New Product News No.6- Planing Side Cutting Profiling adius 5- Applications Pat. No. 5666 Can be chosen from three kind of grade according to the work material. The efficiency improve in finishing process.the efficiency and accuracy improve in semi-finishing process. ATHE for cast iron, ductile cast iron. to semi-finishing for cast iron, carbon steel pre-hardened steel. ATH8D to semi-finishing for ductile cast steel, high hardened steel.
Technology Features of ABPF type New product: -flute ball end mill ( to ) compatible with machines ranging from general-purpose manufacturing machines to the latest high-speed machines Example of large press die for automotive parts Gantry type n vf Not available!! evolution n 5 5 Positioning of ABPF ( insert) n v Conventional conditions 5 5 5 5 Feed ratevf Processing advantage of -flutes end mill High-efficiency Efficiency ABPF flutes Conventional flutes ball end mill Accuracy Point Efficiency improves by -flutes end mill High-accuracy High-efficiency Efficiency - Conventional flutes ball end mill Accuracy ABPF flutes Point Efficiency processing with small pitch educe the processing load on semi-finishing Improve finishing accuracy High-accuracy Compared with conventional -flutes ball end mill, improves cutting performance. Compared with conventional -flutes ball end mill, improves cutting performance and accuracy.
lineup Carbide shank L Numeric figure in a circle. Dc D Ds L L s Item code No.of Insert Stock Master Insert Slave Insert Stocked Items. Dc Mill dia. Ball radius L Overall length Ds Shank dia. Size (mm) L L Under neck length L/D D s Master Insert Inserts L/DLDcL/DUnder-neck length L / Flute diameter Dc Slave Insert Suggested retail price() Steel shank L Numeric figure in a circle. Dc D Ds L L s Item code No.of Insert Stock Master Insert Stocked Items. Slave Insert Dc Mill dia. Ball radius L Overall length Ds Shank dia. Size (mm) L L Under neck length L/D D s L/DLDcL/DUnder-neck length L / Flute diameter Dc Master Insert Inserts Slave Insert Suggested retail price() Parts Parts Clamp screw Screw Driver / Wrench Screw anti-seizure agent Cutter body She Note Fastening Fastening Main insert torque Suggested Sub insert torque Suggested Main insert She Suggested Sub insert She Suggested retail price() retail price() retail price() retail price() Parts are included with the cutter body. When parts become damaged, replace them with new ones. Using damaged parts may result in improper mounting of inserts.
ecommended grades m ecommended grades m based on work materials Hardness Inserts grade Work Low Grade ATHE Hardness of work material Grade FC/FCD S5CPCENA SKD6 SKD 5 Grade / 6 High ATH8D padding material / Frame hard steel HC Inserts P K H Main insert Sub insert Carbon steels Hardened steels She Item code Tolerance class ATH Coated PN Coated General cutting, First recommended General cutting, Second recommended Size Stocked Items. Stocked Items of New products. Main inserts are packaged per case. Sub inserts are packaged per case. A T Suggested retail price() P K H Carbon steels Hardened steels General cutting, First recommended General cutting, Second recommended Main insert She Sub insert Sub insert Item code Tolerance class set items Main inserts are packaged + Sub inserts are packaged Suggested retail price() Stocked Items. Stocked Items of New products. Insert regrinding/recoating orders accepted. Please contact our sales department. egrinding and recoating can be performed only once.
