000 N/mm2) – cooling with ILZ and cold-air nozzle 1)Tool: MULTI-Jet-Cut IKZ dia. 10 mm with corner radius 2 mm (art. no. 2673AZ.010020)
vc 160 m/min – fz 0.05 mm – ap 20 mm – ae 5 mm
Additional technical information:
• ramping angle in short-chipping materials 5-10°; reduce feed speed (vf) by approx. 50%• ramping angle in long-chipping materials 3-5°; reduce feed speed (vf) by approx. 50%• always provide good concentricity and tool holders with high holding force• down-milling will lead to better tool life
1) Cold-air nozzle, see page 11
For videos about the application examples, see our homepage www.emuge-franken.de under Media/downloads
with corner radius
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14
• conventional cutting edge design
• increased application flexibility
• two different constructional lengths• depth of cut 2.5 x d1 to 3 x d1• reduced machining forces
• reduced tendency to vibrations
• tough carbide substrate
• economically efficient solution
Short description
Advantages
• maximum machining volumes due to high-performance carbide substrate
• short, light-weight chips due to a special roughing profile
• dynamic spacing of cutting edges for smooth, low-vibration machining
• positive rake angle for increased application flexibility
• specially adjusted geometry for reduced machining forces
• optimized cutting depth of tools due to relieved shank
What is the right application for the MULTI-Jet-Cut Base?
Application cases for the MULTI-Jet-Cut Base
The MULTI-Jet-Cut Base was developed especially for conventional CNC machines which are not built for working witha high dynamics level, and which offer only moderate spindle speeds.
• pocket milling jobs of any kind where there are no requirements as to surface quality or dimensional accuracy
• rectangular pocket milling jobs, circular pocket milling jobs, slot milling jobs
• relief milling jobs without dimensional or optical function
• high machining volumes for milling jobs where time saving is essential
Application example:
Pocket milling: Length 50 mm x width 70 mm x depth 20 mm
Material: Construction steel St52 (500 N/mm2) – cooling with cold-air nozzle (see page 11)
Tool: MULTI-Jet-Cut Base dia. 10 mm (art. no. 2897A.010) – vc 120 m/min – fz 0.05 mm – ap 10 mm – ae 7.5 mmMaterial: Tool steel 1.1730 (850 N/mm2)
Tool: MULTI-Jet-Cut Base dia. 10 mm (art. no. 2897A.010) – vc 100 m/min – fz 0.04 mm – ap 10 mm – ae 7.5 mm
Material: Tool steel 1.2379 (850 N/mm2)
Tool: MULTI-Jet-Cut Base dia. 10 mm (art. no. 2897A.010) – vc 80 m/min – fz 0.04 mm – ap 10 mm – ae 7.5 mm
Material: Tool steel 1.4301 (700 N/mm2)
Tool: MULTI-Jet-Cut Base dia. 10 mm (art. no. 2897A.010) – vc 60 m/min – fz 0.035 mm – ap 10 mm – ae 7.5 mm
Material: Titanium 3.7164 (800 N/mm2)
Tool: MULTI-Jet-Cut Base dia. 10 mm (art. no. 2897A.010) – vc 40 m/min – fz 0.03 mm – ap 10 mm – ae 7.5 mm
Material: Aluminium 3.4345 (500 N/mm2)Tool: MULTI-Jet-Cut Base dia. 10 mm (art. no. 2897A.010) – vc 350 m/min – fz 0.07 mm – ap 10 mm – ae 7.5 mm
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15
End mills MULTI-Jet-Cut Base – short design DIN 6527 K
ø
d 2
l2l4
l1
ø
d 1
≈ l A
(DIN 6535 HB)
ø
d 3
ø
d 2
l2l4
l1
ø
d 1
≈ l A
(DIN 6535 HB)
ø
d 3
Shank acc.DIN 6535 HA
Shank acc.DIN 6535 HB
ø d1h11
Form l2 l3 l1 ø d3 l4 ø d2h6
l A Z Art. no. Art. no.
3 A 5 9 50 2.9 14 6 14 3 2896A.003 2897A.003
4 A 8 12 54 3.8 18 6 18 3 2896A.004 2897A.004
5 A 9 16 54 4.8 18 6 18 3 2896A.005 2897A.005 6 B 10 – 54 5.8 16 6 18 4 2896A.006 2897A.006
8 B 12 – 58 7.7 20 8 22 4 2896A.008 2897A.008
10 B 14 – 66 9.7 24 10 26 4 2896A.010 2897A.010
12 B 16 – 73 11.6 26 12 28 4 2896A.012 2897A.012
14 B 18 – 75 13.6 28 14 30 4 2896A.014 2897A.014
16 B 22 – 82 15.5 32 16 34 4 2896A.016 2897A.016
20 B 26 – 92 19.5 40 20 42 4 2896A.020 2897A.020
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
Cutting data 11.1 - 1.3 100 - 120 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —1.4 - 1.5 80 - 100 0.004 x d1 1 x d1 1 x d1 Cold air / Pressurized air —
1.10 50 - 70 0.0035 x d1 1 x d1 1 x d1 — Emulsion1.13 40 - 60 0.0035 x d1 1 x d1 1 x d1 — Emulsion22.1 - 2.2 100 - 120 0.006 x d1 1 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 80 - 100 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —33.1 - 3.3 100 - 120 0.004 x d1 1 x d1 1 x d1 — Emulsion3.4 - 3.5 80 - 100 0.004 x d1 1 x d1 1 x d1 — Emulsion55.1 350 - 400 0.007 x d1 1 x d1 1 x d1 — Emulsion5.2 - 5.3 250 - 300 0.007 x d1 1 x d1 1 x d1 — Emulsion77.1 30 - 50 0.003 x d1 1 x d1 1 x d1 — Emulsion7.2 25 - 40 0.003 x d1 1 x d1 1 x d1 — Emulsion88.1 140 - 160 0.007 x d1 1 x d1 1 x d1 — Emulsion99.2 80 - 100 0.004 x d1 1 x d1 1 x d1 — Emulsion
End mills MULTI-Jet-Cut Base – long design DIN 6527 LShank acc.
DIN 6535 HA Shank acc.
DIN 6535 HB
ø d1h11
Form l2 l3 l1 ø d3 l4 ø d2h6
l A Z Art. no. Art. no.
