New New products for cutting tool engineers

2TOTAL TOOLING = QUALITY x SERVICEWNT (UK) Ltd. • Sheffield Business Park • S9 1XU Sheffield • Tel. 0800 073 2 073 • wnt-uk@wnt.com • www.wnt.com

HFC 19 system

The new dimension in high-feed milling

September 2017

2

HFC 19 high-feed milling system

Roughing at the highest level

Product video: HFC 19

www.wnt.com/uk/hfc19

With a depth of cut of ap 3.3 mm and maximum feed per tooth, the new HFC 19 high-feed milling system boasts phenomenal material removal rates, meaning that the system is primarily used when high chip volume and maximum process-security are required. The new indexable inserts feature a patented, rectangular geometry with a large radius and impress with nickel-plated tool holders, high rigidity and soft cutting capability. What’s more, stable mating surfaces ensure effective force transmission and minimise undesirable vibrations.

„These tools should come with a warning!“Robert Frei, Product Manager Indexable Insert Milling Systems

Introduction 2+3

Product programmeA HFC face mill 4

XOLX indexable inserts 5

Cutting Data 6+7

Technical InformationStarting Parameter 8

Technical data 8

Machining strategy 9

Chip breakers 9

Grade designation 10

Premium quality tools for high performance.   The premium quality tools from the WNT Mastertool Performance product line have been designed for specific applications and are distinguished by their outstanding performance. If you make high demands on the performance of your production and want to achieve the very best results, we recommend the Premium tools in this product line.

Advantages of the HFC 19 system ĉ Extremely high material removal rates 

ĉ Extremely quiet running

ĉ Maximum process security

ĉ Effective force transmission

A depth of cut of 3.3 mm and maximum feeds make extremely efficient roughing operations possible.

Cutting forces are exerted primarily in the axial direction, minimising vibration and reducing stress on the spindle, even with long tool overhangs.

Thanks to optimised chip gullets and process-secure chip evacuation.

Stable mating surfaces ensure effective force transmission.

IntroductionMilling tools with indexable inserts

3

HFC 19 high-feed milling system

Practical test

Reduced wear due to MMS-opti-mised coolant supply

Process-secure due to optimised chip gullets for reliable chip evacuation

Long service life thanks to nickel-plated, FEM-optimised tool holder

XOLX 19

Machining time in min52

120

- 58 %

Material: Ti6Al4V (3.7165)Indexable insert: XOLX 190615ER-F40 HCN5240Tool: AHFC.63.R.05-19

Cutting data WNT Competitorvc in m/min 50 50fz in mm 0,71 0,25ap in mm 3,3 3ae in mm 40 40Coolant Emulsion EmulsionTool life/component 3 1

ĉ High rigidity 

ĉ Stable with smooth cutting characteristics

ĉ High chip volume

Reduced power consumption and extremely quiet running; also ideal for machining unstable components

As a result of the patented, rectangular cutting edge geometry and large radius

Thanks to large depth of cut and maximum feed per tooth

IntroductionMilling tools with indexable inserts

4

Shell mill A HFC � Milling with the highest feedrates, fz to 3.0

A

Ød1

a

Ød2

Ød3

NEW 2BDesignation d1 A d2 H6 d3 a nmax. Insert z Article no.

DC OAL DCONMS DHUB APMX RPMX ZNF 50 683 ...mm mm mm mm mm 1/min. £

AHFC.63.R.05-19 63 40 22 48 3.3 5500 XOLX 1906.. 5 484.65 50683263AHFC.80.R.06-19 80 50 27 58 3.3 4700 XOLX 1906.. 6 588.86 50683280AHFC.100.R.08-19 100 52 32 78 3.3 4100 XOLX 1906.. 8 700.88 50683300AHFC.125.R.10-19 125 63 40 88 3.3 3600 XOLX 1906.. 10 880.70 50683325AHFC.160.R.11-19 160 63 40 98 3.3 3100 XOLX 1906.. 11 1064.91 50683360 1)