ae ecommended cutting conditions 赤字は第 推奨材種です ed indicates primary recommended insert grades. 被削材 Work materials 炭素鋼合金鋼 (HC 以下 ) Carbon Steel Alloy Steel (HC or less) 炭素鋼合金鋼 ( 5HC) Carbon Steel Alloy Steel 鋳鉄 Cast Iron 焼入れ鋼 5 55HC Hardened Steels フレームハード鋼 Flame hardening steel 焼入れ鋼 55 6HC Hardened Steels インサート材種 Insert Grade 中仕上げ finishing ATH8D ATH8D ATH8D ATH8D 仕上げ ATH8D ATHE ATH8D ATH8D ATH8D 切削条件 Cutting conditions 中仕上げ finishing φ φ 5 φ 仕上げ 汎用 General 高速加工 High-speed processing 中仕上げ finishing 仕上げ 汎用 General 高速加工 High-speed processing 中仕上げ finishing 仕上げ 汎用 General 高速加工 High-speed processing n (min- ),78 9,,5,6 8,79,9,8 7,6,8 Vc(m/min) 58 65 5 69 8 6 7 95 Vf(mm/min), 6,65 9,,57 7, 8,97,6 6, 8,87 fz(mm/t).8.8....... (mm).......5.. ae(mm).....5.5.5.5.5 n (min- ),67 6,85 7,96,6 6,88 8,8,65 6,5 8,9 Vc(m/min) 5 5 65 5 57 8 Vf(mm/min),6,9 6,7,5 5,5 6,6,,8 6,79 fz(mm/t).8.8....... (mm).......5.. ae(mm)....5.5.5.5.5 n (min- ) 6,69,9,5 5,9,57,6 5,9 9,55,67 Vc(m/min) 6 7 65 8 9 56 9, Vf(mm/min),8 8,5,5,7 8,6,6,75 7,6,67 fz(mm/t).8..5...5...5 (mm).......5.. ae(mm).....5.5.5.5.5 n (min- ),9,78 6,69,79,6 6,,7, 5,8 Vc(m/min) 5 8 6 55 Vf(mm/min),8, 5,5,9,57,89,,,67 fz(mm/t).8.8..8...8.. (mm)......... ae(mm).8...9...5.5 n (min- ),6,9 5,,,57 5,,7,8 5, Vc(m/min) 8 6 9 Vf(mm/min),5,,,,86,8 9,6,6 fz(mm/t).8.8..8...8.. (mm)......... ae(mm).5...6...8.5.5 Maximum fz(mm/t) <.5 <.6 <.7 Maximum (mm) <. <.5 < 5. 突出し比率 Overhang ratio Vc (m/min) V f (mm/min) 注意 この切削条件表は切削条件の目安を示すものです 実際の加工では加工形状 目的 使用機械等により条件を調整してください 上記表は突出し比率 < Dc の超硬シャンクを基準にしています 鋼シャンク使用時は切削条件を約 割下げてください Dc % % 突出し長さ Dc 以上の場合は 上記の表をもとに左記表を参考に調整してください These conditions are for general guidance; in actual machining conditions adjust the parameters according to your actual machine and Dc 8Dc 85% 85% Note work-piece conditions. The above table is for an overhang of <Dc using a carbide shank as the standard. When using a steel shank, reduce the cutting conditions by proximately %. When overhang is Dc or more, values in the above table should be adjusted by referring to the table at left. Set-up Procedures of Inserts To meet the specification for radius tolerance ±.mm, attach inserts according to the procedure below. Inserts must be set up in the order of main insert then sub insert. Clean the insert seat by air-blow etc.apply the Screw anti-seizure agent to the whole clamp screw.excessive tightening torque or the screw to which chip adhered cause screw damage or the problem from which a screw does not separate.please tighten the screw NOT to exceed the torque of the following table. Set-up procedures of main insert Place a top mark on the insert as shown toward a screw tightening side. Tighten the insert screw without pressing down the insert too much strongly. Set-up procedures of sub inserts Install a sub insert along the restraining wall. Pressing the insert firmly against the wall while tighten the insert screw. Inserts must be removed in the order of sub insert then main insert. Main insert Top mark Sub insert Tightening torque Dia(mm) Main insert (Nm) Sub insert (Nm) 5
Cutting performance Compared with cutting surface after semi-finishing (FCD6) ABPF Tool pf n vf Q - ABPF type ( flutes) Conventional ( flutes) Tool For roughing flutes Ball - pf n vf Q Small pitch and high feed cutting ough pitch Tool For finishing flutes Ball pf n vf Q Processing performance (multiple) Performance comparison when cutting flat surfaces vf=8,mm/min fz=.mm/t flutes vf=6,mm/min fz=.mm/t ABPF flutes Conclusion:Double the cutting performance of -flute tools Flat reciprocal cutting Cutting conditions Work material Mill dia. vc n pf Cutting length L Tool For finishing flutes Ball pf n vf Q Cutting length,, Tool life comparison when cutting vertical walls each tool life standard vf=8,mm/min L=,m flutes vf=6,mm/min L=,m ABPF flutes Conclusion:Double the tool life of -flute tools Chatter xxxxxx It s influence to finishing surface roughness when before process is rough. Vertical wall contour reciprocal cutting Cutting conditions Work material Mill dia. vc n ae pf f z 6 Wear comparison when profiling Flank wear... Conventional v f=5,5mm/min(fz=.mm/t) vf=,mm/min(fz=.mm/t) To reach tool life standard of VBmax=.mm.6 5m 8m 8 6 Cutting length Conclusion:Compared to conventional products, provides twice the processing performance..6 times the cutting length was achieved. Cutting conditions Work material n vc pf
