Composite Solutions by kyocera-sgstool

Composite Tooling Solutions

Keeping the world moving.

www.kyocera-sgstool.co.uk 1

Experts in Composites Composites in Aerospace As one of the world’s largest manufacturers of solid carbide rotary cutting tools, SGS has pioneered some of the most advanced cutting technologies specialising in specific challenges and extreme applications. We have a dedicated team to focus on the advancement of technology within the growing Composites segment and address the unique challenges and opportunities of cutting Composite materials.

•

CFRP excels in fatigue performance compared to aluminium.

•

Structurally durable yet lightweight for primary and secondary aircraft structures.

•

Widely used throughout aircraft interiors.

The unique qualities of Composites combines light weight with high strength and resistance to fatigue, corrosion, impact, wear and thermal issues, making it attractive to a wide variety of part manufacturers and fabricators. This carbon fibre material is comprised of a layered resin structure with a variety of complex fibre configurations embedded within the resin giving the material its physical shape while the fibres determine the material properties. SGS has continued to develop industry-leading solutions with a product series unique to Composite. We have given special consideration to the substrate, geometry, coating, edge conditions and manufacturing techniques that conventional cutting tools have a difficult time addressing.

Composites in Power Generation •

Primarily used in wind turbines.

•

Blades must be low weight, possess rotational inertia and have resistance to fatigue and wear.

•

CFRP withstands environmental erosion and degradation.

Benefits of SGS composite tools • Improved surface conditions of workpiece • Eliminate delamination • Minimise fibre breakout • Lower cutting forces • Increased tool life • Greater process efficiencies • Minimise Cutting Temperatures

Composites in Motorsports & Automotive •

Carbon fibre is lightweight, durable and easily moulded.

•

Leading manufacturers targeting Composite for future production of cars.

•

Multi-layered material resists breakage.

• Decreased Production costs

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Scan to read about our aerospace solutions

The most advanced cutting technologies solutions for the unique qualities of Composites. www.kyocera-sgstool.co.uk

Series 120 Composite Drill The key features of the 8 Facet Double Angle Hi-Per Carb drill design offers application benefits beyond that of other high performance drills in its category. Each feature of this 8 facet design was engineered as a solution towards addressing the issues commonly encountered during Composite drilling. This unique high performance design successfully creates an accurate hole without splintering or delamination, ultimately optimising the composite drilling process.

Composite Drill

A B

DOUBLE MARGIN CONSTRUCTION • improves drill stability for better hole finish and size control

Series 120

• allows coolant to reach the point for improved hole quality and extended tool life

DOUBLE ANGLE POINT • minimises workpiece delamination on drill entry and exit • redistributes loads along multiple cutting edges for improved performance

NOTCHED POINT • reduces cutting forces at the drill centre for enhanced performance and tool life • manufactured exclusively with Di-NAMITE® coating for even wear, extended tool life and improved finishes

Performance. Precision. Passion. Series 120 Composite Drill 4

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Performance Validation •

Double margin design stabilised the drill for greater hole accuracy and improved surface finish in the final hole.

•

Minimised delamination at hole entry/exit.

•

Manufactured exclusively with Di-NAMITE® coating for even wear, extended tool life and improved finishes.

Precision A test was conducted of our CFRP drill to determine the necessity of coating when drilling Carbon Fibre material. Fifty holes were drilled using a special size 4.85mm CFRP drill. The tool’s design produces acceptable quality holes; but as shown in the photos, early edge wear on the uncoated drill resulted in holes with frayed edges. The diamond coated drill produced all 50 holes with little to no fraying, and edge wear was 38% less than the uncoated drills. Series 120

The geometry of the 8 Facet drill with the Di-NAMITE coating is a necessity for additional tool life and productivity when manufacturing Carbon Fibre material.

| Composite Drill

5,000 rpm

127 mm/min

4.85mm CFRP drill uncoated

4.85mm

0.00254mm

6mm

50 holes

CFRP

Good hole quality for 1st 3 holes. Fraying starting by 3rd hole. 0.053mm wear.

Vertical Machining Centre

4.85mm CFRP drill diamond

0.00508mm

None

50 holes

Good hole quality all 50 holes. Slightly fraying. 0.033mm wear.

Passion •

The compound angle creates 4 cutting edges along the drill point.

•

Distinct double angle prevents abrasiveness of the Composite from localising along the point and diminishing tool life.

www.kyocera-sgstool.co.uk

Series 120 Composite Drill 2

120

FRACTIONAL & METRIC SERIES

Series 120

Composite Drill

• Double margin construction design stabilises the drill for greater hole accuracy and improved surface finish • Notched point reduces thrust force over conventional designs • 8 facet point reduces fibre breakout and delamination on exit

CUTTING DIAMETER D1

DECIMAL EQUIV.

