Overview: The 2016 Global Product Catalog by KYOCERA SGS Precision Tools (KSPT) showcases their range of solid carbide cutting tools. KSPT is an ISO-certified manufacturer known for high-quality manufacturing processes. The catalog highlights their commitment to innovation through their Global Innovation Center, leading to advanced cutting technologies and patented products.
Key Sections:
- Solid Carbide Tools: Introduction to KSPT's offerings, global presence, and customer service commitment.
- Global Innovation Center: Focus on innovation with cutting-edge equipment for research and development.
- Technical Training & Education: Programs offering classroom and hands-on experiences.
- Application Engineering: Expertise in translating customer needs into commercial strategies, featuring solutions like the Z-Carb HPR and S-Carb APR/APF.
- KYOCERA SGS Precision Tools Europe, Ltd.: Details about the European facility specializing in high-performance tools.
- Tooling Services: Services like reconditioning, recoating, and regrinding to enhance tool life.
- ToolWizard: A tool for calculating application parameters and selecting products based on machining needs.
Product Categories:
- Milling: High-performance and general-purpose end mills.
- Hole Making: High-performance and general-purpose drills, countersinks, and reamers.
- Routing: High-performance and general-purpose routers.
Technical Information: Includes an EDP index, reference information, and charts for decimal equivalents and hardness conversion.
Safety and Ordering Information: Emphasizes wearing safety glasses when using high-speed cutting equipment and provides ordering and return policies.
Shank Types: Various shank types are outlined, including Ball, Corner, Square, Common, Straight, Weldon Flat, and HAIMER Safe-Lock, with translations in Spanish and French.
Helix Angles and Coolant Options: Details on helix angles and coolant options, with translations provided.
Rake Angle and Additional Geometry: Rake angles categorized as Positive, Neutral, Negative, and Variable, with additional geometry features like Flute Spacing Unequal and Chip Breaker.
Coatings and Their Properties: Descriptions of various coatings, including Titanium (TiN), Aluminum Titanium Nitride (AlTiN), and Titanium DiBoride (TiB2), with properties such as hardness and thermal stability.
High Performance End Mills: Lists different series of high-performance end mills with specifications like flute count, helix angle, and coating type.
End Mill Matrix: A matrix guides the selection of end mills based on material type, number of flutes, helix angle, and other parameters.
End Mill Matrix and Guidelines:
Ramping Basics:
- Use 100% of slotting feed rates for 1° ramp.
- Use 50% of slotting feed rates for 3° ramp.
- Use 25% of slotting feed rates for 6° ramp.
Plunging Basics:
- Use 50% of slotting feed rates in non-ferrous materials.
- Use 20% of slotting feed rates for all other plungable materials.
Notes:
- Reduce speed, feed, and cut depths as material hardness increases.
- Long flute or long reach tools require reduced rates and cut depths.
- Machine, tool holding, work holding, and coolant affect rates and cut depths.
Tool Recommendations:
- Select an end mill with the largest diameter, shortest flute length, and shortest overall length for best rigidity.
- Long flute tools are not intended for pocketing, slotting, or heavy profiling.
- High-performance tools minimize cycle time and extend tool life.
Tool Holders:
- Adequate gripping pressure and TIR are required.
- Stub holders or zero-length collet style holders are recommended for heavy stock removal.
Workpiece and Machine:
- Secure clamping reduces chatter and deflection.
- Spindle must be in optimum condition for precise TIR and maximum tool life.
- Sufficient horsepower is required for recommended speeds and feeds.
Coolant:
- Avoid re-milling chips using air blast or liquid coolant.
- Maintain clean coolant with appropriate concentration.
- Water Soluble Oil or Air Blast is recommended for various steels and alloys.
Methods:
- Climb milling is generally preferred.
- Attention to programming details, tool holders, TIR, balance, and fixturing improves cutting tool performance and extends tool life.
Entry Methods:
- Pre-drilling is preferred for most applications.
- Helical and straight ramping are alternative methods.
- High ramp angles require reduced feed; lower ramp angles allow higher feed rates.
- Plunge only in non-ferrous and short-chipping materials using slotting speeds and 25% slotting feeds.
End Milling Guidelines:
- Speeds and feeds are based on radial width and axial depth.
- Reductions may be necessary when using long flute or extended reach tools, long tool holders, or machining harder materials.
Specifications:- Materials: Covers machining parameters for titanium alloys, steels, stainless steels, cast irons, and super alloys.
