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High Speed Aluminum Machining

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High speed aluminum machining

TaeguTec is launching a new line of milling cutters designed for a completely new operational range of aluminum machining-the CHASEALU family of products. Our new line with its expanded insert range is engineered to provide optimum machining results on all aluminum workpieces in general purpose applications. Perfectly adapted for the mould & die as well as aerospace industries, the CHASEALU range of inserts include multiple corner radii enabling the end user more flexibility whilst the V-shaped bottom, securely fitted into either the end-mill or face-mill, guarantee stable machining performance.The screw clamp system delivers strong compression force ensuring secured seating within the pocket. The CHASEALU line and inserts assure excellent results with outstanding productivity in demanding applications such as high helical ramping, straight ramping and step milling.

Exceptional productivity for aluminum and non-ferrous material machining Can be applied to rough and finish machining Available in various corner radii (R0.4mm to R5.0mm) Secure, stable and unique “V” bottom insert design No movement during high ramp machining

FEATURESFEATURES

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FeaturesInsert

Body

Helical cutting edgeand high positiverake angle.

Polishedrake face

Fully groundperiphery

Higher relief anglefor high rampingcapability

V-shapedbottom forrigid clamping

Wiper face

Various Corner Radii

2 face radialcontact for precise90 degreemachining.

Coolant direct tocutting edge.

Simplifed screw clampingdesign for improvedinsert seating

V-shaped pocketenables stablehigh speedmachining

Wide axialsupport forsuperior surfacefinish. Centrifugal

Force

CounterForce

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FE Model Analysis

Given Cutting Condition- Feed 0.15 mm/tooth , RPM 20000, Depth of cut 5mm , Width of cut 10 mm , Down milling

Tool: TE90XE 232-W32-16Insert : XECT 160508R-AL

- V shaped design General type

Insert movement(ramping down cutting)

Stress of Screw

Tool: TE90XE 232-W32-16Insert : XECT 160508R-AL

Surface Roughness Test (Average roughness, Ra)

- Material: Aluminum alloy, RPM 6000, Rd=25mm, Dry, All inserts clamped

XECT 160508R-ALCompetitor ACompetitor B

2.5

2

1.5

1

0.5

0

㎛

fz0.1 0.2 0.3

Ap=1.5mm2

1.81.61.41.2

10.80.60.40.2

0

㎛

fz0.1 0.2 0.3

Ap=8.0mm

➟Cutting force ➟Cutting force10.5㎛3.0㎛

100% 120%

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Target

Safety guidance

- General application – Multi purpose milling

- Where productivity needs to be increased while maintaining accurate machining and high surface quality.- Roughing and finishing with one tool- Reducing tool numbers in the machine magazine by replacing solid carbide end mills for finishing operation. - Components which needs high precision such as aerospace frame part.

1. Use only original inserts and cutters including components.2. Insert pocket must be cleaned before clamping insert.3. Clamp torque of screw: 4.5Nm (46 kgf.cm, 40 in.lbs.)4. For safety reasons, it is recommended to use a new screw after every insert change.5. Since maximum RPM values were determined based on burst test, using RPM beyond maximum values may cause insert breakage, machine damage and personal injury. 6. Because XECT insert has sharp cutting edge, always wear gloves for protection from injury when handling.

Straight ramping

Pocket milling

Shouldering

Slotting Profiling

Helical ramping

Face milling

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t

r

d1

dap

a

t

r

d1

dap

a

t

r

d1

dap

a

Designation Dimension (mm) Grade Applicationd d1 t a r ap K10 End Mill & Cutter

XECT 160504R-AL 22.24 11.23 5.9 1.3 0.4 16

TE90XE TFM90XE

XECT 160508R-AL 22.24 11.23 5.9 1 0.8 16 XECT 160512R-AL 21.74 11.23 5.8 1 1.2 15.5 XECT 160516R-AL 21.22 11.23 5.75 1 1.6 15 XECT 160520R-AL 20.78 11.23 5.75 1 2 14.5 XECT 160530R-AL 19.48 11.23 5.6 1 3 14 XECT 160532R-AL 19.24 11.23 5.6 1 3.2 14 XECT 160540R-AL 18.4 11.23 5.5 1.2 4 13 XECT 160550R-AL 18.35 11.23 5.4 0.4 5 13

