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Keeping the Customer First T-dia AL TAC insert for turning aluminum The ultimate solution for turning aluminum!! Tungaloy Report No. 351-E chipbreaker

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Page 1: R351 AL T-DIA - toolprocure.com.autoolprocure.com.au/assets/Page - Services Images... · Keeping the Customer First T-dia AL TAC insert for turning aluminum The ultimate solution

Keeping the Customer First

T-diaAL

TAC insert for turning aluminum

The ultimate solution for turning aluminum!!

Tungaloy Report No. 351-E

chipbreaker

Page 2: R351 AL T-DIA - toolprocure.com.autoolprocure.com.au/assets/Page - Services Images... · Keeping the Customer First T-dia AL TAC insert for turning aluminum The ultimate solution

2

AL

AL

AC4CVCGT160404-��

Vc = 800 m/min

ap = 1 mm

f = 0.15 mm/rev

AC4C

RCGT0803M0-��

Vc = 1500 m/minap = 2.0 mm

f = 0.4 mm/rev

KS05F

(GP

a)

(HRA)

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

0.5

088 89 90 91 92 93 94

VB (m

m)

0.5

0.4

0.3

0.2

0.1

00 2 4 6 8 10

chipbreaker

Features

For turning aluminum alloy and non-ferrous metal

Non-ferrous

Enhanced adhesion resistance with the lapped rake face!!Lapped surfaceLapped surface

AL chipbreaker greatly prevents adhesion!

Comparison of adhesion resistance

Cutting condition

Work material:Insert:

Cutting speed:

Depth of cut:

Feed:

Coolant:

(Si: 6.5 ~ 7.5%)

Water soluble type

Adhesion

Competitor (without lapping)

■ After 5 min. of machining

AL

Increased wear resistance by adapting a fi ne grained cemented carbide!!

KS05F gradeKS05F grade

Comparison of wear resistance

Cutting condition

Work material:Insert:

Cutting speed:

Depth of cut:

Feed:

Coolant:

(Si: 6.5 ~ 7.5%)

Water soluble type

Conventionalgrade

Hardness

T.R

.S.

Competitor

AL

Increasedabrasion

resistance!

Machining time:

Flan

k w

ear

wid

th:

T (min)

chipbreaker

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3

0.3 0.4 0.5 0.6

1.0

2.0

3.0

4.0

5.0

0.3 0.4 0.5 0.6

1.0

2.0

3.0

4.0

5.0

ap (m

m)

AC4CVCGT220520-��

Vc = 1500 m/min

f (mm/rev)

AC4C

VCGT220520-��

Vc = 800 m/min

ap = 4.0 mm

f = 0.4 mm/rev

1800

1200

600

0

ap (m

m)

f (mm/rev)

(N) 30% down

The deep pocket geometry improves chip packing!!

Large inclinationLarge inclination

Chip packing

Excellent chip control!

Cutting condition

Work material:Insert:

Cutting speed:

Coolant: Water soluble type

Competitor(with chipbreaker) AL

Dep

th o

f cut

:

Feed:

Dep

th o

f cut

:

Feed:

Reduces cutting force with a large rake angle and sharp edge!!

Large rake angleLarge rake angle

Comparison of cutting forceCutting force reducedby 30%!

Cutting condition

Work material:Insert:

Cutting speed:

Depth of cut:

Feed:

Coolant: Water soluble type

(Si: 6.5 ~ 7.5%)

Competitor AL

Cut

ting

resi

stan

ce

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4

AL

Vc (m/min) ap (mm) f (mm/rev)600 (100 ~ 1,200) 2.0 (1.0 ~ 3.0) 0.3 (0.1 ~ 0.6)200 (100 ~ 300) 1.0 (0.5 ~ 1.5) 0.2 (0.1 ~ 0.4)500 (300 ~ 800)

