Milling Technology

Thread Cutting Technology Machining Technology Clamping Technology

AWT 07/99 FR 1

FRANKEN Programm

Thread Cutting Technology Machining Technology Clamping Technology

HighTech

Die- and Mold programme

Base programm

AWT 07/99 FR 2

FRANKEN Programm

Thread Cutting Technology Machining Technology Clamping Technology

Base-programme: Content HSS Milling Programme Standard solid carbide end mills Market situation No or just limited consulting service

HighTech

Die- and Mold programme

Base programm

AWT 07/99 FR 3

FRANKEN Programm

Thread Cutting Technology Machining Technology Clamping Technology

Die and mold programm: Content Solid carbide and indexable cutters Market situation Sales only with consultation Technical know how required

HighTech

Die- and Mold programme

Base programm

AWT 07/99 FR 4

FRANKEN Programm

Thread Cutting Technology Machining Technology Clamping Technology

High Tech Programme: Content Selected tools and solutions, New products Market situation Sales only with consultation Demonstrations and Trainings

HighTech

Die- and Mold programme

Base programm

AWT 07/99 FR 5

Base program

Thread Cutting Technology Machining Technology Clamping Technology

HighTech

Die- and Mold programme

Base programm

AWT 07/99 FR 6

Base program

Thread Cutting Technology Machining Technology Clamping Technology

Solid carbide: Special end mills accord. customer specification.

HSS - E

AWT 07/99 FR 7

Straight shanks DIN 1835 - DIN 6535

DIN 1835
Plain straight shank Type A

Thread Cutting Technology Machining Technology Clamping Technology

DIN 6535
Type HA

Straight shank with driving flat

Type B
up to shank 20 one flat over shank 20 two flats

Type HB
up to shank 20 one flat over shank 25 two flats

Straight shank with bayonet lock

Type C
valid for over 40

Straight threaded shank

Type D
e.g. for DUBLOK collets

Straight shank with inclined driving flat

Type E

Type HE
up to shank 25

Type HE
over shank 20

AWT 07/99 FR 8

Morse taper shanks for milling cutters

Thread Cutting Technology Machining Technology Clamping Technology

DIN 228 Type A

taper shank with internal thread

DIN 228 Type B

taper shank with driving tang

DIN 2207
taper shank according to DIN 228 Type A with driving flats

AWT 07/99 FR 9

ISO taper shanks

Thread Cutting Technology Machining Technology Clamping Technology

DIN 2080-1 Type A

taper shank for tools and clamping devices

DIN 69871-1 Type A

taper shank with trapezoidal groove for automatic tool change

DIN 69871-1 Type AD

taper shank for automatic tool change, with trapezoidal groove and drilled hole for coolant supply

DIN 69871-1 Type B

taper shank for automatic tool change, with trapezoidal groove and coolant supply through the collar
AWT 07/99 FR 10

Hollow taper shanks

Thread Cutting Technology Machining Technology Clamping Technology

DIN 69893-1 Type A

hollow taper shank for automatic tool change, with gripping and indexing slots

DIN 69893-1 Type C

hollow taper shank for manual tool change

DIN 69893-2 Type B

hollow taper shank for automatic tool change, with gripping and indexing slots, and coolant supply through the collar

DIN 69893-2 Type D

hollow taper shank for manual tool change, with coolant supply though the collar

AWT 07/99 FR 11

Clamping chucks
Clamping chuck for straight shanks with driving flat according to DIN 1835 Type B and DIN 6535 Type HB

Thread Cutting Technology Machining Technology Clamping Technology

Clamping chuck for straight shanks with inclined driving flat according to DIN 1835 Type E and DIN 6535 Type HE

AWT 07/99 FR 12

Hydraulic clamping chucks for the clamping of straight shanks

Hydraulic clamping chucks acc. DIN 1835 type A and DIN 6535 type HA

Thread Cutting Technology Machining Technology Clamping Technology

Pressure relieved position

Reduction collets

Pressure engaged position (clamping)

AWT 07/99 FR 13

Shrink-fit chucks, collet chucks for the clamping of straight shanks

Thread Cutting Technology Machining Technology Clamping Technology

AWT 07/99 FR 14

End mills - Different types of cutter faces

Thread Cutting Technology Machining Technology Clamping Technology

AWT 07/99 FR 15

Face designs

Thread Cutting Technology Machining Technology Clamping Technology

Standard design end mills and slot drills HSS and carbide concave face

Transition of primary to secondary (face) tooth with an additional protection chamfer (chamfered edges)

Transition of primary to secondary (face) tooth with an additional corner radius

Transition of primary to secondary (face) tooth with fast-spiral end mills

Radius cutter with full face radius

Torus cutter with corner radius and highly concave face

AWT 07/99 FR 16

Different types of relief

Thread Cutting Technology Machining Technology Clamping Technology

Rake angle

Double plane relief

Rake angle

Measuring point of rake angle

Radial relief

Concave relief

The profile is not constant!

