ENG, GER, FRA, ITA - Kyocera

MFPN FACE MILL
High efficient Face Mill
• Double Sided Pentagonal Insert.
• Tough by Large Dual Cutting Edge Insert.
• Excellent Chip Evacuation.
• Low Cutting Force.
MEGACOAT
Hochleistungsplanfräser Fraise à haut rendement Fresa frontale ad alta prestazione
• Doppelseitige pentagonale
Wendeschneidplatte.
• Sehr große und zähe WSP
mit unterschiedlichen
Schneidwinkeln.
• Hervorragende Spanabfuhr.
• Geringe Schnittkräfte.
• Plaquette pentagonale réversible.
• Bien résistante grâce à la large
plaquette de coupe à 2 arêtes.
• Excellente évacuation des copeaux.
• Faible force de coupe.
• Inserto pentagonale a doppio lato.
• Tenacità grazie all’inserto di grandi
dimensioni con doppio tagliente.
• Evacuazione del truciolo eccellente.
• Bassi sforzi di taglio.
TZZ00025
1

■ Double Sided Pentagonal Insert
Doppelseitige pentagonale Wendeschneidplatte
Plaquette pentagonale réversible
Inserto pentagonale a doppio lato
10 cutting edges per insert and optimized insert holding system by 2 faces.
10 Schneiden pro Wendeschneidplatte und optimaler Plattensitz mit zwei Anlagefl ächen.
10 arêtes de coupe par plaquette et optimisation du serrage par 2 points d’appui.
10 taglienti per inserto e sistema ottimizzato per il supporto bifacciale dell’inserto.
12
10
8
MSRS
6
5
4
3
2
Conventional
MFPN
0.5
0.06 0.1 0.2 0.3 0.4 0.5 0.6
ap (mm) Depth of cut
fz (mm/t) Feed per tooth
0.7
Two-face holding
Zwei Anlagefl ächen
Tenue deux faces
Supporto bifacciale
Primary cutting edge
Hauptschneide
Principale aretes de coupe
Primo tagliente
Highly stabilized accuracy due to optimized holding angle of insert against the cutting force.
Höhere Genauigkeit durch verbesserten Anstellwinkel gegen die Schnittkraft.
Stabilité accrue grâce à l’optimisation du systeme de serrage de la plaquette.
Precisione altamente stabile grazie all’ottimizzazione dell’angolo di supporto dell’inserto contro la forza di taglio.
Cutting edge angle
Schnittwinkel
Angle d’arête de coupe
Angolo del tagliente
■ Low Cutting Force
Geringe Schnittkraft
Faible force de coupe
Bassi sforzi di taglio
Good shearing effect provides better bite into workpiece.
Gute Schnittigkeit für besseren Eingriff ins Werkstück.
Très bonne formation de copeaux dès le
début de l’attaque de la pièce.
Buon effetto di troncatura permette una
migliore presa del pezzo.
+10°
High Axial Rake Angle (Max.+10°).
Großer axialer Spanwinkel (Max. +10°).
Angle axial très positif (Max. +10°)
Alto angolo assiale di inclinazione (massimo +10°)
Cutting force comparison
2000
1600
1200
800
400
0
Comparison of cutting force
Vergleich Schnittkraft
Comparaison des force de coupe
Comparazione degli sforzi di taglio
16% reduction in comparison with competitor A
14% reduction in comparison with GM
GM
SM
Competitor A
Competitor B
Principal force
Feed force
Back force
■ Dual Cutting Edge Design (High Toughness)
Schneide mit unterschiedlichen Schneidwinkeln (Hohe Zähigkeit)
Double arête de coupe réversible (grande ténacité)
Design a doppio tagliente (alta tenacità)
Comparison of fracture resistance
Vergleich Bruchfestigkeit
Comparaison de résistance à la rupture
Confronto della resistenza alla frattura
Wiper edge
Secondary cutting edge
Primary cutting edge
PNMU1205ANER-GM
(PR1225)
Competitor C
(PVD negative insert)
Competitor D
(PVD negative insert)
No. of impacts
0 5 10 15 20
×
×
×
×
×
×
fz=0.5mm/t fz=0.6mm/t fz=0.7mm/t
×
○
×
No cracks
Insert cracks
0.5mm/t
0.6mm/t
0.7mm/t
Primary Edge makes chips thinner and reduces impact force.