1.0 (0.2 ~ 1.5) 0.3 (0.1 ~ 0.6)200 (150 ~ 400)

f - apKS05F ød s ød1 rε

CCGT060202-AL � 6.35 2.38 2.8 0.20.4CCGT060204-AL �

CCGT09T302-AL �

9.525 3.97 4.40.20.40.8

CCGT09T304-AL �

CCGT09T308-AL �

CCGT120402-AL �

12.70 4.76 5.50.20.40.8

CCGT120404-AL �

CCGT120408-AL �

DCGT070202-AL � 6.35 2.38 2.8 0.20.4DCGT070204-AL �

DCGT11T302-AL �

9.525 3.97 4.40.20.40.8

DCGT11T304-AL �

DCGT11T308-AL �

RCGT0602M0-AL � 6.00 2.38 2.8 -RCGT0803M0-AL � 8.00 3.18 3.4 -RCGT1003M0-AL � 10.00 3.18 4.0 -

TCGT110202-AL � 6.35 2.38 2.8 0.20.4TCGT110204-AL �

TCGT16T302-AL �

9.525 3.97 4.40.20.40.8

TCGT16T304-AL �

TCGT16T308-AL �

VCGT160404-AL �

9.525 4.76 4.40.20.81.2

VCGT160408-AL �

VCGT160412-AL �

VCGT220520-AL � 12.70 5.56 5.5 2.03.0VCGT220530-AL �

ød ød1

s

7°rε

55°

ød

ød

1

s

ød ød1

s

7°rε

35°

80°

ød ød1

s

7°rε

ød

s

ød1

7°rε

60°

0 0.2 0.4 0.6 0.8 1.0

10

8

6

4

2

0 0.2 0.4 0.6 0.8 1.0

10

8

6

4

2

0 0.2 0.4 0.6 0.8 1.0

10

8

6

4

2

0 0.2 0.4 0.6 0.8 1.0

10

8

6

4

2

0 0.2 0.4 0.6 0.8 1.0

10

8

6

4

2

a p (m

m)

f (mm/rev)

a p (m

m)

f (mm/rev)

a p (m

m)

f (mm/rev)

a p (m

m)

f (mm/rev)

a p (m

m)

f (mm/rev)

chipbreaker

● : Stocked items

Inserts

■ Positive type

Shape Cat. No.Grade Dimensions(mm)

12 type

09 type

06 type

11 type

07 type

10 type

08 type

06 type

16 type

11 type

22 type

16 type

Standard cutting conditions

Work material Cutting speed FeedDepth of cut

Aluminum alloys(Si < 12%)Aluminum alloys(Si ≥ 12%)Copper, Brass

Bronze

*Attention:It is recommended that this product range is used with a water-soluble coolant. Please be aware that the recommended cutting conditions may change according to the work material, surface fi nish conditions, machining conditions, cutting speeds or the size of the corner radius.

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5

6000

5000

4000

3000

2000

1000

0

f (mm/rev)

� SVHCR2525M22 VCGT220530-AL (KS05F) 0.6

� VCGT220530-AL (KS05F) 0.6

�VCGT220530-AL

(KS05F) 0.3DCGT11T308-AL (KS05F)

� SVHCL2525M22 VCGT220530-AL (KS05F) 0.6

f (mm/rev)

� SVHCR2525M22 VCGT220530-AL (KS05F) 0.6

� SVHCR2525M22 VCGW220530-DIA(DX140) 0.15

f (mm/rev)

� SRDCN2525M06 RCGT060M0-AL (KS05F) 0.45

�VCGT160412-AL

(KS05F) 0.2 ~ 0.3DCGT070204-AL

(KS05F)

VCGT220520-��

A356

Vc = 220 ~ 1630 m/min

f = 0.45 ~ 0.50 mm/rev

ap = 2 ~ 6 mm

Practical examples

Aluminum wheel tooling(Example 1)

● Process 1Number of revolution: n = 1250 min-1 (Constant)Depth of cut: ap = 2 mmCutting speed: Vc = 250 ~ 1500 m/min

Tool number

Processing Operation Cat. No. Inserts Feed

Edge,Externalprofi lingEdge,Bore

profi ling

Boreprofi ling

Edge,Externalprofi ling

Special holder

Special holder

Special holder

Tool number

Processing Operation Cat. No. Inserts Feed

Tool number

Processing Operation Cat. No. Inserts Feed

Facing,Externalprofi ling

Facing,Internalprofi ling

Facing & roughing

Facing & fi nishing

● Process 2Number of revolution: n = 1250 min-1 (Constant)Depth of cut: ap = 1 mmCutting speed: Vc = 300 ~ 1200 m/min

(Example 2)

Number of revolution: n = 1800 min-1 (Constant)Depth of cut: ap = 2 mmCutting speed: Vc = 320 ~ 1500 m/min

Comparison of tool life

Water soluble type

(T6 Castings)

Inserts

Enab les s tab le mach in ing because o f the combination of AL chipbreaker and KS05F grade.

