Reaming Technical Guide Inch - Widia · PDF fileLanguage Version: WID_TopReam_MB_Literature_EN_in November 2, 2016 2:00 PM 2 widia.com Use this diagram when describing features of

Reaming Technical GuideINCH

Language Version: WID_TopReam_MB_Literature_EN_in November 2, 2016 2:00 PM

2 widia.com

Use this diagram when describing features of a Solid Carbide Reamer.

The Anatomy of a Reamer

Minor Cutting Edge

Major Cutting Edge

Cutting Face

Circular Land

Primary Clearance Land

Secondary Clearance Land

Reamers • Function Surfaces

Fp = passive force = radial forceFv = penetrative forceFd = resultant force

Diameter (D1)

Tip Length (L10)

Max Reaming Depth (L4)

Overall Length (L)

Shank Diameter (D)

Shank Length (LS)

Use this diagram when describing features of a Brazed-Tipped Reamer.

Diameter (D1)

Tip Length (L10) Max Reaming Depth (L4)

Overall Length (L)

Shank Diameter (D)

Shank Length (LS)

d


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Tolerance Charts

Tolerances • Shafts:

e8 -.0006-.0011

-.0008-.0015

-.001-.0019

-.0013-.0024

-.0016-.0029

-.0020-.0036

-.0024-.0042

h6 0-.0002

0-.0003

0-.0004

0-.00044

0-.0005

0-.0006

0-.0008

h7 0-.0004

0-.0005

0-.0006

0-.0007

0-.0008

0-.001

0-.0012

h8 0-.0006

0-.0007

0-.0009

0-.0011

0-.0013

0-.0016

0-.0018

h9 0-.001

0-.0012

0-.0014

0-.0017

0-.0021

0-.0025

0-.0030

h10 0-.0016

0-.0019

0-.0023

0-.0028

0-.0034

0-.0040

0-.0048

h11 0-.0024

0-.0030

0-.0036

0-.0044

0-.0052

0-.0064

0-.0076

k8 +.00060

+.00070

+.00090

+.00110

+.00130

+.00160

+.00180

k9 +.0010

+.00120

+.00140

+.00170

+.00210

+.00250

+.00300

k10 +.00160

+.00190

+.00230

+.00280

+.00340

+.0040

+.00480

m7 +.0005+.0001

+.0006+.0002

+.0008+.00024

+.0010+.0003

+.0012+.00032

+.0014+.0004

+.0016+.00044

.118–.236

Tolerances • Holes:

0–.118 .394–.709.236–.394 1.181–1.969.709–1.181 1.969–1.315

P9 -.0002-.0012

-.0005-.0016

-.0006-.0020

-.0007-.0024

-.0009-.0030

-.0010-.0035

-.0013-.0042

H6 +.00020

+.00030

+.00040

+.000440

+.00050

+.00060

+.00080

H7 +.00040

+.00050

+.00060

+.00070

+.00080

+.0010

+.00120

H8 +.00060

+.00070

+.00090

+.00110

+.00130

+.00160

+.00180

H9 +.0010

+.00120

+.00140

+.00170

+.00210

+.00250

+.00300

H10 +.00160

+.00190

+.00230

+.00280

+.00340

+.00400

+.00480

H11 +.00240

+.00300

+.00360

+.00440

+.00520

+.00640

+.00760

H12 +.0000040

+.0000050

+.0000060

+.0000070

+.0000080

+.000010

+.000010

H13 +.0000060

+.0000070

+.0000090

+.0000110

+.0000130

+.0000160

+.0000180

e8-14-28

-20-38

-25-47

-32-59

-40-73

-50-89

-60-106

h60-6

0-8

0-9

0-11

0-13

0-16

0-19

h70

-100

-120

-150

-180

-210

-250

-30

h80

-140

-180

-220

-270

-330

-390

-46

h90

-250

-300

-360

-430

-520

-620

-74

h100

-400

-480

-580

-700

-840

-1000

-120

h110

-600

-750

-900

-1100

-1300

-1600

-190

k8+14

0+18

0+22

0+27

0+33

0+39

0+46

0

k9+25

0+30

0+36

0+43

0+52

0+62

0+74

0

k10+40

0+48

0+58

0+70

0+84

0+100

0+120

0

m7+12+2

+16+4

+21+6

+25+7

+29+8

+34+9

+41+11

Tole

ranc

es

Nominal Size (mm)