Die Hauptschneide produziert dünnere Späne und reduziert Schnittkräfte.
Grâce à l’arête de coupe primaire reduction des efforts d’attaque et naissance de copeaux fi ns.
Il primo tagliente produce un truciolo fi ne riducendo le forze di impatto.
~
1

■ Long tool life with MEGACOAT
Lange Werkzeugstandzeit mit MEGACOAT
Longue durée de vie d’outil grâce au revêtment MEGACOAT
Lunga vita utensile grazie al rivestimento MEGACOAT
Wear comparison
Vergleich des Verschleißverhaltens
Comparaison des usures
Confronto usura
0.30
40
0.25
30
TiC
MEGACOAT
Flank wear [mm]
0.20
0.15
0.10
Competitor E
Competitor F
Hardness(GPa)
20
10
TiCN
TiN
TiAlN
0.05
0.00
0 20 40 60 80
Cutting time [min]
.
Competitor G
PR1225
0 200 400 600 800 1000 1200
Insert Grades
MEGACOAT
(PVD coated carbide)
PR1225
PR1210
Oxidation temperature
Workpiece Material
Steel/Stainless steel
Cast iron/Titanium alloy
MEGACOAT
Long tool life and high-speed milling due to
high hardness and high oxidation resistance.
Lange Standzeit und hohe Geschwindigkeiten durch
hohen Härtegrad und Oxidationsbeständigkeit.
Longue durée de vie et haute vitesse de coupe augmentée
grâce à une plus grande duretée et résistance à l’oxydation.
Lunga vita utensile e fresatura ad alta velocità per merito
della durezza e dell’alta resistenza all’ossidazione.
■ Excellent Chip Evacuation
Hervorragende Spanabfuhr
Excellente evacuation de copeaux
Evacuazione del truciolo eccellente
Smooth chip evacuation reduces chip-biting.
Reduzierterter Spanschlag durch leichte Spanabfuhr.
Design de la plaquette réduit les copeaux sur l’arête de coupe.
L’evacuazione dei trucioli senza attrito, riduce l’impatto dei trucioli.
Chipbreaker Applications Shape
6
SM
GM
General
SM
Low cutting force
ap (mm) Depth of cut
3
GM
GH
1
GH
Heavy milling
0.06 0.1 0.2 0.3 0.4 0.5 0.6 0.7
fz (mm/t) Feed per tooth
2

E
A.R.
R.R.
Rake Angle(°)
max +10°
øD=63 -10°
øD=80 -8°
øD=100-250 -6°
ød
b
6
H
E
a
a
ød
b
ød
b
ø18
6
6
H
H
E
ød2
ød1
øD
øD1
45˚
ød1
øD
øD1
45˚
ød2
ød1
øD
øD1
ø26
45˚
Fig.1 Fig.2 Fig.3
Holder Dimension
Description
Standard
No. of
Insert
Dimension (mm)
øD øD1 ød ød1 ød2 H E a b
Shape
Weight
(kg)
Shim
Bore Dia. mm spec
Bore Dia. Inch spec
Extra fi ne pitch
Fine pitch
Coarse pitch
Extra fi ne pitch
Fine pitch
Coarse pitch
MFPN 45063R-4T-M ● 4 63 76 22 19 11 40 21 6.3 10.4 0.5
Fig.1
45080R-5T-M ● 5 80 93 27 22 13
24 7 12.4 1.1
50
45100R-6T-M ● 6 100 113 32 48
30 8 14.4 1.4
-
Fig.2
