HERE! - Sandvik
Transcription
HERE! - Sandvik
Drilling Cutting fluid volume compensator When using a drill holder with housing for cutting fluid supply together with a Coromant Delta drill, a coolant volume compensator should be used. A Ordering code Drill diameter Dc mm B C 9.50-14.00 14.01-17.00 17.01-30.40 5691 020-01 5691 020-02 5691 020-03 Only for Coromant Delta drills with Coromant Whistle Notch shanks. Recommended maximum wear Drill diameter Flank wear VB mm Crater wear KB mm Zone Dc mm D 1 0.25 0.25 0.30 0.30 0.35 9.50 - 14.00 14.01 - 17.00 17.01 - 20.00 20.01 - 24.00 24.01 - 30.40 Zone 2 0.25 0.25 0.30 0.30 0.35 3 0.25 0.30 0.30 0.40 0.45 E Coromant Delta Wear definition Zone F 2 1 3 Drill centre KB Flank VB G Circular land H E 36 Negative chamfer Face 1 0.30 0.30 0.35 0.35 0.40 2 0.30 0.30 0.35 0.35 0.40 3 0.30 0.30 0.35 0.35 0.40 Chipping of the cutting edge should not exceed “maximum wear” recommendations in order to allow for regrinding and to obtain maximum tool life. Drilling Grades for Coromant Delta K N 20 Average conditions Steel 10 P20 30 K20 40 Difficult K20 H K20 Hardened materials M Aluminium / Non-ferrous Good P Cast iron 01 Stainless steel Wear resistance K20 A Toughness B Tailor Made options Coatings Balinit FUTURA Wear resistant coating for steel and cast iron Grades Balinit HARDLUBE Low friction coating for long chipping materials C H10F Fine grain carbide. In combination with Hardlube coating optimized for stainless steel. D E F G H E 37 Drilling Cutting data – Coromant Delta drill – R411.5 ISO CMC No. Material Grade Cutting speed Drill diameter, mm 9.50-14 vc m/min HB P A 01.0 01.1 Unalloyed steel 01.2 01.3 01.4 B C E 0.10-0.25% C Non-hardened 0.25-0.55% C Non-hardened 0.55-0.80% C High carbon & carbon tool steel 02.1 02.2 Low alloy steel 03.11 03.22 High alloy steel 06.1 06.2 Steel castings 05.11 Non-hardened Hardened Annealed Hardened steel Unalloyed 80-170 90-200 125-225 150-225 180-225 P20 150-260 220-400 P20 150-250 250-400 P20 90-225 P20 Feed fn mm/r 75-100 0.14-0.22 0.15-0.25 0.18-0.31 70-90 0.15-0.23 0.18-0.26 0.20-0.30 55-90 0.14-0.22 0.18-0.26 0.20-0.28 35-65 0.14-0.22 0.15-0.25 0.18-0.26 40-70 0.15-0.20 0.18-0.25 0.20-0.27 40-60 0.15-0.20 0.17-0.20 0.18-0.24 70-90 0.17-0.23 0.19-0.25 0.20-0.26 50-75 0.15-0.21 0.17-0.23 0.19-0.25 25-55 0.14-0.21 0.17-0.24 0.18-0.27 25-55 0.14-0.201) 0.16-0.231) 0.19-0.251) 75-120 0.15-0.26 0.18-0.30 0.21-0.39 75-110 0.15-0.25 0.16-0.29 0.18-0.35 85-115 0.19-0.31 0.23-0.39 0.26-0.46 55-100 0.19-0.30 0.24-0.36 0.28-0.44 65-105 0.16-0.26 0.20-0.35 0.23-0.41 55-95 0.15-0.25 0.18-0.33 0.21-0.39 0.10-0.15 0.12-0.17 0.15-0.20 150-250 Stainless steel Ferritic, Martensitic 13-25% Cr 150-270 05.21 Stainless steel Austenitic Ni > 8%, 18-25% Cr 150-270 07.1 07.2 Malleable cast iron Ferritic (short chipping) 110-145 150-270 K20 08.1 08.2 Grey cast iron Low tensile strength 150-220 200-330 K20 09.1 09.2 Nodular cast iron 125-230 200-300 K20 H 04.1 Extra hard steel HRC 43-47 47-60 P20 N 30.12 75-150 40-100 K20 95-150 0.21-0.33 0.18-0.41 0.18-0.41 50-160 K20 45-150 0.16-0.29 0.20-0.35 0.25-0.44 K F G 0.05-0.10% C Non-hardened 33.1 33.2 Pearlitic (long chipping) High tensile strength Ferritic Pearlitic Aluminium alloys Hardened and tempered Wrought solution treated and aged Cast 30.21 Copper and copper alloys Free cutting alloys (Pb ≥ 1%) Brass and leaded bronzes (Pb ≤ 1%) K20 K20 25-40 15-30 H 1) 17.01-30.40 Low alloyed (alloying elements < 5%) M D Non-hardened 14.01-17 If chip control is difficult to achieve with the recommended cutting data, reduce the feed to 0.08 - 0.10 mm/rev. E 38 Drilling Graphs – Coromant Delta drill — R411.5 Feed force Net power Ff = 0.5 × Dc × fn × kcfz × sinκr [N] 2 (Only for solid drilling) Ff [kN] 8 kW 8 6 6 4 4 2 2 0 0 0 10 15 20 30 Dc [mm] Drill diameter 25 Dc × fn × kcfz × vc [kW] 240 x 103 (Only for solid drilling) Pc = A B 0 10 15 20 25 30 Dc [mm] Drill diameter C Cutting fluid flow [l/min] q 16 14 12 D Min 10 8 6 E 4 2 0 0 10 15 20 25 30 Dc [mm] F Drill diameter The graphs show nominal values which should not be regarded as strict recommendations. The values may need adjusting depending on the machining conditions e.g., the type of material. G Note that only net power ratings are given. Allowance must be made for the efficiency of the machine and the cutting edge wear. H E 39 Drilling Coromant Delta drill R411.5 Drill diameter Mounting type Cylindrical with flat P M K H N Dc Mounting size, dmm 9.50-30.40 16, 20 , 25, 32 Cylindrical Coromant Whistle Notch 16, 20, 25, 32 16, 20, 25 A Cylindrical with flat—CYLPF Coromant Whistle Notch—CWN Cylindrical—CYL 1= Lengths and diameters different to standard, Dc = 9.50-30.40 mm B 2= Drill with chamfering insert, Dc = 12.25-30.40 mm C 3= Drill with pilot, Dc = 9.50-30.40 mm D 4= Drill with pilot and with chamfering insert, Dc = 12.25-30.40 mm E Options F Dc Diameter—9.50-30.40 mm Drill type 1. 3—Dc= 9.50-30.40 mm—1=standard 2. 4—Dc=12.25-30.40 mm ch G l3s D21 type 3 and 4 l21 Chamfer width—0.5-1.5 mm, type 3 and 4 D1 Flange diameter—15-32 mm Drill length—Drill type 1 and 2—17-158 mm l1s Programming length—44-175 mm, depending on l3s, l4, l21 Drill depth—Type 1— 9.9-134.8 mm l2 Overall length—92-236 mm, depending on l3s, l4, l21 Type 2—16.4-134.8 mm l6 Flute length—17-172 mm, Type 3— 9.9-116.8 mm H Type 4—16.4-116.8 mm Mounting Cylindrical shank with flat—CYLPF, type Cylindrical shank—CYL, Coromant Whistle Notch—CWN dmm E 40 Pilot length—18.6-158 mm, only valid for only valid for type 2 and 4 Drill type 3 and 4—17-140 mm l4 Pilot diameter—10-31 mm, only valid for Mounting size—see above depending on Dc and dmm Carbide P20 for general steel applications grade K20 for stainless steel, cast iron and aluminium H10F for stainless steel, titanium and aluminium Coating PVD coating: TiN, TiCN, TiALN (FUTURA), TiALN + WC/C (HARDLUBE) Drilling Chamfering insert for Coromant Delta drills Max. chamfer size 1.5 x 45° 0 3.8 -0.2 Drill dia. > 12.25 mm 10º Drills with the chamfering insert mounted are available as Tailor Made. See next page for detailed information. 