AME type Roughing End Mill AME New Product News No

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1 AME type Roughing End Mill AME New Product News No

New variations of coating, introducing AJ coating series. Nicked inserts enable suppression of chattering in heavy milling!

increasing the Al content of conventional layers. Excellent wear resistance, chipping resistance, and heat resistance!

! The new layer with high Al content employs a new composition and optimizes the crystal structure to improve wear resistance and chipping resistance!

This reduces welding to the work and decreases cutting force!

carbide substrate with high toughness and the new "AJ Coating" to improve wear resistance and chipping resistance when machining stainless-steel

2 New variations of coating, introducing AJ coating series. Nicked inserts enable suppression of chattering in heavy milling! Cutting Applications Roughing Semi Finishing AJ Coating series Features of AJ Coating series Employs an AlTi layer with a new composition created by increasing the Al content of conventional layers. Excellent wear resistance, chipping resistance, and heat resistance! Layer structure Coating structure AJ Coating Welding-resistant low-cutting-force coating surface layer New technology!! The new layer with high Al content employs a new composition and optimizes the crystal structure to improve wear resistance and chipping resistance! Employs a low-friction-effect coating with excellent welding resistance as the top-most surface layer. This reduces welding to the work and decreases cutting force! Carbide Coating with excellent wear resistance and chipping resistance PVD Technology Grade for machining stainless-steel materials Features Employs a carbide substrate with high toughness and the new "AJ Coating" to improve wear resistance and chipping resistance when machining stainless-steel materials. Employs AJ Coating with excellent welding resistance to reduce the welding to work material that occurs when machining stainless steel materials. Strong fields Provides long tool life for general processing of stainless-steel materials VBmax(mm) Flank Wear Cutting performance JM Cutting length Work material Tool Insert Cutting conditions vcfz apae Wet Single-flute cutting 2

3 Line Up ap ap Dc Ds Dc Ds ap Lf R b Shank type AME - - S NT Numeric figure in a circle. L1 Rs L Side Lock Shank L1 Rs L Combination Shank Type Item Code Stock No. of Flutes No. ofinserts For Niked Inserts For Wave-edge and Sharp-edged Inserts 2Nick 3Nick Dc L Ds Size (mm) ap L1 Rs Inserts Shape retail price () Side Lock Shank Combination Shank rεrε rε 1 : Corner rε2.0 and rε3.0 can be used only for tip inserts. 2 : When using corner rε3.0 it is necessary to perform additional machining of body corner areas. 3 : When using nicked inserts, install 2 types of inserts (N2 type and N3 type) on a single holder. Installing only N2 type inserts or only N3 type inserts on the holder will cause tool damage. 4 : When using nicked inserts on a 3-flute type shank, use 4 N2 type inserts and 8 N3 type inserts. Bore Type AMEB RM/S- - NT Numeric figure in a circle. Dd d a d1 Dc Type Item Code Stock No. of Flutes No. ofinserts For Niked Inserts For Wave-edge and Sharp-edged Inserts 2 Nick 3 Nick Dc ap Dd Lf Size (mm) R a b d d1 Inserts retail price () Inside diameter inch Inside diameter mm Shell type rεrε rε 1 : Corner rε2.0 and rε3.0 can be used only for tip inserts. 2 : When using corner rε3.0 it is necessary to perform additional machining of body corner areas. 3 : When using nicked inserts, install 2 types of inserts (N2 type and N3 type) on a single holder. Installing only N2 type inserts or only N3 type inserts on the holder will cause tool damage. 印 : 標準在庫品です :Stocked Items. 3

