Mold and Die Solutions

Mold & Die Solutions

Keeping the world moving.

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Experts in Mold & Die SGS has the tools you need when it comes to high efficiency, high accuracy machining of hardened mold & die materials.

Mold & die work requires tools that can handle difficult workpiece materials, an array of shapes and sizes and the precision required for tight tolerance applications and superior finishes.

The mold & die industry offers many challenging and complex workpiece configurations in equally challenging materials, including carbon steels, hardened steels, stainless steels, tool steels and aluminum.

From the Turbo-Carb and Power-Carb to the groundbreaking Z-Carb-MD, SGS has the tools you need for profitable mold & die production.

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Mold & Die Machining Applications Material: NAK High Hard (45 HRc) Cooling: Air Machine: Haas VM3 and VF3

Pocketing with Z-Carb-MD 12mm EDP 46566

Slotting with Z-Carb-MD 12mm EDP 46566

•

RPM: 4,000 (160 m/min)

•

RPM: 2300 (90m/min)

•

Feed Ramp: 1,270 mm/min

•

Feed Linear: 635mm/min

•

Feed Linear: 1,270 mm/min

•

Ap: 12mm

•

Ap: 6.4mm

•

Ae: 12mm

•

Ae: 5mm

Finishing with Power-Carb 12mm EDP 46143 •

RPM: 7500 (290m/min)

•

Feed Linear: 1900mm/min

•

Ap: 6.4 to 19 mm

•

Ae: 0.05mm

Pocketing with Z-Carb-MD 10mm EDP 46565 •

RPM: 5100 (160m/min)

•

Feed Ramp: 1270mm/min

•

Feed Linear: 2540mm/min

•

Ap: 1.9mm

•

Ae: 1.3mm

4140 Alloy Steel @ 28-30 HRc 100mm x 100mm x 19mm.

Semi-Finishing Roughing Operation •

Tool: Z1MB 10mm EDP 46345

•

Speed: 6,500 RPM

•

Feed: 2540mm/min

•

Ap: 1.9mm

•

Ae: 4mm

•

Ramp: 30° @ 1270mm/min

•

Cooling: Air

•

Time: 1:12 minutes per pocket

•

Tool: Turbo-Carb 8mm EDP 91357

•

Speed: 10,000 RPM

•

Feed: 3810mm/min

•

Ap: .06mm

•

Cooling: Air

•

Time: 1:19 minutes per pocket

Finishing •

Tool: Turbo-Carb 8mm EDP 91357

•

Speed: 10,000 RPM

•

Feed: 2540mm/min

•

Ap: 0.127mm

•

Cooling: Air

•

Time: 9:55 minutes per pocket

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Chatter-Free Z-Carb-MD Chatter poses a big problem when machining hardened steels. Conventional end mills simply can’t leave a smooth surface finish when run at extremely high speeds. At high metal removal rates, the Z-CarbMD produces a chatter-free finish, which leaves minimal stock for the Power-Carb End Mill.

Features & Benefits Patented unequal helix design Reduced Neck Diameters

•

Significantly reduces chatter

•

Superior workpiece finishes

•

Extends tool life

Heavy duty core and negative rake •

Enhances edge strength

•

Lessens deflection, improving workpiece accuracy

•

Allows higher feed rates

Innovative carbide substrate •

Provides higher wear

•

Exceptional chip resistance

Available with extended reach and reduced neck diameters Special corner geometry provides maximum tool life Ti-NAMITE-A (AlTiN) coating eliminates the need for coolants Exceptional performance in steels up to 62 HRc Weldon flats available upon request 200% improved tool life over the nearest competitive traditional product

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Product Range

For patent information visit www.ksptpatents.com

ZD1MCR METRIC SERIES

TOLERANCES (mm)

3–6 DIAMETER DC = +0,000/–0,030 DCON = h6 RE = +0,000/–0,050

>6–10 DIAMETER DC = +0,000/–0,040 DCON = h6 RE = +0,000/–0,050

>10–20 DIAMETER DC = +0,000/–0,050 DCON = h6 RE = +0,000/–0,050

mm

EDP NO.