45125R-7T-M ● 7 125 138
58
2.6
40
32 9 16.4
45160R-8T-M ● 8 160 173 68 66.7
3.8
63
45200R-10T-M ● 10 200 213
Fig.3 6.4
60 110 101.6 40 14 25.7
45250R-12T-M ● 12 250 263 9.1
MFPN 45063R-5T-M ● 5 63 76 22 19 11 40 21 6.3 10.4 0.5
Fig.1
45080R-6T-M ● 6 80 93 27 22 13
24 7 12.4 1.0
50
45100R-8T-M ● 8 100 113 32 48
30 8 14.4 1.4
-
Fig.2
45125R-10T-M ● 10 125 138
58
2.5
40
32 9 16.4
45160R-12T-M ● 12 160 173 68 66.7
3.8
63
45200R-14T-M ● 14 200 213
Fig.3 6.5
60 110 101.6 40 14 25.7
45250R-16T-M ● 16 250 263 9.1
MFPN 45063R-6T-M ● 6 63 76 22 19 11 40 21 6.3 10.4 0.5
Fig.1
45080R-8T-M ● 8 80 93 27 22 13
24 7 12.4 1.1
50
45100R-10T-M ● 10 100 113 32 48 - 30 8 14.4 1.3
Fig.2
45125R-13T-M ● 13 125 138
58 -
2.6
40
32 9 16.4
45160R-16T-M ● 16 160 173 68 66.7
3.9
63
45200R-18T-M ● 18 200 213
Fig.3 6.6
60 110 101.6 40 14 25.7
45250R-20T-M ● 20 250 263 9.3
MFPN 45080R-5T 5 80 93 25.4 22 13
27 6 9.5 Fig.1 1.1
50
45100R-6T 6 100 113 31.75 48
32 8 12.7 1.4
45125R-7T 7 125 138 38.1 58 -
36 10 15.9 Fig.2 2.6
45160R-8T 8 160 173 50.8 72 38 11 19.1 4.0
63
45200R-10T 10 200 213
6.7
47.625 110 101.6 40 14 25.4 Fig.3
45250R-12T 12 250 263 9.4
MFPN 45080R-6T 6 80 93 25.4 22 13
27 6 9.5 Fig.1 1.1
50
45100R-8T 8 100 113 31.75 48
32 8 12.7 1.4
45125R-10T 10 125 138 38.1 58 -
36 10 15.9 Fig.2 2.7
45160R-12T 12 160 173 50.8 72 38 11 19.1 4.0
63
45200R-14T 14 200 213
6.9
47.625 110 101.6 40 14 25.4 Fig.3
45250R-16T 16 250 263 9.6
MFPN 45080R-8T 8 80 93 25.4 22 13
27 6 9.5 Fig.1 1.1
50
45100R-10T 10 100 113 31.75 48
32 8 12.7 1.3
45125R-13T 13 125 138 38.1 58 -
36 10 15.9 Fig.2 2.7
45160R-16T 16 160 173 50.8 72 38 11 19.1 4.0
63
45200R-18T 18 200 213
6.9
47.625 110 101.6 40 14 25.4 Fig.3
45250R-20T 20 250 263 9.6
Yes
Yes
Standard Item Check Availability
3

Spare parts from (mm/inch common spec)
Spare Parts
Description
Clamp Screw
TT
Wrench
DTM
Shim Shim Screw Wrench
Arbar
Clamp Screw
Coarse pitch
Fine pitch
Extra fi ne pitch
MFPN 45063R-4T-M
HH10x30
MFPN 45080R-5T-M SB-50140TR TT-15 MFPN-45 SPW-7050 LW-5 HH12x40
MFPN 45100R-6T-M
-
for Insert Clamp
Recommended torque is 4.2 Nm.
for Insert Clamp
Recommended torque is 6.0 Nm.
-
45250R-12T-M
MFPN 45063R-5T-M
HH10x30
MFPN 45080R-6T-M SB-50140TR TT-15 HH12x40
MFPN 45100R-8T-M
- - - -
for Insert Clamp
Recommended torque is 4.2 Nm.
-
45250R-16T-M
MFPN 45063R-6T-M
HH10x30
MFPN 45080R-8T-M SB-40140TRN - DTM-15 HH12x40
MFPN 45100R-10T-M
- - -
for Insert Clamp
Recommended torque is 3.5 Nm.