AWT 07/99 FR 17

Measuring point of rake angle

Primary relief angle Secondary relief angle

Tool types

Thread Cutting Technology Machining Technology Clamping Technology

Type W Type N Type H

Type WF Type NF Type HF

Type WR Type NR Type HR

AWT 07/99 FR 18

Standard end mills

Type W Type N

Thread Cutting Technology Machining Technology Clamping Technology

Type H

Type WF

Type NF

Type HF

Type WR

Type NR

Type HR

Surface condition after cutting

smoother

Chipping volume
less

Motor power (kW)

more

Material of workpiece
softer harder

rougher

more

less

AWT 07/99 FR 19

Constructional dimensions of milling cutters

For example: End mills Type N, 20 extra short short medium long long

Thread Cutting Technology Machining Technology Clamping Technology

extra long

cutting length 22 mm

cutting length 38 mm

cutting length 56 mm

cutting length 75 mm

Standard catalogue types of shanks: Plain straight shank Straight shank with driving flat Straight threaded shank DIN 1835 Type A DIN 1835 Type B DIN 1835 Type D

cutting length 120 mm

AWT 07/99 FR 20

Web thickness in relation to tool length

Thread Cutting Technology Machining Technology Clamping Technology

Construction length: extra short short

Construction length: medium long long

Construction length: extra long

AWT 07/99 FR 21

FRANKEN End mills Helix angles

Thread Cutting Technology Machining Technology Clamping Technology

20 helix angle

30 helix angle 40 helix angle 45 helix angle 50 helix angle 60 helix angle

= Cutter diameter = Rake angle of primary cutting edge = Primary relief angle of primary cutting edge = Secondary relief angle of primary cutting edge

AWT 07/99 FR 22

Milling cutters with a constant profile

Thread Cutting Technology Machining Technology Clamping Technology Rake angle of primary cutting edge Relief angle of primary cutting edge Stroke

Relief-turned or relief-ground
AWT 07/99 FR 23

Profile calculation, profile grinding and control on form cutters

System for NC programme generation

Thread Cutting Technology Machining Technology Clamping Technology

CAD
Specified contour Grinding wheel geometry Customer drawing
NC programme online

START
NC grinding machine
grinding wheel dressing wheel Actual contour not inside the tolerance, a new cycle starts Actual contour inside the tolerance cutter

System for comparing actual and specified contour

Measuring system

cutter

Measured data

FINISH

Cutter with inspection certificate, ready for shipment

AWT 07/99 FR 24

Climb milling - Conventional milling

Thread Cutting Technology Machining Technology Clamping Technology

Climb milling:

Conventional milling:

AWT 07/99 FR 25

The vectors show the bending direction of an end mill, which is cutting at different radial depths ae
Conventional milling Climb milling

Thread Cutting Technology Machining Technology Clamping Technology

Cutting direction

AWT 07/99 FR 26

Bending of an end mill

Conventional milling
Machine direction

Thread Cutting Technology Machining Technology Clamping Technology

Climb milling
Machine direction

End mill 25 4 teeth 30 helix angle

Bending in mm

Bending in feed direction Bending in machine direction Total bending radial cutting depth ae No bending in feed direction

AWT 07/99 FR 27

Keyway cutting with slot drills in one work process

Thread Cutting Technology Machining Technology Clamping Technology

3-fluted cutter:
Conventional milling Climb milling

2-fluted cutter:
Conventional milling Climb milling

AWT 07/99 FR 28

Cutting of keyways
With one step cutting process (full size cutters) Recommendation: 2-fluted cutters Keyway: 20 P9 ( -0,022 ) 19,978 -0,074 Cutter: 20 e8 ( -0,040 ) -0,073 Advantages:
Time saving, because keyway length = cutting length
19,926

Thread Cutting Technology Machining Technology Clamping Technology

With three step cutting process (under size cutters) Recommendation: 3-fluted cutters Keyway: 20 P9 ( -0,022 ) -0,074

P9 e8

19,960 19,927

Cutter: 19,7 h10 ( -0 ) -0,084 Advantages:

Keyway walls are perpendicular When the cutter is worn out reduction of the tool dia. the tolerance of the keyway can be reached by radial resetting of the cutter the full tool life of the cutter can be used reground cutters can be used again

Disadvantages:
Keyway walls are not perpendicular (cutter displacement) When the cutter is worn out reduction of tool dia. the tolerance of the keyway can no longer be achieved cutter must be exchanged, even if the maximum tool life hasnt been reached reground cutters are not suitable for one step process

Disadvantages:
more time is needed because of longer process only possible on CNC machines

Cutting example:
Keyway 20 P9 x 90 Milling cutter type: 2300.020 (2-flutes) Material of workpiece: 42 CrMo 4 V, Rm = 850 N/mm2 Cutting conditions: ap = 10 mm, vc = 30 m/min, n = 477 min-1
Drilling feed: fz = 0,029 mm, vf = 30 mm/min Cutting feed: fz = 0,073 mm, vf = 70 mm/min

