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)
www.kyocera-sgstool.co.uk
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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
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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
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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
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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
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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