3 A 8 14 57 2.9 20 6 21 3 2892A.003 2893A.003
4 A 11 18 57 3.8 20 6 21 3 2892A.004 2893A.004
5 A 13 18 57 4.8 20 6 21 3 2892A.005 2893A.005
6 B 13 – 57 5.8 20 6 21 4 2892A.006 2893A.006
8 B 19 – 63 7.7 25 8 27 4 2892A.008 2893A.008
10 B 22 – 72 9.7 30 10 32 4 2892A.010 2893A.010
12 B 26 – 83 11.6 35 12 38 4 2892A.012 2893A.012
14 B 26 – 83 13.6 35 14 38 4 2892A.014 2893A.014
16 B 32 – 92 15.5 40 16 44 4 2892A.016 2893A.016
20 B 38 – 104 19.5 50 20 54 4 2892A.020 2893A.020
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
Cutting data 11.1 - 1.3 100 - 120 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —1.4 - 1.5 80 - 100 0.004 x d1 1 x d1 1 x d1 Cold air / Pressurized air —1.10 50 - 70 0.0035 x d1 1 x d1 1 x d1 — Emulsion1.13 40 - 60 0.0035 x d1 1 x d1 1 x d1 — Emulsion22.1 - 2.2 100 - 120 0.006 x d1 1 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 80 - 100 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —33.1 - 3.3 100 - 120 0.004 x d1 1 x d1 1 x d1 — Emulsion3.4 - 3.5 80 - 100 0.004 x d1 1 x d1 1 x d1 — Emulsion55.1 350 - 400 0.007 x d
11 x d
11 x d
1— Emulsion
5.2 - 5.3 250 - 300 0.007 x d1 1 x d1 1 x d1 — Emulsion77.1 30 - 50 0.003 x d1 1 x d1 1 x d1 — Emulsion7.2 25 - 40 0.003 x d1 1 x d1 1 x d1 — Emulsion88.1 140 - 160 0.007 x d1 1 x d1 1 x d1 — Emulsion99.2 80 - 100 0.004 x d1 1 x d1 1 x d1 — Emulsion
(
≈ l A
DIN 6535 HB)
ø d
1
ø d
2
l2l3
l4l1
ø d
3
(
≈ l A
DIN 6535 HB)
ø
d 1
ø
d 2
l2l3
l4l1
ø
d 3
Form A
Form A
Form B
Form B
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16
With only three geometries, nearly all workpiece materials can be machinedwith a high degree of process safety. Due to the redevelopment of our ownsuccessful cutting geometries, enormous increases of the machining volumecould be achieved in a great variety of machining tasks.With the axial (ap) and radial (ae) depth-of-cut values which have become
possible now, highly productive work can easily be done even on conventionalmachines. This means another big plus for our customers in the use of ourmilling tools.
Short description
Advantages
• high-performance carbide substrate
• optimized cutting geometry, specially adjusted to HPC machining• high-heat-resistant TIALN coating
• recessed neck
• shank tolerance h5
• narrowed cutting diameter tolerance
• plane bevel and corner radius for increased stability of the cutting corner
• suitable for all materials up to 56 HRC
• tools for universal application
What is the right application for the HPC-Jet-Cut?
Application cases for the HPC-Jet-Cut
• pocket milling jobs of any kind with high requirements as to surface quality or dimensional accuracy
• rectangular pocket milling jobs, circular pocket milling jobs, slot milling jobs
• relief milling jobs without dimensional or optical function
• milling jobs where a high degree of process safety, combined with high machining volume, is essential
Application example 1:
Slot milling: Length 22 mm x width 10.5 mm x depth 18 mm (width of slot tolerated to H7, unstable workpiece clamping)
Material: St 52-3 forged (600 N/mm2)
Tool: Solid carbide drill (point drilling) – solid carbide roughing cutter (roughing) – solid carbide finishing cutter (finishing)
Machining time: 3 minutes 25 seconds, with emulsion cooling
Roughing:Tool: HPC-Jet-Cut dia. 10 mm (art. no. 2851A.010) – vc 120 m/min – fz 0.05 mm – ap 9.5 mm – ae 10 mmFinishing: without tool changeTool: HPC-Jet-Cut dia. 10 mm (art. no. 2851A.010) – vc 160 m/min – fz 0.03 mm – ap 19 mm – ae 0.25 mmMachining time: 40 seconds, with emulsion cooling
Application example 2:
Slot milling: Milling components out of stainless sheet material (milling path per sheet approx. 16.5 m)
Material: 1.4305 (750 N/mm2)
Tool: Convent, solid carbide milling cutter dia. 5 mm, 3 cutting edges – vc 60 m/min – fz 0.025 mm – ap 3 mm – ae 5 mmMachining time: approx. 62 minutes per sheet, with emulsion cooling – tool worn after finishing one single sheet
Tool: HPC-Jet-Cut dia. 5 mm (art. no. 2814A.005) – vc 80 m/min – fz 0.04 mm – ap 3 mm – ae 5 mm
Machining time: 25 minutes, with EKZ 40 bar 1) – two sheets can be finished with one tool
1) EKZ = external coolant-lubricant supply, emulsion along the shank
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17
• suitable for all steels up to 56 HRC
• low-vibration machining due to irregular spacing of cutting edges
• short chip contact due to chip former
• extra deep chip flute to the length of 1 x d1 cutting length• extremely long tool life due to optimized geometry
• 10° positive rake angle – high application flexibility• rotation-symmetric cutting edge arrangement
• highest concentricity due to proper round grinding
• optimized depth of cut due to recessed shank
• cutting diameter 3-20 mm
N-Cut end mills
End mills HPC-Jet-Cut – long design DIN 6527 L
Shank acc.DIN 6535 HA
Shank acc.DIN 6535 HB
ø d1–0.02
Form r l2 l1 ø d3 l4 ø d2h5
l A Z Art. no. Art. no.
3 A 0.3 8 57 – 18 6 21 4 2815A.003 2814A.003
4 A 0.4 11 57 – 19 6 21 4 2815A.004 2814A.004 5 A 0.5 13 57 – 19 6 21 4 2815A.005 2814A.005
6 B 0.5 13 57 5.9 20 6 21 4 2815A.006 2814A.006
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling LubricationConventional cutting data
• stable clamping
• finish milling
11.1 - 1.3 180 - 220 0.005 x d1 1 x d1 0.5 x d1 Cold air / Pressurized air MMS / Emulsion1.4 - 1.5 120 - 160 0.004 x d1 1.5 x d1 0.25 x d1 Cold air / Pressurized air —1.6 80 - 100 0.004 x d1 2 x d1 0.1 x d1 Cold air / Pressurized air —1.10 - 1.12 60 - 80 0.0035 x d1 1.5 x d1 0.25 x d1 — MMS / Emulsion1.13 40 - 60 0.0035 x d1 1.5 x d1 0.1 x d1 — MMS / Emulsion22.1 - 2.2 140 - 200 0.006 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —2.3 - 2.4 120 - 160 0.005 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —33.1 - 3.3 160 - 200 0.004 x d1 2 x d1 0.25 x d1 — Emulsion3.4 - 3.6 80 - 120 0.004 x d1 2 x d1 0.15 x d1 — Emulsion44.1 - 4.3 20 - 40 0.002 x d1 1.5 x d1 0.05 x d1 — Emulsion55.1 - 5.2 250 - 400 0.006 x d1 1 x d1 0.5 x d1 — Emulsion66.1 - 6.2 160 - 250 0.003 x d1 2 x d1 0.1 x d1 — Emulsion77.1 - 7.2 60 - 100 0.003 x d1 2 x d1 0.05 x d1 — Emulsion
88.1 - 8.2 160 - 200 0.007 x d1 2 x d1 0.25 x d1 — Emulsion99.2 80 - 120 0.004 x d1 1.5 x d1 0.3 x d1 Cold air / Pressurized air Emulsion
Shank acc.DIN 6535 HA
Shank acc.DIN 6535 HB
ø d1–0.04
Form r l2 l1 ø d3 l4 ø d2h5
l A Z Art. no. Art. no.
