PRODUCT NEWS No. 483 NEW NEW PRODUCT for high feed machining with 4corners. SKG/MSG SKS-G SKG / MSG type, innovative high feed cutter achieved extremely excellent chip removal rate!
SKS-G SKS-G Feature of product SKS-G SKG / MSG type, innovative high feed cutterachieved extremely excellent chip removal rate! Features 1 Applicable to deep cutting of mold material or high feed machine aircraft parts that made of titanium alloy & stainless steel. Features 2 Adopted low cutting force & economical 4 corners positive insert, achieved stable high feed machining. Features 3 Large ap machining is possible. (Max.ap=1.5mm in case of using insert 10-type & Max.ap=2.5mm in case of using 14-type insert) Cutting force comparison (N) 8,000 7,000 6,000 5,000 Cutting performance 7% reduction from competitor U, 5% reduction from competitor M Feed force Main force Back force Resultant force 4,000 Material P21 3,000 2,000 1,000 0 DIJET Competitor M Competitor U Tool dia. Insert No. Cutting conditions Dry, Down cut 1
Features 4 3 insert grades JC8118, JC8050 & JC7550 can be widely applied from general & mold steel to hard-to-cut materials such as high hardened die steel, titanium alloy & stainless steel. Application For mold steel more than 38HRC & high hardened die steel less than 50HRC. For general & mold steel less than 36HRC. For titanium alloy & stainless steel. ISO P M K S H P01 P10 P20 P30 P40 M01 M10 M20 M30 M40 K01 K10 K20 K30 S01 S10 S20 S30 H01 H10 H20 JC8118 JC8118 JC8118 Applicable range JC8050 JC7550 JC7550 Features 5 Large chip pocket achieved excellent chip removal. Tool life comparison Flank wear 0.8 0.7 0.6 0.5 0.4 0.3 Competitor M Competitor U Conventional tool 0.2 Competitor M 0.1 Competitor U Conventional (3 corner) 0 0 10 20 30 40 50 60 70 80 90 Cutting length Criterion of tool life SKS-G achieved 3.2 times longer tool life compared with competitor M, 1.8 times longer compared with competitor U, and 1.2 times longer compared with conventional tool. Material: P20 Tool dia. Insert No. Cutting conditions Air blow Down cut Test by one insert 2
SKS-G SKS-G Line up Facemill type (Insert 10-type) Through coolant hole Db d a Lf b Body d1 Dc BoreBore Inch Metric Type Stock No. of inserts Dimensions Standard stock items Stock in Europe. (14 days delivery upon ordering) Dc Lf Db d d1 Note) 1. All cutters are supplied without inserts. 2. mark shows: these cutter body are equipped with the set bolt because of the specified bolt size. Except for these cutter body, please use the set bolt equipped with arbor. 3. Set bolt (M10 1.5 35) is slim head type with 13 head dia. Set bolt Head cap screw (Slim head) Head cap screw (JIS Standard) Head cap screw (Slim head) Head cap screw (JIS standard) Clamp screw Weight Applicable inserts Parts Clamp screw Wrench Recommended torque Adopted GN surface-hardening treatment on thermal resistant high strength steel gives high hardness over 65HRC and secure insert pocket and holder against thermal deformation, improved body durability and tool life by 30% or more. Make it difficult to be damaged even under severe cutting conditions. Also rust-proof and anti-welding effect is much improved. 3