XECT 16Insert

TE90XE --16End mill type

Ø dØ D

lL•κ= 90°

Designation Insert Dimension (mm) MaxRPMD d L l

TE90XE 225-25-16

XECT 1605 R-AL

2 25 25 125 55 38,000 TE90XE 225-25-16-L170 2 25 25 170 70 38,000 TE90XE 232-32-16 2 32 32 150 55 34,000 TE90XE 232-32-16-L200 2 32 32 200 80 34,000 TE90XE 332-32-16 3 32 32 150 55 34,000 TE90XE 332-32-16-L200 3 32 32 200 80 34,000 TE90XE 340-32-16 3 40 32 170 55 30,000 TE90XE 340-32-16-L250 3 40 32 250 55 30,000• Coolant through type • Cutter body for 'XECT 16' insert with corner radius more than 3.2 mm should be modified according to body "R"=insert "R"-0.3 mm

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TE90XE -M-16Modular type

TFM90XE -R-16Face mill type

•κ= 90°

Designation Insert Dimension (mm) MaxRPMD D1 L M

TE90XE 225-M12-16

XECT 1605 R-AL

2 25 21 43 12 38,000 TE90XE 232-M16-16 2 32 29 43 16 34,000 TE90XE 332-M16-16 3 32 29 43 16 34,000 TE90XE 340-M16-16 3 40 29 43 16 30,000• Coolant through type • Cutter body for 'XECT 16' insert with corner radius more than 3.2 mm should be modified according to body "R"=insert "R"-0.3 mm

Ø D

L

MØ

D1

Ø d

Ø D

ap

H90°

90°

•κ= 90°

Designation Insert Dimension (mm) MaxRPM

Weight(Kg) Mounting BoltD d H

TFM90XE 340-16R-16

XECT 1605□□R-AL

3 40 16 50 30,000 0.23 SH M8 x 1.25 x 35-CTFM90XE 450-22R-16 4 50 22 50 27,000 0.34 SH M10 x 1.5 x 30-CTFM90XE 563-22R-16 5 63 22 50 24,000 0.54 SH M10 x 1.5 x 30-CTFM90XE 580-27R-16 5 80 27 50 21,000 0.87 LH M12 x 1.75 x 30-CTFM90XE 6100-32R-16 6 100 32 63 19,000 1.55 SH M16 x 2 x 35-CTFM90XE 7125-40R-16 7 125 40 63 17,000 2.533 SH M20 x 2.5 x 40-C

• Coolant through type• Cutter body for 'XECT 16' insert with corner radius more than 3.2 mm should be modified according to body "R"=insert "R"-0.3 mm

ComponentsScrew Wrench

TS 40085I/HG (D25) T-T15TS 40093I/HG (D32-)

Ø d

Ø D

ap

H90°

90°

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Ramping Data

XECT 16 (0.4R-1.2R)Cutter Dia.(D1)

Straight Ramp Down Helical Ramp Down Step DownMax. Ramp (Aº) Max. ap (mm) Min. Length (L) Min. Dia. Max. Dia. Max. Pitch/Rev. Max. ap

Ø25 22 16 40 29.1 4.4 4.250 26.9 4.2

Ø32 16.5 16 54 43.1 8.8 464 25.3 4

Ø40 11.5 16 79 59.1 10.4 480 21.7 4

Ø50 9.5 16 96 79.1 13.0 4100 22.3 4

Ø63 7 16 130 105.1 13.8 4126 20.6 4

Ø80 5 16 183 139.1 13.8 4160 18.7 4

Ø100 3.5 16 262 179.1 12.9 4200 16.3 4

Ø125 2.5 16 367 229.1 12.1 4250 14.6 4

XECT 16 (1.6R-2.0R)Cutter Dia.(D1)

