High Speed Aluminum Machining - Pro-Active Technical ... Insert Body Helical cutting edge and high...

TaeguTec is launching a new line of milling cutters designed for a completely new operational range of aluminum machining-the 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 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 line and inserts assure excellent results with outstanding productivity in demanding applications such as high helical ramping, straight ramping and step milling.

Features 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

High Speed Aluminum Machining

N e w s a n d T e c h n o l o g y f r o m T a e g u T e c

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NPA New Product Announcement No.196 1/9

Oct. 2011www.taegutec.com

FeaturesInsert

Body

Helical cutting edgeand high positive rake angle.

Polished rake face

Fully ground periphery

Higher relief anglefor high ramping capability

V-shaped bottom for rigid clamping

Wiper face

Various Corner Radii


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2 face radial contact for precise 90 degree machining.

Coolant direct to cutting edge.

Simplifed screw clamping design for improved insert seating

V-shaped pocket enables stable high speed machining

Wide axial support for superior surface finish.

CentrifugalForce

CounterForce

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-W32-16 Insert : XECT 160508R-AL

- V shaped design General type

Insert movement(ramping down cutting)

Stress of Screw

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


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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

148 kgf/mm2 179 kgf/mm2

➟Cutting force ➟Cutting force10.5㎛3.0㎛

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.

Pocket milling

Shouldering

Straight ramping

Slotting Profiling

Helical ramping

Face milling


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Insert

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 16

End 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

TE90XE □□□-□□□- 16


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Modular Type

Face 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

TFM90XE □□□- R□□-16

Ø D

L

MØ

D1

Ø d

Ø D

ap

H90°

90°

•κ= 90。

TFM90XE □□□-□□R-16Designation Insert Dimension (mm) Max

RPMWeight

(Kg) Mounting BoltD d HTFM90XE 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

TS40080I(ø25) T-T15TS40093I(ø32-)

Ø d

Ø D

ap

H90°

90°


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Ramping Data

Helical Ramping Step MillingStraight Ramping

XECT 16 (0.4R-1.2R)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. 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


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. 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


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Max. Ramp 'A'Max. ap

øD1LStep Max. ap

Pitch

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


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 21 14.5 38 29.1 4.2 2.550 25.6 2.5

Ø32 15 14.5 54 43.1 7.9 364 22.9 3

Ø40 10 14.5 82 59.1 9.0 380 18.8 3

Ø50 8 14.5 103 79.1 10.9 3100 18.7 3

Ø63 6 14.5 138 105.1 11.8 3126 17.7 3

Ø80 4 14.5 207 139.1 11.0 3160 14.9 3

Ø100 2.5 14.5 332 179.1 9.2 3200 11.6 3

Ø125 1.5 14.5 554 229.1 7.3 3250 8.7 3


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 18.5 13.5 40 29.1 3.7 2.350 22.3 2.3

Ø32 13.5 13.5 56 43.1 7.1 2.564 20.5 2.5

Ø40 8.5 13.5 90 59.1 7.6 2.580 15.9 2.5

Ø50 7 13.5 110 79.1 9.5 2.5100 16.4 2.5

Ø63 5.5 13.5 140 105.1 10.8 2.5126 16.2 2.5

Ø80 3.5 13.5 221 139.1 9.6 2.5160 13.1 2.5

Ø100 2.5 13.5 309 179.1 9.2 2.5200 11.6 2.5

Ø125 1.5 13.5 516 229.1 7.3 2.5250 8.7 2.5


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Material: AL7050 Component: Aircraft partCutting conditions Competitor

Cutter TFM90XE 450-22R-16 D50 face millDiameter (mm) D50 D50Insert XECT 160404R-AL K10 12mm carbide insertNo. of tooth 4 4Cutting speed 2198m/min (RPM 14000) 2198m/min (RPM 14000)fz (mm/tooth) 0.17 0.17Table Feed (mm/min) 10000 10000Depth of Cut(mm) 5.2 4Width of Cut(mm) 35 35Coolant Wet WetTool life(hrs) 4hrs/corner 3hrs/cornerCutting time(min) 28 45

Material: AL6061 Component: Articulated robot partCutting conditions Competitor

Cutter TE90XE 225-25-16 Soild carbide endmillDiameter (mm) D25 D16Insert XECT 160404R-AL K10 -No. of tooth 2 3Cutting speed 785m/min (RPM 10000) 503m/min (RPM 10000)fz (mm/tooth) 0.15 0.08Table Feed (mm/min) 3000 2400Depth of Cut(mm) Max 10mm Max 10mmWidth of Cut(mm) Varies VariesCoolant Wet Wet

Case Study 1

Case Study 3

Material: AL7050 Component: Aircraft partCutting conditions Competitor

Cutter TE90XE 332-32-16 D32 endmillDiameter (mm) D32 D32Insert XECT 160430R-AL K10 16mm carbide insert.No. of tooth 3 3Cutting speed 905m/min (RPM 9000) 905m/min (RPM 9000)fz (mm/tooth) 0.3 0.277Table Feed (mm/min) 8100 7500Depth of Cut(mm) Rough 3mm, Finish 0.3mm Rough 3mm, Finish 0.3mmWidth of Cut(mm) Varies VariesCoolant Wet WetTool life(pcs) 3pcs/corner 3pcs/corner

Case Study 2

• Reduced cutting load enables higher DOC. Improved productivity with better tool life

• Cost reduction credit to higher feed rate• Good surface quality credit to unique insert geometry

• Reduced cutting load enables improved productivity via a higher feed rate

Cho, Yeo MyeongMilling Product Manager

Sincerely,TaeguTecAvailability

In stock

PriceAvailable in the GAL system


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High Speed Aluminum Machining - Pro-Active Technical ... Insert Body Helical cutting edge and high...

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