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Tools for aluminium machining

The best for aluminium machining

2

1999

Aluminium - a material that has a future

Aluminium in the automobile

2009(Prognosis EAA)

[ mill

. ton

s]

Particularly in the field of transportengineering massive application oflight weight materials representsthe order of the day. The goal ofsaving fuel and other energy formscan mainly be achieved through thereduction of vehicle weights.Apart from various syntheticmaterials, the classical light metalaluminium offers the bestprerequisites for reaching thisobjective.In other application fields, too, itsnumerous favourable propertiesmake aluminium an appreciatedconstruction material for engineers.

Trends in the field of machining

Innovative machining strategies arecharacterised by maximum cuttingspeeds and feed rates in order toobtain the highest possible metalremoval rates.Refraining from massive use ofcooling lubricant represents animportantdemand with reference tothe environmental impact.Process safety and an increase inproductivity are the prerequisitesfor a favourable market positionand thus competitiveness.The machining properties ofaluminium are perfectly suitable forputting modern machiningconcepts into practice.

Aluminium

HPC – High Performance Cutting

conventional

Mac

hini

ng ti

me

[in h

]

HPCmachining

Time saving withHPC machining

Prerequisites forHPC machining

� HSC spindle(> 25,000 rev./min)

� high feed rates(> 40 m/min)

� high acceleration(> 2.5 – 3.0 m/sec)

� fast CNC controls(processing speed < 3.0 ms)

� balanced tools

� adequate cutting materials

machine down timesroughingfinishing

Sou

rce:

Hei

delb

erge

r Dru

ck

3

5

4 - 53 - 53 - 4

3 - 41 - 22 - 3

32

32 - 3

2222

2 - 3

pure

Al

Al 99,9

Al MnAl Mg

Al Mg Mn

Al Mg Simachining alloy stock

Al Cu MgAl Cu Si MgAl Zn Mg Cu

G - Al SiG - Al Si MgG - Al Si CuG - Al Mg

G - Al Mg SiG - Al Cu Ti

G - Al Si Cu Mg Ni

Group Alloy type

It depends on the type of alloy whether materials are easy to machine or not.As far as machinability is concerned you can find any degree of difficulty, ranging from the easily machinedalloy stocks to the diffult to machine pure aluminium.

Relative machinability

mal

leab

le a

lum

iniu

m a

lloys

non

hard

ened

hard

ened

cast

alu

min

ium

allo

ys

Machinability can be defined as the degree of difficulty that a material creates when being machined. In order toassess the machinability of a material basically 4 parameters have to be taken into consideration:

��cutting force��tool life

��surface quality��chip formation

1 - very good machinability5 - bad machinability

Relative machinability

Machinability of aluminium alloys

4

1. Cutting force

Aluminium requires only approx. 30 % of the cutting force necessary forsteel materials. The influence of the material on the cutting force is expressedthrough the special cutting force Ks1.1 . The rake angle of the cutting edge isof particular interest regarding the cutting force. Increasing the rake angleby one degree the cutting force is reduced by ~1.5%.

Important characteristics of PLANSEE TIZIT inserts:

��rake angle > 25°��sharp, uniform cutting edge��extra-smooth rake face

2. Tool life

The time the cutting edge can be used until it is worn out. In the field ofaluminium machining this criterion is determined by three wear forms:

cutting speed Vc [m/min]

Alloys

too

l lif

e t [

min

]

cutting material:HM-K10

flank wearcrater wear built up edges andadhesion to thecutting edge

Reasons for wear:

��thermal and mechanical stress��diffusion processes, friction��abrasive alloy elements��tendency to stick��treatment state of the alloy


��extremely wear resistant hard metal grades��optimised coating��extra-smooth rake face

Machinability of aluminium alloys

Sou

rce:

WZ

L A

ache

n

5

3. Surface finish

With regard to surface finish you can distinguish between kinematicroughness, surface roughness and roughness caused by disturbances. Thekinematic roughness is a function of the relative movement between tooland work piece and the size of the corner radius.The surface roughness is dependent upon the properties of the alloy, thecutting data, geometry, cutting material and the surface quality of the rakeface. Disturbances, e.g. lack of stability of the machining systems, result insurface defects such as chatter marks.


��extra-smooth rake face��optimised micro-geometry of the cutting edge��fine grain substrates

4. Chip formation

Badly formed chips disturb the production process considerably. They interferewith both the work piece and the machine, and are difficult to remove themfrom the machining environment. Precisely machined surfaces showscratches; the quality of the pieces is reduced.