Modular head type (Insert 10-type) Through g coolant hole W C MD Dc Db Body Lf Dimensions Stock No. of inserts Dc Lf Db Applicable inserts Clamp screw Parts Wrench Standard stock items Stock in Europe. (14 days delivery upon ordering) Note) 1. All cutters are supplied without inserts. 2. Please see page17 for recommended tightening torque. 3. In case of using MSG-4040/4042-10-M16, recommend combining with MSN carbide shank straight arbor type. Clamp screw Recommended torque Insert 10-type 4 4 4 R1.5 10.0 4.46 11 R1.5 10.0 4.46 11 R1.5 10.0 4.46 11 JC8050 JC8118 PVD Coated Tolerance Standard stock items 10 inserts per case. 4
SKS-G SKS-G Line up MSN Carbide shank arbor End mill shank type Through coolant holefor high productivity Straight arbor type Through coolant holefor high productivity Fig.1 D2 Coolant hole dia. Fig.2 MD MD D2 Coolant hole dia. MD D2 Coolant hole dia. D1 Ds h6 D1 Ds h6 Ds h6 1 L 1 n L L Dimensions Stock Ds 1 L D1 D2 Weight Standard stock items Note) Please see page 17 for recommended tightening torque. Dimensions Stock Ds L D2 Standard stock items Note) Please see page 17 for recommended tightening torque. Weight MGN G-Body steel shank holder Adopted ultra-rigid and improved body durability "G-Body". Short type Cost-effective and high strength steel shank holder. End mill shank type Through coolant hole D1 MD D2 1 L Coolant hole dia. Dimensions Stock Ds 1 L D1 D2 Standard stock items Note) 1. In case of using modular head combined with MGN steel shank holder, apply the recommended cutting conditions sheet (see page 13). 2. Please see page 17 for recommended tightening torque. Ds h6 Weight 5
D1 3 MSA Arbor integrated carbide shank BT shank type Through coolant holefor high productivity HSK-A shank type Through coolant holefor high productivity L Carbide shank D2-2mm D2 5 2 1 BT No. L Carbide shank D2-2mm D2 5 2 1 HSK No. D1 3 MD MD Coolant duct Dimensions Stock 1 2 L D1 D2 Weight Dimensions Stock 1 2 L D1 D2 Weight Standard stock itemsmake to order Note) 1. In case of using modular head combined with MSA arbor, apply the recommended cutting conditions sheet (see page 13). 2. Please see page 17 for recommended tightening torque. 3. MSA arbor is supplied without pull studs. 4. If you are in urgent need of these products, there are stock in our distributor, too. Standard stock itemsmake to order Note) 1. In case of using modular head combined with MSA arbor, apply the recommended cutting conditions sheet (see page 13). 2. Please see page 17 for recommended tightening torque. 3. If you are in urgent need of these products, there are stock in our distributor, too. 6
SKS-G SKS-G Line up Facemill type (Insert 14-type) Through coolant hole Db d a Without coolant hole Db d a Lf Lf b b d1 d1 Body Dc Dc No. of inserts Dimensions Standard stock items Stock in Europe. (14 days delivery upon ordering) BoreBore Inch Metric Type Stock Dc Lf Db d d1 Note) 1. All cutters are supplied without inserts. 2. mark shows: these cutter body are equipped with the set bolt because of the specified bolt size. Except for these cutter body, please use the set bolt equipped with arbor. 3. Set bolt (M10 1.5 35) is slim head type with 13 head dia. Head cap screw (JIS Standard) Set bolt Head cap screw (Slim head) Head cap screw (JIS standard) Clamp bolt Head cap screw (Slim head) Clamp screw Weight Parts Clamp screw Wrench Recommended torque Applicable inserts 7
Insert 14-type 5.6 R1.5 13.7 5.56 11 JC8050 JC8118 PVD Coated Tolerance Standard stock items 10 inserts per case. 8