Aluminum wheels,rim external turning

Num

ber

of

pie

ces

(pie

ces

/ co

rner

)

Competitor

2.5 times up!!

AL

Cut

ting

co

nditi

on Work

materialCutting speed

Feed

Depth of cut

Coolant

Res

ults

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T-DIA

6

1000500

50

5 10 50 100 500

100

K10 DX140

1.0

0.5

500 100 1000750500

DX140

T-DIA

T (min) Vc (m/min)

Ra

(µm

)

Vc

(m/m

in)

6

Features

T-DIA TAC insert with rake angle!

Wide chipbreaker contributes to excellent chip control.

Ground rake face for excellent sharpnessGround rake face for excellent sharpness

Width breaker

Competitor

Excellent wear resistanceExcellent wear resistance

Increased adhesion resistanceIncreased adhesion resistance

Provides outstanding tool life

Wear resistance

Work material:Holder:Insert:Cutting speed:Feed:Depth of cut:

Aluminum alloy (Si: 18.0%)CSBPR2525M4SPGN120308-DIAVc = 100 ~ 1000 m/minf = 0.1 mm/revap = 0.5 mmDry cutting

(Tool life criteria: VB = 0.3 mm)

Cutting condition

Tool life:Cut

ting

spee

d:

Improved quality of machined surface

Surface fi nishCutting condition

DX140 provides excellent surface fi nish.

Work material:Holder:Insert:

Aluminum alloy (Si: 10.0%)CSBPR2525M4SPGN120308-DIA

Cutting speed:

ap = 0.5 mmf = 0.1 mm/revMachining time: T = 20 min

ap = 0.15 mmf = 0.04 mm/revMachining time: T = 2 min

Carbide(K10)

Sur

face

fi ni

sh:

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7

(µm) (Hv) (GPa)

DX110 < 1 8500 1.8

DX120 4.5 9000 1.8

DX140 12.5 10000 1.7

DX160 28 11000 1.6

DX180 45 12000 1.5

DX

180

DX

160

DX

140

DX

120

DX

110

DX140

DX120

DX160 DX180

DX110

6000 ~ 9000

8000 ~ 12000

( )

Grades

Non-ferrous

Diamond is the hardest known material on the earth. This is an advanced diamond based tool material where tiny diamond crystals are tightly sintered on the cemented carbide alloy base by means of a super high pressure and temperature process. PCD is therefore the optimum choice for cutting non-ferrous and non-metal materials.

Polycrystalline diamond layer

Cemented carbidesubstrate

Comparison of Hardness Tool materials Hardness (HK)

T-DIA

Natural diamond

Incr

easi

ng w

ear

resi

stan

ce (h

ardn

ess)

Incr

easi

ng im

pact

res

ista

nce

(tou

ghne

ss)

Application Grades Microstructure Grain size Strength FeaturesHardness

For precision machining of non-ferrous metals and non-metals where high quality surface fi nish is required. Features the finest grain structure in T-DIA series and excels in cutting edge sharpness.

Used for machining of non-ferrous metals and non-metals. Composed of medium and fi ne grain diamond, provides moderate wear resistance and grind ability.

Can be used for machining half sintered ceramics and cemented carbides, stones and non-ferrous metals. The compact mixed sintered composition of large and fi ne grain diamonds makes the ability to grind superior to that of DX180.

Suitable for turning half sintered ceramics and cemented carbides. Features the highest purity levels with large grain PCD for excellent wear resistance.

Super fine grain T-DIA grade for superior sur face f in ish. Excels in cut t ing edge sharpness and produces consistently high quality surface finish, resulting from gradual wear resistance.

Grade selection guide

1st selection (Grade for general machining)

Excellent cutting edge sharpness and fracture

resistance

Excellent wear resistance

● For precision machining of electronic components● For excellent surface fi nish● For interrupted machining

● For machining of hard material

● For wear resistance

(e.g.: Machining of aluminum with high Si content)

※ If the depth of cut is beyond standard cutting conditions, Please select TH10 (carbide), GH (coated carbide).