��aluminium specific chip grooves��reduced friction between chip and rake face

unfavourable

favourable

��adapted rake and clearance angles��controlled chip formation

��sharp, uniform cutting edges��smooth rake faces

��disturbance free chip flow (claws etc.)��large chip pockets��HSC suitable

Demands on tooling systems suitable for aluminium machining

cut edgeroughness

6

PCD

cutting materials suitable for aluminium machining

CBN

toughness

hea

t re

sist

ance

an

d t

her

mal

sta

bili

ty

oxideceramics

nitrideceramics

whisker reinforcedceramics

hard metalson WC basis

powder metallurgical HSS, coated

HSS

sub-micron gradehard metals

coatedhard metals

coatedcermets

cermets

Overview

Cutting materials suitable foraluminium machining

7

Sm 80

H 216 T / H 10 T(K10 - K15)

TSM 10 (K10)

TSM 30 (K20 - K30)

AMZ (K10)

PKD

TSM 20 (K15 - K20)

PLANSEE TIZIT grades

Coating layer system:CVD Ti(C+N) TiN

Coating thickness:5 µm

Micro-hardness of the coating:HV0,05 2500

Powder metallurgically produced HSS withCVD carbonitride coating.For niche applications in the fields of turning andmilling when highest toughness is required.Suitable only for low and medium cutting speeds.

Due to its regular structure the fine grainsubstrate guarantees high cutting edge stability.Universal grades!

High wear resistance through fineWC grains and low CO content.First choice for solid carbide tools.

Good wear resistance and very good toughness.Fine WC grain and large CO content.First choice for extremely stressed solidcarbide milling tools.

Substrate with extremely hard PVDcoating containing Ti Al N - Al2O3.Reduces wear and tendency to stick.First choice for high cutting speeds andalloys with tendency to stick.

Polycrystalline diamond (PCD segmentbrazed onto a supporting insert).First choice with abrasive Al-Si-alloys,(>18% Si) for polish turning andindustrial scale manufacturing.

Hardness:HV 1630

Grain size:1 µm

CO content:6 %

Hardness:HV 1850

Grain size:0.7 µm

CO content:6 %

Hardness:HV 1550

Grain size:0.7 µm

CO content:10 %

Hardness:HV ~10.000

Grain size:~10 µm

High wear resistance and good toughnessthrough fine WC grain and medium CO content.For special applications with solid carbidetools and certain insert tools.

Hardness:HV 1720

Grain size:0.7 µm

CO content:7.5 %

Coating layer system:PVD / Ti Al N

Coating thickness:3 µm

Micro-hardness of the coating:HV0,05 3600

8

Every aluminium alloy has special demands on an indexable insert.

REM photo: rake face with “microfinish“ the indexable insert with the “P “

Problem:

� Chip particles get stuck in thecutting edge area

� Due to the tendency to stick the timethe tool can be used is decreased

� Not everything that is desired in the field ofsurface quality can be put into practice

Solution:

� The shining surface keeps thecutting edge free of chip particles

� Tool life and wear are optimised� The surface quality of the finished product

meets highest demands

Microfinish

“Microfinish“ is synonymous with a high polish surface finish and therefore represents the logical continuation ofthe advanced PLANSEE TIZIT aluminium line.Indexable inserts with “microfinish“ are perfectly suitable for the extremely high demands in aluminium machining.The indexable insert with the “P “ for the crucial plus in performance.

REM photo: rake face without “microfinish“ chip particles “stuck“ on the rake face

9

f / ap / vc

�

�

�

�

�

Chip formation

Factors influencing chip formation

The chip groove design is of decisive importance. In order to obtain an optimum machining result, chip grooveswhich are adapted to the alloy type or machinability group have to be applied.

Alloy:soft malleable aluminiumalloys(e.g. AlMn, AlMg)

Parts:extrusion parts

Machining methods:turning, reboring

Chip groove -23

� static and dynamic rigidity

Work piece material Machine

Cutting material Cooling

Cutting data Chip control

friction on therake face

� high volume coolant� minimum quantity lubrication� dry machining

� cutting edge geometry� chip groove

alloystype of structuretreatment state

f [mm/rev]

10

Chip grooves

Chip groove -25

Chipgroove -27

Alloy:cast and malleable aluminiumalloys, also with low Sicontent(e.g. G-AlSi2, AlMgSi)

Parts:cast and forged parts

Machining methods:turning, copy turning

Alloy:cast and malleable aluminiumalloys

Parts:cast parts, extrusion androlled parts

Machining methods:turning, reboring(same type of geometry alsofor milling, drilling, parting,grooving and thread cutting!)

f [mm/rev]

f [mm/rev]

11

Competence in aluminium machining

12

R

R R

R R

R

R

R R

R R

R

R R

r

R

R R

R R

R

R

R R

AM

ZH

10

TH

216

TCCGT 060202FN-23PCCGT 060202FN-25PCCGT 060202FN-27CCGT 060204FN-23CCGT 060204FN-23PCCGT 060204FN-25PCCGT 060204FN-27CCGT 09T302FN-25PCCGT 09T302FN-27CCGT 09T304FN-23CCGT 09T304FN-23PCCGT 09T304FN-25PCCGT 09T304FN-27CCGT 09T308FN-23PCCGT 09T308FN-25PCCGT 09T308FN-27

Turning

Maxilock S tooling system

Insert delivery program

The positive screw clamping guarantees a safeconnection of the insert with the tool holder. Chipevacuation is not hindered by obstructive clampingelements. Due to the neutral insert position theeffectively available rake angle is identical with therake angle of the insert.