1) Shell mill with 4 clamping screws, without internal coolant supply

Y7 2A

Key D Clamping screw

Article no. Article no.Spare parts 80 950 ... 70 950 ...Insert £ £XOLX 1906.. 12.13 80950114 3.54 70950302

Milling tools with indexable insertsSystem HFC

5

XOLXDesignation d d1 l s α°

IC D1 L S AN

mm mm mm mm XOLX 1906.. 19.14 6 19 6.35 10

d

l

s

r

d 1

α°

XOLX-F40 -F40

DPX 2245

HCF 5240

XOLX XOLXNEW 17 NEW 1H

ISO r Article no. Article no.RE 51 022 ... 50 504 ...

mm £ £190615ER 1.5 22.97 51022465 22.97 50504515

Steel ● Stainless steel ● Cast iron Non ferrous metals Heat resistant alloys ●hardened materials

XOLX-M50 -M50 -M50 -M50

DCX 1230

DPX 1235

DPX 2240

DCX 3215

XOLX XOLX XOLX XOLXNEW 1B NEW 1B NEW 1B NEW 1B

ISO r Article no. Article no. Article no. Article no.RE 51 017 ... 51 017 ... 51 017 ... 51 017 ...

mm £ £ £ £190615SR 1.5 18.68 51017015 18.68 51017115 18.68 51017415 18.68 51017515

Steel ● ● ○ ○Stainless steel ○ ○ ● Cast iron ●Non ferrous metals Heat resistant alloys hardened materials