SKS-G SKS-G Cutting data 1. High feed machining on mold steel (Insert 10-type) Overhung length Contouring & slotting Part name Plastic mold Work Material (1.2311) Hardness Tool Tool No. Insert No. Cutting speed n Vc Result Achieved high metal removal rate (Q=126/min) by 1.8 times compared with competitor's tool. And finished all the job with one corner, no wear or breakage, with a contact time of 3h 40min. Cutting conditions Feed speed ap ae Coolant Machine Vf fz Air blow Vertical MC 2. High feed machining on mold steel (Insert 14-type) Overhung length Part name Plastic mold Work Material (1.2738) Hardness Tool Tool No. Insert No. n. Cutting speed Vc Result Achieved high metal removal rate (Q=330/min) by 1.2 times compared with competitor's tool. And able to machine about 3 hours per 1 corner. Cutting conditions Feed speed ap ae Coolant Machine Vf fz Air blow Vertical MC 3. High efficient machining on Ti-alloy (Insert 10-type) Overhung length Part name Test piece Work Material Hardness Tool Tool No. Insert No. n. Cutting speed Vc Result Machining test piece shaped like aircraft parts. No chatter & smooth cutting, and achieved good chip removal. Cutting conditions Feed speed ap ae Coolant Machine Vf fz Wet (internal) Vertical MC 9
Definition of corner shape for programming SPNW10 / SPE(M)T type inserts SPNW14 type inserts Over Cut R Corner radius for programming Over Cut Max. ap=1.5 R Corner radius for programming Max. ap=2.5 Remains Remains W=7.6 W=10.8 Corner R for programming Over cut Remains Corner R for programming Over cut Remains Standard Standard Attention for profile milling Ramping L Helical interpolation Dh Calculation of tool pass dia. dcdhdc Tool pass dia. Bore dia. Tool dia. ap Dc Tool dia. ap Depth of cut per one circuit should not exceed max. depth of cut ap. Down cutting is recommended, so tool pass rotation should be counterclockwise. dc In case of ramping and helical interpolation, apply 70% or less feed speed from standard cutting condition table. Ramping Helical interpolation Tool dia. (mm) Eff. Cutting dia. (mm) ap Max. depth of cut (mm) Max. ramping angle ap L Total cutting length at Max. ap Min. bore dia. Dh min (mm) Max. bore dia. Dh max (mm) 10
SKS-G SKS-G Recommended cutting conditions Facemill type (Insert 10-type) Work materials Carbon steel (C50,C55) Below 250HB Die steel (1.2344,1.2379) Below 255HB (1.2311,P20) 30-36HRC (1.2311,P21) 38-43HRC Hardened die steel (1.2344, 1.2379) 42-52HRC Grey & Nodular cast iron (GG, GGG) Below 300HB Stainless steel Below 250HB Titanium alloy Grades Tool dia. No. of teeth No. of teeth No. of teeth ap ae n Vf ap ae n Vf ap ae n Vf Overhung lengthap Axial depth of cutae Radial depth of cutn Spindle speedvf Feed speed nvf Note: *1. The figure to be adjusted according to the machine rigidity or work rigidity. *2. In case of chatter occurring, recommend to reduce the depth of cut ap or Spindle speed and keep feed per tooth. *3. If machine does not have enough power, recommend to reduce the depth of cut ap or Spindle speed and Feed speed. *4. Use air blow. 11
Work materials Carbon steel (C50,C55) Below 250HB Die steel (1.2344,1.2379) Below 255HB (1.2311,P20) 30-36HRC (1.2311,P21) 38-43HRC Hardened die steel (1.2344, 1.2379) 42-52HRC Grey & Nodular cast iron (GG, GGG) Below 300HB Stainless steel Below 250HB Titanium alloy Grades Tool dia. No. of teeth No. of teeth ap ae n Vf ap ae n Vf Overhung lengthap Axial depth of cutae Radial depth of cutn Spindle speedvf Feed speed nvf Note: *1. The figure to be adjusted according to the machine rigidity or work rigidity. *2. In case of chatter occurring, recommend to reduce the depth of cut ap or Spindle speed and keep feed per tooth. *3. If machine does not have enough power, recommend to reduce the depth of cut ap or Spindle speed and Feed speed. *4. Use air blow. 12