Program see special catalogue“Tool holders for turning and boring“(No. 90)

Type,ordering descriptionIndexable inserts

= coated hard metal= uncoated hard metal

R= standard stockr= limited stock or upon request

13

AM

ZH

10

TH

216

T

R

R

R R

R R

R R

R R

R

R R

R R

R

R

R R

R R

R

R R

R

R R

R R

R

R R

R R

CCGT 120402FN-25PCCGT 120402FN-27CCGT 120404FN-25PCCGT 120404FN-27CCGT 120408FN-25PCCGT 120408FN-27CNGM 190612FN-27

DCGT 070202FN-25PDCGT 070202FN-27DCGT 070204FN-23DCGT 070204FN-23PDCGT 070204FN-25PDCGT 070204FN-27DCGT 11T302FN-25PDCGT 11T302FN-27DCGT 11T304FN-23PDCGT 11T304FN-25PDCGT 11T304FN-27DCGT 11T308FN-23PDCGT 11T308FN-25PDCGT 11T308FN-27




14

TCGT 110204FN-27TCGT 16T302FN-27TCGT 16T304FN-27TCGT 16T308EN-27

R

R R

R R

R

AM

ZH

10

TH

216

T

R

R

R

R R

R R

R

R

R

R

RCGT 0602MOFN-27RCGT 0803MOFN-27RCGT 1003MOFN-27RCGT 1204MOFN-27

SCGT 09T304FN-27SCGT 09T308FN-27SCGT 09T308FN-27SCGT 120408FN-25PSCGT 120408FN-27



Turning


15

VCGT 110302FN-25PVCGT 110302FN-27VCGT 110304FN-25PVCGT 110304FN-27VCGT 110308FN-27VCGT 160404FN-25PVCGT 160404FN-27VCGT 160408FN-25PVCGT 160408FN-27VCGT 160412FN-25VCGT 160412FN-25PVCGT 160412FN-27VCGT 220530EN-27VCGT 220530FN-25PVCGT 220530FN-27VCUW 160408FN-DVCUW 160412FN-DVCUW 220530FN-DVPGT 220516FN-25PVPGT 220516FN-27VPUW 220516FN-D

AM

ZH

10

TH

216

TP

KD

R

R

R

R

R

R R

R R

R R

R R

R

R R

R R

R

R R

R

R

R

R

R

R

R

-D



= coated hard metal= uncoated hard metal= hard metal with PCD segment

16

R

R

R

R R

R

R

R

AM

ZH

216

TT

SM

20

PK

DGX16-1E2.00N0.20-27PGX16-2E3.00N0.30-27PGX16-2R1.50N-27PGX16-3E4.00N0.40-27PGX16-3R2.00N-27PGX16-3R2.50N-27PGX16-4E6.00N0.50-27P

GX24-4R3.00N-25P-FGX24-4R3.00N-27PGX24-4R3.00N-DGX24-5R4.00N-25P-FGX24-5R4.00N-27GX24-5R4.00N-27-FGX24-5R4.00N-27PGX24-5R4.00N-27P-FGX24-5R4.00N-35P-FGX24-5R4.00N-D

R R

R

R

R R

R

R

R

R R

R

R

GX 16 - 1 E 2.00 N 0.20 - 27P

-D

Parting & grooving / threading

Program see special catalogue“MSS - The modular parting,grooving and threading system“(No. 148)



MSS

Application

MSS stands for consistent modularity. Through thechange of modules the system can be adapted to therespective machining method.Flexibility, precision, stability and good economyrepresent the main characteristics of thisPLANSEE TIZIT innovation.

