Iscar - GoPro.pro

MILLING
MAY 2007
INCH
12-2007
Page 1/7
Revised
ADKT 1505R8T-FF a Combination of
and
ISCAR is expanding the application range of the HELIMILL tools by a new 15 mm insert with a
FEEDMILL configuration.
The new ADKT 1505R8T-FF insert does not require any new tools. It can be clamped on any
standard HELI2000 tool (.75-12.00 inch diameters) after modifying the corner radius on the tool
to .08 inch.
The HELI2000 cutters, when used with ADKT 1505R8T-FF inserts at small depths of cut (up to
.06 inch), can run at extremely high table feeds.
For example: at .06” DOC, a .06” feed per tooth can be applied.
The tool life under the above-mentioned cutting parameters is remarkably high (see attached DOC
vs. feed application range data).
As with the other FEEDMILL tools, the resultant force exerted on the tool is directed axially towards
the spindle. This feature enables using the tools also on small to medium machines, less rigidly
clamped parts and yet to attain very high metal removal rates.
MILLING
INCH
12-2007
Page / 7
ADKT 1505R8T-FF Inserts for Very High Feed Milling
R.500
R.106
l Ref
ap max (2)
ap (1)
S
Designation
l
ap (1)
ap max (2)
S
ADKT 1505R8T-FF
.626
.06
.138
.244
Tool
Types
1-2
P
M
K
N
S
H
Depth range at which up to .06 IPT feed may be applied.
(2)
At the ap to ap max depth range, a regular HELI2000 ADKT 1506
insert feed recommendations should be applied.
(3)
The cutting diameter of the tool is .020” larger than the nominal
diameter when using this insert.
(1)
Type of
Machining
IC928
.390
Medium
•
Steel
Stainless Steel
Cast Iron
Aluminum
High Temp. Alloys
Hardened Steel
Rampdown angles of the tools can be
applied using this insert.
3°
Tool corner should be
modified to R.08”
D+.020(3)
Feed Recommendations:
fz (IPT)
ap
.06”
Tool with a
Modified Corner
Light Medium Heavy
.031
.047
fz
Tool Types
1 HM90 E90AD
2 HM90 F90A
.06
Standard Tool
✓
✓
✓
✓
MILLING
INCH
12-2007
Page / 7
Recommended Cutting Conditions for ADKT 1506T8-FF Inserts
Workpiece
Materials(1)
Coolant
SAE/AISI
(DIN) (3)
Hardness
Non-Alloy Steel
ST-37
SAE 1020
(DIN 1.0402)
130-180
HB
IC928
2-3*D
Air
Alloy Steels
SAE 4340
(DIN 1.6582)
24-30
HRc
IC928
2-3*D
Air
Mold Steels
P20
(DIN 1.2311)
30-36
HRc
IC928
2-3*D
Air
Tool & Die Steel
H13
(DIN 1.2344)
200-220
HB
IC928
2-3*D
Air
AISI 304L
(DIN 1.4306)
200 HB
IC928
2-3*D
AISI 316L
(DIN 1.4304)
140 HB
IC928
Stainless Steel
)Martenitic(
AISI 420
(DIN 1.4021)
200 HB
Grey
GG25
(DIN 036025)
Nodular
Cast
Iron
High Temp.
Alloys
Hardened Mold
Steel
D.O.C.
Ap max
[inch]
.039 - .059
.059 - .079
.039 - .059
W.O.C.(2)
Ae max
[inch]
0.7*D
Vc
]SFM[
fz
[IPT]
330 - 560
.031 - .059
330 - 490
.028 - .051
.031 - .059
0.7*D
330 - 490
0.7*D
330 - 490
.039 - .059
0.7*D
330 - 490
.024 - .043
Air
.02 - .039
0.7*D
260 - 330
.012 - .028
2-3*D
Air
.02 - .039
0.7*D
260 - 330
.012 - .024
IC928
2-3*D
Air
.02 - .059
0.7*D
260 - 390
.012 - .028
250 HB
IC928
2-3*D
Air
.039 - .059
0.7*D
490 - 720
.039 - .059
GGG50
(DIN 0.705)
200 HB
IC928
2-3*D
Air
.039 - .059
0.7*D
330 - 520
.039 - .059
Titanium
Ti6Al4V
35-45
HRc
IC928
2-3*D
Wet
.039
0.7*D
70 - 150
.016 - .024
Inconell 718
(DIN 1.6582)
200 HB
IC928
2-3*D
Wet
.039
0.7*D
70 - 100
.008
SAE 4340
(DIN 1.6582)
35-45
HRc
IC928
2-3*D
Air
0.7*D
260 - 390
Example of typical material.
As a reference for W.O.C. Ae=0.7*D
D- cutter diameter (inch).