8 B 0.5 19 63 7.9 25 8 27 4 2815A.008 2814A.008
10 B 0.5 22 72 9.5 30 10 32 4 2815A.010 2814A.010
12 B 1 26 83 11.5 35 12 38 4 2815A.012 2814A.012
14 B 1 26 83 13.5 35 14 38 4 2815A.014 2814A.014
16 B 1 32 92 15.5 40 16 44 4 2815A.016 2814A.016
20 B 1 38 104 19.5 50 20 54 4 2815A.020 2814A.020
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HPC cutting data
• stable clamping
• rough milling
11.1 - 1.3 100 - 140 0.005 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air MMS / Emulsion1.4 - 1.5 80 - 120 0.004 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —1.6 60 - 80 0.004 x d1 1 x d1 0.5 x d1 Cold air / Pressurized air —1.10 - 1.12 40 - 60 0.0035 x d1 1 x d1 1 x d1 — MMS / Emulsion22.1 - 2.2 120 - 140 0.005 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 80 - 120 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —33.1 - 3.3 120 - 140 0.004 x d1 2 x d1 1 x d1 — Emulsion3.4 - 3.6 80 - 120 0.004 x d1 2 x d1 0.75 x d1 — Emulsion44.1 - 4.3 15 - 30 0.002 x d1 1.5 x d1 0.25 x d1 — Emulsion5
5.1 - 5.2 200 - 300 0.005 x d1 1 x d1 1 x d1 — Emulsion66.1 - 6.2 120 - 160 0.003 x d1 2 x d1 1 x d1 — Emulsion77.1 - 7.2 30 - 50 0.003 x d1 2 x d1 1 x d1 — Emulsion88.1 - 8.2 100 - 140 0.005 x d1 2 x d1 1 x d1 — Emulsion99.2 60 - 100 0.004 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air Emulsion
+10°
HRC · STEEL · STAINLESS
TITANIUM · ALUMINIUM
r
ø
d 2
l2l4
l1
ø
d 1
≈ l A
(DIN 6535 HB)
ø
d 3
(
≈ l A
DIN 6535 HB)
ø
d 1
ø
d 2
l2l4
l1
r
Form A
Form B
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18
N-Cut end mills
End mills HPC-Jet-Cut – long design DIN 6527 L
Shank acc.DIN 6535 HA
Shank acc.DIN 6535 HB
ø d1–0.02
Form r l2 l1 l4 ø d3 ø d2h5
l A Z Art. no. Art. no.
3 A 0.3 8 57 – – 6 21 4 2850A.003 2851A.003
4 A 0.4 11 57 – – 6 21 4 2850A.004 2851A.004 5 A 0.5 13 57 – – 6 21 4 2850A.005 2851A.005
6 B 0.5 13 57 20 5.9 6 21 4 2850A.006 2851A.006
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling LubricationConventional cutting data
• stable clamping
• finish milling
11.1 200 - 220 0.005 x d1 2 x d1 0.25 x d1 Cold air / Pressurized air MMS / Emulsion1.2 180 - 200 0.004 x d1 1.5 x d1 0.25 x d1 Cold air / Pressurized air MMS / Emulsion1.3 160 - 180 0.004 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —1.4 140 - 160 0.0035 x d1 1.5 x d1 0.5 x d1 — MMS / Emulsion1.5 120 - 140 0.0035 x d1 1.5 x d1 0.5 x d1 — MMS / Emulsion1.6 100 - 120 0.003 x d1 2 x d1 0.1 x d1 Cold air / Pressurized air —22.1 - 2.2 140 - 200 0.006 x d1 2 x d1 0.5 x d1 Cold air / Pressurized air —2.3 - 2.4 120 - 160 0.005 x d1 1.5 x d1 0.25 x d1 Cold air / Pressurized air —33.1 - 3.3 160 - 200 0.005 x d1 2 x d1 0.25 x d1 — MMS / Emulsion3.4 - 3.6 120 - 160 0.004 x d1 1.5 x d1 0.15 x d1 — MMS / Emulsion99.2 80 - 120 0.004 x d1 2 x d1 0.3 x d1 Cold air / Pressurized air MMS / Emulsion
Shank acc.DIN 6535 HA
Shank acc.DIN 6535 HB
ø d1–0.04
Form r l2 l1 l4 ø d3 ø d2h5
l A Z Art. no. Art. no.
8 B 0.5 19 63 25 7.9 8 27 4 2850A.008 2851A.008
10 B 0.5 22 72 30 9.5 10 32 4 2850A.010 2851A.010
12 B 1 26 83 35 11.5 12 38 4 2850A.012 2851A.012
14 B 1 26 83 35 13.5 14 38 4 2850A.014 2851A.014
16 B 1 32 92 40 15.5 16 44 4 2850A.016 2851A.016
20 B 1 38 104 50 19.5 20 54 4 2850A.020 2851A.020
Please note that in the use of these tools, there will always be increased cutting pressures acting on the complete system.In starting on a new machining task, always begin with the lower cutting data.These data have been established under optimal conditions, deviations are possible at any time.
