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RF 100 Programme 2010. Customer Presentation Date: February 10, 2010. Difficulties in a milling process. Situation in a milling application. Vibration in a milling process cause: Bad work piece surface short tool life extreme high noise level high load on spindle

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RF 100 Programme 2010

Customer PresentationDate: February 10, 2010


Difficulties in a milling process
Difficulties in a milling process

Situation in a milling application

  • Vibration in a milling process cause:

  • Bad work piece surface

  • short tool life

  • extreme high noise level

  • high load on spindle

  • bad cost / efficiency relationship


Difficulties in a milling process1
Difficulties in a milling process

Target

  • creating a tool which does not vibrate

  •  high process security

  • usable in a very large RPM-range.

  •  less RPM- adjustment necessary

  • usable in a much higher Feed-Rate-Range (high performance milling)

    •  Increased metal removal rate, reduced cycle times


Difficulties in a milling process2
Difficulties in a milling process

Solution: RF 100

  • General Style / Geometry Basics:

  • different Helix angles

  • uneven pitch

  • micro edge protection

  • optimized flute profile

  • materialspecific coatings


Rf 100 high performance end mills
RF 100 High Performance End Mills

Geometry in detail (un-even helix)

  • 2 different helix angles create an un-even pitch

  • Different pitch on all cutting- levels


Rf 100 high performance end mills1
RF 100 High Performance End Mills

Geometry in detail (micro edge protection)

  • Very stable cutting edge through chamfer and lip-correction

  • Advantages:

  • Increased tool-life

    because of reduced wear

  • Increased feed-rates

  • because of more edge stability

  • Perfect suitable for

    ramp-milling or plunging


Rf 100 high performance end mills2
RF 100 High Performance End Mills

Geometry in detail (flat roughing profile)

  • optimized roughing profile with new 3 radii design

  • Advantages

  • Increased tool life

    because of less wear

  • Increased Feed-rate

    because of more corner stability

  • No additional finishing necessary;

    Work piece quality is Ra = 2-3 µm

3-Radien-Design


Rf 100 high performance end mills3
RF 100 High Performance End Mills

Advantages (summarisation)

  • Reduced vibrations allow:

  • higher feed rates

  • longer tool life

  • better surface quality

  • roughing, finishing and

  • slotting with 1 tool

“High quantities” =

Large batch sizes

“Low quantities” =

Small batch sizes


Rf 100 high performance end mills4
RF 100 High Performance End Mills

deduction of tools in a milling application

Standard

RF 100

+

+

=

+

  • Argument: roughing, slotting & finishing = 1 tool !


Rf 100 high performance end mills5
RF 100 High Performance End Mills

2 Basic Geometries

  • with plain cutting edge

  • (Type U, A, F, A, Ti, VA, H)

  • with flat roughing profile

  • (Type U/HF, VA/NF, A/WF)


Rf 100 high performance end mills6
RF 100 High Performance End Mills

Advantages / Disadvantages


Rf 100 high performance end mills7
RF 100 High Performance End Mills

Performance in comparison

  • RF 100 U (#3732) can run at

    the highest possible feed rate.

  • At the same feed-rate, the

    Rougher RF 100 U/HF (#3508)

    requires a much lower

    power, stability, torque, etc.

     The RF 100 U/HF closes the gap

    between the RF 100 U‘s (5535)

    fine pitch Roughers (#5504).


Rf 100 high performance end mills8
RF 100 High Performance End Mills

„U“ or „U/HF“ – Which is the “better” tool?

  • Vc – Values for both tools are identical.

  • Vf – Values of the Rougher are about 30% lower.

  • RF 100 U with ap = 1,0 x d

  • RF 100 U/HF with ap = 1,5 – 2,0 x d

  • The Argument for the RF 100 U/HF the metal removal rate (Q).

    This means RF 100 U/HF is running with a lower feed rate,

    but with a much higher depth of cut (ae).

     Feed-Rate „U/HF“ is lower; metal-removal-rate (Q) is higher.


Rf 100 high performance end mills9
RF 100 High Performance End Mills

RF 100 Application at “field” customer

  • Tool: RF 100 U 16 mm, # 5735

  • Machine: SK40, 12 KW and max. 8.000 RPM

  • Application & Material: C45 - Roughing 1 x d (ap = 1 x d / ae = 0,5 x d)

  • Cutting data (see Cat.): Vc = 230 m/min. – fz = 0,11 mm/z

  • Possible problems:

  • Machine stops

  • tool is pulled out of the tool holder

  • chips cannot be removed

  • Possible Solution: (tool change)

  • RF 100 U (#3732)  RF 100 U/HF (#3508) with roughing profile

  • Reduction of fz (mm/z) and increasing ap from 1 x d on 2 x d

  • Metal Removal Rate (Q) increases


Rf 100 high performance end mills10
RF 100 High Performance End Mills

What to do on an existing process?