METRIC EQUIV.

SHANK DIAMETER D2

OVERALL LENGTH L1

FLUTE LENGTH L2 / L3

SHANK LENGTH L4

Di-NAMITE® (Diamond) EDP NO.

#40 2,7 mm 3,0 mm 1/8 3,2 mm #30 #28 #22 #21 4,1 mm #19 11/64 3/16 #11 #8 #7 #2 6,0 mm 1/4 .2510 F I J K 5/16 8,0 mm 3/8 V 10,0 mm 7/16 12,0 mm 1/2

0.0980 0.1063 0.1181 0.1250 0.1260 0.1285 0.1405 0.1570 0.1590 0.1614 0.1660 0.1719 0.1875 0.1910 0.1990 0.2010 0.2210 0.2362 0.2500 0.2510 0.2570 0.2720 0.2770 0.2810 0.3125 0.3150 0.3750 0.3770 0.3937 0.4375 0.4724 0.5000

2.49

1/8 6,0 6,0 1/4 6,0 1/4 1/4 1/4 1/4 6,0 1/4 1/4 1/4 1/4 1/4 1/4 1/4 6,0 1/4 5/16 5/16 5/16 5/16 5/16 5/16 8,0 3/8 1/2 10,0 1/2 12,0 1/2

2 63,0 63,0 2-1/2 63,0 2-1/2 2-1/2 2-5/8 2-5/8 66,0 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 2-5/8 66,0 3-1/8 3-1/8 3-1/8 3-1/8 3-1/8 3-1/8 3-1/8 79,0 3-1/2 3-1/2 89,0 4-1/16 102,0 4-1/4

9/16 20,0 20,0 3/4 20,0 3/4 3/4 7/8 7/8 24,0 7/8 7/8 1 1 1 1 1 28,0 1-5/16 1-5/16 1-5/16 1-5/16 1-5/16 1-9/16 1-9/16 41,0 1-27/32 1-27/32 47,0 2-3/16 55,0 2-5/16

1-1/4 32,0 36,0 1-7/16 36,0 1-7/16 1-7/16 1-7/16 1-7/16 36,0 1-7/16 1-7/16 1-7/16 1-7/16 1-7/16 1-7/16 1-7/16 36,0 1-7/16 1-7/16 1-7/16 1-7/16 1-7/16 1-7/16 1-7/16 36,0 1-9/16 1-9/16 40,0 1-9/16 45,0 1-3/4

50000 50001 50002 50003 50004 50005 50006 50007 50008 50009 50010 50011 50012 50013 50014 50015 50016 50017 50018 50019 50020 50021 50022 50023 50024 50025 50026 50027 50028 50029 50030 50031

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3.18 3.26 3.57 3.99 4.04 4.22 4.37 4.76 4.85 5.05 5.11 5.61 6.35 6.38 6.53 6.91 7.04 7.14 7.94 9.53 9.58 11.11 12.70

TOLERANCES (inch) D1 = +.0000/–.0005

TOLERANCES (mm) D1 = +0,000/–0,013

PLASTICS/COMPOSITES

For patent information visit www.ksptpatents.com

Series 120 Composite Drill Series 120 Metric

100 CFRP, AFRP (Carbon Fiber, Aramid Fibre)

(80-120) 75

GFRP (Fibreglass)

(65-90) 120

CARBON, GRAPHITE

DC • mm

Vc (m/min)

(96-144)

RPM

12722

10602

7951

5301

3976

3181

2650

0.012

0.014

0.019

0.028

0.038

0.047

0.057

Feed (mm/ min)

150

RPM

9542

7951

5963

3976

2982

2385

1988

0.012

0.014

0.019

0.029

0.039

0.048

0.058

Feed (mm/ min)

115

RPM

15266

12722

9542

6361

4771

3817

3181

0.015

0.018

0.025

0.037

0.049

0.062

0.074

Feed (mm/ min)

235

Series 120

2.5

Note: • rpm = (Vc x 1000) / (DC x 3.14) • mm/min = Fr x RPM • adjust speed and / or feed based on resin type and / or fibre structure • refer to the KYOCERA SGS Tool Wizard® for complete technical information (www.kyocera-sgstool.co.uk)

Composite Dril

TO SIGN UP FOR THE TOOLWIZARD®: 1. Visit www.kyocera-sgstool.co.uk 2. Sign up for an account 3. Start calculating 4. Start saving

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Series 20 | Carbon Composite Router

CCR CARBON-FIBER COMPOSITE ROUTERS

SGS Carbon Composite Routers were designed for maximum performance in CFRP materials.