-
45250R-20T-M
~
~
~
Classifi cation of usage P Steel ★
Die Steel
Milling Inserts (with hole)
Shape
Handled insert indicates Right-Hand
★Roughing / 1st Choice
★Roughing / 2nd Choice
■Finishing / 1st Choice
■Finishing / 2nd Choice
(Hardened material is applicable only under 45HRC)
Description
★
M Stainless Steel ★
K
Gray Cast Iron ★
Nodular Cast Iron
★
N Non-ferrous Material ★
S
Heat-resistant Alloy ★
Titanium alloy
★
H Hardened material
Dimension (mm)
MEGACOAT
carbide
A T ød X Z PR1225 PR1210
Z
A
Ød
PNMU
1205ANER-GM
●
●
General
X
T
17.88 5.56
Z
A
Ød
PNMU 1205ANER-SM 6.2 2.0 2.0 ● ●
Low cutting force
X
T
Z
A
Ød
PNMU 1205ANER-GH 17.98 6.17 ● ●
Tough Edge (for heavy milling)
X
T
Standard Item Check Availability
Reference for selecting a facemill and insert suitable for each milling purpose
Milling Purpose
Coarse
pitch
Facemill-type
Fine pitch
Extra
fi ne pitch
Chipbreaker
General milling of steel and alloy steel
Steel and alloy steel (at chattering due to low rigidity machine or poor clamping power)
Productivity oriented (Running cost decrease)
General milling of stainless steel
Stainless steel (at chattering due to low rigidity machine or poor clamping power)
Cast iron (for processing effi ciency improvement)
Cast iron (Over ap=4 mm, over fz=0.35 mm/t)
4

Face milling (with meltdown surface)
1500
100
200
ø3000
80
2000
•MFPN facemill enables stable milling due to reduced chip-biting and edge cracks.
•MFPN facemill, no chattering, showed 3 times longer tool life than competitor.
•MFPN facemill showed 1.5 times longer tool life than the competitor.
•High feed rate of MFPN allowed 1.3 times higher milling efficiency compared to the
competitor.
Evaluation by the user
Evaluation by the user
Total D.O.C.
100
ø400
Face milling
3000
300
•MFPN facemill showed 2 times longer tool life than competitor.
•Competitor caused cracks by chip-biting. MFPN facemill had no cracks and allowed
stable milling.
•MFPN facemill enabled twice the table feed rate compared with the competitor. Milling
efficiency improved two-fold.
•Highly stable milling into the entrance of workpiece and less vibration than the
competitor.
•Cleanly curled chips which barely cause chip-biting.
•Cutting speed has been changed Vc=110 m/min of conventional competitor's to Vc=130
m/min, thereby the milling efficiency of MFPN increased 1.2 times.
Evaluation by the user
Evaluation by the user
5

End face milling
80
2000
ø90
•Although the conventional tool causes chattering, MFPN facemill suppresses chattering,
enabling stable milling.
•Even if the feed rate is raised to 1.9 times, the insert wears less and there is no cracks
on the insert.
•Both the milling efficiency and the tool life have been improved.
•MFPN facemill causes no vibration, enabling stable milling, even though the number
of cutting edges of facemill has been increased by 4 and the feed per tooth has been
increased by 1.3 times.
•Does not generate much heat after milling and obtains the lustrous surface finish without
burrs.
•Milling efficiency increased 2.6 times with the high cutting conditions.
Evaluation by the user
Evaluation by the user
600
800
300
400
500
(Conventional)
Vc=140m/min
apxae=3x80mm
fz=0.11mm/t
(Vf=230mm/min)
•Even if the cutting speed and feed rate are raised up to the level of the conventional tool,
the tool life of MFPN remains unchanged and milling efficiency increases by 2.6 times.
•MFPN vibrates less right at entrance and exit on workpiece with reduced cutting sound.
