BNM

Features and benefits 1. Ultimate precision indexable ball nose endmill with two effective teeth Radius form accuracy : below m (Radius form accuracy of insert : below m) 2. Precision clamp screw mounting Easy and strong clamping and accurate location mechanism by using the single precision clamp screw gives high repeatability and rigidity.. Round shape insert with improved edge sharpness Adopting the round shape insert can reduce the risk of vibration even in perpendicular wall millimg and cut smoothly for intricate form in high speed copy milling.. DZ coating Adopting the DZ coating achieves maximum tool life for finishing operation in high speed cutting. HIGH PRECISION Realization of insert radius form accuracy below m fixed to holder (insert radius form accuracy m) and possibility of equal or more high precision machining comparing with solid ball nose end mill machining. COST PERFORMANCE Initial cost % reduction Solid tool Mirror-Ball Body+Insert Running cost 0% reduction Solid tool Regrinding+Coating cost Mirror-Ball Insert cost Mirror Ball finishing can replace with conventional solid carbide ball nose end mill finishing. By adopting economical indexable insert, tool costs of finishing process can be reduced greatly without using solid carbide ball nose end mills. mmtool dia. mm 1

Mirror Ball "Mirror-Ball Carbide Shank" Indexable Ball Nose End Mills Mirror Ball carbide shank series are possible to machine deeper mold making with consistent machining and high accurate finishing at high speed cutting, due to the increase tool rigidity and minimize the vibration. BNML-C BNMM-C BNML-T-C BNMS-C Features and benefits 1. By adopting carbide shank, tool rigidity is equal to solid carbide ball end mill. 2. Tool life increased to twice the tool life comparing with Mirror Ball steel shank is possible.. Carbide shank can be adopted to shrink fit type holders. 2

Example of cutting performance Performance comparison test "Carbide Shank vs Steel Shank". BNML-000T-S BNML-000T-SC Material: SKD 11 DIN1.29 Performance comparison test "Mirror Ball vs Competitors". Condition Test results Tool name Contacttime Wear of rake face Wear of flankface Competitor A maintained tolerance of 0.0 for about Hours only and after that got worth and worth until - hours when it was finished. Dijet Mirror-Ball Carbide Shank (C-Body) finished the workpiece and the wear could not be measured.

Short type BNMS-S type BNMS-T type Straight shank type r r r BNMS-0000T-S BNMS-000T-S BNMS-00T-S BNMS-002S-S BNMS-02S-S1 BNMS-00S-S BNMS-0S-S2 BNMS-000S-S2 BNMS-0S-S2 2 2 2 1 1 1 1 1 1. 1 1 Middle type BNMM-S type 1 2 0 2 1 1. 2 2 0 0 92 92 92 1 1 1.. 1 2 2 1 2 2 2 1' 1' 1 ' FSW-0 FSW- FSW-00 FSW-09 FSW-01 FSW-01 FSW-0 FSW-02 FSW-02 A-0 A-0 A-0 A- A-1 A- A-0 A-0 A-0 BNM-00 BNM-00 BNM-0 BNM-0 BNM- BNM-0 BNM- BNM-00 BNM- RNM-00... RNM-0... RNM-0... RNM-... RNM-0... RNM-... RNM-00... RNM-... r r Fig. Dimensions (mm) r Dimensions (mm) r BNMM-00S-S BNMM-0S-S1 BNMM-00S-S BNMM-0S-S2 BNMM-00S-S2 BNMM-S-S2. 1 1 1 2 0 2 1 11 1 1 1 1 2 2 1 2 2 2 FSW-09 FSW-01 FSW-01 FSW-0 FSW-02 FSW-02 A- A-1 A- A-0 A-0 A-0 BNM-0 BNM- BNM-0 BNM- BNM-00 BNM- RNM-0... RNM-... RNM-0... RNM-... RNM-00... RNM-...