Series 20 | Carbon Composite Router

We partnered with a leading Aerospace company to launch the original Series 20, a design focused on trimming and finishing in demanding applications requiring minimal fibre breakout and delamination. •

The multi-flute design and positive geometry cleanly shear through the material with minimal pressure without delamination issues

•

The unique clearance grind minimises the contact between the tool diameter and workpiece, eliminating friction and pressure concerns

•

Left hand flutes engineered to control the fibres within CFRP, preventing excessive fibre breakout

•

Greater edge finish with longer tool life

•

Available with and without end cut

•

Now available with Di-NAMITE coating option

POS

RHC

20M-CCR

TOLERANCES (mm) D1 = +0,00/–0,13

METRIC SERIES

• Multi-flute design and positive geometry to shear with minimal pressure and delamination • Unique clearance grind minimises contact between tool diameter and workpiece eliminating friction • Left hand flutes engineered to control the fibres within CFRP, preventing excessive fiber breakout • Excels at trimming and profiling difficult and abrasive fibre filled plastics

mm CUTTING LENGTH OVERALL SHANK NO. OF DIAMETER OF CUT LENGTH DIAMETER FLUTES D1 L2 L1 D2

2,0 3,0 4,0 5,0 6,0 6,0 8,0 8,0 10,0 10,0 12,0 12,0

6,0 10,0 12,0 15,0 25,0 25,0 25,0 25,0 28,0 28,0 38,0 38,0

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D2 = h6

EDP NO.

38,0 38,0 50,0 50,0 63,0 63,0 63,0 63,0 63,0 63,0 89,0 89,0

3,0 3,0 4,0 6,0 6,0 6,0 8,0 8,0 10,0 10,0 12,0 12,0

5 5 5 5 8 8 10 10 12 12 12 12

END STYLE

UNCOATED

Ti-NAMITE-B (TiB2)

Di-NAMITE® (Diamond)

End Cutting

82930 82931 82932 82933 82966 82967 82968 82969 82970 82971 82972 82973

83100 83101 83102 83103 83104 83105 83106 83107 83108 83109 83110 83111

83070 83071 83072 83073 83027 83026 83029 83028 83042 83041 83044 83043

End Cutting End Cutting End Cutting No End Cutting End Cutting No End Cutting End Cutting No End Cutting End Cutting No End Cutting End Cutting

PLASTICS/COMPOSITES

Series 20 | Carbon Composite Router

CCR CARBON-FIBER COMPOSITE ROUTERS

POS

LHC

20M-CCR-LHC

TOLERANCES (mm) D1 = +0,00/–0,13

METRIC SERIES

D2 = h6

For patent information visit www.ksptpatents.com

LENGTH OF CUT L2

OVERALL LENGTH L1

SHANK DIAMETER D2

NO. OF FLUTES

END STYLE

UNCOATED

Di-NAMITE® (Diamond)

6,0 6,0 8,0 8,0 10,0 10,0

25,0 25,0 25,0 25,0 28,0 28,0

63,0 63,0 63,0 63,0 63,0 63,0

6,0 6,0 8,0 8,0 10,0 10,0

8 8 10 10 12 12

No End Cutting End Cutting No End Cutting End Cutting No End Cutting End Cutting

83220 83221 83222 83223 83224 83225

83230 83231 83232 83233 83234 83235

• Multi-flute design and positive geometry to shear with minimal pressure and delamination • Unique clearance grind minimises contact between tool diameter and workpiece eliminating friction • Left hand flutes engineered to control the fibres within CFRP, preventing excessive fibre breakout • Excels at trimming and profiling difficult and abrasive fibre filled plastics

Performance by Design The Original CCR is now available in a diamond coated option for maximum abrasion resistance & increased tool life.

www.kyocera-sgstool.co.uk

Series 20 | Carbon Composite Router

PLASTICS/COMPOSITES

EDP NO.