  • in the first try (step) a RF 100 with plain cutting edges should

  • be tried (e.g. RF 100 U #5535)

  • on “unstable” machines, bad coolant, long reach, etc. a RF 100

  • with roughing profile should be used. (e.g. RF 100 U/HF)

  • on existing customers, who are using a RF 100 U

    successfully, the new Rougher will not work “better”!

  • the RF 100 U/HF is also interesting for all new customers,

    also for those who are using HSS-PM Roughing End Mills.


Rf 100 programme
RF 100 Programme

RF 100 U (pages 10-13)

  • Suitable for Slotting, Roughing and Finishing in

  • all materials from 850 N/mm² up to 48 HRC

  • Recessed neck on all tools incl. SL-brand

  • (see footnote in our catalogue)

  • new medium length 3 x d for HPC-milling

  • new long reach tools for die & mould making

  • applications


Rf 100 programme1
RF 100 Programme

RF 100 U with corner radius (pages 14-15)

  • Suitable for Slotting, Roughing and Finishing in all

  • materials from 850 N/mm² up to 48 HRC

  • Available in the most popular corner radius sizes

  • and fully corrected corner radius (NAS-style)

  • recessed neck for best reach in die & mould

  • making applications

  • with „margin“ to increase

  • tool-life and work piece quality.


Rf 100 programme2
RF 100 Programme

RF 100 3-fluted (pages 16-17)

  • larger flutes for applications with chip

  • removal problems

  • especially on diameters smaller than 8 mm

  • in order to guarantee a secure process

  • 7° Rake angle (4-Flute is 4°) for universal

  • applications in various materials

  • Tolerance e8 (undersize) for milling key-slots

  • in one pass acc. to ISO (size P9)


Rf 100 programme3
RF 100 Programme

RF 100 U/HF (pages 18-19)

  • lower cutting forces and power consumption

    because of new roughing profile

  • RF 100 U/HF suitable for unstable conditions,

    low horsepower machines, bad coolant, long

    reach tools holders, etc.

  • feed-rate 30% lower compared to RF 100 U

  • in general usable with higher depth of cut (ap)

    and a higher metal removal rate (Q)


Rf 100 programme4
RF 100 Programme

RF 100 F (pages 20-21)

  • suitable for AlSi and especially soft, gluey long

  • chipping steels and materials up to 850 N/mm²

  • because of high rake angle of 9°

  • current name „INOX“ is deleted

  • For stainless steel in future RF 100 VA

  • chip-evacuation problems in Stainless steel

  • RF 100 F with internal coolant (#3366)

  • RF 100 F with internal coolant (#3366) as an

  • alternative suitable in aluminium


Rf 100 programme5
RF 100 Programme

RF 100 VA (pages 22-23)

  • Suitable for Stainless steels 1.4301 - 1.4405 –

  • 1.4571(ANSI or SUS 303, 304 and 316

  • Suitable for Roughing, Finishing and Slotting

  • nano A- coating

  • New flute profile for optimized chip-removal

  • Round profile lead to less bending of the chips

  • and consequently less heat in the process


Rf 100 programme6
RF 100 Programme

Customer Test RF 100 VA

Machine :  Haas  22,5 KW  Maximum RPM 7.500 1/min SK 50

Material : X20Cr13(1.4028)

Turbine blade ( various sizes )

Coolant : Cold Air Jet (Franken-Emuge)End Mill : 3803     Dia. = 20 mm

Vf = 1.400 mm/min  ( fz = 0,093 mm ) n = 3800 1/min ae = 9 mm ap = up to 30 mm tool life = ~  54m


Rf 100 programme7
RF 100 Programme

Customer Test RF 100 VA

(source: stainless steel catalogue 09/2009)


Rf 100 programme8
RF 100 Programme

RF 100 VA/NF (pages 24-25)

  • lower cutting forces and power consumption

    because of new roughing profile

  • RF 100 VA/NF suitable for unstable

    conditions, low horsepower machines,

    bad coolant, long reach tools holders, etc.

  • feed-rate 30% lower compared to RF 100 U, F

  • in general usable with higher depth of cut (ap)

    and a higher metal removal rate (Q)


Rf 100 programme9
RF 100 Programme

RF 100 A (pages 26-27)

  • for finishing operations in aluminium up to

  • 0,25 x d width of cut (ae)

  • wrought aluminium (aircraft industry) could

  • cause chip-removal problems

  • high performance in AlSi > 3 % (automotive)

  • For slotting high pressure coolant is required

  • to guarantee chip removal

  • on chip-removal problems GA 200 A or

  • RF 100 A/WF should be used


Rf 100 programme10
RF 100 Programme

RF 100 A/WF (pages 28-29)

  • lower cutting forces and power consumption

  • RF 100 A/WF suitable for unstable

    conditions, low horsepower machines,

    bad coolant, long reach tools holders, etc.