Milling tools with indexable insertsSystem HFC

6

Index Material Strength Material number Material designation Material

number Material designation Material number Material designation

N/mm² / HB / HRC

P

1.1 General construction steel < 800 N/mm2 1.0402 EN3B

1.2 Free cutting steel < 800 N/mm2 1.0711 EN1A

1.3 Hardened steel, non alloyed < 800 N/mm2 1.0401 EN32C

1.4 Alloyed hardened steel < 1000 N/mm2 1.7325 25 CD4

1.5 Tempering steel, unalloyed < 850 N/mm2 1.5752 EN36 1.0535 EN9

1.6 Tempering steel, unalloyed < 1000 N/mm2 1.6582 EN24

1.7 Tempering steel, alloyed < 800 N/mm2 1.7225 EN19

1.8 Tempering steel, alloyed < 1300 N/mm2 1.8515 EN40B

1.9 Steel castings < 850 N/mm2 0.9650 G-X 260 Cr 27 1.6750 GS-20 NiCrMo 3.7 1.6582 GS-34 CrNiMo 6

1.10 Nitriding steel < 1000 N/mm2 1.8509 EN41B

1.11 Nitriding steel < 1200 N/mm2 1.1186 EN8 1.1160 EN14A

1.12 Roller bearing steel < 1200 N/mm2 1.3505 534A99

1.13 Spring steel < 1200 N/mm2 EN45 EN47 EN43

1.14 High-speed steel < 1300 N/mm2 1.3343 M2 1.3249 M34

1.15 Cold working tool steel < 1300 N/mm2 1.2379 D2 1.2311 P20

1.16 Hot working tool steel < 1300 N/mm2 1.2344 H13

M

2.1 Cast steel and sulphured stainless steel < 850 N/mm2 1.4581 318

2.2 Stainless steel, ferritic < 750 N/mm2 1.4000 403

2.3 Stainless steel, martensitic < 900 N/mm2 1.4057 EN57

2.4 Stainless steel, ferritic / martensitic <1100 N/mm2 1.4028 EN56B

2.5 Stainless steel, austenitic / ferritic < 850 N/mm2 1.4542 17-4PH

2.6 Stainless steel, austenitic < 750 N/mm2 1.4305 303 1.4401 316 1.4301 304

2.7 Heat resistant steel < 1100 N/mm2 1.4876 Incoloy 800

K

3.1 Grey cast iron with lamellar graphite 100–350 N/mm2 0.6015 Grade 150 0.6020 Grade 220 0.6025 Grade 260

3.2 Grey cast iron with lamellar graphite 300–500 N/mm2 0.6030 Grade 300 0.6035 Grade 350 0.6040 Grade 400

3.3 Gray cast iron with spheroidal graphite 300–500 N/mm2 0.7040 SG 400-12 0.7043 SG 370-17 0.7050 SG 500-7

3.4 Gray cast iron with spheroidal graphite 500–900 N/mm2 0.7060 SG 600-3 0.7070 SG 700-2 0.7080 SG 800-2

3.5 White malleable cast iron 270–450 N/mm2 0.8035 GTW-35 0.8045 GTW-45

3.6 White malleable cast iron 500–650 N/mm2 0.8055 GTW-55 0.8065 GTW-65

3.7 Black malleable cast iron 300–450 N/mm2 0.8135 GTS-35 0.8145 GTS-45

3.8 Black malleable cast iron 500–800 N/mm2 0.8155 GTS-55 0.8170 GTS-70

N

4.1 Aluminium (non alloyed, low alloyed) < 350 N/mm2 3.0255 1050 A 3.0275 1070 A 3.0285 1080 A (A8)

4.2 Aluminium alloys < 0.5% Si < 500 N/mm2 3.1325 2017 A (AU4G) 3.4335 7005 (AZ5G) 3.4365 7075 (AZ5GU)

4.3 Aluminium alloy 0,5 - 10% Si < 400 N/mm2 3.2315 A- G S1 3.2373 A-S9 G 3.2151 A-S 6 U4

4.4 Aluminium alloys 10 - 15% Si < 400 N/mm2 3.2581 A-S12 3.2583 A-S12 U

4.5 Aluminum alloys > 15% Si < 400 N/mm2 A-S18 A-S17 U4

4.6 Copper (non alloyed, low alloyed) < 350 N/mm2 2.0040 Cu-c1 2.0060 Cu-a1 2.0090 Cu-b1

4.7 Copper wrought alloys < 700 N/mm2 2.1247 Cub2 (Berylium Copper) 2.0855 CuN2S (Nickel Copper) 2.1310 CU-Fe2P

4.8 Special copper alloys < 200 HB 2.0916 Cu-A5 2.1525 Cu-S3 M Ampco 8 (Cu-A6Fe2)

4.9 Special copper alloys < 300 HB 2.0978 Cu-Al11 Fe5 Ni5) Ampco 18 (Cu- A10 Fe3)

4.10 Special copper alloys > 300 HB 2.1247 Cu Be2 Ampco M4

4.11 Short-chipping brass, bronze, red bronze < 600 N/mm2 2.0331 Cu Zn36 Pb1,5 2.0380 Cu Zn39 Pb2 (Ms 56) 2.0410 Cu Zn44 Pb2

4.12 Long-chipping brass < 600 N/mm2 2.0335 Cu Zn 36 (Ms63) 2.1293 Cu Cr1 Zr

4.13 Thermoplastics PE PVC PS Polystyrene Plexiglas

4.14 Duroplastics PF Bakelite Pertinax

4.15 Fibre-reinforced plastics Carbon Fibre Fibreglass Aramid Fibre (Kevlar)

4.16 Magnesium and magnesium alloys < 850 N/mm2 3.5812 Mg A7 Z1 3.5662 Mg A9 3.5105 Mg Tr3 Z2 Zn 1

4.17 Graphite R8500X R8650 Technograph 15

4.18 Tungsten and tungsten alloys W-Ni Fe (Densimet) W- Ni Cu (Inermet) Denal

4.19 Molybdenum and molybdenum alloys TZM MHQ Mo W

S

5.1 Pure nickel 2.4066 Ni99 (Nickel 200) 2.4068 Lc Ni99 (Nickel 201)

5.2 Nickel alloys 1.3912 Fe-Ni36 (Invar) 1.3917 Fe -Ni42 (N42) 1.3922 Fe-Ni48 (N48)

5.3 Nickel alloys < 850 N/mm2 2.4375 Ni Cu30 Al (Monel K500) 2.4360 Ni Cu30Fe (Monel 400) 2.4668

5.4 Nickel molybdenum alloys 2.4600 Ni Mo30Cr2 (Hastelloy B4) 2.4617 Ni Mo28 (Hastelloy B2) 2.4819 Ni Mo16Cr16 Hastell. C276