Straight shank type Middle type BNMM-T type r r Dimensions (mm) r r BNMM-000T-S BNMM-00T-S BNMM-00T-S BNMM-0T-S1 BNMM-00T-S BNMM-0T-S2 BNMM-00T-S2 BNMM-T-S2. 1 1 1 2 0 2 1. 22 2 1 9 9 1 1 1 11 1 1 1.2 9 1 2 2 1 2 2 2 2 ' 1 ' 0 ' FSW- FSW-00 FSW-09 FSW-01 FSW-01 FSW-0 FSW-02 FSW-02 A-0 A-0 A- A-1 A- A-0 A-0 A-0 BNM-00 BNM-0 BNM-0 BNM- BNM-0 BNM- BNM-00 BNM- RNM-00... RNM-0... RNM-0... RNM-... RNM-0... RNM-... RNM-00... RNM-... Long type BNML-T type r r Dimensions (mm) r r BNML-000T-S BNML-00T-S BNML-00T-S1 BNML-0T-S BNML-011T-S2 BNML-1T-S2 BNML-00T-S2 BNML-T-S2. 1 1 1 2 0 2 1. 22 2 1 9 9 0 11 1 1 1 191.2 9 1 2 2 1 2 2 2 2 1 ' 0 9' 1 2' 1 1' 1 22' 1 ' 0 2' FSW- FSW-00 FSW-09 FSW-01 FSW-01 FSW-0 FSW-02 FSW-02 A-0 A-0 A- A-1 A- A-0 A-0 A-0 BNM-00 BNM-0 BNM-0 BNM- BNM-0 BNM- BNM-00 BNM- RNM-00... RNM-0... RNM-0... RNM-... RNM-0... RNM-... RNM-00... RNM-...

Morse taper shank type Short and Middle type BNMS-MT type BNMM-MT type r Dimensions (mm) r BNMS-00S-MT2 BNMS-0S-MT BNMS-0S-MT BNMM-00S-MT2 BNMM-00S-MT BNMM-0S-MT. 1. 2 2 2 0 11 1 1 2 MT2 MT MT MT2 MT FSW-01 FSW-0 FSW-02 FSW-01 FSW-0 A- A-0 A-0 A- A-0 BNM-0 BNM- BNM- BNM-0 BNM- RNM-0... RNM-... RNM-... RNM-0... RNM-... Long type BNML-MT type r r Dimensions (mm) r r BNML-011T-MT BNML-1T-MT BNML-T-MT. 1 2 2 1 9 11 1 0 2 2 2 MT MT MT 1 ' 1 ' FSW-01 FSW-0 FSW-02 A- A-0 A-0 BNM-0 BNM- BNM- RNM-0... RNM-... RNM-...

Straight neck type Short type BNMS-S-C type r Dimensions (mm) r BNMS-002S-SC BNMS-0S-S1C BNMS-009S-SC BNMS-0S-S2C BNMS-000S-S2C BNMS-0S-S2C. 1 1 1 2 0 2 2 9 92 1 1 1 11 1 19 2 29 1 1 2 2 2 FSW-09 FSW-01 FSW-01 FSW-0 FSW-02 FSW-02 A- A-1 A- A-0 A-0 A-0 BNM-0 BNM- BNM-0 BNM- BNM-00 BNM- RNM-0... RNM-... RNM-0... RNM-... RNM-00... RNM-... Middle type BNMM-S-C type r Dimensions (mm) r BNMM-000S-S0C BNMM-000S-S0C BNMM-00S-SC BNMM-00S-SC BNMM-00S-SC BNMM-0S-S2C BNMM-000S-S2C BNMM-0S-S2C. 1 1 2 0 2 0 0 92 92 0 1 11 1 0 0..2 9 11 19 2 29 1 2 2 2 FSW-0 FSW- FSW-00 FSW-09 FSW-01 FSW-0 FSW-02 FSW-02 A-0 A-0 A-0 A- A- A-0 A-0 A-0 BNM-00/00 BNM-00 RNM-00 BNM-0/1 RNM-0... BNM-0 RNM-0... BNM-0 RNM-0... BNM- RNM-... BNM-00 RNM-00... BNM- RNM-...

