Download - 100 MillingTools M

7/31/2019 100 MillingTools M

1/32

AWT 07/99 FR 1

Thread Cutting Technology

Machining Technology

Clamping Technology

Milling Technology


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AWT 07/99 FR 2



Clamping Technology

High-Tech

Die- andMold

programme

Base programm

FRANKEN Programm


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Clamping Technology

Die and mold programm:

Content

Solid carbide and indexable cutters

Market situation

Sales only with consultation

Technical know how required

High-

Tech

Die- and

Mold

programme

Base programm

FRANKEN Programm


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6/32AWT 07/99 FR 6



Clamping Technology

High-

Tech

Die- and

Mold

programme

Base programm

Base program


7/32AWT 07/99 FR 7



Clamping Technology

Solid carbide:

HSS - E

Special end mills

accord. customer

specification.

Base program


8/32AWT 07/99 FR 8



Clamping TechnologyStraight shanks DIN 1835 - DIN 6535

Plain straight shank

Straight shankwith driving flat

Straight shankwith bayonet lock

Straight threaded shank

Straight shankwith inclined driving flat

Type Bup to shank 20 one flat

over shank 20 two flats

Type HBup to shank 20 one flat

over shank 25 two flats

Type A Type HA

Type Cvalid for over 40

Type De.g. for DUBLOK collets

Type E Type HEup to shank 25

Type HEover shank 20

DIN 1835 DIN 6535


9/32AWT 07/99 FR 9



Clamping TechnologyMorse taper shanks for milling cutters

DIN 228 Type Ataper shank with internal thread

DIN 228 Type Btaper shank with driving tang

DIN 2207taper shank accordingto DIN 228 Type Awith driving flats


10/32AWT 07/99 FR 10



Clamping TechnologyISO taper shanks

DIN 2080-1 Type Ataper shank for toolsand clamping devices

DIN 69871-1 Type Ataper shank withtrapezoidal groove forautomatic tool change

DIN 69871-1 Type ADtaper shank for automatictool change, with

trapezoidal groove anddrilled hole for coolant supply

DIN 69871-1 Type Btaper shank for automatictool change, with

trapezoidal groove andcoolant supply throughthe collar


11/32AWT 07/99 FR 11



Clamping TechnologyHollow taper shanks

DIN 69893-1 Type Ahollow taper shank forautomatic tool change, withgripping and indexing slots

DIN 69893-1 Type Chollow taper shank formanual tool change

DIN 69893-2 Type Dhollow taper shank formanual tool change, with

coolant supply thoughthe collar

DIN 69893-2 Type Bhollow taper shank forautomatic tool change, with

gripping and indexing slots,and coolant supply throughthe collar


12/32AWT 07/99 FR 12



Clamping TechnologyClamping chucks

Clamping chuck for straight shanks with driving flat

according to DIN 1835 Type B and DIN 6535 Type HB

Clamping chuck for straight shanks with inclined driving flataccording to DIN 1835 Type E and DIN 6535 Type HE


13/32AWT 07/99 FR 13



Clamping Technology

Hydraulic clamping chucksfor the clamping of straight shanks

Pressure relieved position

Pressure engaged position(clamping)

Reduction collets

Hydraulic clamping chucks

acc. DIN 1835 type A and DIN 6535 type HA


14/32AWT 07/99 FR 14



Clamping Technology

Shrink-fit chucks, collet chucksfor the clamping of straight shanks


15/32AWT 07/99 FR 15



Clamping TechnologyEnd mills - Different types of cutter faces


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Clamping TechnologyFace designs

Standard designend mills and slot drillsHSS and carbideconcave face

Transition of primaryto secondary (face) toothwith an additional protectionchamfer (chamfered edges)

Transition of primaryto secondary (face) toothwith an additionalcorner radius

Radius cutter

with full face radius

Torus cutter

with corner radius andhighly concave face

Transition of primary

to secondary (face) toothwith fast-spiral end mills


17/32AWT 07/99 FR 17



Clamping TechnologyDifferent types of relief

Double plane relief

Radial relief

Concave relief

The profile is not constant!