• ramping angle in short-chipping materials 5-10°; reduce work feed (vf) by approx. 50%
• ramping angle in long-chipping materials 3-5°; reduce work feed (vf) by approx. 50%• in case of vibration, reduce speed (rpm) slightly until the tool runs smoothly; keep up work feed (vf)
• with high feed values, tools may be extracted from holders without axial locking device
0°
HRC · STEEL
CAST MATERIALS
• suitable for all steels up to 56 HRC
• low-vibration machining due to irregular spacing of cutting edges
• short chip contact due to chip former
• extra deep chip flute to the length of 1 x d1 cutting length• extremely long tool life due to optimized geometry
• 0° neutral rake angle – high application flexibility• rotation-symmetric cutting edge arrangement
• highest concentricity due to proper round grinding
• optimized depth of cut due to recessed shank
• cutting diameter 3-20 mm
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HPC cutting data
• stable clamping
• rough milling
11.1 140 - 160 0.005 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air MMS / Emulsion
1.2 120 - 140 0.004 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air MMS / Emulsion1.3 100 - 120 0.004 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —1.4 80 - 100 0.0035 x d1 1 x d1 1 x d1 — MMS / Emulsion1.5 80 - 100 0.0035 x d1 1.5 x d1 0.5 x d1 — MMS / Emulsion1.6 80 - 70 0.003 x d1 1 x d1 0.3 x d1 Cold air / Pressurized air —22.1 - 2.2 120 - 140 0.005 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 80 - 120 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —33.1 - 3.3 120 - 140 0.004 x d1 1.5 x d1 1 x d1 — Emulsion3.4 - 3.6 80 - 120 0.004 x d1 1 x d1 0.75 x d1 — Emulsion99.2 60 - 100 0.004 x d1 1 x d1 1 x d1 Cold air / Pressurized air Emulsion
r
ø
d 2
l2l4
l1
ø
d 1
≈ l A
(DIN 6535 HB)
ø
d 3
(
≈ l A
DIN 6535 HB)
ø
d 1
ø
d 2
l2l4
l1
r
Form A
Form B
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19
• suitable for all steels up to 56 HRC
• low-vibration machining due to irregular spacing of cutting edges
• short chip contact due to chip former
• extra deep chip flute to the length of 1 x d1 cutting length• extremely stable cutting edge
• -10° negative rake angle – for short-chipping materials• rotation-symmetric cutting edge arrangement
• highest concentricity due to proper round grinding
• optimized depth of cut due to recessed shank
• cutting diameter 3-20 mm
N-Cut end mills
End mills HPC-Jet-Cut – long design DIN 6527 L
Shank acc.DIN 6535 HB
ø d1–0.02
Form r l2 l1 l4 ø d3 ø d2h5
l A Z Art. no.
3 A 0.3 8 57 – – 6 21 4 1987A.003
4 A 0.4 11 57 – – 6 21 4 1987A.004 5 A 0.5 13 57 – – 6 21 4 1987A.005
6 B 0.5 13 57 20 5.9 6 21 4 1987A.006
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling LubricationConventional cutting data
• stable clamping
• finish milling
11.1 200 - 220 0.005 x d1 2 x d1 0.25 x d1 Cold air / Pressurized air MMS / Emulsion1.2 180 - 200 0.004 x d1 1.5 x d1 0.25 x d1 Cold air / Pressurized air MMS / Emulsion1.3 160 - 180 0.004 x d1 1.5 x d1 0.5 x d1 Cold air / Pressurized air —1.4 140 - 160 0.0035 x d1 1.5 x d1 0.5 x d1 — MMS / Emulsion1.5 120 - 140 0.0035 x d1 1.5 x d1 0.5 x d1 — MMS / Emulsion1.6 100 - 120 0.003 x d1 2 x d1 0.1 x d1 Cold air / Pressurized air —22.1 - 2.2 140 - 200 0.006 x d1 2 x d1 0.5 x d1 Cold air / Pressurized air —2.3 - 2.4 120 - 160 0.005 x d1 1.5 x d1 0.25 x d1 Cold air / Pressurized air —33.1 - 3.3 160 - 200 0.005 x d1 2 x d1 0.25 x d1 — Emulsion3.4 - 3.6 120 - 160 0.004 x d1 1.5 x d1 0.15 x d1 — Emulsion99.2 80 - 120 0.004 x d1 2 x d1 0.3 x d1 Cold air / Pressurized air Emulsion
Shank acc.DIN 6535 HB
ø d1–0.04
Form r l2 l1 l4 ø d3 ø d2h5
l A Z Art. no.
8 B 0.5 19 63 25 7.9 8 27 4 1987A.008
10 B 0.5 22 72 30 9.5 10 32 4 1987A.010
12 B 1 26 83 35 11.5 12 38 4 1987A.012
14 B 1 26 83 35 13.5 14 38 4 1987A.014
16 B 1 32 92 40 15.5 16 44 4 1987A.016
20 B 1 38 104 50 19.5 20 54 4 1987A.020
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HPC cutting data
• stable clamping
• rough milling
11.1 140 - 160 0.005 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air MMS / Emulsion
1.2 120 - 140 0.004 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air MMS / Emulsion1.3 100 - 120 0.004 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —1.4 80 - 100 0.0035 x d1 1 x d1 1 x d1 — MMS / Emulsion1.5 80 - 100 0.0035 x d1 1.5 x d1 0.5 x d1 — MMS / Emulsion1.6 50 - 70 0.003 x d1 1 x d1 0.3 x d1 Cold air / Pressurized air —22.1 - 2.2 120 - 140 0.005 x d1 1.5 x d1 1 x d1 Cold air / Pressurized air —2.3 - 2.4 80 - 120 0.005 x d1 1 x d1 1 x d1 Cold air / Pressurized air —33.1 - 3.3 120 - 140 0.004 x d1 1.5 x d1 1 x d1 — Emulsion3.4 - 3.6 80 - 120 0.004 x d1 1 x d1 0.75 x d1 — Emulsion99.2 60 - 100 0.004 x d1 1 x d1 1 x d1 Cold air / Pressurized air Emulsion
Please note that in the use of these tools, there will always be increased cutting pressures acting on the complete system.In starting on a new machining task, always begin with the lower cutting data.These data have been established under optimal conditions, deviations are possible at any time.
• ramping angle in short-chipping materials 5-10°; reduce work feed (vf) by approx. 50%
• ramping angle in long-chipping materials 3-5°; reduce work feed (vf) by approx. 50%• in case of vibration, reduce speed (rpm) slightly until the tool runs smoothly; keep up work feed (vf)
• with high feed values, tools may be extracted from holders without axial locking device
-10°
HRC · STEEL
CAST MATERIALS
r
ø
d 2
l2l4
l1
ø
d 1
≈ l A
(DIN 6535 HB)
ø
d 3
(
≈ l A
DIN 6535 HB)
ø
d 1
ø
d 2
l2l4
l1
r
Form A
Form B
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20
ae
v f
n
Trochoidal slot milling, programmed with hyper MILL® of OPEN MIND
With their extraordinary performance, the newly developed solid carbide millingcutters of the HSC-Jet-Cut line make it possible to cut down on production costsin a way unheard of before. Due to the multiple effective cutting edges, thedynamics of the milling machine can be used to the limits. As a result, you will beable to achieve machining volumes which can be measured in drastic reductionsof machining time.