4 11 11 Line Up Inserts Pat. No. Wave-edged insert B A 2 Nick type B A 11 r ε r ε T T 3 Nick type r ε T B A Sharp-edged inserts r ε B T A 11 P M K S Type Wave-edged insert 2 Nick 3 Nick Sharp-edged inserts Carbon steels SUS, etc. Titanium Alloy Item Code Tolerance class M JS Coated rεrε AJ Coated General cutting, First recommended Size (mm) A B T r ε General cutting, Second recommended Shape retail price() 1 : Corner rε2.0 and rε3.0 can be used only for tip inserts. 2 : When using nicked inserts, install 2 types of inserts (N2 type and N3 type) on a single holder. Installing only N2 type inserts or only N3 type inserts on the holder will cause tool damage. NotePlease note that the JS coating does not cause a reaction in conductive touch sensors. Arbor screw is not included. Type Shank Bore Cutter body Parts Parts Shape To reduce environmental loads, screw anti-seizure agent is sold separately. We ask for your understanding and cooperation. Clamp screw Fastening torque retail price () Arbor screw Screw Driver With air hole With Air hole retail price () retail price () Screw anti-seizure agent retail price () 4 印 : 標準在庫品です :Stocked Items. 無印 : 受注生産品です No Mark:Manufactured upon request only.

5 Recommended Cutting Conditions ae ap Shoulder Milling Shank type Work material Recommended grade Cutting Speed Vc(m/min) Feed Tooth fz(mm/t) ae ae ae ae ae Mild Steel vc= fz= vc= fz= vc= fz= vc= fz= vc= fz= Carbon / Alloy Steel vc= fz= vc= fz= vc= fz= vc= fz= vc= fz= Carbon / Alloy Steel vc= fz= vc= fz= vc= fz= vc= fz= vc= fz= Stainless Steel Wet Cutting vc= fz= vc= fz= vc= fz= vc= fz= vc= fz= Cast Iron vc= fz= vc= fz= vc= fz= vc= fz= vc= fz= Titanium Alloy Wet Cutting vc= fz= vc= fz= vc= fz= vc= fz= vc= fz= Bore type Work material Recommended grade Cutting Speed Vc(m/min) Feed Tooth fz(mm/t) L/D L/D L/D L/D Mild Steel vc= fz= vc= fz= vc= fz= vc= fz= Carbon / Alloy Steel vc= fz= vc= fz= vc= fz= vc= fz= Carbon / Alloy Steel vc= fz= vc= fz= vc= fz= vc= fz= Stainless Steel Wet Cutting vc= fz= vc= fz= vc= fz= vc= fz= Cast Iron vc= fz= vc= fz= vc= fz= vc= fz= Titanium Alloy Wet Cutting vc= fz= vc= fz= vc= fz= vc= fz= For adjusting cutting amount, refer to the machining region curves on the p8. Q Q(cm 3 /min)=ap(mm) ae(mm) vf()/1000 ae NoteThis table shows general conditions for shoulder cutting. Conditions should be adjusted according to machine rigidity and tooling, workpiece condition, etc. To prevent tool damage due to chip clogging, always use a chip removal method such as an air blower, etc. Since there is a danger of discharged chips flying up and causing cuts, burns, or damaging eyes, during use be sure that protective covers are in place and that workers wear protective equipment such as protective goggles to create a safe work environment. Please note that the JS coating does not cause a reaction in conductive touch sensors. Replace inserts at an early stage to avoid breakage due to excessive use. The following equation can be used to determine the metal removal rate per unit time Q: Q(cm 3 /min)=ap(mm) ae(mm) vf()/1000 This tool is not suitable for slotting. Be sure to supply a water-soluble lubricant when machining titanium alloys. FT breakers are medium-finishing inserts. Recommended for use for ae<3mm. 5

Cutting performance Features and Applications of Insert Selecting the appropriate breaker enables appropriate

Low cutting force, general-purpose type; First recommended Nicked inserts N2 N3 Nicked inserts enable low-resistance

For semi finishing Wave-edged inserts FT Enables shallow-depth, high-feed-rate machining.

For titanium cutting Sharp-edged inserts RS The sharp-edged insert is suited for high-efficiency machining of titanium.

Features and Applications of Cutter Body How to install the nicked inserts.

Install N2 type inserts on insert rows with holder mark. Install N3 type inserts on insert rows without holder mark.