Field data Cutting range Depth of cut (mm) n=8,min - vc=75m/min vf=6,mm/min fz=.mm/t ecommended.5 ae.5mm.5 ae.5mm or less Depth of cut (mm) MachineWork material Scanning line n=9,6min - vc=75m/min vf=7,68mm/min fz=.mm/t ecommended. ae.mm. ae.mm or less Depth of cut (mm) n=,min - vc=75m/min vf=9,6mm/min fz=.mm/t ecommended. ae.mm. ae.mm or less ae Cutting width (mm) ae Cutting width (mm) ae Cutting width (mm) Vc-Tvc-T chart High-hardened steel Plastic mold material Cast Iron Mill dia. ae pf fz Vertical wall contour line cutting Cutting speed vc each tool life standard flutes Cutting time hour Mill dia. ae pf fz Vertical wall contour line cutting Cutting speed vc each tool life standard flutes Cutting time hour Mill dia. ae pf fz Vertical wall contour reciprocal cutting Cutting speed vc each tool life standard Conventional tool flutes flutes Cutting time hour Finished surface roughness Vertical wall contour reciprocal cutting ae pf Flat reciprocal cutting pf vc n Surface roughness Conventional tool,5,, 5, 6, 8,,, 6,, Feed speed vf Surface roughness 7 6 5 Conventional tool,5 5,,, Feed speed vf vc n Surface roughness,,8 6, 8, 9,6,8 6, 9, Feed speed vf Surface roughness 7 6 5, 8, 6,, Feed speed vf vc n Surface roughness 6, 7, 9,6,, 9, Feed speed vf Surface roughness 7 6 5 6, 8,,, Feed speed vf fz nvf nvf nvf Note When a µm is set as the standard, the test results shown above satisfy the standard when cutting vertical walls. However, in order to satisfy a µm when planing, it is necessary to set fz.5mm. To be specific, from the above data the following should be used as general criteria: When n=5,, vf=5, or less; when n=8,, vf=8, or less, when n=,, vf=, or less. 7
Field Data User Company A Company B Tools Work Material Cutting Conditions vc vf pf vc vf pf esult Enables cutting at twice the efficiency of conventional products. Enables cutting at.5 times the efficiency of conventional products. Company C vc vf pf Enables cutting at twice the efficiency of conventional products. Cutting was performed with a single tool for proximately hours. Insert wear was good and low. Hi-Pre makes the whole processing method develop. Is only the finishing process important for high precision machining? For making high precision dies&moulds, the accuracy of roughing and semi-finishing processes are very important as well as finishing. High precision from roughing enables the optimization of the total production process including polishing or adjustment! This is Hi-Pre, Mitsubishi Hitachi Tool propose. High Precision Pre-finishing HiPre = High Precision Pre- High Precision oughing & -finishing High Precision Essence Machining process Total process Polishing or Adjustment Takes advantage for total process including polishing or adjustment! The diagrams and table data are examples of test results, and are not guaranteed values.. Attentions regarding handling. Attentions regarding mounting. Attentions during use. Attention on use of Carbide brazed end mill Carbide brazed tools are made by brazing of carbide and steel. They may occurred breakage due to fatigue in brazing part. Therefore,it is strongly suggest to set board or guard to shut off shattering around the machines for the safety. Don't use in the case of remodeling carbide shank, giving strong impacts and occurring flaw and crack on the surface. 5. Attentions http://www.mmc-hitachitool.co.jp Overseas Dept.: MMC Hitachi Tool Engineering Europe GmbH Itterpark, 7 Hilden, Germany. TEL : +9-()-8, FAX : +9-()-8 TEL:+86-()-66-58, FAX:+86-()-66-5 MITSUBISHI MATEIALS U.S.A. COPOATION 7 Gardenbrook oad, Suite, Novi, MI 875- U.S.A. TEL : +88-6, FAX :+88-67 Hitachi Metals (Thailand) Ltd. Unit B, th Floor,Ploenchit Tower, 898 Ploenchit oad, Lumpini, Pathumwan, Bangkok, Thailand TEL : +66-()-6-89, FAX :+66-()-6-89 Hitachi Metals (India) Pvt. Ltd. Plot No 9 & 95,Sector 8, IMT Manesar, Gurgaon -5, Haryana, India TEL : +9--8, FAX :+9--95 Specifications for the products listed in this catalog are subject to change without notice due to replacement or modification. 5- -6:FP