Short description
Advantages
• high-performance carbide substrate
• stable cutting geometry, specially adjusted to HSC machining
• high-heat-resistant TIALN coating• recessed neck
• shank tolerance h5
• extremely high accuracy of profile
• narrowed cutting diameter tolerance
• suitable for all materials up to 66 HRC
• tools for universal application
What is the right application for the HSC-Jet-Cut?
Application cases for the HPC-Jet-Cut
• pocket milling jobs of any kind with high requirements as to surface quality or dimensional accuracy
• rectangular pocket milling jobs, circular pocket milling jobs, slot milling jobs (trochoidal slot milling)• relief milling jobs with dimensional or optical function
• milling jobs where a high degree of process safety, combined with high machining volume, is essential
Application example:
Slot milling: Length 38 mm x width 12 mm x depth 10 mm (stable workpiece clamping)
Material: 1.2379, hardened to 62 HRCTool: Conventional solid carbide milling cutter for hard milling dia. 12 mm, 6 cutting edges
vc 80 m/min – fz 0.03 mm – ap 0.3 mm – ae 12 mmStrategy: Z-constant, depth of cut 0.3 mmMachining time: 4 minutes 40 seconds, with cooling by pressurized air
Roughing:
Tool: HSC-Jet-Cut dia. 8 mm (art. no. 2887A.008) – vc 80 m/min – fz 0.03 mm – ap 10 mm – ae 0.3 mmStrategy: Trochoidal slot milling in a down-milling process – the cutting edge is effectively used to 100%!
Machining time: 2 minutes 40 seconds, with cold-air nozzle (see page 11)
Result:
The conventional tool was strongly worn over a cutting length of 0.35 mm after producing one single slot!
With the HSC-Jet-Cut end mill, 12 slots could be produced.
Trochoidal slot milling will distribute wear over the whole working length, permitting effective 100% use of the tool.
The actual tooling costs can be reduced accordingly.
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• suitable for all steels up to 66 HRC
• low-vibration machining due to irregular spacing of cutting edges
• load compensation on cutting edges due to irregular rake angles• extra long tool life due to optimized geometry specification
• rotation-symmetric cutting edge arrangement
• highest concentricity due to proper round grinding
• optimized depth of cut due to recessed shank
N-Cut end mills
End mills HSC-Jet-Cut – long design DIN 6527 L
ø
d 2
l2
l1
ø
d 1
ø
d 3
l4
Shank acc.DIN 6535 HA
ø d1–0.02
l2 l1 ø d3 l4 l A ø d2h5
Z Art. no.
6 13 57 5.9 20 21 6 6 2887A.006
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
Conventional cutting data
• stable clamping
• finish milling
11.1 - 1.2 120 - 140 0.0045 x d1 2 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.3 - 1.4 100 - 120 0.004 x d1 2 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.5 100 - 120 0.004 x d1 2 x d1 0.02 x d1 Cold air / Pressurized air —
1.6 80 - 100 0.0035 x d1 2 x d1 0.02 x d1 Cold air / Pressurized air —1.7 60 - 80 0.0035 x d1 2 x d1 0.02 x d1 Cold air —1.8 50 - 60 0.003 x d1 2 x d1 0.015 x d1 Cold air —1.9 50 - 60 0.003 x d1 2 x d1 0.01 x d1 Cold air —1.10 - 1.12 60 - 80 0.003 x d1 2 x d1 0.02 x d1 — MMS / Emulsion1.13 60 - 80 0.003 x d1 2 x d1 0.02 x d1 — MMS / Emulsion22.1 - 2.2 120 - 140 0.006 x d1 2 x d1 0.02 x d1 Cold air / Pressurized air —2.3 - 2.4 100 - 120 0.005 x d1 1.5 x d1 0.02 x d1 Cold air / Pressurized air —33.1 - 3.3 140 - 160 0.005 x d1 2 x d1 0.02 x d1 Cold air / Pressurized air Emulsion3.4 - 3.6 120 - 140 0.004 x d1 1.5 x d1 0.02 x d1 — Emulsion44.1 - 4.3 20 - 30 0.004 x d1 2 x d1 0.01 x d1 — Emulsion77.1 - 7.2 50 - 70 0.004 x d1 2 x d1 0.02 x d1 — Emulsion
Shank acc.DIN 6535 HA
ø d1–0.04
l2 l1 ø d3 l4 l A ø d2h5
Z Art. no.
8 19 63 7.9 25 27 8 8 2887A.008
10 22 72 9.5 30 32 10 10 2887A.010
12 26 83 11.5 35 38 12 12 2887A.012
16 32 92 15.5 40 44 16 16 2887A.016
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HSC cutting data
• stable clamping
• rough milling
11.1 - 1.2 200 - 220 0.007 x d1 2 x d1 0.05 x d1 Cold air / Pressurized air MMS / Emulsion1.3 - 1.4 180 - 200 0.007 x d
12 x d
10.05 x d
1Cold air / Pressurized air MMS / Emulsion
1.5 160 - 180 0.007 x d1 1.5 x d1 0.05 x d1 Cold air / Pressurized air —1.6 140 - 160 0.007 x d1 1.5 x d1 0.04 x d1 — MMS / Emulsion1.7 120 - 140 0.006 x d1 1.5 x d1 0.03 x d1 — MMS / Emulsion1.8 100 - 120 0.006 x d1 1.5 x d1 0.02 x d1 Cold air / Pressurized air —1.9 80 - 100 0.005 x d1 1.5 x d1 0.015 x d1 Cold air / Pressurized air —22.1 - 2.2 180 - 200 0.008 x d1 2 x d1 0.05 x d1 Cold air / Pressurized air —2.3 - 2.4 160 - 180 0.006 x d1 1.5 x d1 0.05 x d1 Cold air / Pressurized air —33.1 - 3.3 180 - 200 0.005 x d1 2 x d1 0.05 x d1 Cold air / Pressurized air Emulsion3.4 - 3.6 160 - 180 0.004 x d1 1.5 x d1 0.05 x d1 — Emulsion77.1 - 7.2 70 - 90 0.004 x d1 2 x d1 0.03 x d1 — Emulsion
Please note that in the use of these tools, there will always be increased cutting pressures acting on the complete system.In starting on a new machining task, always begin with the lower cutting data.These data have been established under optimal conditions, deviations are possible at any time.