Cutting example:
Keyway 20 P9 x 90 Milling cutter type: 2310.0197 (3-flutes) Material of workpiece: 42 CrMo 4 V, Rm = 850 N/mm2 Cutting conditions: ap = 10 mm, vc = 30 m/min, n = 477 min-1
Drilling feed: fz = 0,029 mm, vf = 40 mm/min Cutting feed: fz = 0,073 mm, vf = 105 mm/min Cutting feed: fz = 0,200 mm, vf = 286 mm/min

Cutting time: approx. 80 sec./keyway

Cutting time: approx. 85 sec./keyway

AWT 07/99 FR 29

Average analysis values of high-speed steels

Thread Cutting Technology Machining Technology Clamping Technology

Short designation acc. DIN 17006 S S S SC S S S S S S S S S S S S S S S S S 3-3-2 2-9-1 6-5-2 6-5-2 6-5-3 9-1-2 18-0-1 12-1-4 12-1-2-5 12-1-4-5 6-5-2-5 7-4-2-5 10-4-3-10 18-1-2-5 18-1-2-10 2-10-1-8 6-5-2-8 6-5-3 6-5-3-9 6-7-6-10 3-3-1-8

Former DIN designation ABC lll BMo 9 DMo 5 DMo 5 h EMo 5 V 3 ABC ll B 18 EV 4 ECo 5 EV 4 Co EMo 5 Co 5 EMo 5 Co 5 h EW 9 Co 10 E 18 Co 5 E 18 Co 10 *PM (23) *PM (30) *PM (60) *PM (2017)

American AISI designation M1 M2 M3 Class 2 T1 T9 T15 M35 M41 M36 T4 T5 M42 (M3 Class 2)

Material code acc. DIN 17007 1.3333 1.3346 1.3343 1.3342 1.3344 1.3316 1.3355 1.3302 1.3251 1.3202 1.3243 1.3246 1.3207 1.3255 1.3265 1.3247 1.3222 1.3344 1.3241

Chemical analysis (%) C 0,95 0,85 0,90 1,00 1,30 0,82 0,75 1,25 0,80 1,30 0,90 1,12 1,25 0,80 0,75 1,08 1,45 1,28 1,28 2,30 0,80 Cr 4,20 3,90 3,80 3,80 4,10 4,20 4,20 4,30 4,00 4,30 4,10 4,10 4,10 4,30 4,30 4,00 4,25 4,20 4,20 4,00 4,00 Mo 2,60 8,60 5,00 5,00 4,90 0,90 1,00 1,20 1,00 4,90 4,00 3,90 1,00 1,00 9,50 5,90 5,00 5,00 7,00 3,00 V 2,40 1,20 1,80 1,80 3,00 1,60 1,10 4,00 1,80 4,00 1,80 1,70 3,50 1,60 1,60 1,20 2,30 3,10 3,10 6,50 1,00 W 3,10 1,80 6,40 6,40 6,30 8,50 18,00 12,50 12,50 12,50 6,30 6,40 9,50 18,00 18,00 1,50 6,40 6,40 6,40 6,50 3,00 Co 5,50 5,00 4,80 4,80 10,50 5,00 9,50 8,00 8,00 8,50 10,50 8,00

*PM = powder-metallurgically produced steel

= high-speed steels especially favoured by FRANKEN

AWT 07/99 FR 30

Average analysis values of carbide ISO groups

Thread Cutting Technology Machining Technology Clamping Technology

ISO carbide grade K10 K20 K40 K01-K10 micro grain K05-K10 fine grain K10-K30 fine grain K20-K40 P20-P25 P30-P40 P40 Cermet P10-P20 K10-K30 micro grain

Percent in weight tungsten carbide 94,20 93,20 87,20 94,00 94,00 92,50 90,00 71,50 76,50 77,00

Percent in weight TIC/TaNbc 0,30 0,80 0,80 20,00 11,50 12,00

Percent in weight cobalt 5,5 6,0 12,0 6,0 6,0 7,5 10,0 8,5 12,0 11,0

Average grain size m 1,0 2,0 2,0 0,5 0,7 0,7 0,7 2,0 - 3,0 2,0 - 3,0 3,0

Bending Specific strength weight g/cm3 N/mm2 1900 2000 2500 3300 3300 3500 3700 1800 2200 2400 2100 4000 14,8 14,7 14,3 14,9 14,9 14,7 14,5 12,4 13,1 13,3 7,1 14,1

Hardness Vickers HV 30 1750 1610 1370 2000 1850 1720 1550 1575 1390 1420 1600 1730

Crushing strength KN/mm2 14,8 14,7 14,3 14,9 14,9 14,7 14,5 12,4 13,1 13,3 7,1 14,1

86,65

rest (mixed carbides)

12,0

0,4

AWT 07/99 FR 31

Coatings

Thread Cutting Technology Machining Technology Clamping Technology

Wear protection coatings on milling tools

other coatings TiN MONOLAYER TiCN MULTILAYER TiAlN MULTI- or MONOLAYER Diamond MONOLAYER CBN TiAlCN CrN Al2O3 DLC Silver-TiN etc.

AWT 07/99 FR 32