PRODUCT NEWS No. 301
NEW PRODUCT
AL- OCHE One-Cut Helical End Mill Helical Interpolation
Spot Facing
Drilling
High efficient hole making end mill for Aluminum
DIJET INDUSTRIAL CO., LTD.
Sholder Milling
Slotting
One-Cut Helical End Mill Feature of product
One-Cut Helical can achieved: Intensive tool management High efficient machining
1
For Aluminum
Helical through coolant holes
2
Wider pocket for better chip evacuation.
The helical coolant holes along the flute was adopted. Excellent chip evacuation by using coolant through the tool.
3
Helix
4
30° for better surface finishing on holes shoulder.
6
Cutting edge
The high efficient machining was achieved by devising original geometry.
New developed coating
Adopted new developed coating ''JC 20015'' to prevent the chip welding problem.
5
Tool surface
Lapping surface finishing on the tool's cutting edges, substrate is K 10 carbide.
The high efficient hole making that equaled a drill processing was achieved by having enabled farther deep helical milling depth H per revolution so far.
Newly developed cooting "JC 20015" By improving the hardness and lubricating compared with conventional coating,achieved excellent chip evacuation and longer tool life on aluminum machining by high helical milling.
JC 20015
High hardness and lubricating
Hardness㧔Hv 㧕
New machining method
3000
TiAIN TiCN TiN
2000 Lapping surface on K10 carbide
H
0.1
0.5
0.9
Coefficient of friction 㧔Ǵ㧕
Chip removal productivity Chip evacuation comparison between One-Cut Helical and Conventional end mill on AC4B machining. عType of machining Conventional end mill
After 3 holes, chips are welded and jammed.
After 20 m, no chips are welded and jammed. Excellent chip ejection!
ǾDc
H
ǾD
1
عCutting conditon
One-Cut Helical
Material Dc D Hole depth Vc f H Helical interpolation depth/tool path rev Internal coolant
㧦AC4B 㧦ø 8 㧦ø 10 㧦30mm 㧦200m/min 㧦0,25mm/rev 㧦4,65mm :H
Improved machining method Comparison between helical milling vs drilling Improved method:by high efficient helical milling
Current method: by Drilling ٨ The tool reduction is a problem because the tool for the hole making is use of a small amount of many varieties. ٨ Time hangs in the tool exchange to make various holes.
Ô™
ø10
ø10
Tool exchange
Tool exchange
Ô˜
No tool exchange!
ø12.5
ø12.5
30হ
㧌ø10‍ޔ‏ø12.5‍ޔ‏ø15㧔3 drills㧕 㧌120m/min 㧌0.2mm/rev
ø8
ø15
ø15
30হ
Material Hole depth Internal coolant
ø8
ø10
30হ
ĚŞ 1 each hole making
Cutting conditon by Current 3 drills Tool dia. Vc f
٨ This problem is solved by doing the original developed helical milling method by using One-Cut Helical.
ø8
ø12.5
30হ
30হ
ø15
30হ
ĚŞ 1 each hole making
Cutting conditon by One-Cut Helical
㧌AC4B 㧌30mm
Tool dia.㧌ø8 AL-OCHES2080 H㧌Helical interpolation depth/tool path rev. Vc 㧌200m/min Hole dia. D㧊10mm ĎˆH㧊4.65mm Hole dia. D㧊12.5mmĎˆ H㧊8.81mm f 㧌0.25mm/rev Hole dia. D㧊15mm ĎˆH㧊10.99mm
Material 㧌AC4B Hole depth 㧌30mm Internal coolant
㧔Drilling by same cutting condition 㧕
Total machining time: 10.4 sec.
One-Cut Helical
Ô˜ Reduced total machining time 8.5 sec. 45% reduction. ‍ޓޓ‏ Ô™ Reduced the no. of use tools from 3 pcs to 1 pc. ‍ޓޓ‏
Total machining time: 18.9 sec.