.2 9 11 1 19 2 29 1 1 2 2 2 2 2 2 0 2 2 2 2 0 00 2 2 00 2 00 00. 1 1 9 0 9 9 0 0 0 1 0 0 2 0 0 2 0 0 2 0 2 1 2 0 2 BNM-00 BNM-0/1 BNM-0 BNM- BNM-0 BNM- BNM-00 BNM- RNM-00... RNM-0... RNM-0... RNM-... RNM-0... RNM-... RNM-00... RNM-... A-0 A-0 A- A-1 A- A-0 A-0 A-0 FSW- FSW-00 FSW-09 FSW-01 FSW-01 FSW-0 FSW-02 FSW-02 r BNML-000S-S0C BNML-0009S-S0C BNML-00S-SC BNML-000S-SC BNML-009S-SC BNML-0S-SC BNML-009S-SC BNML-00S-SC BNML-0S-SC BNML-0S-SC BNML-00S-S1C BNML-0S-S1C BNML-0S-S1C BNML-1S-S1C BNML-S-S1C BNML-00S-SC BNML-0S-SC BNML-0S-SC BNML-00S-SC BNML-02S-SC BNML-0S-S2C BNML-S-S2C BNML-0S-S2C BNML-2S-S2C BNML-000S-S2C BNML-000S-S2C BNML-002S-S2C BNML-0S-S2C BNML-2S-S2C Long type BNML-S-C type Straight neck type Dimensions (mm)

Taper neck type Short-Middle-Long type BNMS/M/L-T-C type r r Dimensions (mm) r r BNMS-0000T-SC BNMM-000T-S0C BNML-000T-SC BNML-00T-SC BNML-00T-S1C BNMM-0T-SC BNML-0T-SC BNML-011T-S2C BNML-1T-S2C BNML-00T-S2C. 1 1 2 0 1. 2 2 0. 0 0 11 1 0 92 1 1 191..2 9 1 2 1 2 2 2 1' 1 ' 0 9' 1 2' 2 ' 1 1' 1 22' 1 ' 0 2' FSW-0 FSW- FSW-00 FSW-09 FSW-01 FSW-01 FSW-0 FSW-02 A-0 A-0 A-0 A- A-1 A- A-0 A-0 BNM-00/00 BNM-00 RNM-00... BNM-0/1 RNM-0... BNM-0 RNM-0... BNM- RNM-... BNM-0 BNM- BNM-00 RNM-0... RNM-... RNM-00... 9

for Mirror-Ball BNM-00 BNM-00 BNM-00 BNM-0 BNM-1 BNM-0 BNM- BNM-0 BNM- BNM-00 BNM- JC00 (Z0) Coated JC0 (K) (Z~) JC01 (Z~) Uncoated JC000 KT9 (K) R... 1 1 Dimensions (mm) A 11 1 2 0 2 B.. 9 1 1. 22. 2. T 2 2 2. 2. 2. BNM-00-AAA BNM-00-AAA BNM-0-AAA BNM-0-AAA BNM--AAA BNM-0-AAA BNM--AAA BNM-00-AAA BNM--AAA Coated (Z~) R. 1 1 Dimensions (mm) A 1 2 0 2 B. 1 1. 22. 2. T 2 2. 2. Note: BNM-00 insert can be suited to BNM mm dia bodies and BNM-1 insert can besuited to BNM mm dia bodies. In case of wet cutting. Grade JC01 is recommended.

Torque control wrench (with fixed blade) Torque limiting when loosening and tightening a screw. Torque control wrench are fitted with a special limit stop that controls the loosening torque. In this way, screws, components and the tool itself are all protected against damage during both the tightening and loosening processes. This wrench is recommended to use with Mirror Ball. Size: T, T, T, T Exchange blades Torque control wrench (with fixed blade) Torx No. Torque value Applicable blades Applicable holders TQC-0 TQC-0 TQC-0 TQC- Blades B-0 B-0 B-0 B- T T T T T T T T 0.Nm 0.9Nm 1.2Nm 2.0Nm B-0 B-0 B-0 B- TQC-0 TQC-0 TQC-0 TQC- Torx No. Applicable torque control wrench Attention to mounting insert 1. Clean the insert seat carefully. 2. Clean the insert, especially hole and location face.. Change the clamp screw when the screw gets worn out.. Do not tightened the clamp screw too hard. Recommend to use Torque control wrenches. See the right table for recommended tightening torque. (See table) Dimensions (mm) 1 2 0 2 Recommended Torque 0. 1.0 1. 2..0.0.0.0.0 11