(3)
Same or equivalent grade.
(2)
Cutter (2
Overhang
]inch[
)
Material
Stainless Steel
)Austenitic(
(1)
Cutting Conditions
Carbide
Grade
.059 - .079
.039 - .059
.059 - .079
.02 - .039
.02
.02 - .039
.024 - .047
.02 - .031
.016 - .031
.004 - .067
MILLING
INCH
Page / 7
Machining Examples
Sholder Milling
Tool: HM90 E90AD-D1.25-3-W1.25
Insert: ADKT 1505R8T-FF IC928
Tool: HM90 E90AD-D1.25-3-W1.25
Insert: ADKT 1505R8T-FF IC928
Workpiece: SAE 4340 HRc 26-28
Workpiece: SAE 4340 HRc 26-28
Vc = 560 SFM
Vc = 560 SFM
Fz = .06 IPT
Fz = .04 IPT
Ap = .06 inch
Ap = .08 inch
B = .866 inch
B = .866 inch
P = 13.4 HP
P = 13.4 HP
Tool life = 25 min
Tool life = 40 min
Metal removal rate = 15.3 in /min
Metal removal rate = 14.2 in3/min
Tool: HM90 E90AD-D1.25-3-W1.25
Insert: ADKT 1505R8T-FF IC928
Tool: HM90 E90AD-D1.25-3-W1.25
Insert: ADKT 1505R8T-FF IC928
Workpiece: SAE 4340 HRc 26-28
Workpiece: SAE 4340 HRc 26-28
Vc = 560 SFM
Vc = 430 SFM
Fz = .04 IPT
Fz = .04 IPT
Ap = .06 inch
Ap = .031 inch
B = .866 inch
B = .866 inch
P = 11.4 HP
P = 6.7 HP
Tool life = 60 min
Tool life = 120 min
Metal removal rate = 10.2 in3/min
Metal removal rate = 4.15 in3/min
3
Tool: HM90 E90AD-D1.25-3-W1.25
Insert: ADKT 1505R8T-FF IC928
Workpiece: SAE 4340 HRc 26-28
Vc = 560 SFM
Fz = .06 IPT
Ap = .04 inch
B = .866 inch
P = 11.4 HP
Tool life = 70 min
Metal removal rate = 10.2 in3/min
12-2007
MILLING
INCH
Page / 7
Pocket Milling + Rampdown
Tool: HM90 E90AD-D1.25-3-W1.25
Insert: ADKT 1505R8T-FF IC928
Tool: HM90 E90AD-D1.25-3-W1.25
Insert: ADKT 1505R8T-FF IC928
Workpiece: SAE 4340 HRc 26-28
Workpiece: AISI 420 HB 160
Vc = 590 SFM
Vc = 330 SFM
Fz = .06 IPT
Fz = .04 IPT
Ap = .04 inch
Ap = .04 inch
B = .67 inch
B = .67 inch
P = 11.3 HP
P = 6.7 HP
Tool life = 40 min
Tool life = 60 min
Metal removal rate = 8.36 in3/min
Metal removal rate = 3.05 in3/min
Rampdown 3 Deg
Rampdown 3 Deg
Tool: HM90 E90AD-D1.25-3-W1.25
Insert: ADKT 1505R8T-FF IC928
Workpiece: AISI 316L HB160
Vc = 330 SFM
Fz = .024 IPT
Ap = .04 inch
B = .67 inch
P = 3.9 HP
Tool life = 65 min
Metal removal rate = 1.83 in3/min
Rampdown 3 Deg
12-2007
MILLING
12-2007
INCH
Page / 7
Field Report
Application
Square Shoulder + Slotting
(see pictures)
Workpiece Material
Milling cutter
Armor plate (30-36 HRc),
HM90 E90AD-D1.00-2-W1.00
Spindle
Cutter Diameter [inch]
During Operation
Z- Number of Teeth
Overhang [inch]
BT40- Vertical
1.00
1.00
2
2
3.54 (3.6*D)
3.54 (3.6*D)
ADKT 1505R8T-FF
ADKT 150524R-HM
Carbide Grade
IC928
IC950
Tool stability
Good
Good
Coolant Type
---
Emulsion
Vc - Cutting Speed
[SFM]
395
515
Spindle Speed [rpm]
1528
1970
.019-.024
.010
Insert
fz – Feed [IPT]
After Machining
Square Shoulder + Slotting
(see pictures)
Vf – Table Speed [IPM]
55.7-71
38.8
Ae – Width of Cut [inch]
.59-1.00
.59-1.00
Ap – Depth of Cut [inch]
.040
.02
Q – metal removal rate
[in3/min]
2.8
.76
Number of components
per cutting edge
15
8
Time for one part [min]
7
12.5
105
96
Tool life per
corner [min]