Primary relief angle

Secondary relief angle

Rake angle

Rake angle

Measuringpoin

tofrakeangle

Measuringpoin

tofrakeangle


18/32AWT 07/99 FR 18



Clamping TechnologyTool types

Type W Type WF

Type N Type NF Type NR

Type HRType HFType H

Type WR

Th d C tti T h l


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Clamping TechnologyStandard end mills

Material of workpiecesofter harder

Surface condition after cuttingsmoother

rougher

Chipping volumeless

more

Motor power (kW)more

less

Type NF

Type NType W

Type WF

Type NR

Type H

Type HF

Type HRType WR

Th d C tti T h l


20/32AWT 07/99 FR 20



Clamping TechnologyConstructional dimensions of milling cutters

Standard catalogue types of shanks:

Plain straight shank DIN 1835 Type A

Straight shank with driving flat DIN 1835 Type BStraight threaded shank DIN 1835 Type D

cuttinglength2

2mm

cuttinglength38mm

cuttinglength56mm

cuttinglength75mm

cutti

nglength120mm

For example: End mills Type N, 20

extra short short medium long long extra long

Th d C tti T h l


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Clamping TechnologyWeb thickness in relation to tool length

Construction length:medium long

long

Construction length:extra short

short

Construction length:extra long

Thread C tting TechnologFRANKEN End mills


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Clamping Technology

FRANKEN End millsHelix angles

= Cutter diameter

= Rake angle of primary cutting edge

= Primary relief angle of primary cutting edge

= Secondary relief angle of primary cutting edge

20helix angle

30helix angle

40helix angle

45helix angle

50helix angle

60helix angle



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Clamping TechnologyMilling cutters with a constant profile

Relief-turned or relief-ground

Rake angle of primary cutting edge

Relief angle of primary cutting edge

Stroke

Thread Cutting TechnologyProfile calculation profile grinding


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Clamping Technology

Profile calculation, profile grindingand control on form cutters

START

FINISH

Customer drawing

CADSpecified contour

Grinding wheel geometry

System for NC

programme generation

NC programmeonline

NC grinding machine

grinding wheel

dressing wheel

cutter

cutter

Measuring

system

Measured

data

System for comparing

actual and specified contour

Actual contourinside the tolerance

Actual contour notinside the tolerance,

a new cycle starts

Cutter with

inspection certificate,ready for shipment



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Clamping TechnologyClimb milling - Conventional milling

Climb milling: Conventional milling:

Thread Cutting TechnologyThe vectors show the bending direction of an end


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Clamping Technology

The vectors show the bending direction of an endmill, which is cutting at different radial depths ae

Cutting direction

Climb millingConventional milling



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Clamping TechnologyBending of an end mill

Bending in feed direction

Bending in machine direction

Total bending

Conventional milling Climb milling

Machine

direc

tion

Mach

ine

direction

End mill 25

4 teeth

30 helix angle

radial cutting depth ae

No bending in

feed direction

Bendin

ginmm

Thread Cutting TechnologyKeyway cutting with slot drills


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Clamping Technology

Keyway cutting with slot drillsin one work process

3-fluted cutter: 2-fluted cutter:

Conventionalmilling

Climbmilling

Conventionalmilling

Climbmilling



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AWT 07/99 FR 29



Clamping TechnologyCutting of keyways

With one step cutting process(full size cutters)

Recommendation:2-fluted cutters

Keyway:20 P9 ( )-0,022-0,074

Cutter:

20 e8 ( )-0,040-0,073

Advantages:

Time saving, because keyway length

= cutting length

Disadvantages: Keyway walls are not perpendicular (cutter displacement)

When the cutter is worn out reduction of tool dia.

the tolerance of the keyway can no longer be achieved

cutter must be exchanged, even if the maximum tool life

hasnt been reached

reground cutters are not suitable for one step process

Cutting example:

Keyway 20 P9 x 90Milling cutter type: 2300.020 (2-flutes)Material of workpiece: 42 CrMo 4 V, Rm = 850 N/mm2

Cutting conditions: ap = 10 mm, vc = 30 m/min, n = 477 min-1

Drilling feed: fz = 0,029 mm, vf= 30 mm/minCutting feed: fz = 0,073 mm, vf= 70 mm/min

Cutting time: approx. 80 sec./keyway

With three step cutting process(under size cutters)

Recommendation:3-fluted cutters

Keyway:20 P9 ( )-0,022-0,074

Cutter:

19,7 h10 ( )-0-0,084

Advantages:

Keyway walls are perpendicular

When the cutter is worn out reduction of the tool dia.

the tolerance of the keyway can be reached by

radial resetting of the cutter the full tool life of

the cutter can be used

reground cutters can be used again

Disadvantages: more time is needed because of longer process

only possible on CNC machines

Cutting example:Keyway 20 P9 x 90Milling cutter type: 2310.0197 (3-flutes)Material of workpiece: 42 CrMo 4 V, Rm = 850 N/mm2

Cutting conditions: ap = 10 mm, vc = 30 m/min, n = 477 min-1

Drilling feed: fz = 0,029 mm, vf= 40 mm/minCutting feed: fz = 0,073 mm, vf= 105 mm/minCutting feed: fz = 0,200 mm, vf= 286 mm/min