= coated hard metal= uncoated hard metal= hard metal with PCD-segment

chip groove codecorner radiusorientationparting and grooving widthinsert shapewidth classinsert sizeinsert system

17

FX 2.2N0.10-27PFX 3.1N0.15-27PFX 4.1N0.15-27P

R

R

R

AM

ZH

216

TT

SM

20

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

FX 3.1 N 0.15 - 27P

TC 16 - 2 I 2,0 ISO - 27P

TC16-1 E 0,5 ISO-27PTC16-1 E 0,75 ISO-27PTC16-1 E 1,0 ISO-27PTC16-1 E 1,25 ISO-27PTC16-1 E 1,5 ISO-27PTC16-2 E 1,75 ISO-27PTC16-2 E 2,0 ISO-27PTC16-2 E 2,5 ISO-27PTC16-2 E 3,0 ISO-27PTC16-1 I 1,0 ISO-27PTC16-1 I 1,5 ISO-27PTC16-2 I 2,0 ISO-27PTC16-2 I 3,0 ISO-27PTC16-1 EI 19 W-27PTC16-2 EI 14 W-27PTC16-2 EI 11 W-27PTC16-1 EI-A60-27PTC16-2 EI-G60-27PTC16-2 EI-AG60-27PTC16-3 EI-N60-27P



Application


chip groove codethread standardpitchinsert shapewidth classinsert sizeinsert system

turning

milling

chip groove codecorner radiusorientationparting and groving widthinsert system

18

R

R

R

R

U 1

7 T

WCGT 030204FNWCGT 050304FNWCGT 060304FNWCGT 07T304FN

Drilling

Maxidrill


Program see special catalogue“Hard metal for precision tools“ (No. 147)

Program see special catalogue“ Tools and indexable insertsfor drilling into full material“ (No. 149)

Rods for solid carbide drills

Tested and tried short hole drill system with trigoninserts. The special insert position corresponds to aPLANSEE TIZIT patent and ensures compensatedradial forces. This prevents the drill reliably fromrunning off centre.Maxidrill – first choice for drilling through-holes andblind holes without flat bottom

� ∅∅∅∅∅ range 14 – 53 mm


PLANSEE TIZIT tip

= uncoated hard metal

Application

19

H 2

16 T

XCET 040104FR-27PXCET 040104FL-27P

XCET 050204FN-27PXCET 060204FN-27PXCET 070304FN-27PXCET 080304FN-27PXCET 09T304FN-27PXCET 10T304FN-27PXCET 130404FN-27PXCET 170508FN-27P

R

R

R

R

R

R

R

R

R

R

EcoCut

Drilling / turning

Program see special catalogue“EcoCut Drilling and turningwith only one tool“ (No. 143)



The unique multi-function tool for unbelievableincrease in productivity.A PLANSEE TIZIT patent. Drilling of blind holes withflat bottom, step bores, turning of plane surfaces andexternal profiles with only one tool.

� ∅∅∅∅∅ range 6 – 32 mm


Application

20

R

H 1

0 T

H 2

16 T

Sm

80

SPEX 1204EETR

78 18 028 R

R

RPMT 120400ENRPHT 120400FN

78 18 029 R

R

SEHT 1204AEFN-27SEHT 1204AEFN-27P

78 18 031 r

R

R

r

R

R

SDHT 1204AEFN-27SDHT 1204AEFN-27PSDHT 1204AEFN-RSDHW 1204AEFNSDHW 1204AEFN-RXDHW 1204AEFN

78 18 018

S...

X...

A 260 system

Milling

Delivery program - cartridges and inserts

Program see special catalogue“ Tools and inserts for milling“(No. 126)

The cartridge milling tool with the new dimensionconcerning the number of variations and flexibility.

� a standard basic body for all cartridge styles!� three adjustment possibilites for axial run out� possibility to combine roughing and finishing cartridge� ∅∅∅∅∅ range 80 – 400 mm

Type,ordering descriptionCartridge ApplicationInserts

wiper insert

21

78 18 032 R

R

H 1

0 T

H 2

16 T

SDHT 1504AEFN-27SDHW 1504AEFN

78 18 036 R

R

R

R

LDHT 120404FR-27PLDHT 120408FR-27PLDHT 120425FR-27PLDHT 120440FR-27P

78 18 039 R

R

SDHT 120508FR-27PSDHT 120525FR-27P

78 18 041 R

R

SDHT 0903AEFN-27P

XDHW 0903AEFN

78 18 042 R

R

APHT 100304FR-27PAPHT 100308FR-27P

78 18 051 R

R

LDFT 150408FR-27PLDFT 150408FR-P

S...

X...

Delivery program - cartridges and inserts

Type,ordering descriptionCartridge ApplicationInserts

= Goldmaster coated HSS= uncoated hard metal


22

R

R

r

R

R

r

R

R

R

R

H 1

0 T

H 2

16 T

Sm

80

SDHT 0903AEFN-27P

XDHW 0903AEFN

SDHT 1204AEFN-27SDHT 1204AEFN-27PSDHT 1204AEFN-RSDHW 1204AEFNSDHW 1204AEFN-R

XDHW 1204AEFNSDHT 1504AEFN-27SDHW 1504AEFN

09

12

S...

X...

S...

X...