- Hardness: Specifications for materials with hardness up to 440 Bhn or 47 HRc.
- Tool Geometry: Includes patented variable rake geometry and unequal helix design to suppress chatter and harmonics.
Procedures:- RPM Calculation: RPM is calculated using the formula: (Vc x 1000) / (D1 x 3.14).
- Feed Rate: Feed rate is determined by the formula: Fz x 5 x RPM for metric units.
- Machining Recommendations: Reduce speed and feed for harder materials and when finish milling.
Norms and Recommendations:- Tool Usage: Recommended for materials ≤ 45 HRc (≤ 420 Bhn).
- Coolant Technology: Utilizes JetStream patented coolant technology for enhanced performance.
- Stock Availability: Some tools are not stocked and require a call for delivery.
Key Data from Tables:- Feed and Speed: Detailed tables provide specific feed rates and RPMs for different materials and tool diameters.
- Tool Dimensions: Tables list cutting diameter, length of cut, overall length, shank diameter, and corner radius for various tools.
Critical Information:- Patented Designs: Highlights patented designs that improve machining efficiency and tool life.
- Material-Specific Guidelines: Specific guidelines for different material types, emphasizing the need to adjust parameters based on material hardness and type.
Specifications: The catalog lists end mills with specific cutting diameters, lengths of cut, overall lengths, shank diameters, and corner radii. The coatings used include Ti-NAMITE-A (AlTiN), which enhances performance in high-temperature applications.
Key Features: The Z-Carb series features a patented unequal helix design that reduces damaging harmonics by altering the angle of cutting edge entry and exit. Unequal flute spacing disrupts rhythmic patterns, aiding in harmonic suppression. The design is optimized for material removal rates with increased feed and depth of cut, suitable for materials up to 45 HRc (420 Bhn).
Material Recommendations: Provides specific recommendations for different materials, including carbon steels, alloy steels, tool steels, cast irons, stainless steels, super alloys, and titanium alloys. Each material type has associated hardness limits and recommended cutting parameters.
Tolerances: Tolerances for cutting diameters (D1), shank diameters (D2), and corner radii (R) are specified for different diameter ranges, ensuring precision in machining operations.
Performance Data: Includes tables with performance data such as RPM, feed rates, and cutting speeds for various materials and end mill diameters. This data helps in selecting the appropriate tool and settings for specific machining tasks.
Conclusion: The document serves as a comprehensive guide for selecting and using end mills in various industrial applications, emphasizing the importance of choosing the right tool for the material and application to achieve optimal performance and tool life.
Specifications:- V-Carb Series: Features unequal indexing, high helix, and an ideal rake and relief combination for superior finishing capabilities. Recommended for materials with hardness ≤ 45 HRc (≤ 420 Bhn).
- T-Carb Series: Engineered for high-speed milling using trochoidal and peel milling techniques. Designed for aggressive ramping at high speeds, with eccentric relief for superior strength and smoother surface finish. Recommended for materials ≤ 45 HRc (≤ 420 Bhn).
Stock and Availability:- Items marked with a circle (●) are U.S. stock standards.
- Items marked with a square (◾) are not stocked and require a call for delivery.
Material Compatibility:- Suitable for a range of materials including steels, stainless steels, cast iron, high temp alloys, titanium, and hardened steels.
Technical Tolerances:- For V-Carb: D1 = +0.000/–0.050 mm, D2 = h6.
- For T-Carb: D1 = +0.000/–0.050 mm, D2 = h6, R = +0.000/–0.050 mm.
Machining Parameters:- Detailed tables provide recommended RPM, feed rates, and cutting speeds for various materials and hardness levels.
- High-speed machining (HSM) parameters are specified for different material types, with adjustments recommended for harder materials.
Recommendations:- Reduce speed and feed for materials harder than listed.
- Reduce feed and Ae when finish milling (0.02 x D1 maximum).
- Reduce Ap to 1 x D1 (maximum) when profile milling with long or extra-long flute length tools.
Specifications: The document outlines the specifications for different series of end mills, including Series 33, 7M, 7MB, 56MB, and 57M. Each series is designed for specific materials and applications, such as stainless steels, super alloys, titanium alloys, and hardened steels. The specifications include cutting diameter, length of cut, overall length, and shank diameter.
Machining Parameters: Provides detailed machining parameters for various materials, including carbon steels, alloy steels, tool steels, cast irons, stainless steels, super alloys, and titanium alloys. Parameters such as RPM, feed rate, and feed per tooth (Fz) are specified for different hardness levels (measured in Brinell and Rockwell C scales).