11º 2.5 ± 0.1 A r=1 P M K H N 90º ± 15´ 45º ± 20´ 4 ± 0.04 0.4 ± 0.1 × 45º B 0 ø5 -0.02 0 4 -0.2 Ordering code Spare parts Insert Tension pin (delivered with the insert). H10F 6 ± 0.2 L142.01-05 06 00 3113 030-304 ✩ Coromant grade C Ordering example: 5 pieces L142.01-05 06 00 H10F D Building in dimensions E 4 0 +0.2 F 0.2 ± 0.1 × 45º ø 5H8 ø 2H8 2.1 l4 2.5 ± 0.03 G ch × (45º) l21 = l4 + 2.1 - ch l21 Dc H l4 l21 = l4 + 2.1 - ch l21 l4 ch max = Position of chamfering insert = Drill depth = 1.5 × 45° ± 0.3 E 41 Drilling Drill specifications Coromant Delta 3.5 × Dc R 411.5 Cylindrical shank with flat according to ISO 9766 A κr 70° Drill diameter: Hole depth: Hole tolerance: Surface finish: Cutting fluid: Tolerances: B 9.50-30.40 mm 3.5 × Dc IT8-9 Ra 1-2 µm Emulsion or Neat oil Dc = js7 dmm = h6 l4 = Recommended drilling depth 5 × Dc R 411.5 Cylindrical shank with flat according to ISO 9766 C κr 70° D Drill diameter: Hole depth: Hole tolerance: Surface finish: Cutting fluid: Tolerances: 9.50-20.00 mm 5 × Dc IT9-10 Ra 2-4 µm Emulsion or Neat oil Dc = js7 dmm = h6 l4 = Recommended drilling depth 3.5 × Dc R 411.5 E Whistle Notch shank κr 70° Drill diameter: Hole depth: Hole tolerance: Surface finish: Cutting fluid: F Tolerances: G 9.50-30.40 mm 3.5 × Dc IT8-9 Ra 1-2 µm Emulsion or Neat oil Dc = js7 dmm = h6 l1s = Programming length l4 = Recommended drilling depth 5 × Dc R 411.5 Whistle Notch shank κr 70° H Drill diameter: Hole depth: Hole tolerance: Surface finish: Cutting fluid: Tolerances: 9.50-20.00 mm 5 × Dc IT9-10 Ra 2-4 µm Emulsion or Neat oil Dc = js7 dm = h6 l1s = Programming length l4 = Recommended drilling depth E 42 Drilling Indexable insert drills CoroDrill 880 drill, Coromant U drills and T-Max U drills and trepanning tool A Coromant U drill R416.2 T-Max U large-diameter drill R416.9 B C CoroDrill 880 T-Max U stack drill R416.01 T-Max U trepanning tool R416.7 CoroDrill 880: first choice for short hole drilling (14 – 29 mm diameters) R416.2: tool for short hole drilling ( 12.7 – 58 mm diameters) R416.21: step and chamfer combination drill (17.5 – 41 mm diameters) L416.1: left-hand drill (17.5 – 58 mm diameters) R416.01: stack drill (27 – 59 mm diameters) R416.9: large-diameter drill (60 – 80 mm diameters) R416.7: trepanning tools (60 – 110 mm diameters) +/- 0.05 mm are kept and Wiper technology gives good surface finsih. With their increased capability to produce closer tolerances and better surface finish, the indexable insert drill is a very versatile tool as regards materials, machinery and operation. Hole depths: up to 4 times the drill diameter (5 for Tailor made drills) Workpiece materials: all kinds Hole tolerances: generally – 0.1/+ 0.3 mm but CoroDrill 880 provides a 0/+ 0.25 mm tolerance, when used in finishing operation tolerances within With the right choice of drill - type, size and shank, along with tool holder - most hole making operations can today be performed in a very efficient way. A wide range of machine tools are used, including special-purpose machines, although CNC lathes, turning centres and machining centres dominate with a growing number of multi-task machines. Today’s range of drills covers a wide variety of applications and when the right drill has been selected, the tool can be optimized to suit the operation. Indexable insert drills generally offer clear advantages in most respects and for holes falling within their capability, these should be considered as first choice for stationary and rotating set-ups. The indexable insert drill combines the toughness of a steel drill-shank with the wear resistance of cemented carbide inserts, without the need for re-grinding. The life of the drill is long and can be applied to suit different machining demands. Reliability and accuracy is higher than ever, coupled with the ability to produce good machining economics. D E F The following few application hints will ensure smooth performance and optimum results. G H Operational possibilities with indexable insert drills. E 43 Drilling Application hints A B C D E Correct alignment of the drill is vital. There is about as many stationary drills as rotating since they are often used in CNC lathe turrets where the workpiece revolves. In these cases, it is important to ensure that the centre axis of the drill is sufficiently aligned to the rotary axis of the workpiece. Faulty centering – run-out - is the most common cause of poor tool performance and bad results. The drill should also be set up so that the face of the peripheral insert is parallel to the machine axis of transverse movement. Misalignment also has the effect of radial off-setting, which produces either an over-sized or under-sized hole. Rotating drill alignment can be somewhat more demanding but not difficult if a few guidelines are followed. If there are problems with oversize or undersize holes or if the centre insert tends to chip or break, the drill should be positioned in different