CUTTING DIAMETER D1

Series 20 | Carbon Composite Router

CCR CARBON-FIBER COMPOSITE ROUTERS

Series 20M Metric

Slot

CFRP, AFRP (CARBON FIBRE, ARAMID FIBRE)

Profile

Series 20 | Carbon Composite Router

HSM

Slot

GFRP (FIBREGLASS)

Profile

HSM

Ae x D1

Ap x D1

≤1

CARBON, GRAPHITE

Profile

HSM

Slot

PLASTICS

Profile

HSM

(96-164) 150

≤ 1.5

(120-180) 250

≤ 0.05

≤2

(200-300) 100

≤1

(80-120) 120

≤ 0.5

≤ 1.5

(96-164) 200

≤ 0.05

≤2

N Slot

Vc (m/min)

120

≤ 0.5

(160-240) 145

≤1

(116-174) 185

≤ 0.5

≤ 1.5

(148-222) 300

≤ 0.05

≤2

(240-360) 245

≤1

(196-294) 305

≤ 0.5

≤ 1.5

(244-366) 505

≤ 0.05

≤2

(404-606)

HSM (high speed machining) rpm = (Vc x 1000) / (D1 x 3.14) mm/min = Fr x rpm Adjust parameters based on resin type and fibre structure Reduce speed when overheating causes melting or damage to resin Reduce feed if delamination or fraying occur

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Diameter (D1) (mm) 3

RPM

12722

6361

4771

3817

3181

0.055

0.113

0.243

0.366

0.439

Feed (mm/min)

700

720

1160

1395

RPM

15903

7951

5963

4771

3976

0.055

0.113

0.243

0.366

0.439

Feed (mm/min)

875

900

1450

1744

RPM

26504

13252

9939

7951

6626

0.126

0.260

0.556

0.833

1.000

Feed (mm/min)

3350

3450

5527

6625

RPM

10602

5301

3976

3181

2650

0.054

0.111

0.236

0.357

0.428

Feed (mm/min)

570

587

940

1135

RPM

12722

6361

4771

3817

3181

0.054

0.111

0.236

0.357

0.428

Feed (mm/min)

684

704

1128

1362

RPM

21203

10602

7951

6361

5301

0.124

0.261

0.557

1.011

1.213

Feed (mm/min)

2629

2765

4430

6430

RPM

15372

7686

5765

4612

3843

0.069

0.152

0.323

0.482

0.579

Feed (mm/min)

1061

1165

1860

2224

RPM

19613

9807

7355

5884

4903

0.069

0.152

0.323

0.482

0.579 2838

Feed (mm/min)

1353

1486

2373

2838

RPM

31805

15903

11927

9542

7951

0.159

0.348

0.740

1.109

1.331 10580

Feed (mm/min)

5057

5535

8820

10580

RPM

25974

12987

9740

7792

6494

0.069

0.150

0.319

0.477

0.572

Feed (mm/min)

1792

1945

3107

3717

RPM

32335

16168

12126

9701

8084

0.069

0.150

0.319

0.477

0.572

Feed (mm/min)

2231

2421

3868

4627

RPM

53538

26769

20077

16062

13385

0.159

0.344

0.732

1.097

1.316

Feed (mm/min)

8513

9220

14690

17617

Finish cuts typically required reduced feed and cutting depths Rates shown are for use without coolant; rates may be increased with coolant Rust collection is vital when machining dry Diamond coating will increase tool life in graphite and composite materials Refer to the KYOCERA SGS Tool Wizard® for complete technical information (www.kyocera-sgstool.co.uk)

Series 31 | Coarse Cut Carbon

CCR CARBON-FIBER COMPOSITE ROUTERS

The addition of the Series 31 geometry adds the benefit of fewer and deeper flutes than the original Series 20 CCR to avoid clogging during heavy routing CFRP applications. The multi-flute design and positive geometry cleanly shear through the material with minimal pressure without delamination issues.

•

The unique clearance grind minimises the contact between the tool diameter and workpiece, eliminating friction and pressure concerns.

•

Left hand flutes engineered to control the fibres within CFRP, preventing excessive fibre breakout.

•

Fewer flutes to avoid potential clogging in demanding applications.

•

Available with and without end cut.

•

Optional Di-NAMITE coating option available for greater edge finish and longer tool life.

POS

RHC

31M-CCR

TOLERANCES (mm) D1 = +0,00/–0,13

METRIC SERIES

D2 = h6 PLASTICS/COMPOSITES

EDP NO.