Tool Design and Features: The end mills feature variable pitch for chatter suppression, raised land and increased core diameter for enhanced tool life, and specific geometries like ball nose design for finishing operations. The document also highlights the use of coatings like Ti-NAMITE-X for improved performance.
Recommendations: Recommends reducing speed and feed for materials harder than specified and adjusting feed and Ae for finish milling. It also suggests consulting the SGS Tool Wizard for complete technical information.
Applications: Suitable for a wide range of applications, including roughing, slotting, profiling, and finishing in various materials such as plastics, composites, and hardened steels.
Stock and Availability: Lists the stock status of different end mill sizes, indicating which are standard U.S. stock and which require special delivery arrangements.
Specifications: Provides detailed specifications for various end mills, including cutting diameter (D1), length of cut (L2), overall length (L1), shank diameter (D2), and corner radius (R). The end mills are coated with Ti-NAMITE-B (TiB2) and are available in different sizes ranging from 6.0 mm to 25.0 mm.
Features: The S-Carb series end mills feature a circular land for increased control, symmetrical end gashing for balance at high speeds, open fluting for deep slotting, and polished flutes for enhanced chip evacuation. They are recommended for materials with hardness ≤ 150 Bhn (≤ 7 HRc).
Tolerances: Outlines tolerances for different diameter ranges:
- 6 Diameter: D1 = +0.000/–0.008 mm, D2 = h6, R = +0.00/–0.05 mm
- >6–10 Diameter: D1 = +0.000/–0.009 mm, D2 = h6, R = +0.00/–0.05 mm
- >10–18 Diameter: D1 = +0.000/–0.011 mm, D2 = h6, R = +0.00/–0.05 mm
- >18–20 Diameter: D1 = +0.000/–0.013 mm, D2 = h6, R = +0.00/–0.05 mm
Stock Information: Products marked with a dot (●) are U.S. stock standards, while those marked with a square (◾) are not stocked and require a call for delivery.
Applications: Suitable for non-ferrous materials, plastics, and composites. Designed for various operations such as slotting, profiling, and high-speed machining (HSM).
Performance Data: Includes performance data for different materials like aluminum alloys, aluminum die-cast alloys, and copper alloys. Provides recommended speeds (RPM), feed rates (mm/min), and cutting parameters (Fz) for slotting, profiling, and HSM operations.
Conclusion: Serves as a comprehensive guide for selecting and using end mills from the S-Carb series, providing essential specifications, features, tolerances, and application guidelines to ensure optimal performance in machining operations.
Specifications: Lists end mills in different series (47M, 47MB, 47ML, 47MLB, 44M) with specific dimensions such as cutting diameter (D1), length of cut (L2), overall length (L1), and shank diameter (D2). Specifies tolerances for these dimensions.
Machining Parameters: Provides feed rates (mm/min) and cutting speeds (RPM) for various materials like aluminum alloys, copper alloys, and plastics. Includes specific parameters for slotting, profiling, and high-speed machining (HSM).
Material Recommendations: Recommends using these tools for materials with hardness up to 150 Bhn (7 HRc) for non-ferrous materials and plastics. Advises reducing speed and feed for harder materials and adjusting parameters for long flute and long reach tools.
Tool Features: The end mills feature circular lands to reduce edge aggressiveness, two flutes for effective chip management, and excellent balance for high-speed operations. Some designs include a necked design for clearance and a ball nose for finishing operations.
Additional Guidelines: Advises consulting the SGS Tool Wizard for complete technical information and provides a formula for calculating RPM and feed rates. Highlights the importance of reducing feed and Ae when finish milling.
Stock Information: Indicates which tools are standard stock in the U.S. and which require special delivery arrangements.
Specifications: Lists end mills with different flute configurations (2, 3, and 4 flutes) and end types (square, ball, corner radius). Each entry includes cutting diameter (D1), length of cut (L2), overall length (L1), and shank diameter (D2). Tolerances for D1 and D2 are specified as +0.000/-0.050 mm and h6, respectively.
Coatings: End mills are available in uncoated, Ti-NAMITE (TiN), Ti-NAMITE-C (TiCN), and Ti-NAMITE-A (AlTiN) coatings, which enhance tool performance and longevity.