ways until it achieves better results. For instance, if the drill cuts oversize in one position, it should cut undersize in another. Turning the drill 180 degrees in its holder may solve the described problem of hole F G H Correct drill alignment is critical. E 44 size. In fact, various types of repositioning often lead to dimensional and alignment deviations being eliminated. When the workpiece and drill are out of true, due to inaccuracy in the machine, such as spindle, chuck, tool holder or the drill itself, the centre axis of the drill and axis of rotation may not be sufficiently parallel which then gives rise to inaccurate holes. In order to achieve the tolerances of the drill capability, it is important that the centering between the workpiece and the drill is within certain limits: Stationary indexable insert drills can also generate tapered holes, with the help of the CNC programme. Also chamfering and reliefs can be cut with the drill. When off-setting the drill, the peripheral insert should be parallel to the x-axis of the machine. The peripheral insert is located on the same side as and parallel to the flat for clamping the ISO-shank. The position of the drill in the turret will then determine the off-set which will increase the hole diameter. Drilling A B C A Possibilities with a stationary drill. (Operation C not possible with CoroDrill 880) Preparing a hole for threading can be done in one pass along with chamfering (A). Larger holes than the diameter of the drill (B). Drilling and finishing can be done in one operation where boring is performed during withdrawal of the drill (C). Possible radial adjustment depends upon the diameter of the drill. Hole tolerances are possible to within +/-0.05 mm. By presetting stationary drills, manufacturing tolerances of drill and inserts can be eliminated and the hole tolerances on a 3 x D drill be improved to within +/- 0.05 mm. Radial drill adjustment Stationary drills can be radially adjusted from 0.8 mm to 3.5 mm depending on drill diameter. Moreover, if the first value (d1) is larger than the second (d2), a funnel-shaped hole is obtained. In applications with a rotating drill, a funnel-shaped hole is obtained if the runout of the workpiece and drill axes cross each other. The relationship between values δ1 and δ2 determines the shape of the funnelshaped hole. When δ1 corresponds with δ2, the size of the hole becomes smaller along half the depth of the hole and then increases again. If δ1 is larger than δ2, the size of the hole becomes smaller as it proceeds from the start of the hole. But if δ2 is larger than δ1, the size of the hole increases. Positioning the drill for stability can be done when the set-up or machine is weak. This is done by turning the drill into the most suitable position. With a normal tool setting, a weak set-up will lead to the drill becoming misaligned when the machine axes are forced out of line. A likely consequnce is that the centre insert is damaged. If a somewhat oversize hole is acceptable, a 90° rotation of the drill is recommended. If a somewhat undersize hole can be accepted, a 270° rotation of the drill is recommended. It should be noted however, that if the drill is rotated 180°, the core diameter increases which can damage the drill during machining. B C D E Off-setting of rotating drills can be done with adjustable tool holders in a range from -0.4 mm to +1.4 mm. Hole diameter variations are common if the stationary drill is misaligned. Particularly if the centre difference on engagement (δ1) is smaller than the centre difference at the end of the hole (δ2). F Improving stability of stationary drill by turning the drill. G H Possible mis-formation of holes with a stationary drill. Possible mis-formation of holes with a rotating drill. E 45 Drilling A A B C D Various type of initial penetration in drilling operations. All but A need initial feed reductions. B Initial drill penetration ... C D ... is an important factor for successful drilling. One way of ensuring good hole quality, is to make sure the penetration surface of the workpiece is at right angles to the drill centre axis. An indexable insert drill can, however, cope with initial penetration of convex, concave, inclined and irregular surfaces when accompanied with an adjustment of feed rates. For a convex surface (A) the conditions are relatively good since the centre of the drill ideally makes contact with the workpiece first, giving normal torque. E With an inclined surface (B) the cutting edges will be unevenly loaded which may result in the drill wearing prematurely. An uneven load means that a exra stable tool (short length in relation to diameter) is required in order to cope with vibration and keep within tolerances. If the angle of the inclined surface is larger than two degrees, the feed should be reduced to a third of that recommended for the drill. When entering assymetriacally curved surfaces (D) the drill tends to bend out from the centre, as when penetrating against an inclined surface. The feed should be reduced to a third of the recommended for the initial penetration of concave surfaces. With a concave surface (C) the drill engagement varies depending on the radius of the concave surface and the diameter of the hole in relation to the height of the drill point, If the radius of the concave surface is small in relation to the hole diameter, the periphery of the drill will be engaged first. To reduce the tendency for the drill to deflect, the feed rate should be