• the tool cannot start work in a ramping mode – start drilling is always necessary
• in case of vibration, reduce speed (rpm) slightly until the tool runs smoothly; keep up feed speed (vf)• all tools are provided with a straight plain shank and should be used in appropriate holders (e.g. clamping system powRgrip®
or thermal shrink-fit technology)
• after use, it is possible to regrind and recoat the tools – for this, the tools can be returned to FRANKEN
powRgrip® is a registered trademark of REGO-FIX AG.
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• developed for 3D HSC finish milling
• suitable for all steels up to 66 HRC
• up to 8 effective cutting edges• extra long tool life due to optimized geometry specification
• rotation-symmetric cutting edge arrangement
• highest concentricity due to proper round grinding
• optimized depth of cut due to two dimensional series and recessed shank
Hard-Cut torus cutters
Torus cutters HSC-Jet-Cut – short design Internal standard
r
ø
d 2
l2
l3
l4
l1
ø
d 1
ø
d 3
β
α
Shank acc.DIN 6535 HA
ø d1±0.01
r±0.005
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
3 0.75 A 2 10 57 2.8 20 6 11.5° 5° 4 1936A.003 4 1 A 2.5 12 57 3.8 20 6 11° 3.5° 4 1936A.004
5 1.25 A 3 14 57 4.7 20 6 10° 2° 4 1936A.005
6 1.5 B 4 – 57 5.6 20 6 – – 4 1936A.006
Shank acc.DIN 6535 HA
ø d1±0.02
r±0.01
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
8 2 B 5 – 63 7.6 25 8 – – 4 1936A.008
8 1 B 5 – 63 7.6 25 8 – – 4 1936A.008010
10 2.5 B 6 – 72 9.6 30 10 – – 4 1936A.010
10 1 B 6 – 72 9.6 30 10 – – 4 1936.010010
12 3 B 7 – 83 11.5 35 12 – – 4 1936A.012
12 1 B 7 – 83 11.5 35 12 – – 4 1936A.012010
16 4 B 8 – 92 15.5 40 16 – – 4 1936A.016
r
ø
d 2
l2
l4
l1
ø
d 1
ø
d 3
Shank acc.DIN 6535 HA
ø d1±0.02
r±0.01
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
10 1 B 6 – 72 9.6 30 10 – – 6 2876A.010010
10 2.5 B 6 – 72 9.6 30 10 – – 6 2876A.010
12 1 B 7 – 83 11.5 35 12 – – 8 2876A.012010
12 3 B 7 – 83 11.5 35 12 – – 8 2876A.012
Form A
Form B
Torus cutters HSC-Jet-Cut – long design Internal standard
Shank acc.
DIN 6535 HA ø d1±0.02
r±0.01
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
6 1.5 B 4 – 80 5.6 30 6 – – 4 2832A.006
8 2 B 5 – 80 7.6 35 8 – – 4 2832A.008
8 1 B 5 – 80 7.6 35 8 – – 4 2832A.008010
10 2.5 B 6 – 100 9.6 45 10 – – 4 2832A.010
10 1 B 6 – 100 9.6 45 10 – – 4 2832A.010010
12 3 B 7 – 100 11.5 50 12 – – 4 2832A.012
12 1 B 7 – 100 11.5 50 12 – – 4 2832A.012010
16 4 B 8 – 120 15.5 60 16 – – 4 2832A.016
Shank acc.DIN 6535 HA
ø d1±0.02
r±0.01
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
10 1 B 6 – 100 9.6 45 10 – – 6 2877A.010010
10 2.5 B 6 – 100 9.6 45 10 – – 6 2877A.010
12 1 B 7 – 100 11.5 50 12 – – 8 2877A.012010
12 3 B 7 – 100 11.5 50 12 – – 8 2877A.012
16 4 B 8 – 120 15.5 60 16 – – 8 2877A.016
r
ø
d 2
l2
l4
l1
ø
d 1
ø
d 3
Form B
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vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
Conventional cutting data
• stable clamping
• finish milling
• normal surfaces
11.1 160 - 180 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.2 140 - 160 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.3 120 - 140 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.4 100 - 120 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.5 100 - 120 0.0035 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —1.6 80 - 100 0.0035 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —
1.7 60 - 80 0.003 x d1 0.02 x d1 0.02 x d1 Cold air —1.8 50 - 60 0.002 x d1 0.015 x d1 0.015 x d1 Cold air —1.9 50 - 60 0.002 x d1 0.01 x d1 0.01 x d1 Cold air —22.1 - 2.2 120 - 140 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —2.3 - 2.4 100 - 120 0.003 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —33.1 - 3.3 140 - 160 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air Emulsion3.4 - 3.6 120 - 140 0.003 x d1 0.02 x d1 0.02 x d1 — Emulsion
Additional technical information:
• ramping angle for tools with 4 cutting edges in short-chipping materials 2-4°; reduce feed speed (vf) by approx. 50%
• for tools with 6 or 8 cutting edges, use a ramping angle of 1° max.
• all tools are provided with a straight plain shank and should be used in appropriate holders (e.g. clamping system powRgrip® or thermal shrink-fit technology)
• grinding a driving flat or similar on the tools is not to be recommended, since it might lead to damages of the carbide substrate,
and hence to uncontrolled tool breakage• in case of vibration, reduce speed (rpm) slightly until the tool runs smoothly; keep up feed speed (vf)
• HSC-Jet-Cut torus cutters were developed in order to achieve highest surface qualities; please store and handle these tools accordingly
• after use, it is possible to regrind and recoat the tools – for this, the tools can be returned to FRANKEN
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HSC cutting data
• stable clamping
• finish milling
• fine surfaces
11.1 260 - 280 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.2 240 - 260 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.3 220 - 240 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.4 200 - 220 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.5 160 - 180 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air —1.6 140 - 160 0.007 x d1 0.01 x d1 0.02 x d1 Cold air / Pressurized air —1.7 120 - 140 0.006 x d1 0.01 x d1 0.02 x d1 Cold air —1.8 100 - 120 0.006 x d1 0.005 x d1 0.015 x d1 Cold air —
1.9 80 - 100 0.005 x d1 0.005 x d1 0.01 x d1 Cold air —22.1 - 2.2 180 - 200 0.008 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —2.3 - 2.4 160 - 180 0.006 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —33.1 - 3.3 180 - 200 0.005 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air Emulsion3.4 - 3.6 160 - 180 0.004 x d1 0.02 x d1 0.02 x d1 — Emulsion
powRgrip® is a registered trademark of REGO-FIX AG.