‍ ؚ‏Hole size: ø10
Drilling by 3 Drills
‍ ؚ‏Hole size: ø12.5 ‍ ؚ‏Hole size: ø15
Machining time㧔sec.㧕
‍ ؚ‏Tool changing time
Applicable hole range by each end mills ‍ ؚ‏Applicable hole range by each endmills
‍ؚ‏Helical milling by ‍ޓ‏Tool dia. 8mm.
ø12 ø11.5
ø13
ø13.5
ø14
ø11 ø14.5 ø10.5 ø10
ø15
Tool dia.㧔mm㧕
ø12.5
Applicable hole range㧔mm㧕
Wide range with only one tool
22
One-Cut Helical End Mill Cutting performance
ޓԘ Helical milling Cutting condition Material Dc D Hole depth
㧦AC4B 㧦8mm 㧦10mm 㧦30mm
Vc n f Vf
㧦201m/min 㧦8,000min-1 㧦0.25mm/rev 㧦2,000mm/min
ǾDc
Helical interpolation depth/ tool path rev H: 4.65 mm. Machining time by 1hole :
H
2.2 sec.
Machining time 2.2 sec.
Internal coolant
ǾD
Result: Cutting length and VBmax عAfter 22.4m
0.200
VBmax: 0.074mm Normal wear
VBmax㧔mm㧕
0.160
0.120
Able to continue
0.080 0.074 0.040
After 22.4 m cutting length with H㧩4.65mm tool wear was normal VB max: 0.074
0.000 0
5
10 15 Cutting length㧔m㧕
20
22.4
25
Result: Cutting length and Cylindricity عCylindricity㧩㧔Dmax㧙Dmin㧕
0.050
max
Cylindricity㧔mm㧕
0.040 Cylindricity: 0.02mm Cutting length 22.4m
0.030
min
0.020
0.010
0.000
0
5
10 15 Cutting length㧔m㧕
20 22.4
25
After 22.4 m cutting length the hole cylindricity is 0.02 mm.
Result: Cutting length and Surface roughness 6.00
㧔mm㧕
Surface roughness Rz 㧔Ǵm㧕
10.0
Rz: 2.94Ǵm Cutting length 22.4m
5.00
5.0 0.0
4.00
-5.0 -10.0
3.00
0.5
1.0
1.5
2.0
2.5
3.0
2.00 1.00 0.00 0
3
0.0
5
10 15 Cutting length㧔m㧕
20 22.4
25
After 22.4 m cutting length surface roughness Rz㧩2.94Ǵm.
3.5
4.0 㧔mm㧕
ޓԙ Spot facing Machining process Starting from hole ø 31mm. tool ø 16 mm. enlarge hole ø 45 with first helical milling. Make Spot facing ø 67 mm. by second helical milling 33mm. deep. Flood coolant
Internal coolant
Helical milling
Water soluble㧦2㨪3% dilution
Coolant pressure㧦1.5MPa
Cast aluminum alloy
Enlarge hole
Spot facing
㧔AC4B㧕
㧔ø31ψø45߳㧕
㧔ø45ψø67߳㧕
Through hole
㧝
㧝
ø67 ø45 ø31
ø31 Through hole making by helical interpolation.
Tool dia. 㧔mm㧕
16
V㧔m㧛min㧕 c
200
㧔 n min -1㧕
4,000
㧔mm㧛rev㧕 f
0.25
V㧔mm㧛min㧕 f
1,000
Max. helical interpolation depth/ tool path rev:H 㧔mm㧕
13 㧔on Spot facing 10mm㧕
㧞 33
ø45
Enlarge the hole by helical interpolation.
Spot facing by helical & circular interpolations.
Power consumption and machining time UGE
Ǿ Ǿ ⽾ㅢⓣ 31 ⽾ㅢⓣടᎿᤨ Through ടᎿᤨhole Through 㧦3.03 hole㧦 M9 M9 kW
Spot ࠩࠣടᎿᤨ facing Spot 㧦1.77kW facing㧦 M9 M9
M9
Ǿ Ǿ ➅ࠅᐢߍ 45 ➅ࠅᐢߍടᎿᤨ Enlarge ടᎿᤨ Enlarge hole hole
Tool ø16 make full operation bore ø 45mm. and spot facing in 135 seconds. Through hole ø 31mm. power require 3.03 Kw. enlarge the hole at ø 45 mm. total machining time 67 seconds. Spot facing with the same tool from ø 45 to Ø 67 machining time 68 seconds.