reduced to a third of that recommended. When drilling into irregular surfaces (E) there is a risk of the inserts chipping and this may also be the case when exiting an irregular surface. The feed rate should therefore be rediced. When it comes to pre-drilled holes (F) in order to avoid deflection of the drill, the pre-drilled hole should not be larger than 25% of the drill diameter. F G H E Irregular surface need feed reductions and pre-drilled holes should not be larger than 25% of drill diameter. E 46 F Drilling A G Multi-diameter hole drilling should be carried out in the right order. B When making a multi-diameter hole (different diameters in the same hole), (G) it should be noted that drills are generally not designed for counterboring, which is the process involved. Conventional twistdrills do not provide sufficient accuracy and modern, self-centering twist-drills have too much room for deviation when seeking the centre, which results in oval holes. If indexable insert drills with asymmetric geometry are used, deflection of the drill can take place. These problems can be remedied in certain cases by reducing the feed, but the procedure of drilling the largest hole first, then the smaller one is rec- ommended. The following hole-diameter is then drilled from the opposite side. When drilling crossing holes - a hole that crosses the axis of another hole - the drill will exit from a concave surface and then re enter a concave surface. In the transition there is a risk of problems occurring with chip evacuation. The safest procedure is to drill the hole from the opposite direction. If, despite these problems, the drill is to cross the hole in one operation great emphasis should be placed on the stability of the tool. When exiting from the concave surface the front part of the drill loses the support of the walls of the hole. The drill then has to have the stability to provide support until the drill head has entered the workpiece on the other side of the hole being crossed. When crossing another hole in the workpiece, the diameter of which exceeds a quarter of the drill diameter, the feed rate should be reduced to a quarter of the recommended feed rate. C D E F G H Drilling crossing holes should be carried out according to operations 1 and 2. Stability of the drill is essential. E 47 Drilling A B C Guarding against ejected discs in through-holes is important. When drilling through-holes in rotating workpieces with an indexable insert drill, a disc will be produced as the drill breakes through. This disc is often ejected at high speed from between the jaws of the chuck and because the disc is sharp, it can inflict damage or injury. It is therefore recommended that the chuck is enclosed with an adequate guard. If the cutting fluid contains chip particles the slit sealings may seize and as a result the housing will rotate. The supply tubing will consequently be pulled round with the housing which can cause a serious accident. A rotation stop must therefor always be used. If the rotating connector has not been used for a long time check that the holder rotates in the housing before the machine spindle is started. Optimization for close tolerance/high surface finish. D E F A number of factors that affect the quality of holes drilled should be looked at when hole quality levels are high: - the machine tool needs to be in a good condition. Wear and misalignment in the spindle will affect accuracy. Stability generally is important. - the condition of the drill should be monitored regularily throughout its tool-life to establish a safe and predictable tool-life. Unsuitable tool wear and any risk of cutting edge breakdown should be eliminated. - chipbreaking and chip evacuation must always be satisfactory. G H - choice and setting of drill type and insert geometry affect quality of holes. - as regards obtaining high straightness accuracy, especially for deeper holes, the best result is obtained when both the workpiece and drill rotate. Alternatively, a rotating workpiece with a stationary tool is satisfactory. E 48 Safety against dangerous discs. Rotating stop is an important measure. Drilling On trepanning set-ups, stationary drills must not be offset from the workpiece centre line, with reference to the peripheral insert, by more than -0.15 mm. The peripheral cutting edge (P) should be set to within +0.1 mm in the horizontal plane from centre-line of spindle (CL). On stationary tool applications, the drill should be positioned with the inserts on the horizontal axis. The peripheral insert must be set 0.20 mm behind the inner cartridge by means of the axial adjusting screw of the peripheral cartridge. Core handling usually does not represent a problem for short hole depths, particularly with stationary tools. Coolant flow and pressure are normally adequate to safeguard the cutting edges from being chipped due to the falling core (C). When heavy and long cores are produced a drilled hole into the core with a rigid plunger or plug can be made to support the core from falling. The diameter of the drilled hole should be a little larger than the diameter of the plug. The unit is housed in a seal cup which is externally fixtured. If the fixture is fitted with a core support, the drill should be mounted with the cartridges located on the vertical axis. Supports for the core may be required to ensure its stability on breakout, and to protect the cutting edges. 