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• developed for 3D HSC finish milling
• suitable for all steels up to 66 HRC
• up to 8 effective cutting edges• extra long tool life due to optimized geometry specification
• rotation-symmetric cutting edge arrangement
• highest concentricity due to proper round grinding
• optimized depth of cut due to two dimensional series and recessed shank
Hard-Cut ball nose cutters
Ball nose cutters HSC-Jet-Cut – short design Internal standard
Ball nose cutters HSC-Jet-Cut – long design Internal standard
l4
l2l3
l1
α
β
ø d 2
ø d 1
ø d 3
r
Shank acc.DIN 6535 HA
ø d1±0.01
r±0.005
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
3 1.5 A 3.5 10 57 2.8 20 6 11.5° 5° 4 2834A.003 4 2 A 4 12 57 3.8 20 6 11° 3.5° 4 2834A.004
5 2.5 A 5 14 57 4.7 20 6 10° 2° 4 2834A.005
6 3 B 6 – 57 5.6 20 6 – – 4 2834A.006
Shank acc.DIN 6535 HA
ø d1±0.02
r±0.01
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
8 4 B 7 – 63 7.6 25 8 – – 4 2834A.008
10 5 B 8 – 72 9.6 30 10 – – 4 2834A.010
12 6 B 10 – 83 11.5 35 12 – – 4 2834A.012
Shank acc.DIN 6535 HA
ø d1±0.02
r±0.01
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
10 5 B 6 – 72 9.6 30 10 – – 6 2836A.010
12 6 B 7 – 83 11.5 35 12 – – 8 2836A.012
Form A
Form B
l4l2
l1
ø d 2
ø d 1
ø d 3
r
r l2
l4
l1
ø
d 3
ø
d 2
ø
d 1
Form B
Shank acc.DIN 6535 HA
ø d1
±0.01
r±0.005
Form l2 l3 l1 ø d3 l4 ø d2
h5
α β Z Art. no.
6 3 B 6 – 80 5.6 30 6 – – 4 2842A.006
Shank acc.DIN 6535 HA
ø d1±0.02
r±0.01
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
8 4 B 7 – 80 7.6 35 8 – – 4 2842A.008
10 5 B 8 – 100 9.6 45 10 – – 4 2842A.010
12 6 B 10 – 100 11.5 50 12 – – 4 2842A.012
Form B
Shank acc.
DIN 6535 HA ø d1±0.02
r±0.01
Form l2 l3 l1 ø d3 l4 ø d2h5
α β Z Art. no.
10 5 B 6 – 100 9.6 45 10 – – 6 2837A.010
12 6 B 7 – 100 11.5 50 12 – – 8 2837A.012
16 8 B 8 – 120 15.5 60 16 – – 8 2837A.016
l4l2
l1
ø d 2
ø d 1
ø d 3
r
r l2
l4
l1
ø
d 3
ø
d 2
ø
d 1
Form B
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vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
Conventional cutting data
• stable clamping
• finish milling
• normal surfaces
11.1 160 - 180 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.2 140 - 160 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.3 120 - 140 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.4 100 - 120 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.5 100 - 120 0.0035 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —1.6 80 - 100 0.0035 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —
1.7 60 - 80 0.003 x d1 0.02 x d1 0.02 x d1 Cold air —1.8 50 - 60 0.002 x d1 0.015 x d1 0.015 x d1 Cold air —1.9 50 - 60 0.002 x d1 0.01 x d1 0.01 x d1 Cold air —22.1 - 2.2 120 - 140 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —2.3 - 2.4 100 - 120 0.003 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —33.1 - 3.3 140 - 160 0.004 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air Emulsion3.4 - 3.6 120 - 140 0.003 x d1 0.02 x d1 0.02 x d1 — Emulsion
Additional technical information:
• ramping angle for tools with 4 cutting edges in short-chipping materials 2-4°; reduce feed speed (vf) by approx. 50%
• for tools with 6 or 8 cutting edges, use a ramping angle of 1° max.
• all HSC-Jet-Cut ball nose cutters are made with 2 cutting edges to the centre, accordingly the machining of plane surfaces with
HSC-Jet-Cut ball nose cutters should be done with the milling axis til ted to a minimum of 20°; this must be taken into account also
in the calculation of cutting data; from a tilting angle of approx. 20°, the 4, 6 or 8 effective cutting edges are effectively engaged
• all tools are provided with a straight plain shank and should be used in appropriate holders (e.g. clamping system powRgrip®
or thermal shrink-fit technology)
• grinding a driving flat or similar on the tools is not to be recommended, since it might lead to damages of the carbide substrate,
and hence to uncontrolled tool breakage• in case of vibration, reduce speed (rpm) slightly until the tool runs smoothly; keep up feed speed (vf)
• HSC-Jet-Cut ball nose cutters were developed in order to achieve highest surface qualities; please store and handle these tools accordingly
• after use, it is possible to regrind and recoat the tools – for this, the tools can be returned to FRANKEN
vc [m/min] fz [mm] ap [mm] ae [mm] Cooling Lubrication
HSC cutting data
• stable clamping
• finish milling
• fine surfaces
11.1 260 - 280 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.2 240 - 260 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.3 220 - 240 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.4 200 - 220 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air MMS / Emulsion1.5 160 - 180 0.007 x d1 0.015 x d1 0.02 x d1 Cold air / Pressurized air —1.6 140 - 160 0.007 x d1 0.01 x d1 0.02 x d1 Cold air / Pressurized air —1.7 120 - 140 0.006 x d1 0.01 x d1 0.02 x d1 Cold air —1.8 100 - 120 0.006 x d1 0.005 x d1 0.015 x d1 Cold air —
1.9 80 - 100 0.005 x d1 0.005 x d1 0.01 x d1 Cold air —22.1 - 2.2 180 - 200 0.008 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —2.3 - 2.4 160 - 180 0.006 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air —33.1 - 3.3 180 - 200 0.005 x d1 0.02 x d1 0.02 x d1 Cold air / Pressurized air Emulsion3.4 - 3.6 160 - 180 0.004 x d1 0.02 x d1 0.02 x d1 — Emulsion
powRgrip® is a registered trademark of REGO-FIX AG.
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26
Circular line-by-line milling - Slotting on an HSC machining centre
Method description
A new method to produce slots on an HSC machining centre is circular line-by-line milling. The procedure is based on a semi circle cuttingpath which is moved several times repeatedly. Due to the use of the entire cutting edge length, the metal removal rate is many times higherthan under conventional conditions.
Circular line-by-line milling (down milling)
v f
ae
n
For circular line-by-line milling, a pocket with a semi circle is programmed. When the end millreaches the slot width, the zero offset will be moved in working direction. The end mill is usedin a peripheral milling operation in a down milling process.
Trochoid slot milling (down milling)
ae
v f
n
For trochoid line-by-line milling, a spiral semi circle is programmed. This is repeated in workingdirection for the complete slot length. For programming this method, a CAM system is required.