Through hole making time 67sec
Spot facing time 68sec
Total machining time㧦 135sec
Result Y
Tool dia.㧦16mm
X
Input dia. of spot facing (d)
67㧔X㧕
67㧔Y㧕
Actual diameter (A)
66.990
66.974
Actual diameter (B)
66.993
66.982
66.992
66.986
Actual diameter (C) ǾA
Inclination (max-min)
0.019 mm 㧔66.993㧙66.974㧩0.019㧕
ǾB ǾC
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One-Cut Helical End Mill Line up ޓOne-Cut Helical End Mill
ø Ds h6
ޓޓ0 ø Dc 㧙0.02
AL- OCHE type
N
R0.5
Cat. No.
L
Dimensions㧔㨙㨙㧕 øD c
l
L
øDs
AL-OCHES2040
4
16
60
4
AL-OCHES2060
6
22
74
6
AL-OCHES2080
8
31
90
8
AL-OCHES2100
10
37
105
10
AL-OCHES2120
12
43
113
12
AL-OCHES2160
16
55
130
16
Recommended cutting conditions ޓHelical milling Aluminum alloy 㧔A5052ޔA7075㧕
Materials
øDc H
tool path dia. Helical interpolation depth/ tool path rev D㧔mm㧕 k H㧔mm㧕
Depth T㧔mm㧕
4
5㨪7
max 15
16,000
960
6
7㨪11
max 21
10,600
1,060
1
8
10㨪15
max 30
8,000
2,000
2
5
10
12㨪19
max 36
6,400
1,600
3
6.4
12
14㨪23
max 42
5,300
1,300
4
7.4
16
18㨪31
max 54
4,000
1,000
5
8.2
6
8.8
7
9.4
Cast aluminum alloy 㧔Up to 13% Si 㧕
Materials
2.6
8
9.8
9
10.2
860
10
10.6
950
11
11
7,200
1,800
12
11.3
5,700
1,400
13
11.5 11.8 12
Hole dia. D㧔mm㧕
Depth T㧔mm㧕
4
5㨪7
max 15
14,400
6
7㨪11
max 21
9,500
8
10㨪15
max 30
10
12㨪19
max 36
Tool dia. D㧔 c mm㧕
øD
Spindle speed Feed speed V f㧔mm/min㧕 n㧔min-1㧕
Hole dia. D㧔mm㧕
Tool dia. D㧔 c mm㧕
Spindle speed Feed speed n㧔min-1㧕 V f㧔mm/min㧕
12
14㨪23
max 42
4,800
1,200
14
16
18㨪31
max 54
3,600
900
15
NOTE 1㧚Tool path dia.: Dk㧩Hole dia. DTool dia. Dc. 2㧚In case of blind hole, last revolution of H reduce to 0.8-2.0mm. 3㧚In case of through hole, top of tool must come off by 1mm or more because tool has R0.5mm corner radius. 4㧚In case of requring the hole accuracy, after making a little small bore(a e=0.03mm) by helical interpolation, enlarged bore by full depth circular interpolation with 20% reduced speed and feed speed. 5㧚Use internal coolant. 6㧚Above data applys for from solid work.In case of enlarging hole from pre-hole, apply same conditions.In this case, a e should be 75% of Dc or less. also in case of machining from pre-hole and casting hole, recommend to use flood coolant,too. 7㧚 In case of lack of machine & work rigidity and also chattering, reduce speed and feed with same ratio or H.