SKS-G SKS-G Recommended cutting conditions Modular head type (Insert 10-type) Tool dia. Work materials Grades No. of teeth No. of teeth No. of teeth ap ae n Vf ap ae n Vf ap ae n Vf Carbon steel (C50,C55) Below 250HB Die steel (1.2344,1.2379) Below 255HB (1.2311,P20) 30-36HRC (1.2311,P21) 38-43HRC Hardened die steel (1.2344, 1.2379) 42-52HRC Grey & Nodular cast iron (GG, GGG) Below 300HB Stainless steel Below 250HB Titanium alloy Overhung lengthap Axial depth of cutae Radial depth of cutn Spindle speedvf Feed speed nvf Note: *1. The figure to be adjusted according to the machine rigidity or work rigidity. *2. In case of chatter occurring, recommend to reduce the depth of cut ap or Spindle speed and keep feed per tooth. *3. If machine does not have enough power, recommend to reduce the depth of cut ap or Spindle speed and Feed speed. *4. Use air blow. 13
Recommended cutting conditions Facemill type (Insert 14-type) Work materials Carbon steel (C50,C55) Below 250HB Grades Die steel (1.2344,1.2379) Below 255HB (1.2311,P20) 30-36HRC (1.2311,P21) 38-43HRC Hardened die steel (1.2344, 1.2379) 42-52HRC Grey & Nodular cast iron (GG, GGG) Below 300HB Tool dia. No. of teeth No. of teeth No. of teeth ap ae n Vf ap ae n Vf ap ae n Vf Overhung lengthap Axial depth of cutae Radial depth of cutn Spindle speedvf Feed speed nvf Note: *1. The figure to be adjusted according to the machine rigidity or work rigidity. *2. In case of chatter occurring, recommend to reduce the depth of cut ap or Spindle speed and keep feed per tooth. *3. If machine does not have enough power, recommend to reduce the depth of cut ap or Spindle speed and Feed speed. *4. Use air blow. 14
SKS-G SKS-G Work materials Carbon steel (C50,C55) Below 250HB Grades Die steel (1.2344,1.2379) Below 255HB (1.2311,P20) 30-36HRC (1.2311,P21) 38-43HRC Hardened die steel (1.2344, 1.2379) 42-52HRC Grey & Nodular cast iron (GG, GGG) Below 300HB Tool dia. No. of teeth No. of teeth No. of teeth ap ae n Vf ap ae n Vf ap ae n Vf Overhung lengthap Axial depth of cutae Radial depth of cutn Spindle speedvf Feed speed nvf Note: *1. The figure to be adjusted according to the machine rigidity or work rigidity. *2. In case of chatter occurring, recommend to reduce the depth of cut ap or Spindle speed and keep feed per tooth. *3. If machine does not have enough power, recommend to reduce the depth of cut ap or Spindle speed and Feed speed. *4. Use air blow. 15
Work materials Carbon steel (C50,C55) Below 250HB Grades Die steel (1.2344,1.2379) Below 255HB (1.2311,P20) 30-36HRC (1.2311,P21) 38-43HRC Hardened die steel (1.2344, 1.2379) 42-52HRC Grey & Nodular cast iron (GG, GGG) Below 300HB Tool dia. No. of teeth ap ae n Vf Overhung lengthap Axial depth of cutae Radial depth of cutn Spindle speedvf Feed speed nvf Note: *1. The figure to be adjusted according to the machine rigidity or work rigidity. *2. In case of chatter occurring, recommend to reduce the depth of cut ap or Spindle speed and keep feed per tooth. *3. If machine does not have enough power, recommend to reduce the depth of cut ap or Spindle speed and Feed speed. *4. Use air blow. 16