Cutting data for "MIRROR BALL" Machining high hardened die (No hand finishing) Part name R/L door inner die Material Hardness Tool No. Insert No. Cutting speed Feed speed Currently they do hand finishing after induction hardening. Mirror ball could machine hardened die directly and finished entire Coolant job for hours. Machine Result Work Tool Cutting conditions Improved surface quality by BNM Mirror Ball Competitor Result is suitable for stainless steel Part name Material Hardness Tool No. Insert No. Cutting speed Feed speed Competitor could cut pcs only, but Mirror Ball could cut pcs. Coolant Improved the tool life times. Machine Result Mirror ball finished the entire job for hours and improved the surface quality and tool life than competitor with oil coolant condition. Work Tool Cutting conditions Work Tool Cutting conditions Part name Material Hardness Tool No. Insert No. Cutting speed Feed speed Coolant Machine High speed finishing for hardened steel (Polishing less) Part name Material Hardness Tool No. Insert No. Cutting speed Feed speed After hours, insert showed just normal wear under high speed Coolant machining for high hardened steel. Machine Result Work Tool Cutting conditions

General cutting data recommendations for "MIRROR BALL" / Calculation of cutting data 1./ Spindle speed N= V x 00 (rev/min) x De D De=2 x Apx(D-Ap) (mm) 2./ Feed F=N x fr (mm/min) fr=h max. x D Apx(D-Ap) (mm/rev) De N V De Ap Ae F fr h max. = (rev/min) = (m/min), Table 1. = (mm), Table 2. = (mm) = (mm) = (mm/min) = 1 (mm/rev), Table 1. = (mm), Table. N V De Ap Ae F fr h max. = Spindle speed (rev/min) = Cutting speed (m/min), See table 1. = Effective tool diameter (mm), See table 2. = Axial depth of cut (mm) = Pick feed, radial depth of cut(mm) = Feed speed (mm/min) = feed / rev (mm/rev), See table 1. = Max. chip thickness (mm), See table. Nominal cutting speed and feed values. Nominal feed : frmm/rev Cutter dia. : Dmm Insert Grade Work Materials Hardness Cutting speed Vm/min JC00 JC000 FC, FC00 Grey cast iron ~HB 0~00 0.2 FCD00, FCD00 Nodular cast iron 0~00HB ~0 0.2 ~HB ~ 0.2 S0C, SC Carbon steel SCM0 Low alloy steel HPM, NAK Mold steel SKD1, SKD11 Tool & die steel SKD1, SKD11 Hardened die steel SUS0, SUS1 Stainless steel Copper alloy Aluminum alloy Graphite ~HB ~00HB ~2HB 0~HRC ~HB 0~HB 0~0HB Note : 1.Data is relevent to short series tools & middle series tools (over mm). 2.See table for additinal data e. g. using series tools & middle series tools (up to ~0 0.2 ~0 0.2 0. 0~00 0.2 0. 0~00 0. 1 2 0 2 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 1~0 0.1 0.2 0. 0. ~ 0.1 0.2 0. 0. 0~ 0.1 0.2 0. 0. ~ 0.1 0.2 0. 0. 1. 2. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0.9 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0.9 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0.9 Max. Depth Apmm D/ D/1 D/1 D/1 D/ D/ D/0 D/ D/ D/ D/ Max. Pick Aemm D/ D/1 D/1 D/1 D/ D/ D/0 D/ D/ D/ D/ 1