6 Cutting performance Features and Applications of Insert Selecting the appropriate breaker enables appropriate machining for various applications. Low cutting force, general-purpose type; First recommended Nicked inserts N2 N3 Nicked inserts enable low-resistance machining. It has low resistance machining and suppresses chatter vibration even for deep cutting. For semi finishing Wave-edged inserts FT Enables shallow-depth, high-feed-rate machining. Use of a wave-edged flute shape improves insert tip strength. For titanium cutting Sharp-edged inserts RS The sharp-edged insert is suited for high-efficiency machining of titanium. Sharp cutting edge enables machining to be performed with low resistance. Features and Applications of Cutter Body How to install the nicked inserts. The effective inserts arrangement reduces chatter vibration at heavy milling. Install N2 type inserts on insert rows with holder mark. Install N3 type inserts on insert rows without holder mark. N2 insert row The tip blade also has an insert clamping surface in the tool axis direction to achieve secure clamping. Note When using nicked inserts, install 2 types of inserts (N2 type and N3 type) on a single holder. Installing only N2 type inserts or only N3 type inserts on the holder will cause tool damage. Installing nicked inserts in the wrong position will cause tool damage. Be sure to exercise sufficient care. N3 insert row 6

7 Cutting Performance Since AME adopted nicked insert, it is able to reduce cutting force 30~40%. FT type Insert Nicked inserts B A Cutting Conditions vc ap ae Titanium Cutting By using a sharp-edged insert, free-cutting machining of titanium alloys has become possible. Cutting performance is also good, and good chip removal is achieved. Since machining is performed at low resistance, stable machining even at long extension amounts becomes possible and good tool life is achieved. a p a e =30 30 Chip shape comparison a p a e =10 30 Tool life comparison (Single-flute cutting) 1 chip shape AME s chip shape Maximum flank wear width VBmax (mm) JS Cutting scene Cutting time (min) Work material Tool model Insert model Overhang Machine used Coolant Emulsion oil (Dilution ratio: 5 to 8%) vcn Cutting speed v ffz Feed rate 7

Cutting performance Overhang and Cutting range Shank Type 75 Bore Type 50 AME1250S42-73-4NT apdepth cut (mm) 60 45 30 15 Overhang 90mm(1.

4Dc) Overhang 250mm(5Dc) 0 10 20 30 40 50 AMEB1250R-42-4NT 0 10 20 30 40 aecutting width (mm) aecutting width (mm) Cutting Conditions

according to the cutting material and machine rigidity and tooling.

8 Cutting performance Overhang and Cutting range Shank Type 75 Bore Type 50 AME1250S NT apdepth cut (mm) Overhang 90mm(1.8Dc) Overhang apdepth cut (mm) Overhang 170mm(3.4Dc) Overhang 250mm(5Dc) AMEB1250R-42-4NT aecutting width (mm) aecutting width (mm) Cutting Conditions Machine used Insert Work material Carbon Steels With nick vcn Cutting speed v ffz Feed rate For actual machining, adjust the cutting amount according to the cutting material and machine rigidity and tooling. Machined Surfaces Comparison Both nicked inserts and wave-edged inserts provide good machined surfaces. Nicked Insert N2/N3 Breaker Wave-edged Insert FT Breaker 2.0 mm 0.2mm 2.0 mm 0.2mm Cutting Conditions Machine used Work material Carbon Steels vcn Cutting speed v ffz Feed rate aeap Depth of cut 8

9 Field data Cutting examples of press mold Cutter body 50-4Flutes, Shank type Cutter body 63-6Flutes, Bore type Insert Nicked inserts Insert Nicked inserts Cutting Conditions Vc = 95m/min (n=600 ) Vf = 300 (fz=0.125mm/t) ap ae = 40 5OH=100mm Work material : Press mold cast steel Air-blow, Depth constant trimming Cutting Conditions Vc = 180m/min (n=900 ) Vf = 1,500 (fz=0.28mm/t) ap ae = mm FC250OH = 250mm Work material Air-blow, Depth constant cutting Cutting scene Cutting scene Cutting Examples of Titanium Cutter body 40-4Flutes, Shank type Cutter body 40-4Flutes, Shank type Insert Sharp-edged inserts Insert Sharp-edged inserts Cutting Conditions Vc = 40m/min (n=320 ) Vf = 130 (fz=0.1mm/t) ap ae = 43 3 Ti-6Al-4V Work material : Titanium Alloy Emulsion oil, Side cutting Cutting Conditions Vc = 40m/min (n=320 ) Vf = 190 (fz=0.15mm/t) ap ae = Ti-6Al-4V Work material : Titanium Alloy Emulsion oil, Side cutting Comment By using an insert for titanium alloy machining, 2 the efficiency and 2 the tool life was achieved. Comment Due to low cutting resistance, cutting noise were lower and machining conditions were stable. Cutting scene Cutting scene 9