Straight Ramp Down Helical Ramp Down Step DownMax. Ramp (Aº) Max. ap (mm) Min. Length (L) Min. Dia. Max. Dia. Max. Pitch/Rev. Max. ap

Ø25 22 15.5 38 29.1 4.4 3.750 26.9 3.7

Ø32 16 15.5 54 43.1 8.5 3.564 24.5 3.5

Ø40 11 15.5 80 59.1 9.9 3.580 20.7 3.5

Ø50 9 15.5 98 79.1 12.3 3.5100 21.1 3.5

Ø63 6.5 15.5 136 105.1 12.8 3.5126 19.1 3.5

Ø80 4.5 15.5 197 139.1 12.4 3.5160 16.8 3.5

Ø100 3 15.5 296 179.1 11.1 3.5200 14.0 3.5

Ø125 2 15.5 444 229.1 9.7 3.5250 11.6 3.5

Straight ramping

Max. Ramp 'A'Max. ap

øD1L

Step milling

Step Max. ap

Helical ramping

Pitch

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Recommended Cutting ConditionsMaterial HB Speed (m/min) Best grade Feed (mm/tooth)

Aluminum wrought alloy

Not cureable 60 300-5000 K10 0.15-0.35Cured 100 200-2000 K10 0.1-0.25

Aluminum-cast,alloyed

<=12% Si Not cureable 75 200-2000 K10 0.15-0.3Cured 90 200-1500 K10 0.1-0.25

>12% Si High temp. 130 200-1000 K10 0.07-0.15

Copper alloys>1% Pb Free cutting 110 200-800 K10 0.07-0.15

Brass 90 300-1000 K10 0.1-0.15Electrolitic copper 100 300-800 K10 0.1-0.15

Non-metallicDuroplastics, fiber plastics - 100-500 K10 0.1-0.15Hard rubber - 100-300 K10 0.1-0.15

XECT 16 (3.0R-3.2R)Cutter Dia.(D1) Straight Ramp Down Helical Ramp Down Step Down

Max. Ramp (Aº) Max. ap (mm) Min. Length (L) Min. Dia. Max. Dia. Max. Pitch/Rev. Max. apØ25 21 14.5 38 29.1 4.2 2.5

50 25.6 2.5Ø32 15 14.5 54 43.1 7.9 3

64 22.9 3Ø40 10 14.5 82 59.1 9.0 3

80 18.8 3Ø50 8 14.5 103 79.1 10.9 3

100 18.7 3Ø63 6 14.5 138 105.1 11.8 3

126 17.7 3Ø80 4 14.5 207 139.1 11.0 3

160 14.9 3Ø100 2.5 14.5 332 179.1 9.2 3

200 11.6 3Ø125 1.5 14.5 554 229.1 7.3 3

250 8.7 3

XECT 16 (4.0R-5.0R)Cutter Dia.(D1) Straight Ramp Down Helical Ramp Down Step Down

Max. Ramp (Aº) Max. ap (mm) Min. Length (L) Min. Dia. Max. Dia. Max. Pitch/Rev. Max. apØ25 18.5 13.5 40 29.1 3.7 2.3

50 22.3 2.3Ø32 13.5 13.5 56 43.1 7.1 2.5

64 20.5 2.5Ø40 8.5 13.5 90 59.1 7.6 2.5

80 15.9 2.5Ø50 7 13.5 110 79.1 9.5 2.5

100 16.4 2.5Ø63 5.5 13.5 140 105.1 10.8 2.5

126 16.2 2.5Ø80 3.5 13.5 221 139.1 9.6 2.5

160 13.1 2.5Ø100 2.5 13.5 309 179.1 9.2 2.5

200 11.6 2.5Ø125 1.5 13.5 516 229.1 7.3 2.5

250 8.7 2.5