Materials: Suitable for machining a variety of materials, including steels, stainless steels, cast iron, high-temperature alloys, titanium, hardened steels, non-ferrous metals, and plastics/composites.
Performance Data: Provides detailed performance data, including recommended RPM, feed rates, and cutting speeds for different materials and hardness levels. This data is crucial for optimizing machining processes and ensuring tool efficiency.
Stock Information: Some items are marked as U.S. Stock Standard, while others require a call for delivery, indicating availability status.
Applications: Categorized by their suitability for different machining operations, such as profiling and slotting, across various material types, including carbon steels, alloy steels, tool steels, cast irons, stainless steels, super alloys, and titanium alloys.
Material Specifications:- Aluminum Alloys: Includes alloys such as 2017, 2024, 356, 6061, and 7075 with hardness limits of ≤ 150 Bhn or ≤ 7 HRc.
- Copper Alloys: Covers aluminum bronze, C110, and Muntz brass with hardness limits of ≤ 140 Bhn or ≤ 3 HRc.
- Plastics: Includes polycarbonate, PVC, and polypropylene.
- Graphite: Specific machining parameters are provided.
- Stainless Steels: Differentiates between free machining and difficult stainless steels with hardness limits of ≤ 275 Bhn or ≤ 28 HRc.
- High-Temperature Alloys: Includes super alloys like Inconel and Monel with hardness limits of ≤ 300 Bhn or ≤ 32 HRc.
- Titanium Alloys: Various titanium alloys with hardness limits of ≤ 350 Bhn or ≤ 38 HRc.
- Carbon Steels: Includes steels like 1018, 1040, and 1080 with hardness limits of ≤ 175 Bhn or ≤ 7 HRc.
- Alloy Steels: Includes steels like 4140 and 4150 with hardness limits of ≤ 275 Bhn or ≤ 28 HRc.
- Tool Steels: Includes steels like A2, D2, and H13 with hardness limits of ≤ 250 Bhn or ≤ 24 HRc.
- Cast Irons: Includes gray, malleable, and ductile cast irons with hardness limits of ≤ 220 Bhn or ≤ 19 HRc.
Machining Parameters:- RPM and Feed Rates: Detailed RPM and feed rate tables are provided for each material type, specifying the optimal conditions for both profiling and slotting operations.
- Tool Specifications: Includes details on cutting diameter, length of cut, overall length, shank diameter, corner radius, and number of flutes for various end mills and drills.
- Coatings: Information on Ti-NAMITE (TiN), Ti-NAMITE-C (TiCN), and Ti-NAMITE-A (AlTiN) coatings is provided.
Coolant Recommendations:- Coolant is essential for mobilizing chips, reducing heat, minimizing friction, and improving tool life.
- Proper coolant pressure and application are crucial for optimal performance.
- Charts are provided for recommended coolant pressure by drill diameter in both psi and bar.
Best Practices:- Reduce speed and feed for materials harder than listed.
- Limit cut depths for long and extra-long flute mills.
- Refer to the SGS Tool Wizard for complete technical information.
Coolant Recommendations and Specifications:
To maintain the beneficial properties of the coolant and prevent issues such as pressure reduction or clogging in coolant channels, it is recommended to reduce the nozzle size. This increases the velocity and maximizes the cooling benefits of the Hi-PerCarb drill's double margin design. Proper nozzle alignment with the secondary flute is crucial for optimal results.
Recommended Coolant Pressure:
Graphs provided indicate the recommended coolant pressure by drill diameter, both in psi and bar. Smaller tips require high velocity for complete coverage, while larger tips may not provide coverage at maximum depth.
Coolant Application Benefits:
Proper coolant application enhances operational parameters, material removal rates, surface finishes, tool life predictability, energy consumption, and cycle times. Consistent pressure and application are more critical than pressure alone to avoid thermal stress and microfractures.
Drill Specifications:
Includes detailed specifications for various drill sizes, including cutting diameter, decimal and metric equivalents, shank diameter, overall length, flute length, cleared length, and shank length. The Hi-PerCarb drill features a double margin design for improved accuracy and surface finish, a self-centering notched point to eliminate spot drilling, and engineered edge protection for increased feed rates. Recommended for materials with hardness ≤ 56 HRc (≤ 577 Bhn).
Tolerances:
Tolerances are specified for different diameter ranges in both inches and millimeters, ensuring precision in manufacturing and application.
Overview: Provides detailed specifications and guidelines for the Hi-PerCarb 135 5xD series of drills, covering both fractional and metric sizes. Includes information on design features, recommended materials, tolerances, and operational parameters.