5.5 Nickel-chromium alloys < 1300 N/mm2 2.4951 Ni Cr20TiAl (Nimonic 80A) 2.4858 Ni Cr21Mo (Inconel 825) 2.4856 Ni Cr22Mo9Nb Inconel 625

5.6 Cobalt Chrome Alloys < 1300 N/mm2 2.4964 Co Cr20 W15 Ni10 Co Cr20 Ni16 Mo7 Co Cr28 Mo 6

5.7 Heat resistant alloys < 1300 N/mm2 1.4718 Z45 C S 9-3 1.4747 Z80 CSN 20-02 1.4845 Z12 CN 25-20

5.8 Nickel-cobalt-chromium alloys < 1400 N/mm2 2.4851 Ni Cr23Fe (Inconel 601) 2.4668 Ni Cr19NbMo (Inconel 718) 2.4602 Ni Cr21Mo14 Hastelloy C22

5.9 Pure titanium < 900 N/mm2 3.7025 T35 (Titanium Grade 1) 3.7034 T40 (Titanium Grade 2) 3.7064 T60 (Titanium Grade 4)

5.10 Titanium alloys < 700 N/mm2 T-A6-Nb7 (367) T-A5-Sn2-Mo4-Cr4 (Ti17) T-A3-V2,5 (Gr18)

5.11 Titanium alloys < 1200 N/mm2 3.7165 T-A6-V4 (Ta6V) T-A4-3V-Mo2-Fe2 (SP700) T-A5-Sn1-Zr1-V1-Mo (Gr32)

H

6.1

Tempered steel

< 45 HRC

6.2 46–55 HRC

6.3 56–60 HRC

6.4 61–65 HRC

6.5 65–70 HRC

Material examples referring to the WNT cutting data tablesCutting Data

Milling tools with indexable inserts

7

Cutting Material hard (vc↑) → tough (vc↓)

Index

DCX1230 DPX1235 DPX2240 DPX2245 DCX3215 HCF 5240

1.1 280 170 240 140 220 130 350 2101.2 230 140 190 110 170 100 300 1801.3 280 170 240 140 220 130 350 2101.4 250 150 220 130 200 120 2501.5 250 150 210 130 190 110 320 1901.6 250 150 210 130 190 110 320 1901.7 250 150 220 130 200 120 2201.8 190 110 160 100 140 80 1801.9 230 140 200 120 180 100 250 300 1801.10 250 150 220 130 200 120 2201.11 140 90 120 70 100 60 1801.12 250 150 220 130 200 120 2501.13 250 150 210 130 190 110 250 320 1901.14 100 60 90 50 90 50 1201.15 130 80 110 70 120 70 2201.16 130 80 110 70 120 70 1602.1 90 60 80 50 80 50 2402.2 130 80 110 70 120 70 2402.3 90 60 80 50 80 50 2602.4 130 80 110 70 120 70 2802.5 190 110 190 110 180 1602.6 190 110 210 120 200 1802.7 190 110 210 120 150 1303.1 360 1603.2 360 1603.3 230 1403.4 160 1003.5 250 1503.6 250 1503.7 210 1303.8 210 1304.14.24.34.44.54.64.74.84.94.104.114.124.134.144.154.164.174.184.195.1 505.2 505.3 505.4 405.5 405.6 405.7 405.8 405.9 905.10 605.11 606.16.26.36.46.5

Cutting data appoximate valuesCutting Data

Milling tools with indexable inserts

8

Starting parameter – HFC

Technology data/Cutting data recommendations

System HFC

fz in mm

a p in m

m

lapR

r

Ø d1

X B X

ae max.