CUTTING LENGTH OVERALL SHANK NO. OF DIAMETER OF CUT LENGTH DIAMETER FLUTES D1 L2 L1 D2

6,0 6,0 8,0 8,0 For patent 10,0 information visit www.ksptpatents.com 10,0 12,0 12,0

25,0 25,0 25,0 25,0 28,0 28,0 38,0 38,0

63,0 63,0 63,0 63,0 63,0 63,0 89,0 89,0

6,0 6,0 8,0 8,0 10,0 10,0 12,0 12,0

5 5 7 7 8 8 10 10

END STYLE

UNCOATED

Ti-NAMITE-B (TiB2)

Di-NAMITE® (Diamond)

End Cutting No End Cutting End Cutting No End Cutting End Cutting No End Cutting End Cutting No End Cutting

82974 82975 82976 82977 82978 82979 82980 82981

83200 83201 83202 83203 83204 83205 83206 83207

82982 82983 82984 82985 82986 82987 82988 82989

• Fewer, deeper flutes to prevent clogging in heavy routing • Unique clearance grind minimises contact between tool diameter and workpiece eliminating friction • Left hand flutes engineered to control the fibres within CFRP, preventing excessive fibre breakout • Excels at trimming and profiling difficult and abrasive fibre filled plastics

www.kyocera-sgstool.co.uk

Series 31 | Coarse Cut Carbon Composite Router

•

Series 31 | Coarse Cut Carbon Composite Router Ap

Series 31M Metric

Slot

Series 31 | Coarse Cut Carbon Composite Router

CFRP, AFRP (CARBON FIBRE, ARAMID FIBRE)

Profile

HSM

Slot

GFRP (FIBREGLASS)

Profile

HSM

Ae x D1

Ap x D1

≤1

CARBON, GRAPHITE

Profile

HSM

Slot

PLASTICS

Profile

HSM

(96-164) 150

≤ 1.5

(120-180) 250

≤ 0.05

≤2

(200-300) 100

≤1

(80-120) 120

≤ 0.5

≤ 1.5

(96-164) 200

≤ 0.05

≤2

N Slot

Vc (m/min)

120

≤ 0.5

(160-240) 145

≤1

(116-174) 185

≤ 0.5

≤ 1.5

(148-222) 300

≤ 0.05

≤2

(240-360) 245

≤1

(196-294) 305

≤ 0.5

≤ 1.5

(244-366) 505

≤ 0.05

≤2

(404-606)

www.kyocera-sgstool.co.uk

Diameter (D1) (mm) 6

RPM

6361

4771

3817

3181

0.071

0.170

0.244

0.366

Feed (mm/min)

450

810

930

1165

RPM

7951

5963

4771

3976

0.071

0.170

0.244

0.366

Feed (mm/min)

563

1013

1163

1456

RPM

13252

9939

7951

6626

0.162

0.388

0.555

0.832

Feed (mm/min)

2150

3860

4415

5515

RPM

5301

3976

3181

2650

0.069

0.165

0.237

0.357

Feed (mm/min)

365

655

755

945

RPM

6361

4771

3817

3181

0.069

0.165

0.237

0.357

Feed (mm/min)

438

786

906

1134

RPM

10602

7951

6361

5301

0.163

0.390

0.557

0.834

Feed (mm/min)

1725

3100

3540

4420

RPM

7686

5765

4612

3843

0.095

0.226

0.321

0.483

Feed (mm/min)

728

1300

1480

1855

RPM

9807

7355

5884

4903

0.095

0.226

0.321

0.483

Feed (mm/min)

929

1659

1888

2367

RPM

15903

11927

9542

7951

0.217

0.517

0.739

1.111

Feed (mm/min)

3450

6170

7050

8830

RPM

12987

9740

7792

6494

0.094

0.223

0.318

0.477

Feed (mm/min)

1215

2175

2475

3100

RPM

16168

12126

9701

8084

0.094

0.223

0.318

0.477

Feed (mm/min)

1513

2708

3081

3859

RPM

26769

20077

16062

13385

0.215

0.512

0.731

1.098

Feed (mm/min)

5760

10280

11745

14700

Finish cuts typically required reduced feed and cutting depths Rates shown are for use without coolant; rates may be increased with coolant Dust collection is vital when machining dry Diamond coating will increase tool life in graphite and composite materials refer to the KYOCERA SGS Tool Wizard® for complete technical information (www.kyocera-sgstool.co.uk)

Scan to watch our tools in action.

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Series 25 | Compression Router For finish milling of CFRP

Series 25 | Compression Router

A major challenge in machining with Composite material is preventing separation of material layers during the machining process. By incorporating both a left and right hand helix, the cutting pressure to the centre of the workpiece is compressed, eliminating the fraying of the material. •

A left handed helix directs cutting forces downward in a pushing action, great for holding parts securely against a fixture.

•

A right handed helix directs cutting forces upward in a pulling action, great for chip evacuation.

•

The lower portion of the flute directs loads upward and the upper portion of the flute directs loads downward, minimising the forces which cause delamination and fraying.