● For greater wear resistance than DX160

For special machining

Excellent surface fi nish

● For even higher machined surface quality

Non-ferrous

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T-DIA

8

DX120 DX140 DX160 ød s ød1 rε a

CNMM120402-DIA � 12.7 4.76 5.160.2 3.5

CNMM120404-DIA � 0,4 3.5

DNMM150402-DIA � 12.7 4.76 5.16 0.2 3.3DNMM150404-DIA � 0.4 3.1

TNMM160402-DIA � 9.525 4.76 3.81 0.2 3.3TNMM160404-DIA � 0.2 3.2

VNMM160402-DIA �9.525 4.76 3.81

0.2 4.8VNMM160404-DIA � 0.4 4.4VNMM160408-DIA � 0.8 3.6

ød

s

rε 80ºa

ød

1

ød

s

rε55ºa

ød

1

ød

s

a

ød1

ød

s

rε35º

a

ød

1

DX120 DX140 DX160 ød s ød1 rε a

CNGA120404-DIA � 12.7 4.76 5.16 0.4 3.5CNGA120408-DIA 0.8 3.4

DNGA150404-DIA � � 12.7 4.76 5.16 0.4 3.1DNGA150408-DIA � 0.8 2.8

TNGA160304-DIA

9.5253.18

3.81

0.4 3.2TNGA160308-DIA 0.8 2.9TNGA160404-DIA � � 4.76 0.4 3.2TNGA160408-DIA � � 0.8 2.9

SNGA120404-DIA � � 12.7 4.76 5.16 0.4 3.6SNGA120408-DIA � � 0.8 3.6

SNGN090308-DIA 9.525 3.18 − 0.8 3.6SNGN120408-DIA � 12.7 4.76 − 0.8 3.6

ød

ød1

s

a

ød

s

rε55º

a

ød1

øds

a

ød

1

80º

ød

s

rεa

ød1

ød s

a

● : Stocked items

Inserts

■ Negative type (with chipbreaker)