Circular line-by-line milling (up and down milling)
v f
ae
n The method with the highest efficiency is circular line-by-line milling in an up and down millingprocess. This method is based on a programmed semi circle cutting path. The end mill is usedon this cutting path in an up and down milling process. This procedure can increase productivityby 100% because the end mill is always in use.
For downloading our diverse parameter programmes, please see our Technology Homepage
www.frankentechnik.de
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27
Description of material groups
Materialgroup
Material typeTensile strength
rangeMaterial examples
1 Steel materials1.1 Cold-extrusion steels,
Magnetic soft iron ≤ 400 N/mm2 Q-St37-3R-Fe80
1.01231.1014
1.2 Free-cutting s teels,General construction steels ≤ 600 N/mm
2 9SMnPb28St37-2
1.07181.0037
500-700 N/mm2
340-470 N/mm21.3 Free-cutting steels, Construction steels,
Alloyed steels, Steel castings ≤ 850 N/mm2 St70-2GS-25CrMo4
1.00701.7218
700-900 N/mm2650-950 N/mm2
1.4 Cementation steels,Heat-treatable steels,Nitriding steels, Cold work steels
≤ 1100 N/mm216MnCr5Ck45100Cr6
1.71311.11911.3505
500-700 N/mm2600-800 N/mm2700-900 N/mm2
1.5 Heat-treatable steels, Nitriding steels,Hot work steels,Hardened steels up to 44 HRCCold work steels
≤ 1400 N/mm242CrMo4VX30WCrV5-3X38CrMoV5-3X155CrVMo12-1
1.72251.25671.23671.2379
1200-1400 N/mm21100 N/mm2
900-1100 N/mm2900-1100 N/mm2
1.6 Hardened steels > 44 - 55 HRC 55NiCrMoV6 1.2713 47-52 HRC1.7 Hardened steels > 55 - 60 HRC 45WCrV7 1.2542 56-57 HRC1.8 Hardened steels > 60 - 63 HRC X155CrVMo12-1 1.2379 60-63 HRC1.9 Hardened steels > 63 - 66 HRC X210CrW12 1.2436 63-64 HRC1.10 Corrosion-proof steels,
Acid-proof steels,Heat-resistant steels
≤ 850 N/mm2X10NiCrAlTi32-20 [INCOLOY800]X12CrNiTi18-9X6CrNiMoTi17-12-2
1.48761.48781.4571
610-850 N/mm2500-700 N/mm2500-730 N/mm2
1.11 Corrosion-/Acid-proof steels, Heat-resistant steels ≤ 1100 N/mm2
X45SiCr4 1.4704 900-1100 N/mm2
1.12 Corrosion-/Acid-proof steels, Heat-resistant steels ≤ 1400 N/mm2 X5NiCrTi26-15 1.4980 1200 N/mm2
1.13 Special steel materials ≤ 1400 N/mm2 FerroTiCHardox500
800-900 N/mm21300-1400 N/mm2
2 Cast materials2.1 Cast iron GG 20
GG 300.60200.6030
120-220 HB220-270 HB
2.2 Cast iron with nodular graphite GGG 40GGG 70
0.70400.7070
400 N/mm2700-1050 N/mm2
2.3 Cast iron with vermicular graphite GGV (80% Perlit)GGV (100% Perlit)
220 HB230 HB
2.4 Malleable cast iron GTW 40GTS 65
0.80400.8165
360-420 N/mm2580-650 N/mm2
2.5 Hard castings up to 400 HB - 400 HB3 Cooper, Cooper alloys, Bronze, Brass3.1 Pure copper and low alloyed copper ≤ 500 N/mm2 E-Cu 2.0060 250-350 N/mm2
3.2 Copper-zinc alloys(brass, long-chipping)
CuZn40 [Ms60]CuZn37 [Ms63]
2.03602.0321
340-490 N/mm2310-550 N/mm2
3.3 Copper-zinc alloys (brass, short-chipping) CuZn39Pb2 [Ms58] 2.0380 380-500 N/mm23.4 Copper-aluminium alloys (alubronze, long-chipping)
Copper-tin alloys (bronze, long-chipping)CuAl10Ni 2.0966 500-800 N/mm2
3.5 Copper-tin alloys(bronze, short-chipping)
GCuSn5ZnPb [Rg5]GCuSn7ZnPb [Rg7]
2.10962.1090
150-300 N/mm2150-300 N/mm2
3.6 Special copper alloys, up to Q 18 Ampco16 630 N/mm2
3.7 Special copper alloys over Q 18 Ampco20 600 N/mm2
4 Nickel/Cobalt alloys4.1 Nickel/Cobalt alloys heat-resistant ≤ 850 N/mm2 NiCu30Fe [MONEL400] 2.4360 420-610 N/mm2
4.2 Nickel/Cobalt alloys high-heat resistant 850 - 1400 N/mm2 NiCr19NbMo [INCONEL718] 2.4668 850-1190 N/mm2
4.3 Nickel/Cobalt alloys high-heat resistent > 1400 N/mm2 Haynes 25 (L605) 1550-2000 N/mm2
5 Aluminium alloys5.1 Aluminium wrought alloys Al 99.5 [F13]
AlCuMg1 [F39]3.02553.1325
100-250 N/mm2300-500 N/mm2
5.2 Aluminium cast alloys Si ≤ 5% G-AlMg3 3.3541 130-190 N/mm2
5.3 Aluminium cast alloys 5% < Si ≤ 12 % GD-AlSi9Cu3GD-AlSi12
3.21633.2582
240-310 N/mm2220-300 N/mm2
5.4 Aluminium cast alloys 12 % < Si ≤ 17% G-AlSi17Cu4 180-250 N/mm26 Magnesium alloys6.1 Magnesium wrought alloys MgAl6 3.5662 300-500 N/mm2
6.2 Magnesium cast alloys GMgAl9Zn1 3.5912 300-500 N/mm2
7 Titanium, Titanium alloys7.1 Pure titanium,
Titanium alloys ≤ 900 N/mm2 Ti3 [Ti99.4]TiAl6V4
3.70553.7164
700 N/mm2700-900 N/mm2
7.2 Titanium alloys 900 - 1250 N/mm2 TiAl4Mo4Sn2 3.7185 900-1250 N/mm2
8 Synthetics8.1 Duroplastics (short-chipping) BAKELIT 110 N/mm2
8.2 Thermoplastics (long-chipping) HOSTALEN 80 N/mm2
8.3 Fibre-reinforced synthetics CFK / GFK / AFK 800-1500 N/mm2
9 Materials for special applications9.1 Graphite C-8000 60 N/mm2
9.2 Tungsten-copper alloys W-Cu 80/20 230-250 HV
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