•Even when the cutting depth, cutting speed and feed rate cannot be raised due to the
low rigidity of a workpiece, MFPN facemill enables stable milling without chattering and
also has an improved tool life of 1.5 times.
Evaluation by the user
Evaluation by the user
6

1. Be sure to remove dust and chips from the insert mounting pocket.
2. After applying anti-seize compound, while pressing the insert against the constraint surfaces, put the screw into the hole of the insert and tighten the screw with
appropriate torque. See Fig. 1 and Fig. 2.
Recommended tightening torqueThe torque for coarse pitch and cross pitch (using M5 screw) is 4.2 Nm.
The torque for extra cross pitch (using M4 screw) is 3.5 Nm.
3. After tightening the screw, make sure that there is no clearance between the insert seat surface and the bearing surface of the holder and between
the insert side surfaces and the constraint surface of the holder.
4. To change the cutting edge of the insert, turn the insert counterclockwise (see Fig. 3). Insert corner identifi cation number is stamped on the
top surface of insert (Fig. 4). To protect the wiper edge, use the corners of insert in the sequence of corner numbers.
Side surface of insert
Top surface of insert
Constraint surface
Insert corner
identification number
(mm/t)
Workpiece Material Insert Grade Cutting Speed (m/min) Chipbreaker
0.06 0.1 0.2 0.3 0.4 0.5 0.6 0.7
GM 0.1 0.2 0.4
Carbon Steel
PR1225 120~180~250 SM 0.06 0.12 0.25
GH 0.2 0.4 0.7
GM 0.1 0.2
0.4
Alloy Steel
PR1225 100~160~220 SM 0.06 0.12
0.25
GH 0.2 0.4
0.6
GM 0.1 0.2
0.35
Die Steel
PR1225 80~140~180 SM 0.06 0.1 0.2
GH 0.2 0.35 0.5
Stainless Steel PR1225 100~150~200
GM 0.1 0.2
0.4
SM 0.06 0.12 0.25
GM 0.1 0.2
0.4
Gray Cast Iron PR1210 120~180~250 SM 0.06 0.12 0.25
GH 0.2 0.4 0.7
GM 0.1 0.2
0.35
Nodular Cast Iron PR1210 100~150~200 SM 0.06 0.1 0.2
GH 0.2 0.35 0.5
Titanium Alloy PR1210 30~50~70 SM 0.06 0.08 0.15
Coarse pitch (with shim)
Type
Fine pitch (without shim)
(For GH chipbreaker, recommend under fz=0.4 mm/t.)
Extra fi ne pitch (without shim)
The use of the GH breaker is not recommended.
The bold-faced number indicates a center value of recommended condition.
★: 1st Recommendation ✩: 2nd Recommendation
KYOCERA Fineceramics GmbH
Cutting Tool Division
Hammfelddamm 6, 41460 Neuss, Germany
Phone: +49 (0) 2131 1637-115
Fax: +49 (0) 2131 1637-152
www.kyocera.de / www.kyocera.eu
ceratip@kyocera.de
KYOCERA Fineceramics SAS.
Cutting Tool Division
4, allee du Commandant Mouchotte
Paray-vieille-poste 91781,Wissous Cedex, France
Phone: +33 (0) 1 45 12 06 93 Fax: +33 (0) 1 56 72 18 94
www.kyocera.fr
KYOCERA Fineceramics GmbH sp. z o.o. Poland Branch Office
Cutting Tool Division
Leg. ul.Europejska 4, 55-220, Jelcz-Laskowice, Poland
Phone: +48-(0)71-381-12-15 Fax: +48-(0)71-381-12-16
www.kyocera.eu
KYOCERA Fineceramics GmbH Italy Branch Office
Cutting Tool Division
Via Torino 51, 20123 Milan, Italy
Phone: +39-02 00620 845 Fax: +39-02 00620 848
www.kyocera.it
KYOCERA Fineceramics GmbH Spain Branch Office
Cutting Tool Division
Avenida Manacor 4, 28290 Las Matas, Madrid, Spain
Phone: +91-631-83-92-802 Fax: +91-631-82-19
www.kyocera.es