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RF 100 Programme 2010

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

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  1. RF 100 Programme 2010 Customer PresentationDate: February 10, 2010

  2. 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

  3. 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

  4. 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

  5. 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

  6. 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

  7. 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

  8. 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

  9. RF 100 High Performance End Mills deduction of tools in a milling application Standard RF 100 + + = + • Argument: roughing, slotting & finishing = 1 tool !

  10. 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)

  11. RF 100 High Performance End Mills Advantages / Disadvantages

  12. 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).

  13. 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.

  14. 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

  15. 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.

  16. 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

  17. 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.

  18. 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)

  19. 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)

  20. 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

  21. 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

  22. 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

  23. RF 100 Programme Customer Test RF 100 VA (source: stainless steel catalogue 09/2009)

  24. 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)

  25. 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

  26. 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.)

  27. 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

  28. 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

  29. 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

  30. 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

  31. 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

  32. 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

  33. RF 100 Programme Customer Test RF 100 S/F

  34. 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

  35. 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

  36. 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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