•

Available with Di-NAMITE coating for longer, cleaner performance.

•

Specialised geometry for maximum load reduction.

POS

RHC

TOLERANCES (mm) D1 = +0,00/–0,08 D2 = h6

25M

METRIC SERIES mm

PLASTICS/COMPOSITES

For patent information visit www.ksptpatents.com

EDP NO.

CUTTING DIAMETER D1

LENGTH OF CUT L2

OVERALL LENGTH L1

SHANK DIAMETER D2

INTERSECT LENGTH L3

NO. OF FLUTES

UNCOATED

Di-NAMITE® (Diamond)

6,0 8,0 10,0 12,0

25,0 25,0 28,0 38,0

63,0 63,0 63,0 89,0

6,0 8,0 10,0 12,0

4,10 5,58 7,05 8,60

4 4 6 8

82990 82992 82994 82996

82991 82993 82995 82997

• Compressionstyle helixes direct cutting forces inward, eliminating fibre breakout and delamination • Primary/secondary relief grind for reduced friction and pressure • Rigid, heavy core

Performance by Design Incorporates both a left and right hand helix, eliminating the fraying of material. 14

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Series 25 | Compression Router For finish milling of CFRP Ap

Series 25M Metric

Ae x D1

Profile CFRP, AFRP (CARBON FIBRE, ARAMID FIBRE)

HSM

≤ 0.05

≤ 0.5

Ap x D1

≤ 1.5

≤2

≤ 1.5

GFRP (FIBREGLASS) HSM

Profile

≤ 0.05

≤ 0.5

≤2

≤ 1.5

CARBON, GRAPHITE HSM

Profile

≤ 0.05

≤ 0.5

≤2

≤ 1.5

PLASTICS HSM

Profile MACHINABLE CERAMICS MACHINABLE GLASS

HSM

≤ 0.05

≤ 0.5

≤ 0.05

≤2

≤ 1.5

≤2

Diameter (D1) (mm)

Vc (m/min)

150

RPM

7951

5963

4771

3976

0.040

0.065

0.075

0.100

(96-164)

Feed (mm/ min)

1272

1550

2147

3181

250

RPM

13252

9939

7951

6626

0.095

0.145

0.175

0.235

(200-300)

Feed (mm/ min)

5036

5765

8349

12457

120

RPM

6361

4771

3817

3181

0.040

0.065

0.075

0.100

(96-164)

Feed (mm/ min)

1018

1240

1717

2544

200

RPM

10602

7951

6361

5301

0.095

0.145

0.175

0.235

(160-240)

Feed (mm/ min)

4029

4612

6679

9966

185

RPM

9807

7355

5884

4903

0.050

0.080

0.095

0.125

(148-222)

Feed (mm/ min)

1961

2354

3354

4903

300

RPM

15903

11927

9542

7951

0.115

0.185

0.220

0.290

(240-360)

Feed (mm/ min)

7315

8826

12595

18447

305

RPM

16168

12126

9701

8084

0.050

0.080

0.095

0.125

(244-366)

Feed (mm/ min)

3234

3880

5529

8084

505

RPM

26769

20077

16062

13385

0.115

0.185

0.220

0.290

(404-606)

Feed (mm/ min)

12314

14857

21201

31052

RPM

795

596

477

398

0.020

0.035

0.045

0.050

(12-18)

Feed (mm/ min)

129

159

RPM

1325

994

795

663

0.045

0.075

0.085

0.115

Feed (mm/ min)

239

298

406

610

(20-30)

HSM (high speed machining) rpm = (Vc x 1000) / (D1 x 3.14) mm/min = Fz x number of flutes x rpm Adjust parameters based on resin type and fibre structure Reduce speed when overheating causes melting or damage to resin Reduce feed if delamination or fraying occur

Series 25 | Compression Router

Profile

≤ 0.5

Finish cuts typically required reduced feed and cutting depths Rates shown are for use without coolant; rates may be increased with coolant Dust collection is vital when machining dry Diamond coating will increase tool life in graphite and composite materials Refer to the KYOCERA SGS Tool Wizard® for complete technical information (www.kyocera-sgstool.co.uk

www.kyocera-sgstool.co.uk

Series 27 | Slow Helix End Mill

Series 27 | Slow Helix End Mill •

The slow helix design adds strength to the edge making the tool more capable of milling of highly abrasive materials.

•

The stable configuration and full cutting edge leads to improved surface finishes.

•

This rigid design of a slow helix is complemented with a variable helix to help to reduce vibration and deflection.

•

The slow helix provides shear without delamination or damage.

