Pokolm-Voha

Oxydazation? Quadworx® "S" from practice to practice
17.04.2009

Machine:   DMU 60P

Material:   1.4534

Programmiing system: MillPlus

Job title:

Process optimizing of a component from material 1.4534 (X3CrNiMoAl13-8-2). This is equal to the US-alloy PH 13-8Mo, a high-tensile stainless steel with aircraft- and space conditions. Previously, a slot was produced with a Pokolm threaded shank end mill body No. 3 15 235/12 (15 mm diam., r=3.5). The slot is curved and open on both ends. Dimensions are: 150 mm long, 20 mm wide and 70 mm deep. With this tool mentioned, the customer
could produce 1 complete slot. After that, inserts had to be turned in order to secure continued process reliability. This additional downtime had significant influence on the component’s costs.

The customer had to find a solution, to reduce machining time as well as downtime. The new tool Quadworx® “S” was selected to be the right tool for this application. It was assumed, that the milling cutter 2 16 247 (16 mm diam., rp 1,3)
together with our new insert 2 47 896 should be the correct selection for this job.

The slots of this component have been produced countour-parallel in z-constant cycle in climb milling as well as conventional milling. Regarding machining time, the feed rate and the chip volume have been more than doubled. This Quadworx® “S” combination allows a 7-times increase of tooth load compared with the previous end mills with round inserts. The high tensile and forged component was machined using constant coolant supply, in
order to avoid any heating up of the component.

EXAMPLE FROM PRACTICE:
	previously:	now:
machining:	slot
material:	1.4534 (Alloy PH13-8)
arbor:	00 16 750 S (Ø 16, SK 40)
extension:	40 08 601
tool:	3 15 235/12 (Ø15 /R 3,5)	2 16 247 (Ø16 /R 1,3)
inserts:	01 07 895	02 47 896, M40
coating:	PVGM	PVST
overhang:	73 mm	73 mm
v_c(speed):	170 m/min	170 m/min
v_f(feed rate):	900 mm/min	1.800 mm/min
S (revolutions):	3.400 1/min	3.400 1/min
f_z (feed per tooth):	0,083 mm	0,59 mm
a_p (depth of cut):	0,3 mm	0,3 mm
a_e (width of cut):	5 - 15 mm	4 - 16 mm
chip volume:	2,13 cm³/min = 0,13 cu. in./min	4,32 cm³/min = 0,264 cu. in./min
machining time:	40 min.	20 min.

RESULT:

Machining time of this component has been reduced from 40 to 20 minutes. At the same time, tool life increased to 2 components with these new inserts Quadworx® “S” 02 47 896, without any insert change. Even the increased costs for using this new Quadworx® “S”-combination has already payed itself off after machining only 1 component.

Further Information:

Quadworx® „S" From Practice to Practice

and Machining Stainless Steels

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