SKS-G SKS-G Attention Attention to mounting head and MSN/ MGN shank holder. Tightening procedure Cleaning Remove dirt and chips with air from the connecting thread and shank holder. Initial Tightening Tighten by hand until the head and the shank holder faces meet. Final Tightening Tighten slowly with torque control spanner wrench or DIJET DS type spanner wrench and confirm that there is no gap. Attention : Final tightening without initial tightening cause connecting thread break. NOTE Note) 1. Only use the torque control spanner wrench or DIJET DS type spanner wrench. 2. Please turn the spanner wrench slowly during use. 3. Please confirm that there is no gap. Thread Tightening torque Spanner size Note) 1. Modular heads are supplied without spanner wrench. 2. In case of choosing torque control spanner wrench, confirm that the wrench size is match to the dimensions W & C of each modular head. (There are some cases that modifying the thickness of spanner wrench is necessary) 3. mark shows: DIJET have a stock of DS-8 and 12 type spanner wrenches. Selection of "MSN Carbide shank holder" In case of using modular head over 16mm, please select MSN carbide shank that diameter (D1) is 1mm or more smaller than modular head (Dc). A wrong selection causes the carbide shank damage. MSN carbide shank neck diameter Clearance necessary more than 0.5mm Coolant or air blow is recommended to remove the chips. Modular head tool diameter Caution for the mounting to shrink fit holder. When you use a carbide shank and a modular head on the shrink fit holder, please shrink fit the only carbide shank without mounting a modular head together. Please mount a modular head after shrinking fit. Note) If it shrink fit with mounting a modular head, the head and insert will become difficult to loose. 17
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Headquarters 2-1-18, Kami-Higashi, Hirano-ku, Osaka 547-0002, Japan Phone: 81-6-6791-6781 Fax: 81-6-6793-1221 DIJET GmbH (Europe) Immermannstr.9 40210 Düsseldorf, Germany Phone. 49-211-50088820, 50088822 Fax. 49-211-50088823 DIJET INDUSTRIAL CO., LTD. (Bangkok Representative Office) 699 Srinakarindr Road, Modernform Tower 15th Floor, Kweang Suanluang Khet Suanluang, Bangkok 10250, Thailand Phone. 66-2-722-8258, 8259 Fax. 66-2-722-8260 DIJET INDUSTRIAL CO., LTD. (Shanghai Representative Office) Room No.1008 Tomson Commercial Building., 710 Dongfang Rd., Shanghai 200122, China Phone. 86-21-5058-1698 Fax. 86-21-5058-1699 DIJET INDUSTRIAL CO., LTD. (Guandong Representative Office) Rm. 1J2F, A Building, Lotus Plaza, Xianxidadao Road, Changan Town, Dongguan City, Guangdong Provence, 523850 P. R., CHINA Phone. 86-769-8188-6001, 6002 Fax. 86-769-8188-6608 DIJET INDUSTRIAL CO., LTD. (Chengdu Office) RM.No.2015, No.1BLDG.A-B Stand, Hi-Tech Incubation Garden, No.1480 Tianfu Avenue North, Hi-Tech District, Chengdu City, Sichuan, P.R.CHINA Phone. 86-28-8511-4585 Fax86-28-8511-2758 DIJET INDUSTRIAL CO., LTD. (Wuhan Office) B-2513, Jiayu Jianyin Business Masion, No.10 Chuangye Road, Wuhan Eco. & Tech. Development Zone, Wuhan City, Hubei 430056, China Phone. 86-27-8773-8919 Fax86-27-8773-8959 DIJET INDUSTRIAL CO., LTD. (Mumbai Representative Office) 322, ARCADIA Hiranandani Estate, Patlipada, G.B. Road, Thane (W) 400 607, India Phone. 91-22-4012-1231 Fax. 91-22-4024-0919 DIJET Incorporated (U.S.A.) 45807 Helm Street, Plymouth, MI 48170 U.S.A. Phone. 1-734-454-9100 Fax. 1-734-454-9395 FAX 06-6793-1230 Grinding produces hazardous dust. To avoid adverse health, use adequate ventilation and read Material Safety Data Sheet first. WARNING: Cutting tools may fragment in use. Wear eye protection in the vicinity of their operation.