  • feed-rate 30% lower compared to RF 100 U

  • in general usable with higher depth of cut (ap)

    and a higher metal removal rate (Q)

  • also working with lower Vc (cutting speed)

    (e.g. 300 m/min. compared to 900 m/min.)


Rf 100 programme11
RF 100 Programme

RF 100 H (pages 30-31)

  • Finishing in hardened steel (up to 60 HRC) and

  • roughing up to ap = 1 x d ( up to 54 HRC)

  • Extra core stability suitable for slotting ap = 1 x d

  • and finishing up to 2,5 x d

  • Negative rake angle for HPC-milling with

  • increased tool life.

  • Suitable for HPC milling (“Trochoid”) of key slots

  • in materials up to 60 HRC and bigger.

  • Extra core stability for less deflection


Rf 100 programme12
RF 100 Programme

Customer Test RF 100 H

Machine :  Taimac MCFV 1060  HSK63  Max RPM 18.000 1/min

Material : 1.2343 52 HRC

Coolant : dry

Tool : # 3896     Dia. = 16 mm

Vf = 636 mm/min  ( fz = 0,08 mm ) n = 1990 1/min ( Vc = 100 m/min ) ae = 1 mm ap = 16,5 mm tool life = 60-70m


Rf 100 programme13
RF 100 Programme

RF 100 Ti (pages 32-34)

  • Suitable for Roughing, Slotting, Finishing in

  • Titanium Alloys (TiAl6v4 - 1.200 N/mm²)

  • Especially designed for Slot Milling with

  • cutting depths of up to 2 x d in one pass.

  • Available only with fully corrected corner radius

  • to aircraft industry’s demands (NAS style).

  • new flute profile for best chip evacuation

  • 3-facette + margin design for best tool-life

  • and highest surface qualities


Rf 100 programme14
RF 100 Programme

Customer Test RF 100 Ti

  • No vibration = very high surface quality (Ra 0,2 – 0,4 µm)

  • No additional finishing operation necessary


Rf 100 programme15
RF 100 Programme

RF 100 S/F (pages 35-36)

  • 6-Fluter with 3 different helix angles

  • suitable for all materials up to 52 HRC

  • (incl. AlSi and CrNi- alloys)

  • Finishing and Semi-Roughing with up to 0,3 x d width of cut (ae)

  • with HPC-strategy (“Trochoid”) also suitable for slotting with full depth of cut

  • Less bending and increased stability


Rf 100 programme16
RF 100 Programme

RF 100 S/F (pages 35-36)

  • 5-Fluter with un-even flute spacing

  • suitable for all materials up to 52 HRC

  • (incl. AlSi and CrNi- alloys)

  • Finishing and Semi-Roughing with up to

  • 0,25 x d width of cut (ae)

  • with HPC-strategy (“Trochoid”) also suitable for slotting with full depth of cut (ap = 3 x d)

  • Less bending and increased stability


Rf 100 programme17
RF 100 Programme

Customer Test RF 100 S/F


Rf 100 programme18
RF 100 Programme

Diameter and Length

  • Complete programme:

  • Diameter-Range 3 – 25 mm

  • With HA-shank (plain) and HB (flatted)

  • With recessed neck on all RFs

  • Short and long DIN- length

  • Medium and extra long length

  • Long and extra long reach style


Rf 100 programme19
RF 100 Programme

Conclusion

  • Do we have a solution for all work-piece materials?

  •  Yes, RF 100 Types U, F, A, Ti, H, VA, S/F

  • 2. Do we have a solution for unstable conditions and machines?

  •  Yes, RF 100 Types U/HF, VA/NF, A/WF

  • Do we have a full offering of diameters, length and styles?

  •  Yes, RF 100 complete programme


Rf 100 high performance end mills11
RF 100 High Performance End Mills

RF 100 – the highest performance!

  • We deliver the prove:

  • “Request your free

  • trial end mill!*”

  • Please contact our sales-representative

  • or your Guhring-Partner

    • * Participation conditions:

    • We will provide each customer with one trial end mill. Type and dimensions from our standard

    • RF 100 program as requested by the customer. The trial end mill is delivered personally by our

    • representative. The test results are documented in a Guhring test report and remain available

    • to Guhring for further use without restriction. Offer valid until 31.0X.2010.


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