0.15 ±0.1 A B Setting stationary trepanning tools. C D C E Core handling in trepanning. F G H E 49 Drilling Cutting fluid A B C D E F G The cutting fluid supply in drilling is an important factor for successful performance. Chip evacuation and lubrication between drill and hole-wall are the primary functions which have to be supported. Cutting fluid pressure and volume define the supply and are shown in nominal values. These values are not strict overall and may need adjustment depending on machining conditions. Recommended minimum pressures are indicated in diagrams relative to drill diameter for stationary and rotating drills. It should also be noted that there is always a drop in pressure along pipes between pump and drill and that the minimum pressure is achieved at the drill point. A simple minimum pressure indicator is for a horizontal drill to have a stream of cutting fluid coming out of the drill supply-holes without any downward drop for at least 30 cm. Smaller drill diameters need higher pressure. While volume is less, the cutting fluid pressure is critical for smooth chip evacuation at the high speeds of small high-performance drills. While modern CNC machines usually have adequate cutting fluid pressure and volume, some machines can have pressure raised through compressed air coupled to the system. Large-diameter drills need larger volumes of cutting fluid, while the pressure requirement becomes less as diameters increase. The cubic capacity of cutting fluid tank should be between 5-10 times larger than the volume of fluid that the pump supplies per minute. The volume capacity can be checked using a stop-watch and a suitably sized bucket. A hose can be fitted over the drill and the pump turned on to check the time taken to pump a certain volume. H E 50 q [l/min] 60 20 15 10 5 50 0 12.7 20 40 30 c. Re 20 . Min 10 0 0 12.7 20 30 40 50 60 70 80 Cutting fluid flow – drilling q [l/min] 70 60 c. Re 50 40 . in M 30 20 0 0 Cutting fluid flow – trepanning 60 70 80 90 100 110 Dc [mm] Dc [mm] Drilling Insert wear Chipping of cutting edges can be caused by various circumstances: - off-centre drill - drill deflection caused by excessive tool overhang, feed rate or drill length - poor insert stability due to incorrect seating in drill or damaged seat and screws - poor drill stability due to wrong tool holding, poor spindle or turret condition and alignment - poor machine and workpiece stability - cutting fluid supply insufficient - incorrect inserts, grade or geometry not suitable for demands at centre and peripheral cutting edges A Chipping B Flank wear If chipping occurs on the cutting edges of a regrindable cemented carbide twistdrill, type Coromant Delta, a change to indexable insert drill should be considered, especially if instability prevails. The option of tougher edges on an indexable insert drill is in some cases a solution to the problem. C Creater wear D Chipping of cutting edges should never be allowed to occur, instead it should be taken as an indication that something needs rectifying in the machining process. The two most common types of tool wear are flank wear and crater wear. The former is normally the natural wear pattern, especially on the periphery insert, where higher cutting speed prevails. This wear will eventually lead to the insert cutting edge not maintaining the tolerance and/or surface finish required for the operation, when a finished criterion is required. For drilling operations, where finish and accuracy are not within particularly close limits, flank and crater wear should not be allowed to go beyond certain values for production security. Excessive wear will lead to increasing friction and incorrect cutting geometry, resulting in higher forces and poor chip information. It will also lead to a higher risk of cutting edge fracture. E F Drill adaptor for silent drilling To improve the work environment this patented dampened adaptor has been developed and it should be used with Coromant U indexable insert drills in specific applications where high pitch noise is a problem. G It is available for Coromant Capto, ISO taper 7388/1 and MAS-BT40 and 50. Every single adaptor will be individually optimised for the drill size requested. H E 51 Drilling Application procedure for new operations An application routine can be adopted for setting up new operations or for new workpiece materials to ensure satisfactory operation. Performance, chip-control, -evacuation and hole-quality can be checked at the start. A B • Make sure which insert cutting edge leads the drill. Measure at end of drill to see which insert protrudes furthest axially, to establish the point position of the drill for programming. • Start drilling with the minimum recommended feed rate for the drill in question, to a depth of just a few mm. Check chip formation and measure hole size. Also inspect the drill to make sure no drill-to-hole rubbing is taking place. • Increase feed rate in increments of 0.015 mm to arrive at optimum machining rates. C D • Drill a hole to about 10 mm in depth to analyze and then, if positive complete the hole. • Check the power needed on the machine during drilling for any surges or flickering in power reading. These may indicate chip congestion. • Feed rates can be raised but not lowered during an operation. Long, uncontrolled chips may be the result of a lower feed with subsequent chip congestion or damaged hole. E F On the other hand, excessive feed rates can lead to drill deflection, giving rise to incorrect holes, poor cutting action and rubbing between drill and hole wall. Avoid the use