Shape Cat. No.Grades Dimensions(mm) Applicable

toolholdersImproved

SharpnessWear resistance

Higher

A, D, P, Mtype

A, D, P, M, E, W-type

A, D, P ,Mtype

M-type

Shape Cat. No.Grades

Dimensions(mm) Applicabletoolholders

A, D, P, M,E, W-type

A, D, P, M, E-type

C-type

A, D, P, Mtype

A, D, P, Mtype

■ Negative type

Improved Sharpness

Wear resistance Higher

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9

DX120 DX140 DX160 θ ød s ød1 rε a

CCMT060202-DIA �

7°6.35 2.38 2.8 0.2 2.4

CCMT060204-DIA � 0.4 2.4CCMT09T302-DIA �

9.525 3.97 4.4 0.2 2.4CCMT09T304-DIA � 0.4 2.4

DCMT070202-DIA �

7° 6.35 2.38 2.8 0.2 2.3

DCMT070204-DIA � 0.4 2.1DCMT11T302-DIA �

9.525 3.97 4.4 0.2 3.2DCMT11T304-DIA � 0.4 3.0

TCMT080202-DIA �

4.762.38

2.7 0.2 2.2TCMT080204-DIA � 0.4 2.0TCMT110202-DIA �

6.35 2.8

0.2 2.4TCMT110204-DIA � 0.4 2.2TCMT110302-DIA �

3.18 0.2 2.4TCMT110304-DIA � 0.4 2.2

VCMT160402-DIA �7° 9.525 4.76 4.4 0.2 4.8

VCMT160404-DIA � 0.4 4.4

DX120 DX140 DX160 θ ød s ød1 rε a

CCGW060200-DIA �

6.35 2.38 2.80.03 2.4

CCGW060202-DIA � 0.2 2.4CCGW060204-DIA � 0.4 2.4CCGW09T302-DIA �

9.525 3.97 4.40.2 3.5

CCGW09T304-DIA � � 0.4 3.5CCGW09T308-DIA � � 0.8 3.4DCGW070200-DIA �

6.35 2.38 2.80.05 2.4

DCGW070202-DIA � � 0.2 2.3DCGW070204-DIA � 0.4 2.1DCGW11T302-DIA �

9.525 3.97 4.40.2 3.2

DCGW11T304-DIA � 0.4 3.0DCGW11T308-DIA � 0.8 2.7SPGN090302-DIA

11°

9.525

3.18 −

0.2 3.6SPGN090304-DIA � 0.4 3.6SPGN090308-DIA � 0.8 3.6SPGN120302-DIA �

12.7

0.2 3.6SPGN120304-DIA � � 0.4 3.6SPGN120308-DIA � � 0.8 3.6SPGN120312-DIA 1.2 3.6TCGW110202-DIA

6.35 2.38 2.8 0.2 2.4TCGW110204-DIA 0.4 2.2TCGW16T302-DIA

9.525 3.97 4.40.2 3.3

TCGW16T304-DIA 0.4 3.2TCGW16T308-DIA 0.8 2.9ød

s

rεa

ød1

θ

ød

s

rε 80ºa

ød1

θ

ød

s

rε55º

a

ød1

θ

ød

s

rεa

ød1

θ

ød

rε35º

a

ød1

s

θ

ød

s

rε 80ºa

ød1

θ

ød

θ

s

rε55º

a

ød1

øds

a

θ

● : Stocked items

Shape Cat. No.Grades Dimensions(mm) Applicable

toolholders

For boring holesS-type

For boring holesS-type

For boring holesS-type

For boring holesS-type

Shape Cat. No.Grades Dimensions(mm) Applicable

toolholders

For boring holesS-type

For boring holesS-type

For boring holesC-type

For boring holesS-type

■ Positive type (with chipbreaker)

■ Positive type

Improved Sharpness

Wear resistance Higher

Improved Sharpness

Wear resistance Higher

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T-DIA

10

DX120 DX140 DX160 θ ød s ød1 rε a

TPGW080202-DIA �

11°

4.76 2.38 2.3 0.2 2.4TPGW080204-DIA � 0.4 2.3TPGW090202-DIA � � 5.56 2.38 2.5 0.2 2.4TPGW090204-DIA � 0.4 2.2TPGW110202-DIA � � 6.35 2.38 2.8 0.2 2.4TPGW110204-DIA � 0.4 2.2TPGW130302-DIA � � 7.94 3.18 3.4 0.2 3.3TPGW130304-DIA � 0.4 3.2TPGW16T302-DIA �

9.525 3.97 4.40.2 3.3

TPGW16T304-DIA � 0.4 3.2TPGW16T308-DIA � 0.8 2.9TPGN090204-DIA �

11°

5.56 2.38

0.4 2.2TPGN090208-DIA 0.8 2.0TPGN110301-DIA

6.35 3.18

0.1 3.4TPGN110302-DIA 0.2 3.3TPGN110304-DIA � � 0.4 3.2TPGN110308-DIA � 0.8 2.9TPGN160301-DIA

9.525 3.18

0.1 3.4TPGN160302-DIA � 0.2 3.3TPGN160304-DIA � � � 0.4 3.2TPGN160308-DIA � 0.8 2.9TPGN160312-DIA 1.2 2.6TPGA090202-DIA �

11°

5.556 2.38 3.2 0.2 2.4TPGA090204-DIA � 0.4 2.2TPGA110202-DIA �

6.35

2.38

3.0

0.2 2.4TPGA110204-DIA � 0.4 2.2TPGA110302-DIA �

3.180.2 2.4

TPGA110304-DIA � 0.4 2.2TPGA110308-DIA � 0.8 2.0TPGA160302-DIA �

9.525 3.18 4.00.2 3.3

TPGA160304-DIA � 0.4 3.2TPGA160308-DIA � 0.8 2.9VCGW160402-DIA �

7° 9.525 4.76 4.4

0.2 4.8VCGW160404-DIA � 0.4 4.4VCGW160408-DIA 0.8 3.6VCGW160412-DIA 1.2 2.7VCGW220530-DIA 12.7 5.56 5.5 3.0 5.0

EPGW040102-DIA � 11° 3.97 1.59 2.3 0.2 2.0EPGW040104-DIA � 0.4 1.9

CPGA090202-DIA � 11° 9.525 2.38 4.0 0.2 2.4CPGA090204-DIA � 0.4 2.4

ød

s

a

ød

1

θ

ød

s

a

ød1

θ

80º

ød

s

rεa

ød1

θ

ød

s

a

θ

35º

ød

s

rεa

ød1

θ

ød

s

rε 80ºa

ød1

θ

● : Stocked items

Shape Cat. No.Grades

Dimensions(mm) Applicabletoolholders

For boring holesS-type,Top borer tools

For boring holesC-type

For boring holesC-type

For boring holesS-type

For boring holes S-type,TAC boring bar tools, Round shank, Top borer tools

For boring holesS-type

■ Positive type

(Tungaloy’s standard hole)