•

Design creates a short path for material evacuation during machining.

•

Balanced geometry reacts positively to address complexity of Composite fibre matrix.

•

Optional Di-NAMITE Coating for ultimate protection and extended tool life.

POS

4 ≠

27M

TOLERANCES (mm) D1 = +0,000/–0,080

METRIC SERIES

• Slow helix design adds strength to the edge allowing ease for milling highly abrasive materials • Two levels of chatter suppression: variable helix and indexing • Excels at roughing (slotting, profiling) and finishing in a variety of plastics and composites

D2 = h6

EDP NO.

CUTTING DIAMETER D1

LENGTH OF CUT L2

OVERALL LENGTH L1

SHANK DIAMETER D2

UNCOATED

Di-NAMITE® (Diamond)

6,0 8,0 10,0 12,0 16,0

25,0 25,0 28,0 38,0 48,0

63,0 63,0 63,0 89,0 115,0

6,0 8,0 10,0 12,0 16,0

83056 83058 83060 83062 83064

83057 83059 83061 83063 83065

PLASTICS/COMPOSITES

For patent information visit www.ksptpatents.com

Performance by Design Stable configuration and full cutting edge leads to improved surface finishes.

www.kyocera-sgstool.co.uk

Series 27M Metric

Ae x D1

Slot

CFRP, AFRP (CARBON FIBER, ARAMID FIBRE)

Profile

HSM

Slot

GFRP (FIBREGLASS)

Profile

Slot

CARBON, GRAPHITE

Profile

HSM

Slot

PLASTICS

Profile

HSM

Slot

MACHINABLE CERAMICS MACHINABLE GLASS

Profile

HSM

≤ 0.5

Ap x D1

≤1

≤ 1.5

≤2

≤1

≤ 1.5

≤2

≤1

≤ 1.5

≤2

≤1

≤ 1.5

≤2

≤1

≤ 1.5

≤2

Diameter (D1) (mm)

Vc (m/min)

120

RPM

6361

4771

3817

3181

2385

0.040

0.065

0.075

0.100

0.120

(96-164)

Feed (mm/ min)

1018

1240

1145

1272

1145

150

RPM

7951

5963

4771

3976

2982

0.040

0.065

0.075

0.100

0.120

(120-180)

Feed (mm/ min)

1272

1550

1431

1590

1431

250

RPM

13252

9939

7951

6626

4970

0.095

0.145

0.175

0.235

0.280

(200-300)

Feed (mm/ min)

5036

5765

5566

6228

5566

100

RPM

5301

3976

3181

2650

1988

0.040

0.065

0.075

0.100

0.120

(80-120)

Feed (mm/ min)

848

1034

954

1060

954

120

RPM

6361

4771

3817

3181

2385

0.040

0.065

0.075

0.100

0.120

(96-164)

Feed (mm/ min)

1018

1240

1145

1272

1145

200

RPM

10602

7951

6361

5301

3976

0.095

0.145

0.175

0.235

0.280

(160-240)

Feed (mm/ min)

4029

4612

4453

4983

4453

145

RPM

7686

5765

4612

3843

2882

0.050

0.080

0.095

0.125

0.150

(116-174)

Feed (mm/ min)

1537

1845

1752

1922

1729

185

RPM

9807

7355

5884

4903

3677

0.050

0.080

0.095

0.125

0.150

(148-222)

Feed (mm/ min)

1961

2354

2236

2452

2206

300

RPM

15903

11927

9542

7951

5963

0.115

0.185

0.220

0.290

0.350

(240-360)

Feed (mm/ min)

7315

8826

8397

9223

8349

245

RPM

12987

9740

7792

6494

4870

0.050

0.080

0.095

0.125

0.150

(196-294)

Feed (mm/ min)

2597

3117

2961

3247

2922

305

RPM

16168

12126

9701

8084

6063

0.050

0.080

0.095

0.125

0.150

(244-366)

Feed (mm/ min)

3234

3880

3686

4042

3638

505

RPM

26769

20077

16062

13385

10038

0.115

0.185

0.220

0.290

0.350

(404-606)

Feed (mm/ min)

12314

14857

14134

15526

14054

RPM

530

398

318

265

199

0.020

0.035

0.045

0.050

0.060

(8-12)

Feed (mm/ min)

RPM

795

596

477

398

298

0.020

0.035

0.045

0.050

0.060

(12-18)

Feed (mm/ min)

RPM

1325

994

795

663

497

0.045

0.075

0.085

0.115

0.140

Feed (mm/ min)

239

298

270

305

278

(20-30)