A 270 / C 270 / C 272 systems

Milling


Program see special catalogue“Tools and inserts for milling“(No. 126)

Shell end and end mill cutter program with45° approach angle.

� close, normal and course pitch� internal coolant supply� finishing insert for insert size 09 and 12� face milling, chamfering, circular

reboring and plunging� ∅∅∅∅∅ range 16 – 160 mm

Type,ordering description ApplicationInserts

= goldmaster coated HSS= uncoated hard metal

23

R

R

R

R

R

H 2

16 T

RDHX 0501MOFN

RDHX 0802MOFN

RPHX 10T3MOFN-27P

RPHX 1204MOFN-27P

RPHX 1605MOFN-27P

A 251 / C 251 systems


Shell end and end mill cutter program withbutton inserts.

� positive insert indexing� internal coolant supply� face milling, milling of clearance faces with

particularly high feed rates� ∅∅∅∅∅ range 20 – 125 mm



Program see special catalogue“Maximill A251 / C251“ (No. 153)

24

R

R

H 2

16 T

SDHT 120508FR-27PSDHT 120525FR-27P

A 490 system

Milling



Shell end milling cutters with 90° approach angle.

� four efficient cutting edges!� integrated face chamfer� economic, robust� close pitch, integral coolant supply� face and shoulder milling,

milling of 90° grooves� ∅∅∅∅∅ range 50 – 125 mm



25

R

R

H 2

16 T

APHT 100304FR-27PAPHT 100308FR-27P

A 210 / C 210 / C 212 / A 244 / C 244 systems




Shell end and end mill cutters with 90° approachangle.

� one insert form and sizefor all milling cutters!

� complete family forshoulder and slot milling

� internal coolant supply� exceptionally quiet machining,

low power consumption� ∅∅∅∅∅ range 16 – 125 mm


26

R

R

R

H 2

16 T

Sm

80

LDFT 150408FR-27PLDFT 150408FR-PLDHT 15T3PD-FR

A 241 / C 241 systems

Milling



Shell end and end mill cutterswith 90° approach angle.

� robust construction� depth of cut up to 14 mm� internal coolant supply� ∅∅∅∅∅ range 16 – 125 mm


= goldmaster coated HSS= uncoated hard metal

27

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

TS

M 3

0

E110.02.R.02-ALE110.03.R.02-ALE110.04.R.02-ALE110.05.R.02-ALE110.06.R.02-ALE110.08.R.02-ALE110.10.R.02-ALE110.12.R.02-ALE110.16.R.02-ALE110.20.R.02-ALE110.25.R.02-ALE110.32.R.02-ALE110.40.R.02-AL

R112.02.R.02-ALR112.03.R.02-ALR112.04.R.02-ALR112.05.R.02-ALR112.06.R.02-ALR112.08.R.02-ALR112.10.R.02-ALR112.12.R.02-ALR112.16.R.02-ALR112.20.R.02-AL

Helimax system

Delivery program

ApplicationTool


End mills manufactured from solid carbide and endmills with brazed helical carbide strip.

� E110 suitable for drilling� long and precisely ground peripheral cutting

edge for optimal finishing (milling)� HSC suitable� high rigidity, precise radial run out� fine grain grade� ∅∅∅∅∅ range 2 – 40 mm


Type,ordering description

28

R

R

R

R

H 2

16 T

LDHT 120404FR-27PLDHT 120408FR-27PLDHT 120425FR-27PLDHT 120440FR-27P

HSC-12 system

Milling



Shell end and end mill cutter programwith 90° approach angle.

� patented positive insert clamping� balanceable� internal coolant supply� ∅∅∅∅∅ range 16 – 100 mm� ap max 10 mm; vc max 5000 m/min



29

r

R

R

H 1

0 T

H 2

16 T

VCGT 220530FN-27MVCGT 220530FN-27MPVCGX 220530FN-27MP

...T ...X

HSV system




Shell end and end mill programwith 90° approach angle.

� robust V-formed insert with R 3.0� large chip pockets (only 2 cutting edges)� well-suited for plunging� ∅∅∅∅∅ range 40 – 100 mm� ap max 15 mm



30

R

R

H 2

16 T

XDHT 200450FR-27PXDHT 230440FR-27P

HSX system

Milling



� cutting edge lengths 20 and 23 mm� corner radius R 4.0 and R 5.0� well-suited for plunging� large chip pocket� ∅∅∅∅∅ range 25 – 80 mm� ap max 23 mm



Program see special catalogue“ Tools and inserts for machiningaluminium components“ (No. 170)

31

R

R

R

R

R

R

R

R

H 2

16 T

XDHX 190402FR-27PXDHX 190404FR-27PXDHX 190408FR-27PXDHX 190420FR-27PXDHX 190425FR-27PXDHX 190432FR-27PXDHX 190440FR-27PXDHX 190450FR-27P