of the feed over-ride on the machine while the drill is in cut. • Deflection of component, fixture or machine can lead to excessive sudden feed force increases, as the drill breaks out of a through-hole being drilled. G H E 52 Drilling Benefits of using a modern indexable insert drill ... ... in comparison to out-dated conventional indexable drills, carbide tipped drills, spade drills and high speed steel twist-drills there are several areas in the diameter range 12.7 to 110 mm where benefits can be obtained: A - shorter cycle times - lower machining costs - less machine down-time - improved utilization of production resources - higher production security B - longer tool-life and more consistent performance - extended hole-quality area of indexable insert drills - simple to use and maintain - lower tool inventory - lower power consumption - more suitable for poor-stability set-ups/components C - versatile as regards workpiece materials and machinery Drill characteristics that contribute to benefits: D - faster penetration rate (feed and cutting speed) - smaller axial feed force - no peck-drilling necessary - self-centering - applicable for varying workpiece conditions/hole demands E - diameter-variation possibilities with one drill - finishing bore-stroke possible on drill withdrawal - one grade/one geometry covers many applications - optimization possibilities with dedicated insert grade/geometries - twin coolant holes leading supply to cutting edges F - specially developed helical flutes, providing unrestricted chip evacuation and high stability - large chipbreaking area, chip size and shape less limited - good for long-chipping materials, stainless steel, etc. - strong insert cutting edges with long, predicable tool-life - no regrinding G - individual design and identification of centre and peripheral inserts - choice of drill shanks and Coromant Capto integrated drills - large, developing programme H E 53 Drilling CoroDrill 880 indexable insert drill – new generation drilling - First choice drill for high productivity providing good machining economy - Improved hole quality providing broader application range for indexable insert drills. A - High machining security through unique cutting action and efficient chip evacuation B Basic features Diameter range: 14 to 29.5 mm (a growing range) Radial adjustment: steps of 1.0 mm for 2xD and 4xD; 0.5 for 3xD Length to diameter alternatives: 2xD, 3xD and 4xD Coolant supply and type: internal, emulsion; pressure: 6 – 10 bar; volume: 10 – 50 l/min C Hole tolerance: 2 – 3xD: 0/0.25 mm; 4 – 5xD: 0/0.40 mm. Thread holes. Surface finish: Ra 2 – 4 microns Flat bottom holes are produced. D E F G H Operational versatility Rotating and stationary drill in most machine tool types. As a rotating drill hole machining can be performed through drilling, boring, helical interpolation and plunge drilling. Angular, concave, convex and irregular surfaces can be entered, and cross drilling carried out, in most cases necesitating feed reductions of a quarter of that recommended – see general application hints for indexable insert drilling. Entering of surface angles up to 89 degrees is possible with the CoroDrill 880. A finishing return pass, with the drill boring on its way back out of the hole is not possible with the 880-drill as it is with the Coromant U drill. The 880-drill can however perform a boring operation on straight and tapered holes on a forward pass. A stationary drill can also machine chamfers on holes in one pass, such as when preparing holes for threading. Boring of straight and tapered holes can be performed but no finishing passes on the return stroke. Improving hole quality... ... can be achieved by pre-setting a non-rotating drill in the machine or a rotating drill in an adjustable holder. In so doing, the manufacturing tolerances of the tool will be compensated for and only the insert indexing will influence the effect of the drill diameter on the hole dimension. This means that hole tolerances inside +/- 0.05 mm can be achieved with 2xDc drills. If high surface finish is required, a lower feed can be applied (fn about 0.05 mm/rev) in combination with a high cutting speed. Surface finish values as small as Ra 0.5 microns can be achieved in steel under normal conditions. E 54 The sound level... ... of the drill during machining can be influenced by various measures. The drill diameter and length; the tool holder and overhang; the spindle stability; the workpiece fixturing; the machine tool, the cutting data – higher feed and lower cutting speed may lower the sound level; the insert geometry; the use of a Silent Tool tuned drill adapter. Drilling TOOLING ALTERNATIVES Convetional turrets Clamping alternatives – shank type – VDI – hydraulic If these turrets are equipped with Coromant’s clamping units, all types of tools can be applied. A Coromant Capto quick change system • Best choice when quick change is required. • A wide offer of clamping units and drills • Best choice for economy B Conventional, cylindrical shank tools • Easy to install in all conventional turrets C Coromant Capto integrated Multi-task machines Modular tooling with Coromant Capto The Coromant Capto modular tooling system can easily be integrated into Multi-task machines. D Take advantage of the strength of Coromant Capto, offering optimal performance in both rotating and non-rotating applications. E F G H E 55 Drilling General information – CoroDrill 880 Insert grades A B for Central insert for Peripheral