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Recommended cutting conditions ޓShoulder cutting and Slotting Ԙ Shoulder cutting Materials
ԙ Slotting
Aluminum alloy
Aluminum alloy
㧔A5052㧕
㧔A7075㧕
ae Type of machining
ae
ap a p =1.5D c a e =0.4D c
Cast aluminum alloy (Up to 13% Si)
Materials
ap
a p =1.5D c a e =0.4D c
Aluminum alloy
㧔A5052㧕
㧔A7075㧕
ae
ae
ap
Aluminum alloy
ae
Type of machining
a p =1.5D c a e =0.4D c
Cast aluminum alloy (Up to 13% Si)
ae
ap a p =D c a e =D c
ap a p =D c a e =D c
ap a p =D c a e =D c
Tool dia.
Spindle speed Feed speed Spindle speed Feed speed Spindle speed Feed speed
Tool dia.
Spindle speed Feed speed Spindle speed Feed speed Spindle speed Feed speed
Dc 㧔mm㧕
n Vf n Vf n Vf 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕
Dc 㧔mm㧕
n Vf n Vf n Vf 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕
4
16,000
1,800
16,000
1,800
14,000
1,700
4
14,000
1,000
14,000
1,000
12,000
850
6
10,000
1,800
10,000
1,800
9,500
1,700
6
9,500
1,000
9,500
1,000
8,500
850
8
8,000
1,600
8,000
1,600
7,000
1,500
8
7,000
1,000
7,000
1,000
6,400
850
10
6,000
1,300
6,000
1,300
5,700
1,200
10
5,700
1,000
5,700
1,000
5,000
850
12
5,000
1,300
5,000
1,300
4,700
1,200
12
4,700
1,000
4,700
1,000
4,200
850
16
4,000
1,200
4,000
1,200
3,500
1,100
16
3,500
1,000
3,500
1,000
3,200
850
H.S.C. Recommended cutting conditions ޓShoulder cutting and Slotting Ԙ Shoulder cutting Materials
ԙ Slotting
Aluminum alloy
Aluminum alloy
㧔A5052㧕
㧔A7075㧕
ae
ae
ap
Type of machining
a p D c a e D c
Cast aluminum alloy (Up to 13% Si)
ap
Aluminum alloy
Aluminum alloy
㧔A5052㧕
㧔A7075㧕
ae
ae
ap a p D c a e D c
Materials
ae
Type of machining
a p D c a e D c
Cast aluminum alloy (Up to 13% Si)
ae
ap a p D c a e D c
ap a p D c a e D c
ap a p D c a e D c
Tool dia.
Spindle speed Feed speed Spindle speed Feed speed Spindle speed Feed speed
Tool dia.
Spindle speed Feed speed Spindle speed Feed speed Spindle speed Feed speed
Dc 㧔mm㧕
n Vf n Vf n Vf 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕
Dc 㧔mm㧕
n Vf n Vf n Vf 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕 㧔min-1㧕 㧔mm/min㧕
4
32,000
3,800
32,000
3,800
28,000
3,300
4
28,000
1,900
28,000
1,900
24,000
1,600
6
21,000
3,800
21,000
3,800
18,000
3,300
6
19,000
1,900
19,000
1,900
16,000
1,600
8
16,000
3,200
16,000
3,200
14,000
3,300
8
14,000
1,900
14,000
1,900
12,000
1,600
10
12,000
3,200
12,000
3,200
11,000
3,000
10
11,000
1,900
11,000
1,900
9,500
1,600
12
10,000
3,200
10,000
3,200
9,000
2,700
12
9,500
1,900
9,500
1,900
8,000
1,600
16
8,000
2,800
8,000
2,800
7,000
2,450
16
7,000
1,800
7,000
1,800
6,000
1,600
Note: 1. Use water soluble oil. 2. It is important for grasping the shank to defend and keep proper grasping length. The figures to be adjusted according to machining shape, rigidity of machine and work clamping. 3. If machine does not have enough spindle speed, recommend to reduce the feed speed to the same ratio. 4. Full slotting is not recommended. But in case of working, reduce depth of cut up to 0.2D and reduce the feed speed 30 to 60% above data.
6