HSC-HP system



� positive insert clampingfor the upper HSC range

� centrifugal force test for all milling cutters� well-suited for plunging� ∅∅∅∅∅ range 25 – 63 mm


Program see special catalogue“ Tools and inserts foraluminium component machining“(No. 170)


32

R

R

R

R

R

R

R

R

H 2

16 T

XDHT 190402FR-27PXDHT 190404FR-27PXDHT 190408FR-27PXDHT 190420FR-27PXDHT 190425FR-27PXDHT 190432FR-27PXDHT 190440FR-27PXDHT 190450FR-27P

HSC-19 system



� for the medium HSC range� well-suited for plunging� ∅∅∅∅∅ range 25-100 mm



Program see special catalogue“ Tools and inserts for aluminiumcomponent machining“ (No. 170)

Milling

33

LDHT

R

H 1

0 T

H21

6T

LDHT 15T308FR

OFHR

R

H 1

0 T

H21

6T

OFHR 070410FR-27P

SPKR

R

H 1

0 T

H21

6T

SPKR 1203EDFR-AL

SFAN

R

H 1

0 T

H21

6T

SFAN 1203EFFR





Special inserts


Milling

34

General

System solutions

Offering component specific systemsolutions is indispensable.

In this field PLANSEE TIZIT provides the followingservices for selected customer segments:

� complete tool solutions� optimised cutting materials and geometries� engineering know-how and application

support at the respective company� training courses and seminars� extensive support with regards to O.E.M. projects� construction and manufacture of special tools� coordination of project teams

35

System solutions

Aluminium rim machiningProgramsee special brochure“Tools and insertsfor aluminium wheelmachining“ (No. 129)

Screw bores / valve bores

Hub

Internal machining

External machiningFront / “mirror“

36

System solutions

Aerospace

High performance milling tools

for machining aluminium components

Program see special catalogue“ Tools and inserts for aluminiumcomponent machining“ (No. 170)

37

AlCu

AlSiMgTiAlSi7Mg

AlSi10Mg

AlSi

AlSi5Cu

AlSi9Cu

AlSi(Cu)

AlSiCuNiMgAlMg

AlZnMg

DIN 1725-2 DIN EN 1706

G-AlCu4TiMgG-AlCu4Ti

––

G-AlSi7Mg–

G-AlSi10Mg–

G-AlSi10Mg(Cu)G-AlSi9Mg

GD-AlSi10MgG-AlSi11

–G-AlSi12

GD-AlSi12–

3.13713.1841

––

3.2371–

3.2381–

3.23833.23733.23823.2211

–3.25813.2582

–

EN AC-21000EN AC-21100EN AC-4100EN AC-42000EN AC-42100EN AC-42200EN AC-43000EN AC-43100EN AC-43200EN AC-43300EN AC-43400EN AC-44000EN AC-44100EN AC-44200EN AC-44300EN AC-44400

EN AC-Al Cu4MgTiEN AC-Al Cu4TiEN AC-Al Si2MgTiEN AC-Al Si7MgEN AC-Al Si7Mg0,3EN AC-Al Si7Mg0,6EN AC-Al Si10Mg/a)EN AC-Al Si10Mg(b)EN AC-Al Si10Mg(Cu)EN AC-Al Si9MgEN AC-Al Si10Mg(Fe)EN AC-Al Si11EN AC-Al Si12(b)EN AC-Al Si12(a)EN AC-Al Si12(Fe)EN AC-Al Si9

G-AlSi6Cu4––––

GD-AlSi9Cu3–

G-AlSi9Cu3––––

G-AlSi12(Cu)GD-AlSi12(Cu)

––

G-AlMg3GD-AlMg9G-AlMg5

G-AlMg5Si–

3.2151––––

3.2163–

3.2163––––

3.25833.2982

––

3.35413.32923.35613.3261

–

EN AC-45000EN AC-45100EN AC-45200EN AC-45300EN AC-45400EN AC-46000EN AC-46100EN AC-46200EN AC-46300EN AC-46400EN AC-46500EN AC-46600EN AC-47000EN AC-47100EN AC-48000EN AC-51000EN AC-51100EN AC-51200EN AC-51300EN AC-51400EN AC-7100

EN AC-Al Si6Cu4EN AC-Al Si5Cu3MgEN AC-Al Si5Cu3MnEN AC-Al Si5Cu1MgEN AC-Al Si5Cu3EN AC-Al Si9Cu3(Fe)EN AC-Al Si11Cu2(Fe)EN AC-Al Si8Cu3EN AC-Al Si7Cu3MgEN AC-Al Si9Cu1MgEN AC-Al Si9Cu3(Fe)(Zn)EN AC-Al Si7Cu2EN AC-Al Si12(Cu)EN AC-AlSi12Cu1(Fe)EN AC-Al Si12CuNiMgEN AC-Al Mg3(b)EN AC-AlMg3(a)EN AC-Al Mg9EN AC-Al Mg5EN AC-Al Mg5 (Si)EN AC-Al Zn5Mg