(Tungaloy’s standard hole)

Improved Sharpness

Wear resistance Higher

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11

DX120

0

10

DX120 DX140 DX160 DX180

20

30

40

50

60

70

DX140

Vc (m/min) ap (mm) f (mm/rev) DX120 DX140 DX160 DX1801500 (1000-2500) 0.5 (0.05-2.0) 0.1 (0.05-0.2) ○ ◎

600 (400-800) 0.5 (0.05-2.0) 0.1 (0.05-0.2) ○ ◎ ○800 (500-1500) 0.5 (0.05-2.0) 0.1 (0.05-0.2) ○ ◎400 (300-500) 0.5 (0.05-2.0) 0.1 (0.05-0.2) ○ ◎400 (300-500) 0.5 (0.05-2.0) 0.1 (0.05-0.2) ◎ ○ ○700 (500-1000) 0.2 (0.05-0.5) 0.05 (0.03-0.1) ◎ ○700 (500-1000) 0.2 (0.05-0.5) 0.03 (0.01-0.05) ◎ ○

15 (10-20) 0.1 (0.05-0.2) 0.03 (0.01-0.05) ○ ○ ◎130 (100-150) 0.5 (0.05-2.0) 0.05 (0.03-0.1) ○ ◎

SVHCR2525M22VCGW220530-DIA (DX140)

Vc = 300 ~ 1200 m/min f = 0.15 mm/revap = 1 mm

DX160, DX140, DX120

100~125900 ~ 1,200 m/min30~ 60 min-1

♯ 800 / 1000,ø150

1600 min-1

6 min

Standard cutting conditions

Aluminum alloys(Si < 12%)Aluminum alloys(Si ≥ 12%)

Copper and BrassBronze

Carbon / GraphiteFRP

PlasticCemented carbide(D40 ~ D50)

Ceramics (sintered tentative)

Grade selectionWork material

FeedDepth of cutCutting speed

 ◎:First choice ○:Second choice

Practical example

Inserts

Tools

Aluminum alloys

DX140 provides excellent surface fi nish. It also enables accurate and high speed machining without chipping.

Wheel machining

Workpiece sketch

Work materialCutting speed

FeedDepth of

cut

Water soluble typeCut

ting

co

nditi

on

Res

ults

Re-grinding methodGrades

Machinery Universal tool grinding machine with high rigidity

Diamond wheel

Bitorifaindobondo

Rough processing ♯ 400 ~♯ 600Finish machining #1,000 or alternate small dimensions

■ NoteGenerally there is no need for pre-honing.■ Operating precaution・Please apply enough grinding coolant.・Please apply the dressing consistently to prevent loading the grinding wheel.■ AttentionPlease pay extra attention to the wheel dressing and also the rigidity of the spindle and its runout. As the sharpness of the cutting edge greatly affects the surface fi nish and the tool life.

The smaller the particle, the sharper the insert. This improves surface finish reduces the burr on the machined part.

Grinder Diamond grinding machine

Vitrifi ed

Cup-type diamond wheel

 T-DIA,(4 grades)

Grinding area 64 mm2

type

Bonding material

Granularity

Degree of concentrarion

Wheel peripheral speed

Wheel swing

Grinding ComparisonAfter 6 min. of grinding

Gri

ndin

gG

rind

ing

co

nditi

on

Whetstone

Work material

Wheel rotation speed

Grinding time

Am

ount

of g

rind

ing

(µm

)

Coolant

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Dec. 2010 (TJ)

ISO 9001 certifi ed ISO 14001 certifi edQC00J0056 EC97J1123Tungaloy Corporation Tungaloy Group Japan site and Asian production site18/10/1996 26/11/1997

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