HSM (High Speed Machining) Rates shown are for use without coolant; rates may be increased with coolant rpm = Vc x 3.82 / D1 Dust collection is vital when machining dry ipm = Fz x 4 x rpm Diamond coating will increase tool life in graphite and composite materials Adjust parameters based on resin type and fibre structure Refer to the KYOCERA SGS Tool Wizard® for complete technical information Reduce speed when overheating causes melting or damage to resin (www.kyocera-sgstool.co.uk) Reduce feed if delamination or fraying occur www.kyocera-sgstool.co.uk Finish cuts typically required reduced feed and cutting depths

Series Series27 25 |Compression Slow Helix End Router Mill

HSM

In-house Coatings Ti-NAMITE® B and Di-NAMITE® Tool Coatings are specifically engineered for our Composite range.

Coating

Titanium DiBoride (TiB2)

Crystalline Diamond (Diamond)

Identifying Colour

light grey-silver

black

Layer Structure

Thickness

Monolayer 1–2 microns

Monolayer

6–20 microns

Coefficient Hardness of Friction (HV) (Fretting)

4000

>8000

0.45

0.15–0.2

Thermal Stability

General Information

850°C / 1562°F

This ceramic based coating ensures a smooth surface and a low affinity to cold welding or edge build up, which makes it optimal for Aluminum and copper applications. It has high toughness and high hardness.

800°C / 1470°F

This is the hardest coating available with the best abrasion resistance. It is carbon based so it is limited in application capabilities. This coating is suitable for machining highly abrasive, non-ferrous materials such as CFRP and graphite.

Other coatings The coating lineup includes proprietary processes that result in optimised tool life and increased speed and feed rates in a variety of applications. Coating

Identifying Colour

Titanium Nitride (TiN)

gold

Aluminum Titanium Nitride (AlTiN)

dark grey

Titanium Carbonitride (TiCN)

pink-red

Proprietary (TX)

Proprietary (TM)

black

copper

www.kyocera-sgstool.co.uk

Layer Structure

Thickness

Multilayer 1–4 microns

Coefficient Hardness of Friction (HV) (Fretting) 2200

0.4–0.65

Thermal Stability

General Information

600°C / 1112°F

A general purpose coating with good adhesion and abrasion resistant properties. Suitable for a wide variety of materials.

1–4 microns

3700

0.30

1100°C / 2010°F

Excellent thermal and chemical resistance allows for dry cutting and improvements in performance of carbide. The coating has a high hardness giving great protection against abrasive wear and erosion.

Multilayer 1–4 microns

3000

0.3–0.45

400°C / 752°F

A very wear-resistant coating with high toughness and shock resistance. Good in interrupted cuts found in applications like milling.

Nano structure

Nano 1–4 microns Composite

3600

0.45

The structural design of Ti-Namite-X is adapted to meet a diverse range of applications; everything from high- and low-alloy steels to hardened 1150°C / materials 2100°F (up to 65 HRC core hardness). Ti-Namite-X is suitable for operations which require high cutting speeds, high temperatures at the cutting edge, and high metal removal rates.

0.45

Features include high wear resistance, reduced friction, and excellent prevention of edge build up. This coating 1150°C / provides superior material removal 2100°F rates and tool life when used in high performance operations with difficult to machine materials like Titanium.

VISIT OUR WEBSITE

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NEW EASY-TO-USE

ONLINE QUOTE FORM FOR SPECIAL TOOLING

PROCESS DEVELOPMENT

BESPOKE TOOLING

SGS tech hubs can help obtain the best from our high-performance range of tooling by applying the correct tools and optimum strategies.

SGS R&D can develop specific tooling unique to your requirements, through extensive knowledge and creative thinking.

Using our in-house Multi-Axis CNC milling machines we can perfect a process working in conjunction with our partners.

Using the latest technology in spindle monitoring and high-magnification measuring equipment, we can develop tooling to suit your application and material specification.

Whether it be machine tools, tool holding, work holding or software suppliers of the latest CADCAM, we are committed to help find the best solution.

www.kyocera-sgstool.co.uk

What you can expect from us

Product research and development

Product engineering and tool application support

CAD/CAM software support

Same-day despatch on stock items

On-site customer training

Annual Customer Satisfaction Survey

KYOCERA SGS Precision Tools Europe Ltd, 10 Ashville Way, Wokingham, Berkshire RG41 2PL +44 (0) 1189 795 200 saleseu@kyocera-sgstool.com www.kyocera-sgstool.co.uk KYOCERA SGS Precision Tools Europe Ltd 20