insert Grade GC1044 ISO P, M, K, N, S and H PVDcoated grade with layered TiAlN-coating contributing to a good edge security. The substrate is a submicron cemented carbide with good balance of toughness and wear resistance. Basic choice for mixed production. Grade GC4014 ISO P Finishing to light roughing of steel and steel castings. Low to medium feed rates at very high cutting speed. High wear resistance and good resistance to plastic deformation permits high metal removal rates. ISO K Very good grade for high high cutting speeds in stable conditions. C Grade GC4024 ISO P Basic chioce with excellent toughness behaviour and very high wear resistance. For moderate to high cutting speeds. MT-CVD coated grade. ISO M Excellent edge toughness and very high wear resistance. Very good resistance against build-up edges. For medium to high cutting speeds. MT-CVD coated grade. D ISO K Very good combination of toughness and wear resistance. Universal grade for medium to high cutting speeds. MT-CVD coated grade. E ISO H Good toughness behaviour and high wear resistance. For moderate to high cutting speeds. MT-CVD coated grade. F G Central insert H E 56 Peripheral insert Grade GC4044 ISO P, M, K, N, S and H PVDcoated grade with layered TiAlN-coating contributing to a good edge security. The substrate is a submicron cemented carbide with good balance of toughness and wear resistance. Basic choice for mixed production. Drilling Grades for CoroDrill 880 Peripheral insert grades (always black colour) P K P M P M K K GC4014 The choice for high cutting speeds, excellent wear resistance in steel and cast iron. H GC4024 The basic choice, for most materials. N GC4044 The tough choice, excellent toughness behaviour in most materials S H A Central insert grades (always bronze colour) P M K N S B GC1044 The basic choice, for all materials. H C Insert geometries for peripheral and central inserts for CoroDrill 880 The high feed choice, – general geometry for steel and cast iron. Roughing, insert with strong, reinforced edge. P K P M K N S H P M S D The basic choice, – general geometry for most materials. Medium feed. E The choice for Long chipping materials – low carbon steel and stainless steels. Medium feed, insert with sharp positive edge. N F CoroDrill 880 G Wear resistance 01 P M K N S H 10 20 4014 4014 4024 4024 30 40 1044 4044 1044 4044 4024 1044 4044 1044 4044 1044 4044 4024 H 1044 4044 50 Toughness E 57 Drilling Specifications for CoroDrill 880 2 - 3 × Dc Drill diameter 20.00 – 29.50 mm Cylindrical shank Drill dia. Max radial adjustment Flat according to ISO 9766 Dc mm A l1s = programming length Hole tolerance Tolerance, Dc B Max hole depth, l4 ±0.00/+0.25 mm 2 × Dc ± 0.1 mm 3 × Dc ± 0.1 mm 2 – 3 x Dc C D 4 × Dc E Drill diameter 20.00 – 29.00 mm F G H E 58 Hole tolerance ±0.00/+0.40 mm Tolerance, Dc ± 0.1 mm Max hole depth, l4 4 x Dc l1s = programming length Dc 20 20.5 20.9 21 21.5 22 22.5 23 23.5 23.9 24 24.5 25 25.5 26 26.4 26.5 27 27.5 28 28.5 29 29.4 29.5 +0.9 +0.8 +0.8 +0.8 +0.7 +0.6 +0.5 +0.5 +0.4 +0.3 +1.1 +1.0 +1.0 +0.9 +0.9 +0.8 +0.8 +0.7 +0.6 +0.6 +0.5 +0.5 +0.4 +0.4 21.8 22.2 22.4 22.6 22.9 23.3 23.5 24.0 24.3 24.5 26.2 26.5 27.0 27.3 27.8 28.0 28.1 28.4 28.7 29.2 29.5 30.0 30.2 30.3 Drill dia. Max radial adjustment Dc mm 20 21 22 23 24 25 26 27 28 29 +0.9 +0.8 +0.6 +0.5 +1.1 +1.0 +0.9 +0.7 +0.6 +0.5 Dc 21.8 22.6 23.2 24.0 26.2 27.0 27.8 28.4 29.2 30.0 Drilling Inserts for CoroDrill 880 Central insert Peripheral insert 880-04…C Dc 20 – 23.99 mm 880-04…P Dc 20 – 23.99 mm 880-05…C Dc 24 – 29.99 mm 880-05…P Dc 24 – 29.99 mm A = Central insert Dimensions, mm Insert size = Peripheral insert Insert code Ic s d1 rε B Central insert Medium feed 04 05 880- 040305H-C-LM 6.8 2.8 2.8 0.5 040305H-C-GM 6.8 2.8 2.8 0.5 880- 050305H-C-LM 8.4 3 3.2 0.5 050305H-C-GM 8.4 3 3.2 0.5 880- 0403W07H-P-LM 7.4 2.8 2.8 0.7 0403W05H-P-GM 7.4 2.8 2.8 0.5 880- 0503W08H-P-LM 8.9 3 3.2 0.8 0503W05H-P-GM 8.9 3 3.2 0.5 880- 040305H-C-GR 6.8 2.8 2.8 0.5 880- 050305H-C-GR 8.4 3 3.2 0.5 880- 0403W07H-P-GR 7.4 2.8 2.8 0.7 880- 0503W08H-P-GR 8.9 3 3.2 0.8 Peripheral insert 04 05 C High feed Central insert 04 05 D Peripheral insert 04 05 E F G H Rotating drill Stationary drill E 59 Drilling Cutting data for CoroDrill 880 ISO CMC Material HB P C D M E F G S H N -LM (m/min) -GR -LM Drill length 4xD -GM -GR Dc mm fnmm/rev. fn mm/rev. fn mm/rev. fn mm/rev. fn mm/rev. fnmm/rev. 220-400 230-380 190-235 20.00-23.99 24.00-29.99 0.04-0.12 0.04-0.12 0.04-0.08 0.04-0.08 0.04-0.08 0.04-0.08 0.04-0.12 0.04-0.12 0.04-0.08 0.04-0.08 0.04-0.08 0.04-0.08 Unalloyed steel (Non hardened) 0.05-0.10% C 80-170 01.1 Non hardened 0.05-0.25% C 90-200 4014* 4024 4044 235-380 225-345 165-220 20.00-23.99 24.00-29.99 0.04-0.14 0.04-0.14 0.04-0.10 0.04-0.10 0.04-0.08 0.04-0.08 0.04-0.14 0.04-0.14 0.04-0.10 0.04-0.10 0.04-0.08 0.04-0.08 01.2 Non hardened 0.25-0.55% C 125-225 4014* 4024 4044 200-320 190-290 120-180 20.00-23.99 24.00-29.99 0.06-0.14 0.06-0.14 0.06-0.18 0.06-0.18 0.12-0.26 0.12-0.30 0.06-0.14 0.06-0.14 0.06-0.18 0.08-0.18 0.12-0.20 0.12-0.22 01.3 Non hardened 0.55-0.80% C 150-225 4014* 4024 4044 175-305 170-275 105-175 20.00-23.99 24.00-29.99 0.06-0.14 0.06-0.14 0.06-0.18 0.06-0.18 0.12-0.26 0.12-0.30 0.06-0.14 0.06-0.14 0.06-0.18 0.08-0.18 0.12-0.20 0.12-0.22 01.4 High carbon & carbon tool steel 180-275 4014* 4024 4044 175-300 200-275 105-170 20.00-23.99 24.00-29.99 0.06-0.14 0.06-0.14 0.06-0.18 0.06-0.18 0.12-0.26 0.12-0.30 0.06-0.14 0.06-0.14 0.06-0.18 0.08-0.18 0.12-0.20 0.12-0.22 02.1 