Standard materials

Cast alloys

Alloy group Material Alloy designation

designation numericnumber chem. symbol

38

DIN 1725-1/DIN 1712-3 DIN EN 573-3

AlCuMgPbAlCuBiPb

–AlMgSiPb

–AlMgSi0,5

–AlMgSi1

AlCuSiMnAlCuMg1AlCuMg2

AlZn4,5Mg1AlZnMgCu0,5AlZnMgCu1,5

Al99,5E-Al

AlMg3AlMg5

AlMg4,5Mn

3.16453.1655

–3.0615

–3.3206

–3.23153.12553.13253.13553.43353.43453.43653.02553.02573.35353.35553.3547

EN AW-2007EN AW-2011EN AW-2030EN AW-6012EN AW-6262EN AW-6060EN AW-6063EN AW-6082EN AW-2014EN AW-2017AEN AW-2024EN AW-7020EN AW-7022EN AW-7075EN AW-1050AEN AW-1350EN AW-5754EN AW-5019EN AW-5083

EN AW-Al Cu4PbMgMEN AW-Al Cu6BiPbEN AW-Al Cu4PbMgEN AW-Al MgSiPbEN AW-Al Mg1SiPbEN AW-Al MgSiEN AW-Al Mg0,7SiEN AW-Al Si1MgMnEN AW-Al Cu4SiMgEN AW-Al Cu4MgSi(A)EN AW-Al Cu4Mg1EN AW-Al Zn4,5Mg1EN AW-Al Zn5Mg3CuEN AW-Al Zn5,5MgCuEN AW-Al 99,5EN AW-Eal 99,5EN AW-Al Mg3EN AW-Al Mg5EN AW-Al Mg4,5Mn0,7

Standard materials

Malleable aluminium alloys - bars

Material Alloy designation


= hardenable materials= naturally hard materials

Attention: EN755-2 (extruded bars) and EN754-2 (drawn bars) contain numerous othermaterials and alloy variations which are less common.

39

DIN 1725-1/DIN 1712-3 DIN EN 573-3

Al99,5AlMg3

AlMg4,5MnAlMg1SiCu

AlMgSi1AlCuMg1AlCuMg2

AlZn4,5Mg1AlZnMgCu0,5AlZnMgCu1,5

3.02553.35353.35473.32113.23153.13253.13553.43353.43453.4365

EN AW-1050AEN AW-5754EN AW-5083EN AW-6061EN AW-6082EN AW-2017AEN AW-2024EN AW-7020EN AW-7022EN AW-7075

EN AW-Al 99,5EN AW-Al Mg3EN AW-Al Mg4,5Mn0,7EN AW-Al Mg1SiCuEN AW-Al Si1MgMnEN AW-Al Cu4MgSi(A)EN AW-Al Cu4Mg1EN AW-Al Zn4,5Mg1EN AW-Al Zn5Mg3CuEN AW-Al Zn5,5MgCu

Malleable aluminium alloys - inserts

Alloy designation


= naturally hard materials= hardenable materials

Attention: EN 485-2 contains some other materials and alloy variations which are less common

Material

40

Practical examples

Housing

Problem / criteria:

��surface finish��formation of burrs��clamping

Results:

��surface roughness Rz 3.4 µm��excellently quiet machining��minimal burr formation at exit points

Aluminium rim

Application data:

Vc [m/min] 500ap [mm] 3ae [mm] 32 – 45vf [mm/min] 2500fz [mm] 0.25

Work piece: housingMaterial: SiluminMachine: SHWTools: A 270.80.R.05

SDHT 1204AEFN-27P H216T

Problem / criteria:

��vibrations��chip formation��wet machining

Results:

��good surface quality��long cutting edge life (80’)��short machining times

Application data:

Vc [m/min] 300 – 2200ap [mm] 1.0 – 2.5f [mm/rev.] 0.25 – 0.6

Work piece: aluminium rimMaterial: G-AlSi12MgMachine: IMTTools: Maxilock S and MSS

VCGT 160412FN-27P H216TGX24-5R4.00N-35P-F H216T

41

TIZIT

Aluminium rim

Tube

Problem / criteria:

��surface finish��free from blow holes

Results:

��good surface quality��long cutting edge life (approx. 1,400 pieces)

Application data:

Vc [m/min] 1800 – 2200ap [mm] 0.3f [mm/rev.] 0.2

Work piece: aluminium rimMaterial: G-AlSi12MgMachine: OkumaTools: UT40-SVHCR-16

VCUW 160412FN-D

Problem / criteria:

��dimensional accuracy��deformation

Results:

��no deformation of thin walled work piece

Application data:

Vc [m/min] 216 – 280ap [mm] 2,0f [mm/rev.] 0,1

Work piece: tubeMaterial: AlCuBiPbMachine: WasinoTools: SDJR 2020 K11

DCGT11T304-FN-27 H216T

42

Practical examples

Screw

Problem / criteria:

��surface finish��chip evacuation

Results:

��good chip control�� clean and even cut surface

Housing

Application data:

Vc [m/min] 70 – 350ap [mm] 3.1f [mm/rev.] 0.1

Work piece: screwMaterial: G-AlSi12CuMachine: OerlikonTools: XLCFN 3203 M31

FX3,1FN-27P H216T

Problem / criteria:

��suitable for plunging��chip evacuation

Results: Ergebnis:

��good chip control��more economic machining compared to HSS (only Helimax)

Work piece: housingMaterial: AlCuMgMachine: Maho MC 600Tool: C-HSC-HP-25-R-02-19-ZS20 L60

Application data:

Vc [m/min] 320ap [mm] 3.0 – 20ae [mm] 5.0 – 25vf [mm/min] 570fz [mm] 0.07

43

General information

Advantages

PLANSEE TIZIT aluminium inserts are characterised by large rake angles, sharp cutting edges,extra-smooth rake faces and wear resistant hard metal grades.

With reference to practical application, these properties result in the following advantages:

� low cutting forces� low tolerances maintained (component stability)� low burr formation� clean surface at the component� good swarf control� long tool life

These advantages are not only relevant for aluminium!

Additional application fields for PLANSEE TIZIT aluminium inserts:

RFinishing and fine finishing of:

� stainless steel, steel� cast iron� titanium� molybdenum

RGeneral machining of:

� magnesium� copper alloys� plastics� graphite

RIn the branches:

� light engineering� medical systems� watch and clock making industry� gen. mechanical engineering

RMachining of composite materials:

� soft and hard materials

steel

hard

ened

mat

eria

ls

non ferrousmetals

stainless

super alloys cast

iron

162

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162 E 09.00

Parent companyPLANSEE TIZIT Aktiengesellschaft‘A-6600 Reutte/TirolTel.: +43 (5672) 600-0Fax: +43 (5672) 600-502 Cutting Tools

+43 (5672) 600-503 Wear PartsE-Mail: [email protected]: [email protected]://www.plansee.com

AustriaPLANSEE TIZIT AktiengesellschaftA-6600 Reutte/TirolTel.: +43 (5672) 600-0Fax: +43 (5672) 600-505E-Mail: [email protected]

= Sales Cutting Tools

BulgariaINSTRUMENT AGBoulevard Stoletov 157BG-5301 GabrovoTel.: +359 (66) 438-11Fax: +359 (66) 437-42E-Mail: [email protected]


GermanyPLANSEE TIZIT GmbHSchützenstraße 29D-72574 Bad UrachTel.: +49 (7125) 1501-0Fax: +49 (7125) 8594E-Mail: [email protected]


FranceSociété PLANSEE TIZIT S.A.R.L.20, Rue LavoisierF-95300 PontoiseTel.: +33 (1) 3433-3180Fax: +33 (1) 3030-9339E-Mail: [email protected]


Great BritainPLANSEE TIZIT (UK) Ltd.Cliff LaneGrappenhallWarrington WA4 3JXTel.: +44 (1925) 261-161Fax: +44 (1925) 267-933E-Mail: [email protected]


ChinaPLANSEE TIZIT Hong Kong Ltd.Room 1201-1202Hollywood Centre233 Hollywood Rd., Sheung WanHong KongTel.: (+852) 2542-1838Fax: (+852) 2854-3777E-Mail: [email protected]


IndiaSiel TIZIT Limited58, Motilal Gupta RoadBarishaIN-700 008 CalcuttaTel.: +91 (33) 447-5435Fax: +91 (33) 447-6472Telex: 021 8142 ihm inE-Mail: [email protected]


ItalyTIZIT S.p.APiazza F. Martelli, 7I-20162 MilanoTel.: +39 (02) 6441-111Fax: +39 (02) 6611-6040E-Mail: [email protected]


SpainPLANSEE TIZITVía de las Dos Castillas, 9cPortal 2, Bajo BE-28224 Pozuelo (Madrid)Tel.: +34 (91) 351-0609Fax: +34 (91) 351-2813E-Mail: [email protected]


USASCHWARZKOPFTECHNOLOGIES Corporation115 Constitution BoulevardFranklin, MA 02038Tel.: +1 (508) 553-3800Fax: +1 (508) 553-3823E-Mail: [email protected]


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