0,0–3,0 3,0–6,0 6,0–10,0 10,0–18,0 18,0–30,0 30,0–50,0 50,0–80,0

P9 -6-31

-12-40

-15-51

-18-61

-22-74

-26-88

-32-106

H6 +60

+80

+90

+110

+130

+160

+190

H7 +100

+120

+150

+180

+210

+250

+300

H8 +140

+180

+220

+270

+330

+390

+460

H9 +250

+300

+360

+430

+520

+620

+740

H10 +400

+480

+580

+700

+840

+1000

+1200

H11 +600

+750

+900

+1100

+1300

+1600

+1900

H12 +0,10

+0,120

+0,150

+0,180

+0,210

+0,250

+0,30

H13 +0,140

+0,180

+0,220

+0,270

+0,330

+0,390

+0,460

k10 +400

+480

+580

+700

+840

+1000

+1200

m7 +12+2

+16+4

+21+6

+25+7

+29+8

+34+9

+41+11

Tole

ranc

es

Nominal Size (mm)

0,0–3,0 3,0–6,0 6,0–10,0 10,0–18,0 18,0–30,0 30,0–50,0 50,0–80,0

Tole

ranc

es

Nominal Size (inch)

.118–.2360–.118 .394–.709.236–.394 1.181–1.969.709–1.181 1.969–1.315

Tole

ranc

es

Nominal Size (inch)


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Reamers • Manufacturing Tolerances

The manufacturing tolerances indicated in this standard are assigned to certain tolerance zones of the holes to be reamed. Generally, they ensure that the reamed hole lies within the relevant tolerance zone and that the reamer can be used most economically. Besides the manufacturing tolerance, it has to be considered that the size of the reamed hole also depends on other factors, e.g. angle on the edge, lead angle of the reamer, clamping of the workpiece, toolholder, condition of the machine tool, lubrication, and material of the workpiece to be reamed in. Therefore, special cases can occur, where other manufacturing tolerances are more favorable. With regard to an economic way of manufacturing and storekeeping, as well as the possibility to have interchangeable reamers of different manufacturers, other manufacturing tolerances should only be required in exceptional cases.

Excerpt from DIN 1420:Principles for the determination of the manufacturing tolerances of reamers.

Determination of the maximum and minimum permitted sizes of reamers:The maximum permitted diameter, D1max, of the reamer is 15% of the respective drilling tolerance (0,15 IT) below the maximum permitted size of the hole (see picture). Here, the value 0,15 IT is rounded to the next highest whole or half µm value so that the results for D1max are even µm values. The minimum permitted diameter D1min of the reamer is 35% of the respective hole tolerance (0,35 IT) below the maximum permitted diameter of the reamer D1max.

In special cases, reamers with maximum and minimum sizes, which differ from the standard, are ordered, the ISO-symbol for the drilling tolerance zone has to be replaced by the upper and lower deviation of the reamer in µm, e.g. for a reamer with a nominal diameter of 20mm, upper deviation = + (p) 25 µm and lower deviation = + (p) 15 µm: reamer 20 p 25 p 15 DIN… In the description, the plus sign is replaced by a p and the minus sign is replaced by an m.

Description (excerpt):

Zero Line

Tolerance Zone of HoleTolerance Zone of Reamer

Max

imum

Per

mitt

ed S

ize

of th

e H

ole

Min

imum

Per

mitt

ed S

ize

of th

e H

ole

D1

Max

imum

Per

mitt

ed

Dia

met

er o

f the

Rea

mer

D1

Min

imum

Per

mitt

ed

Dia

met

er o

f the

Rea

mer

Nom

inal

Dia

met

er D

1U

pper

Dev

iatio

n

Low

er D

evia

tion

0,35

IT0,15

IT


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Causes of and remedies for reaming problems:

Hole diameter too large

Problem Cause Possible Remedy

1. Reaming tool running out-of-center. 2. Concentricity of pilot hole and ream machining unsatisfactory. 3. Built-up edge. 4. Unsuitable cooling lubricant.5. Reaming tool diameter too large.

• Use equalizing adapter.• Re-align, use floating head.• Change cooling lubricant.• Change cutting speed.• Measure reamers and send for repairs.