CUTTING DIAMETER DC

LENGTH OF CUT APMX

OVERALL LENGTH LF

SHANK DIAMETER DCON

REACH LU

NECK DIAMETER DN

CORNER RADIUS RE

Ti-NAMITE-X

3,0 4,0 5,0 6,0 8,0 10,0 12,0 16,0 20,0

4,0 5,0 6,0 7,0 10,0 12,0 15,0 20,0 24,0

57,0 57,0 57,0 57,0 63,0 72,0 83,0 92,0 104,0

6,0 6,0 6,0 6,0 8,0 10,0 12,0 16,0 20,0

15,0 15,0 15,0 15,0 25,0 30,0 35,0 45,0 55,0

2,62 3,61 4,60 5,61 7,62 9,60 11,61 15,60 19,61

0,2 0,3 0,5 1,0 1,0 1,0 1,0 1,5 2,0

46560 46561 46562 46563 46564 46565 46566 46567 46568

• The original Z-Carb design with negative rake, heavy core, and higher helix for strength and shearing of hard mold & die materials • Unequal flute spacing helps to disrupt the rhythmic pattern created by the cutting edge helping to suppress damaging harmonics • Enhanced corner geometry with tight tolerance corner radii • Recommended for materials 35-60HRc (327 to 654 Bhn)

Performance Data 18000 16000

Usage (mm)

14000

Ae = Dia 16002

Ap = 0.5xDia

12000

1,650 RPM

10000

571mm/min

8000 6000 4000 2000 0

Z-Carb-MD

•

Pressurized air with oil extends tool life in materials <40 HRc

•

Use dry air when roughing materials harder than 40 HRc

•

Unique coating eliminates flood coolant requirements Climb milling is preferred

3658

Competitor F

Application Tips

•

H13 @ 50 HRc

5690

Competitor H

•

Attention to programming details, tool holders, TIR, balance, etc.

•

contribute to additional tool life

•

Ramping at 10 to 30 degrees is the preferred entry method. Use slotting

•

speeds with 25-50 percent slotting feed. Avoid plunging. www.kyocera-sgstool.co.uk

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Speed and Feed Recommendations Series ZD1MCR Metric

Hardness

Ae x DC

Ap x DC

Profile ≤ 0.4 TOOL STEELS A2, D2, H13, L2, M2, P20, S7, T15, W2

≤ 375 Bhn or ≤ 40 HRc

Slot

Profile

H

TOOL STEELS A2, D2, H13, L2, M2, P20, S7, T15, W2

≤ 475 Bhn or ≤ 50 HRc

Slot

Profile TOOL STEELS A2, D2, H13, L2, M2, P20, S7, T15, W2

≤ 655 Bhn or ≤ 60 HRc

Slot

1

≤ 0.4

1

≤ 0.4

1

≤1

≤ 0.4

≤1

≤ 0.4

≤1

≤ 0.4

Diameter (DC) (mm)

Vc (m/min)

3

6

8

10

12

16

20

123

RPM

13087

6544

4908

3926

3272

2454

1963

Fz

0.012

0.029

0.049

0.061

0.072

0.083

0.112

(99-148)

Feed (mm/ min)

628

754

963

963

942

817

879

98

RPM

10340

5170

3878

3102

2585

1939

1551

Fz

0.012

0.029

0.049

0.061

0.072

0.083

0.112

(78-117)

Feed (mm/ min)

496

596

761

761

744

645

695

64

RPM

6786

3393

2545

2036

1696

1272

1018

Fz

0.010

0.024

0.041

0.051

0.060

0.068

0.093

(51-77)

Feed (mm/ min)

261

326

413

413

407

347

380

52

RPM

5493

2747

2060

1648

1373

1030

824

Fz

0.010

0.024

0.041

0.051

0.060

0.068

0.093

(41-62)

Feed (mm/ min)

211

264

334

334

330

281

308

27

RPM

2908

1454

1091

872

727

545

436

Fz

0.005

0.012

0.021

0.027

0.031

0.036

0.048

(22-33)

Feed (mm/ min)

56

70

93

93

91

79

84

21

RPM

2262

1131

848

679

565

424

339

Fz

0.005

0.012

0.021

0.027

0.031

0.036

0.048

Feed (mm/ min)

43

54

72

72

71

62

65

(17-26)

Bhn (Brinell) HRc (Rockwell C) rpm = (Vc x 1000) / (DC x 3.14) ipm = Fz x 4 x rpm reduce speed and feed for materials harder than listed reduce feed and Ae when finish milling (.02 x DC maximum) feed rates listed have chip thinning adjustments included where applicable refer to the SGS Tool Wizard® for complete technical information (www.kyocera-sgstool.com)

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Turbo-Carb Solid Carbide High Performance End Mills

For machining complex, contour shapes in tough and hardened mold & die steels.