General cutting data recommendations for "MIRROR BALL" Effective tool diameter chart Cutter dia. Dmm 1 2 0 2 Effective tool diameter : Demm Axial depth of cut : Apmm 0.2 0. 0. 1.0 1. 2.0 2..0..0..0..0 2. 2..1...9....9..2.9....2..9.... 9.. 11.1.2.1.9 9.. 11.9 1.1 1..9. 1. 1 1. 9. 11. 1.2 1 1..2. 1. 1.2 1 1. 1.2. 19. 1 1...2 19.2. 22.2 22. 2.2 2.2 2.1 2 2 Maximam chip thickness chart Work materials FC, FC00 Grey cast iron FCD00, FCD00 Nodular cast iron S0C, SC Carbon steel SCM0 Low alloy steel HPM, NAK Mold steel SKD1, SKD11 Tool & die steel SKD1, SKD11 Hardened die steel SUS0, SUS1 Stainless steel Copper alloy Aluminum alloy Graphite Hardness ~HB 0~00HB ~HB ~HB ~00HB ~2HB 0~HRC ~HB 0~HB 0~0HB 0.0 0.0 0.0 0.0 0.0 0.0 0.02 0.0 0. 0. 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0. 0.1 0. Max. chip thickness : h maxmm 0. 0. 0. 0. 0.0 0.0 0.0 0.0 0.1 0.1 0.2 Cutter dia. : Dmm 1 2 0 2 0.1 0. 0. 0. 0.0 0.1 0.22 0.2 0.1 0.1 0. 0. 0. 0.2 0.2 0.1 0.1 0. 0. 0. 0.2 0.2 0. 0. 0.1 0.1 0.1 0.2 0.0 0. 0. 0. 0.1 0.1 0.1 0.2 0.0 0. 0. 0. 0.1 0.1 0.1 0.2 0.0 0. Reduced cutting data for longer series tools. Cutter dia. D(mm) 1 2 0 2 Short series Middle series Long series l1 l1/d min -1 % Feed % l1 l1/d min -1 % Feed % l1 l1/d min -1 % Feed % 0 2 2.0.. 2.2 2.0 1.9 1. 1. 1. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.....9.... 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 11 1 9...1.....0 0 0 0 0 0 0 0 0 0 Note : Long tools need to be used with reduced cutting data. The above percentages should be applied. 1

H.S.C. data recommendations for carbide shank "MIRROR BALL" Work materials Hardness Insert grade FC, FC00 Grey cast iron FCD00, FCD00 Nodular cast iron S0C, SC Carbon steel SCM0 Low alloy steel HPM, NAK Mold steel SKD1, SKD11 Tool & die steel SKD1, SKD11 Hardened die steel SKD1, SKD11 Hardened die steel SUS0, SUS1 Stainless steel Copper alloy Aluminum alloy Graphite ~HB ~2HB 0~HRC 0~0HB Cutting speed V(m/min) JC00 00~00 0. 0~00HB ~HB ~HB JC00 JC00 JC00 00~00 0. 00~00 0. 00~00 0. 0. 0. 0. ~00HB JC00 00~0 0.2 0. JC00 00~0 0.2 0. JC000 00~00 0. 0. JC00 ~0 0.2 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. HRC~ JC00 ~ 0.2 0.2 0. 0. 0. 0. ~HB JC00 0~00 0.2 0. 0. 0. 0. 0. 0~HB JC00 00~00 0. 0. 0. 0. 0. 0. JC00 00~00 0. 0. Nominal feed : fr(mm/rev) Cutter dia. : D(mm) 1 2 0 2 0. 0. 1.0 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0.9 1.0 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0.9 1.0 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0.9 Max. Max. Depth Pick Ap(mm) Ae(mm) 0.1~0. 0.1~0. 0.1~0. 0.1~0. 0.1~0.2 0.1~0.2 0.1~0.2 0.1~0.2 0.1~0.2 0.1~0. 0.1~0. 0.1~0. D/0 D/0 D/0 D/0 D/0 D/0 D/0 D/0 D/0 D/0 D/0 D/0 Note : Data is relevant to short series tools & middle series tools. 1