Hole diameter too small 1. Reamer worn. 2. Unsuitable cooling lubricant. 3. Reaming allowance too small.

• Replace and refit tool.• Change cooling lubricant.• Increase reaming allowance.

Conical hole profile wider towards drill runout 1. Concentricity of pilot hole and reaming unsatisfactory. 2. Positioning accuracy of pilot hole to reaming.

• Re-align, use equalizing adapter. • Correct positioning accuracy.

Conical hole profile wider at drill entry point1. Concentricity of pilot hole and reaming unsatisfactory. 2. Reaming tool skim cutting with ledger.

• Re-align, use floating head.• Securely clamp reaming tool axially.

Hole out-of-center and/or showing chatter marks 1. Reaming tool running out-of-center. 2. Slanted cutting surface/asymmetrical cutting. 3. Workpiece twisted.

• Use equalizing adapter.• Spot face as drilling preparation.• Take the direction of impact into

account when clamping the workpiece.

Surface quality does not meet specification 1. Tool cutters worn. 2. Reaming tool running out-of-center. 3. Incorrect technology data (cutting parameters). 4. Inadequate chip evacuation.

• Use equalizing adapter.• Re-align, use floating head.• Change cooling lubricant.• Change cutting speed.• Measure reamers and send for repairs.

Feed grooves 1. Built-up edge. • Change cooling lubricant.• Change cutting speed.

dNom

dNom

dNom

dNom


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Custom Reaming Tools

Machining Questionnaire for Custom Reaming ToolsPlease make a copy of this form and give it to your WIDIA Representative or Authorized WIDIA Distributor.

Name:

Company:

Phone/Fax:

Address:

Date:

1. Workpiece material

Material:

MPa or psi:

Heat treatment/Hardness:

2. Machining

Drill diameter:

Drilling tolerance:

Surface requirement:

Rz:

Ra:

Hole length:

Premachining:Drilled: r Spindle: r

Machining of drill hole base:

Yes r No r

For any crossholes or interruptions in the bore, please provide a sketch

Hole type:

3. Production quantity

Hole number/year:

4. Tool interface

Interface designation and size:

(e.g., straight shank 20)

5. Machine tool

Machining:

Horizontal: r Vertical: r

Tool:

Rotating: r Stationary: r

Internally cooled tools:

Yes: r No: r

Cooling lubricant:

Oil: r Emulsion: r

Cooling lubricant pressure:

p [bar]:

Machine manufacturer/type:

Spindle interface:

(e.g. HSK 63)

Cutting parameters:

Variable: Yes: r No: r

If not variable:

n [rev/min]

F [mm/min]

Please provide a sketch of the chuck with any foul conditions and machine tasks. Include all relevant dimensions as well as forming and positioning tolerances.

Hole depth:


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Custom Reaming Tools

Required Details:Material to Be Worked:

Type of Tool:

Right Hand Spiral r Left Hand Spiral r Straight Fluted r

Internal Coolant:

Yes r MMKS r No r

Fixture:

Grade:

HM/TCT r PKD/PCD r CBN r

Coating: Nor DCFD rShank According to DIN 6535:

HA r HB r HE rOther Information:

Ø

ØØ

Ø

Ø Z =

º

Custom Solution Reamers — Available Upon Request

*Noted phone and fax numbers are not toll free.

Contacts for Our Distribution PartnersAuthorized WIDIA™ Distributors should contact their local WIDIA Representative or one of the below contacts for additional information.

Country Language Phone Fax Email

Australia English 001-724-539-6921 * 001-724-539-6830 * [email protected]

Austria German 0800 291630 0049-911-9735-429* [email protected]

Belgium English/French 0800 80410 0049-911-9735-429* [email protected]

China Chinese 400-889-2237 +86-21-58999985 * [email protected]

Denmark English 808 89295 001-724-539-6830 * [email protected]

Finland English 0800 919413 001-724-539-6830 * [email protected]

France French 080 5540 379 0049-911-9735-429* [email protected]

Germany German 0800 1015774 0911-9735-429* [email protected]

India English 1 800 103 5227 no fax number [email protected]

Israel English 1809 449907 001-724-539-6830 * [email protected]

Italy Italian 800 916568 02 89512146 * [email protected]

Japan English 001-724539-6921 * 001-724-539-6830 * [email protected]