Low-alloy steel (Non hardened) 150-260 4014* 4024 4044 175-320 180-290 115-180 20.00-23.99 24.00-29.99 0.06-0.14 0.06-0.14 0.06-0.18 0.06-0.18 0.12-0.26 0.12-0.30 0.06-0.14 0.06-0.14 0.06-0.18 0.08-0.18 0.12-0.20 0.12-0.22 02.2 Hardened steel 220-450 4014* 4024 4044 150-255 90-230 75-140 20.00-23.99 24.00-29.99 0.06-0.14 0.06-0.14 0.06-0.18 0.06-0.18 0.12-0.22 0.12-0.26 0.06-0.14 0.06-0.14 0.06-0.18 0.08-0.18 0.12-0.20 0.12-0.22 03.11 High-alloy steel (Annealed) 50-250 4014* 4024 4044 155-300 160-275 100-170 20.00-23.99 24.00-29.99 0.06-0.14 0.06-0.14 0.06-0.18 0.06-0.18 0.12-0.26 0.12-0.30 0.06-0.14 0.06-0.14 0.06-0.18 0.08-0.18 0.12-0.20 0.12-0.22 03.21 Hardened steel 250-450 4014* 4024 4044 100-215 80-200 70-125 20.00-23.99 24.00-29.99 0.06-0.14 0.06-0.14 0.06-0.18 0.06-0.18 0.12-0.22 0.12-0.26 0.06-0.14 0.06-0.14 0.06-0.18 0.08-0.18 0.12-0.20 0.12-0.22 06.1 Steel castings (Unalloyed) 90-225 4014* 4024 4044 190-350 140-310 125-190 20.00-23.99 24.00-29.99 0.04-0.08 0.04-0.08 0.04-0.10 0.04-0.10 0.04-0.14 0.04-0.14 0.04-0.08 0.04-0.08 0.04-0.10 0.04-0.10 0.04-0.14 0.04-0.14 06.2 Low alloyed (alloying elements less than 5%) 150-250 4014* 4024 4044 125-265 110-250 100-150 20.00-23.99 24.00-29.99 0.06-0.14 0.06-0.14 0.06-0.18 0.06-0.18 0.12-0.26 0.12-0.30 0.06-0.14 0.06-0.14 0.06-0.18 0.08-0.18 0.12-0.20 0.12-0.22 05.11 Stainless steel Ferritic/ Martensitic 13-25% Cr 150-270 4024 4044 120-265 115-165 20.00-23.99 24.00-29.99 0.06-0.18 0.06-0.18 0.06-0.14 0.06-0.14 0.06-0.14 0.06-0.14 0.06-0.16 0.06-0.16 0.06-0.14 0.06-0.14 0.06-0.14 0.06-0.14 05.21 Austenitic Ni>8% 13-25% Cr 150-275 4024 4044 120-250 115-180 20.00-23.99 24.00-29.99 0.06-0.16 0.06-0.16 0.06-0.12 0.06-0.12 0.06-0.12 0.06-0.12 0.06-0.14 0.06-0.14 0.06-0.12 0.06-0.12 0.06-0.12 0.06-0.12 05.51 05.52 Austenitic/Ferritic (Duplex) 180-320 4024/4044 90-145 85-125 20.00-23.99 24.00-29.99 0.06-0.16 0.06-0.16 0.06-0.12 0.06-0.12 0.06-0.12 0.06-0.12 0.06-0.14 0.06-0.14 0.06-0.12 0.06-0.12 0.06-0.12 0.06-0.12 15.21 Austenitic castings 150-250 4024 4044 120-250 115-180 20.00-23.99 24.00-29.99 0.06-0.16 0.06-0.16 0.06-0.12 0.06-0.12 0.06-0.12 0.06-0.12 0.06-0.14 0.06-0.14 0.06-0.12 0.06-0.12 0.06-0.12 0.06-0.12 07.1 Malleable cast iron Ferritic (short chipping) 110-145 4014 4024 4044 140-255 140-230 80-145 20.00-23.99 24.00-29.99 0.08-0.14 0.08-0.14 0.10-0.18 0.10-0.20 0.14-0.28 0.16-0.32 0.08-0.14 0.08-0.14 0.10-0.18 0.10-0.20 0.14-0.19 0.16-0.25 07.2 Pearlitic (long chipping) 150-270 4014 4024 4044 100-185 105-170 65-105 20.00-23.99 24.00-29.99 0.08-0.14 0.08-0.14 0.10-0.16 0.10-0.18 0.12-0.24 0.14-0.28 0.08-0.14 0.08-0.14 0.10-0.16 0.10-0.18 0.12-0.18 0.14-0.22 08.1 Grey cast iron Low tensile strength 150-220 4014 4024 4044 225-345 210-310 130-195 20.00-23.99 24.00-29.99 0.08-0.14 0.08-0.14 0.10-0.18 0.10-0.20 0.14-0.28 0.16-0.32 0.08-0.14 0.08-0.14 0.10-0.18 0.10-0.20 0.14-0.19 0.16-0.25 08.2 High tensile strength 200-330 4014 4024 4044 110-250 125-230 75-140 20.00-23.99 24.00-29.99 0.08-0.14 0.08-0.14 0.10-0.16 0.10-0.18 0.12-0.24 0.14-0.28 0.08-0.14 0.08-0.14 0.10-0.16 0.10-0.18 0.12-0.18 0.14-0.22 09.1 Nodular cast iron (Ferritic) 150-230 4014 4024 4044 120-235 125-215 80-135 20.00-23.99 24.00-29.99 0.08-0.14 0.08-0.14 0.10-0.16 0.10-0.18 0.12-0.24 0.14-0.28 0.08-0.14 0.08-0.14 0.10-0.16 0.10-0.18 0.12-0.18 0.14-0.22 09.2 Pearlitic 200-330 4014 4024 4044 100-215 110-200 70-125 20.00-23.99 24.00-29.99 0.08-0.14 0.08-0.14 0.10-0.16 0.10-0.18 0.12-0.24 0.14-0.28 0.08-0.14 0.08-0.14 0.10-0.16 0.10-0.18 0.12-0.18 0.14-0.22 04.1 Hardened and tempered 450 4024 30-80 20.00-23.99 24.00-29.99 0.05-0.14 0.05-0.14 0.07-0.18 0.07-0.18 0.05-0.14 0.05-0.14 0.05-0.12 0.05-0.12 0.07-0.15 0.07-0.15 0.05-0.12 0.05-0.12 20.21 20.22 20.24 Heat resistant alloys, Ni Based 140-425 4044 15-25 20.00-23.99 24.00-29.99 0.05-0.08 0.06-0.10 0.05-0.10 0.06-0.12 0.05-0.08 0.06-0.08 0.04-0.08 0.05-0.10 0.05-0.08 0.06-0.10 0.05-0.08 0.06-0.08 23.21 23.22 Ti alloys Rm (Mpa) 600-1500 4024/4044 40-50 20.00-23.99 24.00-29.99 0.08-0.16 0.12-0.18 0.08-0.14 0.10-0.16 0.08-0.12 0.10-0.14 0.08-0.14 0.10-0.16 0.06-0.12 0.08-0.14 0.08-0.12 0.10-0.14 30.12 Al. alloys Wrought or wrought and aged 30-150 4044 300-385 20.00-23.99 24.00-29.99 0.06-0.16 0.10-0.18 0.06-0.18 0.10-0.20 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 30.21 Cast, non aging 40-100 4044 300-385 20.00-23.99 24.00-29.99 0.06-0.16 0.10-0.18 0.06-0.18 0.10-0.20 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 30.22 Cast or cast and aged 70-140 4044 250-335 20.00-23.99 24.00-29.99 0.06-0.16 0.10-0.18 0.06-0.18 0.10-0.20 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 33.1 Copper and copper alloys 50-160 4044 250-380 20.00-23.99 24.00-29.99 0.06-0.16 0.10-0.18 0.06-0.18 0.10-0.20 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 33.2 Brass and leaded alloys (Pb <1%) 50-160 4044 180-230 20.00-23.99 24.00-29.99 0.06-0.16 0.10-0.18 0.06-0.18 0.10-0.20 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 0.06-0.16 0.10-0.18 0.06-0.14 0.10-0.16 * Only in -GM geometry. E 60 Geometry/Feed Drill length 2-3xD -GM 01.0 K H Peripheral insert Drill diameter 4014* 4024 4044 A B Cutting speed Grade Note: Bold text is recommended grade, geometry and cutting data. Central insert grade is always 1044. This catalogue has been split into smaller parts to enhance downloading speeds. If you want to view the next page please click HERE! (To go back to the last viewed page, use the integrated green arrows at the bottom of the Acrobat® user interface)