Cutting depth and remaining material Cutting width for flat surfaces Cutting depth when plunging

l in mm r in mm ap max in mm d1 in mm X in mm B in mm ap max in mm fz in mm X

initial min. max.19,14 1,5 3,3 63–160 d1–(2 x B) 13,1 12 0,2 0,10 0,25 <0,65 x d1

Programmed radius 5 mm

Machining strategy

For HFC-19 indexable insertsF M R

Material vc in m/min fz in mm ap in mm vc in m/min fz in mm ap in mm vc in m/min fz in mm ap in mm

Steel 120 – 280 0,1 – 3,0 0,5 – 1,5 120 – 280 0,1 – 2,0 1,5 – 3,3Stainless steel 140 – 280 0,1 – 3,0 0,5 – 1,5 140 – 280 0,1 – 2,0 1,5 – 3,3Cast iron 110 – 230 0,1 – 3,0 0,5 – 1,5 110 – 230 0,1 – 2,0 1,5 – 3,3Non-ferrous metalsHeat resistant alloys 25 – 75 0,1 – 1,5 0,5 – 1,5 25 – 75 0,1 – 1,0 0,5 – 2,5Tempered steel

Detailed information on cutting speed for each grade can be found on → page 6+7

0 0,50 1,00 1,50 2,00 2,50

0,50

0

1,50

0,75

1,25

1,00

1,75

2,00

2,25

3,00

2,50

2,75

3,00

3,25

3,50

3,50

a p in

mm

fz in mm

XOLX 19

Milling tools with indexable insertsTechnical Information

9

System HFCModel

Machiningsectional illustration fz in mm

fine Medium rough

-F40 DPX2245 DPX2245

15°

0,20–1,25

ĉ Positive geometry ĉ Finish and rough machining ĉ For unstable clamping

situations ĉ For heat-resistant materials,

titanium and super alloys

DPX2245 DPX2245 DPX2245

HCF5240 HCF5240 HCF5240

-M50 DCX1230/DPX1235 DCX1230/DPX1235 DCX1230/DPX1235

12°

0,23

0,50–3,00

ĉ Universal geometry ĉ Light to medium rough

machining ĉ First choice for general steels

DPX2240 DPX2240

DCX3215 DCX3215

Chip Breakers Overview

Machining strategy

axial Angled

Plunging

d1 Xmax. α R max. ap max.

mm mm ° mm63

1,7

2,9

3,380 1,8100 1,3125 1,0160 0,7

circular

Helical plunging (helical plunging into solid material)

d1 Dmin. Dmax. α R max.

mm mm mm °63 97 123 2,580 131 157 1,4100 171 197 1125 221 247 0,7160 291 317 0,5

αR 360°

Milling tools with indexable insertsTechnical Information

10

Grade designation

D C X 1 2 2 0 (Example)

Main application - material

1 Steel2 Stainless steel3 Cast iron4 Light and non ferrous metals5 Heat resistant alloys, titanium6 Hard materials

Application

1 Turning2 Milling3 Grooving4 Drilling5 Thread turning6 Others

Degree of hardness

05 ISO K/M/P 0510 ISO K/M/P 1015 ISO K/M/P 15

...

Grade designation

DPX 1235

DPX 2245

DCX 1230

CVD TiN/MT-TiCN/Al2O3 | ISO – P30 First choice for dry machining of steel with high cutting data.

PVD TiAlTaN | ISO – P35 Particularly suitable for wet machining of steels.

PVD TiAlTaN Particularly suitable for machining high-alloy steels (martensitic).

DCX 3215

CVD TiN/MT-TiCN/Al2O3 | ISO – K15 The first choice for the machining of cast materials at high cutting speeds.

HCF 5240

CVD/TiN/TiAlN | ISO – M40 Special grade for machining titanium and titanium alloys.

DPX 2240

PVD TiAlTaN | ISO – M40 First choice for machining austenitic steels.

Milling tools with indexable insertsTechnical Information

11

Milling tools with indexable inserts

09/2

017

- 99

022

0021

7

2TOTAL TOOLING = QUALITY x SERVICE

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