Design Features:- Double margin design enhances accuracy and surface finish, providing increased strength for aggressive drilling.
- A specialized self-centering notched point eliminates the need for spot drilling, reducing thrust and deflection.
- Engineered edge protection improves edge strength and reduces fatigue, allowing for increased feed rates.
Material Recommendations:- Suitable for materials with hardness ≤ 56 HRc (≤ 577 Bhn).
Tolerances:- For diameters ≤ 3 mm: D1 = +0.002/+0.012 mm, D2 = h6.
- For diameters > 3–6 mm: D1 = +0.004/+0.016 mm, D2 = h6.
- For diameters > 6–10 mm: D1 = +0.006/+0.021 mm, D2 = h6.
- For diameters > 10–18 mm: D1 = +0.007/+0.025 mm, D2 = h6.
- For diameters > 18–30 mm: D1 = +0.008/+0.029 mm, D2 = h6.
Operational Parameters:- Detailed tables provide cutting speeds (Vc), feed rates (Fr), and RPM for various materials including carbon steels, alloy steels, tool steels, cast irons, stainless steels, super alloys, titanium alloys, aluminum alloys, and copper alloys.
- Specific recommendations are given for different hardness levels (Bhn, HRc, HRb).
Additional Information:- For complete technical information, users are directed to the SGS Tool Wizard available on the Kyocera SGS Tool website.
Overview: Provides detailed specifications and guidelines for the ICe-Carb 140 5xD drill series, covering both fractional and metric sizes. Includes information on design features, recommended materials, tolerances, and operational parameters.
Design Features:- Coolant through design for controlled temperatures and improved coolant flow.
- Split point geometry enhances drill penetration and accuracy.
- Controlled edge honing for increased longevity.
- Negative corner position for added strength and protection.
- Recommended for materials with hardness ≤ 60 HRc (≤ 654 Bhn).
Tolerances:- For diameters ≤3 mm: D1 = +0.002/+0.012 mm, D2 = h6.
- For diameters >3–6 mm: D1 = +0.004/+0.016 mm, D2 = h6.
- For diameters >6–10 mm: D1 = +0.006/+0.021 mm, D2 = h6.
- For diameters >10–18 mm: D1 = +0.007/+0.025 mm, D2 = h6.
- For diameters ≤.1181 inch: D1 = +.00008/+.00047 inch, D2 = h6.
- For diameters >.1181–.2362 inch: D1 = +.00016/+.00063 inch, D2 = h6.
Material Recommendations:- Suitable for carbon steels, alloy steels, tool steels, cast irons, stainless steels, super alloys, titanium alloys, aluminum alloys, and copper alloys.
- Specific RPM and feed rates are provided for different material hardness levels.
Operational Parameters:- RPM and feed rates vary based on material type and hardness, with detailed tables provided for each category.
- For example, carbon steels with ≤ 175 Bhn hardness should be drilled at 425 RPM with a feed rate of 51.0 ipm.
Additional Information:- U.S. Stock Standard items are marked, while non-stocked items require a call for delivery.
- Technical information and further guidance can be accessed via the SGS Tool Wizard on the Kyocera SGS Tool website.
Machining Specifications and Formulas: Provides detailed machining specifications, including tolerances for various size ranges and machining formulas for both inch and metric systems. Key formulas include calculations for surface feet per minute (sfm), revolutions per minute (rpm), feed rates, and material removal rates (mrr). These formulas are essential for optimizing machining processes and ensuring precision in manufacturing.
Decimal Equivalents: A comprehensive table of decimal equivalents for inch and metric measurements is provided. This table is crucial for converting between different measurement systems and ensuring accuracy in machining operations.
Hardness Conversion Chart: Includes a hardness conversion chart that correlates Rockwell, Brinell, and Vickers hardness scales with tensile strength. This chart is useful for selecting appropriate materials and tools based on hardness requirements.
Company Overview: KYOCERA SGS Precision Tools is highlighted as a leader in solid carbide cutting tool technology, serving industries such as aerospace, metalworking, and automotive. The company is ISO-certified and known for its high-performance tooling solutions, including patented geometries that enhance tool life and part quality.
Global Presence: Lists contact information for KYOCERA SGS Precision Tools' global network, including locations in Poland, Spain, Eastern Europe, Russia, China, the USA, the UK, France, and Germany. This global reach ensures accessibility and support for customers worldwide.