•

Designed for high speed rough and finish milling of mold and die steels up to 60 Rc

•

Application specific carbide improves wear resistance and toughness

•

Ti-NAMITE-A (AlTiN) coated for maximum heat and wear resistance

•

Helical ball gashing for improved shearing action

•

Available with extended reach and reduced neck diameters

•

Rigid construction

Suggestions for using Turbo-Carb®End Mills •

Pressurized air with oil extends tool life in materials <40 Rc

•

Use dry air when finish milling or roughing materials

•

harder than 40 Rc

•

Unique coating eliminates flood coolant requirements

•

The Z-level cutting method and climb milling extend tool life in roughing applications

•

Helical interpolation is the preferred entry method.

•

Avoid direct plunging

•

Attention to programming details, tool holders, TIR, & balance contribute to additional tool life

•

Speed and feed recommendations are based on using the tool tip

www.kyocera-sgstool.co.uk

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Product Range

METRIC

56MB

METRIC SERIES

• Short flute length and rigid design to reduce deflection • S-Gash Ball geometry minimizes load and heat produced during the cutting process, ultimately enhancing tool life • Ideal for machining complex contoured shapes in hardened steels • Recommended for materials 35 to 60 HRc (327 to 654 Bhn)

mm CUTTING DIAMETER DC

LENGTH OF CUT APMX

1,0 1,0 1,5 1,5 2,0 2,0 2,5 2,5 3,0 3,0 4,0 4,0 5,0 5,0 6,0 6,0 8,0 8,0 10,0 10,0 12,0 12,0 16,0 16,0 20,0 20,0 Neck Option Available

OVERALL LENGTH LF

76,0 76,0 76,0 76,0 76,0 76,0 89,0 89,0 102,0 102,0 114,0 140,0 165,0

RE = 1/2 Cutting Diameter (DC)

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EDP NO.

SHANK CENTER LINE DIAMETER ANGLE DCON α

6,0 6,0 6,0 6,0 6,0 6,0 6,0 6,0 8,0 10,0 12,0 16,0 20,0

8°10' 7°45' 7°10' 6°35' 6° 4°30' 2°30' – – – – – –

REACH LU

NECK DIAMETER DN

Ti-NAMITE-X

2,0 3,0 4,0 5,0 6,0 8,0 10,0 12,0 16,0 20,0 24,0 32,0 40,0

0,91 1,37 1,83 2,29 2,72 3,63 4,55 5,49 7,49 9,47 11,48 15,62 19,61

91349 91350 91351 91352 91353 91354 91355 91356 91357 91358 91359 91360 91361

TOLERANCES (mm)

1–2,5 DIAMETER DC = +0,000/–0,025 DCON = h6 RE = +0,000/–0,0013

>2,5–6 DIAMETER DC = +0,000/–0,030 DCON = h6 RE = +0,000/–0,0013

>6–10 DIAMETER DC = +0,000/–0,040 DCON = h6 RE = +0,000/–0,0020

>10–20 DIAMETER DC = +0,000/–0,050 DCON = h6 RE = +0,000/–0,0025

For patent information visit www.ksptpatents.com

Speed and Feed Recommentations

Series 56MB Metric

Hardness

Ae x DC

Ap x DC

191 Rough TOOL STEELS MOLD AND DIE STEEL ≤ 375 300M, 4340, 52100, Bhn HP-9-4-20, M50, A2, or D2, H13, L2, M2, P20, ≤ 40 HRc HSM S7, T15, W2

≤ 0.4

≤ 0.1

(153-229) 290

≤ 0.4

≤ 0.03

(232-348) 229

Rough

H

TOOL STEELS MOLD AND DIE STEEL ≤ 475 300M, 4340, 52100, Bhn HP-9-4-20, M50, A2, or D2, H13, L2, M2, P20, ≤ 50 HRc HSM S7, T15, W2

≤ 0.4

≤ 0.05

(183-275) 351

≤ 0.4

≤ 0.02

(281-421) 152

Rough TOOL STEELS MOLD AND DIE STEEL ≤ 655 300M, 4340, 52100, Bhn HP-9-4-20, M50, A2, or D2, H13, L2, M2, P20, ≤ 60 HRc HSM S7, T15, W2

≤ 0.4

≤ 0.04

(122-182) 305

≤ 0.4

≤ 0.01

DC • mm

Vc (m/min)

(244-366)

1

RPM

1.5

3

5

6

10

12

20

60748 40498 20249 12150 10125

6075

5062

3037

Fz

0.015

0.038

0.076

0.102

0.127

0.203

0.254

0.305

Feed (mm/ min)

1822

3078

3078

2479

2572

2466

2572

1853

92235 61490 46117 18447 15372

9223

7686

4612

Fz

0.018

0.043

0.084

0.112

0.117

0.224

0.279

0.330

Feed (mm/ min)