Cutting time: approx. 85 sec./keyway

e8

19,978

19,926

19,960

19,927

P9



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Clamping TechnologyAverage analysis values of high-speed steels

S 3-3-2 ABC lll 1.3333

Chemical analysis (%)

MoC Cr V W Co

2,600,95 4,20 2,40 3,10

Short desig-nation acc.DIN 17006

FormerDINdesignation

AmericanAISIdesignation

Materialcode acc.DIN 17007

S 2-9-1 BMo 9 M1 1.3346 8,600,85 3,90 1,20 1,80

S 6-5-2 DMo 5 M2 1.3343 5,000,90 3,80 1,80 6,40

SC 6-5-2 DMo 5 h 1.3342 5,001,00 3,80 1,80 6,40

S 6-5-3 EMo 5 V 3 M3 Class 2 1.3344 4,901,30 4,10 3,00 6,30

S 9-1-2 ABC ll 1.3316 0,900,82 4,20 1,60 8,50

S 18-0-1 B 18 T1 1.3355 0,75 4,20 1,10 18,00 S 12-1-4 EV 4 T9 1.3302 1,001,25 4,30 4,00 12,50

S 12-1-2-5 ECo 5 1.3251 1,200,80 4,00 1,80 12,50 5,50

S 12-1-4-5 EV 4 Co T15 1.3202 1,001,30 4,30 4,00 12,50 5,00

S 7-4-2-5 EMo 5 Co 5 h M41 1.3246 4,001,12 4,10 1,70 6,40 4,80

S 18-1-2-5 E 18 Co 5 T4 1.3255 1,000,80 4,30 1,60 18,00 5,00

S 18-1-2-10 E 18 Co 10 T5 1.3265 1,000,75 4,30 1,60 18,00 9,50

S 6-5-2-8 1.3222 5,901,45 4,25 2,30 6,40 8,00S 6-5-3 *PM (23) (M3 Class 2) 1.3344 5,001,28 4,20 3,10 6,40

S 6-7-6-10 *PM (60) 1.3241 7,002,30 4,00 6,50 6,50 10,50

S 3-3-1-8 *PM (2017) 3,000,80 4,00 1,00 3,00 8,00

S 6-5-2-5 EMo 5 Co 5 M35 1.3243 4,900,90 4,10 1,80 6,30 4,80

S 10-4-3-10 EW 9 Co 10 M36 1.3207 3,901,25 4,10 3,50 9,50 10,50

S 2-10-1-8 M42 1.3247 9,501,08 4,00 1,20 1,50 8,00

S 6-5-3-9 *PM (30) 5,001,28 4,20 3,10 6,40 8,50

= high-speed steels especially favoured by FRANKEN*PM = powder-metallurgically

produced steel



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Clamping TechnologyAverage analysis values of carbide ISO groups

K10 94,20 0,30 5,5

ISOcarbide grade Percent inweight tungstencarbide

Percent inweightTIC/TaNbc

Percentin weightcobalt

K20 93,20 0,80 6,0

K40 87,20 0,80 12,0

K01-K10micro grain

94,00 6,0

K05-K10fine grain

94,00 6,0

K10-K30fine grain

92,50 7,5

K20-K40 90,00 10,0

P30-P40 76,50 11,50 12,0

CermetP10-P20

P20-P25 71,50 20,00 8,5

P40 77,00 12,00 11,0

K10-K30

micro grain

86,65 rest (mixed

carbides)

12,0

1,0

Averagegrain sizem

2,0

2,0

0,5

0,7

0,7

0,7

2,0 - 3,02,0 - 3,0

3,0

0,4

1900

BendingstrengthN/mm2

2000

2500

3300

3300

3500

3700

22001800

2400

4000

2100

14,8

Specificweightg/cm3

14,7

14,3

14,9

14,9

14,7

14,5

13,112,4

13,3

14,1

7,1

1750

HardnessVickersHV 30

1610

1370

2000

1850

1720

1550

13901575

1420

1730

1600

14,8

CrushingstrengthKN/mm2

14,7

14,3

14,9

14,9

14,7

14,5

13,112,4

13,3

14,1

7,1



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g gy


Clamping TechnologyCoatings

Wear protection coatingson milling tools

TiCN

MULTILAYER

TiN

MONOLAYER

Diamond

MONOLAYER

TiAlN

MULTI- orMONOLAYER

other coatings

CBN

TiAlCNCrN

Al2O3DLC

Silver-TiN etc.

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