Korea (South) English 001-724539-6921 * 001-724-539-6830 * [email protected]

Malaysia English 001-724539-6921 * 001-724-539-6830 * [email protected]

Netherlands English 0800 0201131 001-724-539-6830 * [email protected]

New Zealand English 001-724539-6921 * 001-724-539-6830 * [email protected]

Norway English 800 10081 001-724-539-6830 * [email protected]

Poland Polish 00800 4411943 06166 56504* [email protected]

Russia (landline) Russian landline: 8800 5556395 0048 6166 56504* [email protected]

Russia (cell phone) Russian cell phone: +7 8005556395 0048 6166 56504* [email protected]

Singapore English 001-724539-6921 * 001-724-539-6830 * [email protected]

South Africa English 0800 981644 001-724-539-6830 * [email protected]

Sweden English 020798794 001-724-539-6830 * [email protected]

Taiwan English 001-724539-6921 * 001-724-539-6830 * [email protected]

Thailand English 001-724539-6921 * 001-724-539-6830 * [email protected]

United Kingdom English 0800 028 2996 001-724-539-6830 * [email protected]

Ukraine Russian 800502665 0048 6166 56504* [email protected]

USA English 888 539 5145 001-724-539-6830 * [email protected]


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TRF and TRM

Common reamers of this category have single tips, brazed onto a steel body. The new WIDIA™ TRF and TRM reamers have a solid carbide disc brazed onto the steel body instead. This allows for more regrinds than a regular tipped reamer, which brings down the cost-per-hole significantly. Additionally, the new coating WU05PR™ holds the surface finish more than twice as long as conventional coatings applied on reamers, depending on the workpiece material.

Disc Style Versus Regular Tipped Reamers• Stronger brazing joint than conventional tipped reamers. • Practically no influence of temperature on runout. • More rigidity and less vibrations due to full carbide front-end. • Minimum of four regrinds possible versus regularly tipped reamers

with an average of three regrinds, depending on wear situation. • No damage of flutes, compared to the steel portion of regularly

tipped reamers when chips constantly rub across.

Top Ream System • TRF and TRM


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The new disc style design combined with

the new reaming coating WU05PR allows for

significant cost-per-hole improvements.

New Coating WU05PR™

• WU05PR was specifically developed for reaming applications and shows superior results versus usual market grades applied on reamers.

• Holds surface finish more than 3x as long in steel compared to regular TiAlN thin coatings.

• Holds surface finish more than 2x as long in cast iron compared to regular TiAlN thin coatings.


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TRF

In comparison to solid carbide reamers or single-tipped reamers, TRF is the economic alternative without any disadvantages in regards to productivity or hole quality.

• Solid carbide disc at front instead of single-tipped carbide blanks.

• Unique coating, specially developed for reaming applications.

• High-speed and high-performance ready. • Superior surface finish due to lapped ground leads. • Improved hole straightness and roundness due to

unequal flute spacing (less vibrations) and runout <3 microns.

• Helical and straight flutes for chip control in through and blind holes.

Customization• All diameters between .5512–1.6732" (14–42,5mm). • Variation of leads and cylindrical margin for application-specific optimization.

Top Ream System • TRF

WORLD HEADQUARTERS

EUROPEAN HEADQUARTERS

ASIA-PACIFIC HEADQUARTERS

INDIA HEADQUARTERS

WIDIA Products Group




Kennametal Inc.1600 Technology WayLatrobe, PA 15650 USATel: 1 800 979 [email protected]

Kennametal Europe GmbHRheingoldstrasse 50CH 8212 Neuhausen am RheinfallSwitzerlandTel: +41 52 6750 [email protected]

Kennametal (Singapore) Pte. Ltd.3A International Business ParkUnit #01-02/03/05, ICON@IBPSingapore 609935Tel: +65 6265 [email protected]

Kennametal India LimitedCIN: L27109KA1964PLC0015468/9th Mile, Tumkur RoadBangalore - 560 073Tel: +91 80 2839 [email protected]

2016 WIDIA Products Group l All rights reserved. l A-16-05196EN_in

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Reaming Technical GuideINCH

Documents

Reaming Technical Guide Inch - Widia · PDF fileLanguage Version: WID_TopReam_MB_Literature_EN_in November 2, 2016 2:00 PM 2 widia.com Use this diagram when describing features of