3320

5288

7748

4132

3597

4132

4289

3044

72833 48556 24278 14567 12139

7283

6069

3642

Fz

0.013

0.028

0.058

0.076

0.097

0.152

0.191

0.216

Feed (mm/ min)

1894

2719

2816

2214

2355

2214

2319

1573

74424 37212 22327 18606 11164

9303

5582

RPM

RPM

RPM Fz

0.015

0.030

0.064

0.084

0.107

0.168

0.208

0.254

Feed (mm/ min)

3349

4465

4763

3751

3982

3751

3870

2836

48344 32229 16115

9669

8057

4834

4029

2417

Fz

0.010

0.020

0.043

0.058

0.074

0.114

0.145

0.160

Feed (mm/ min)

967

1289

1386

1122

1192

1102

1168

773

97005 64670 32335 19401 16168

9701

8084

4850

Fz

0.013

0.023

0.048

0.064

0.081

0.127

0.160

0.180

Feed (mm/ min)

2522

2975

3104

2483

2619

2464

2587

1746

RPM

RPM

Bhn (Brinell) HRc (Rockwell C) HSM (High Speed Machining) rpm = (Vc x 1000) / (DC x 3.14) mm/min = Fz x 2 x rpm reduce speed and feed for materials harder than listed reduce feed and Ae when finish milling (.02 x DC maximum) feed rates listed have chip thinning adjustments included where applicable refer to the SGS Tool Wizard® for complete technical information (www.kyocera-sgstool.com)

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9

Maximize your Milling Performance of Mold Grade Steels up to 65 HRc

Power-Carb® Design Features Eccentric Relief / Extreme Negative Radial Rake: These features significantly increase edge strength, and are especially critical when finish milling hard materials. Without exceptional strength, edges are prone to chip.

Engineered Carbide: This material is specifically designed for difficult machining operations.

High Helix / Multi-Edge Design: Multiple cutting edges increase rigidity and feed rate capabilities, while the 45 degree helix angle increases shearing ability without sacrificing edge strength. The combination of these features improves surface finishes by reducing cutter deflection and maintaining a more consistent cuttertoworkpiece contact.

Long Reach: Power-Carbs® are manufactured with extra long shanks for extended reach capabilities.

Superior Performance in High Temperature Applications The chemical composition of aluminum titanium nitride (AlTiN) maximizes heat and wear resistance, making it most suitable for wet or dry milling in hardened steels, and many other applications.

Advantages of Dry Milling Extensive testing has shown that elimination of flood coolant often prolongs tool life. Milling applications in hardened steels generate extremely high temperatures and the rapid quenching of conventional flood coolant can produce thermal shock, which reduces tool life. Semi-cooling and chip removal with air and oil blast stabilizes tool temperatures. Dry milling does require an effective heat resistant coating. Ti-NAMITE-A® provides this required protection and is a standard feature of the Power-Carb® end mill.

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Ti-NAMITE-A® (AlTiN)

(TiN)

Vickers Hardness (HV)

30003500

23003000

Oxidation Temperature

800° C 1472° F

600° C 1112° F

Product Range

57M

METRIC SERIES mm CUTTING DIAMETER DC

6,0 8,0 10,0 12,0 16,0 20,0 Neck Option Available

TOLERANCES (mm)

EDP NO.

LENGTH OF CUT APMX

OVERALL LENGTH LF

SHANK DIAMETER DCON

Ti-NAMITE-X

13,0 18,0 22,0 26,0 32,0 38,0

89,0 102,0 102,0 114,0 140,0 165,0

6,0 8,0 10,0 12,0 16,0 20,0

46140 46141 46142 46143 46145 46147

• Ideal in Trochoidal milling applications in hardened steels and dry machining • Short flute length and large core design to reduce deflection • Unsurpassed edge strength with extreme negative rake and eccentric relief • Recommended for materials 45 to 65 HRc (421 to 739 Bhn)

6 DIAMETER DC = +0,000/–0,030 DCON = h6 8 DIAMETER DC = +0,000/–0,040 DCON = h6

10 DIAMETER DC = +0,000/–0,040 DCON = h6

12–20 DIAMETER DC = +0,000/–0,050 DCON = h6

For patent information visit www.ksptpatents.com

www.kyocera-sgstool.co.uk

11

Performance Data 30000

Milling D2 @ 58 HRc 26670

25000

MM of Use

20000

19050

15000 10000

•

TOOL USED: 10 mm

•

Ae: 0.5 mm

•

Ap: 12mm

•

TOOL SPEED / FEED RATE: 2384 RPM

•

COOLING METHOD: Air/Oil

11430

5000 0

T-NAMITE-A®

Competitor

Exceptionally strong geometry, specifically engineered carbide and TI-NAMITE-A® (AlTiN) coating for:

12

•

Slot and finish milling applications

•

Improved surface finishes

•

High feed rates

•

Wet or dry machining

•

High speed or conventional machining

•

Maximum hardness and fracture resistance

www.kyocera-sgstool.co.uk

TiN

Additional benefits of dry milling •

Eliminates procurement costs for cutting fluids*

•

Eliminates coolant disposal costs

•

Reduces chip disposal costs

•

Reduces cutting fluid related health issues (stricter standards have been proposed)

Speed and Feed Recommendations Series 57M Metric

Hardness

Ae x DC

Ap x DC

66 Slot

TOOL STEELS MOLD AND DIE STEEL ≤ 420 Bhn Profile 300M, 4340, 52100, or HP-9-4-20, M50, A2, ≤ 45 HRc D2, H13, L2, M2, P20, S7, T15, W2

1

≤ 0.3

(53-79) 81

≤ 0.1

≤ 1.5

(65-97) 171

HSM

≤ 0.04

≤ 1.5

(137-205) 37

Slot

H

TOOL STEELS MOLD AND DIE STEEL ≤ 560 Bhn Profile 300M, 4340, 52100, or HP-9-4-20, M50, A2, ≤ 55 HRc D2, H13, L2, M2, P20, S7, T15, W2

1

≤ 0.3

(30-44) 46

≤ 0.1

≤ 1.5

(37-55) 149

HSM

≤ 0.04

≤ 1.5

(119-179) 20

Slot

TOOL STEELS MOLD AND DIE STEEL ≤ 740 Bhn Profile 300M, 4340, 52100, or HP-9-4-20, M50, A2, ≤ 65 HRc D2, H13, L2, M2, P20, S7, T15, W2

1

≤ 0.3

(16-24) 24

≤ 0.1

≤ 1.5

(19-29) 76

HSM

≤ 0.04

≤ 1.5

DC • mm

Vc (m/min)

(61-91)

6

8

10

12

16

20

RPM

3499

2624

2099

1749

1312

1050

Fz

0.032

0.048

0.064

0.079

0.094

0.109

Feed (mm/ min)

672

756

806

829

740

686

RPM

4294

3220

2576

2147

1610

1288

Fz

0.046

0.066

0.089

0.112

0.132

0.152

Feed (mm/ min)

1185

1275

1376

1443

1275

1175

RPM

9064

6798

5439

4532

3399

2719

Fz

0.056

0.084

0.112

0.140

0.170

0.200

Feed (mm/ min)

3046

3426

3655

3807

3467

3263

RPM

1961

1471

1177

981

735

588

Fz

0.025

0.038

0.051

0.064

0.077

0.090

Feed (mm/ min)

294

335

360

377

340

318

RPM

2438

1829

1463

1219

914

732

Fz

0.036

0.053

0.071

0.089

0.107

0.125

Feed (mm/ min)

527

582

623

651

587

549

RPM

7898

5924

4739

3949

2962

2369

Fz

0.046

0.066

0.089

0.112

0.135

0.158

Feed (mm/ min)

2180

2346

2531

2654

2399

2246

RPM

1060

795

636

530

398

318

Fz

0.020

0.028

0.038

0.048

0.058

0.068

Feed (mm/ min)

127

134

145

153

138

130

RPM

1272

954

763

636

477

382

Fz

0.028

0.041

0.053

0.066

0.078

0.090

Feed (mm/ min)

214

235

243

252

223

206

RPM

4029

3021

2417

2014

1511

1209

Fz

0.033

0.048

0.064

0.079

0.094

0.109

Feed (mm/ min)

798

870

928

955

852

790

Bhn (Brinell) HRc (Rockwell C) HSM (High Speed Machining) rpm = (Vc x 1000) / (DC x 3.14) mm/min = Fz x 6 x rpm reduce speed and feed for materials harder than listed reduce feed and Ae when finish milling (.02 x DC maximum) feed rates listed have chip thinning adjustments included where applicable refer to the SGS Tool Wizard® for complete technical information (www.kyocera-sgstool.com)

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13

OUR SERVICES

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.

REGRIND, RECOAT AND ALTERATION SERVICES Before

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Re-manufactured to original geometry

14

NEW EASY-TO-USE

ONLINE QUOTE FORM FOR SPECIALS TOOLING

VISIT OUR WEBSITE

Scan this QR code to visit our website and request a quote

En

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Ask us about our bespoke barrel tools designed to suit specific applications. Our bespoke range includes micro barrel tools.

ire

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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 16