10 Field data Example of 50% machining reduction (S45C) of side machining of plate Tool/insert costs Yen/Tool Corner count per insert Number of flutes Tool life Tool replacement time Machine cost Machining time per workpiece Machining cost per workpiece Machining cost ratio Corner/Insert Inserts Min./Tool Min./Tool Yen/Min. Min./Workpiece Yen/Workpiece Indexable tool roughing Proposal AME1250S NT Proposal CO2 emissions per machining of workpiece kg-co2/workpiece Annual CO2 emissions kg-co2/year Possible annual CO2 emissions reductions kg-co2/year vc (m/min) vf () apae (mm) Q (cm 3 /min) AME Cutting cost Reduced 10

Field data User Work Tools Cutting Conditions Note Result Company A Machine parts Equivalent to JM4160 vc vf apae Air-blow Compared to corresponding conventional, machining noise of AME type is less

Company B Press mold Cast steel vc vf apae AME type was tested under the same cutting conditions as conventional products, and was found to provide lower cutting force for stable machining.

11 Field data User Work Tools Cutting Conditions Note Result Company A Machine parts Equivalent to JM4160 vc vf apae Air-blow Compared to corresponding conventional, machining noise of AME type is less and machining surface is virtually flat, providing good results. Company B Press mold Cast steel vc vf apae AME type was tested under the same cutting conditions as conventional products, and was found to provide lower cutting force for stable machining. Applicable to low-rigidity M/C. Company C Mold parts vc vf apae vc vf apae Low cutting force of AME type enabled approx. 4.5 machining efficiency with stable machining status. Company D Machine parts Equivalent to JM4160 vc vf apae vc vf apae AME type provided 1.5 the machining efficiency of conventional HSS roughing end mills. Company E Machine parts vc vf apae vc vf ap ae Machining time of 15 minutes with conventional shoulder mill was reduced to 8 minutes with AME type. Company F Machine parts vc vf apae Tool life was 1.3 that of corresponding conventional. Note: Comments from actual users. Cautions during use r When using corner rε3.0 it is necessary to perform additional machining of body corner areas as indicated below. R2.0 11

12 The diagrams and table data are examples of test results, and are not guaranteed values. is registered trademarks of Mitsubishi Hitachi Tool Engineering, Ltd. in Japan. Attentions on Safety 1. Attentions regarding handling 2. Attentions regarding mounting 3. Attentions during use International Sales Dept.: MMC Hitachi Tool Engineering Europe GmbH Itterpark 12, Hilden, Germany. TEL : +49-(0) , FAX : +49-(0) TEL:+86-(0) , FAX:+86-(0) MITSUBISHI MATERIALS U.S.A. CORPORATION Gardenbrook Road, Suite 120, Novi, MI U.S.A. TEL : , FAX : MMC METAL DE MEXICO, S.A. DE C.V. Av. La Cañada No.16, Parque Industrial Bernardo Quintana, El Marques, Querétaro, CP 76246, México TEL : MMC HardmetalThailandCo.,Ltd. HT-Division CTI Tower 24 Floor, 191/32 Ratchadapisek Road, Klongtoey, Klongtoey, Bangkok 10110, Thailand TEL:+66-(0) FAX:+66-(0) Hitachi Metals (India) Pvt. Ltd. Plot No 94 & 95,Sector 8, IMT Manesar, Gurgaon , Haryana, India TEL : , FAX : Specifications for the products listed in this catalog are subject to change without notice due to replacement or modification. Printed using vegetable oil ink.

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