DR-50/450 Application Examples

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DR-50/DR-450 Application Examples

HARDENED STEEL – FINISHING DR-50

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Special Bearing

Traub CNC Lathe

En31 (100Cr6) (AISI 52100) through hardened to 58/60 HRc

Boring (Form)

0.4 mm (0.015”)

DNMA 150606T DE DR-50

140 m/min (465 ft/min) cutting with coolant

0.1 mm/rev (0.004”/rev)

Must be better than 0.8 Ra (32 Cla)

Average 40 minutes contact

Form grinding on a CNC lathe with a single point tool

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Gear

EN36B (14NiCr14) (AISI 3415) Case hardened to 58/60 HRc

Harrison 400 Manual Lathe

Boring and Facing (interrupted)

0.5 mm (0.020”) Roughing - 0.05 mm (0.002”) finishing

CNMA 120408T DE DR-50

150 m/min (500 ft/min) boring wet-facing dry

0.2 mm/rev (0.008”/rev)

Not important

Average 40 minutes contact boring – 30 minutes facing

Quicker, cheaper, and better squareness than grinding

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Gas Turbine Engine Bearing Cage

Nitrided Steel 64 HRc

Newall Jig Borer

Boring

0.1mm per pass

TNMA 110304T DE DR-50

100 m/min (330 ft/min) cutting without coolant

0.05 mm/rev (0.002”/rev)

Must be better than 0.8 Ra (32 Cla)

2 parts

It takes longer to load the part than machine it as opposed to 1 Days grinding and there is no danger of surface abuse.

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Cam rotor

EN36B (14NiCr14) (AISI 3415) Case hardened to 58/62 Hrc

Cincinnati Sabre Vertical machining Centre

Fly cutting (Milling)

0.175 mm (0.007”)

TNMN 160308T DE DR-50

160 m/min (530 ft/min) cutting without coolant

0.05 mm/rev (0.002”/rev)

7 micron Rt achieved over batch of 130 parts

Entire batch of components with 2 sides of 1 insert

1 days machining versus 1 weeks grinding

CAST IRON – FINISHING DR-50

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Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Compressor Flange

Makino Horizontal Machining Centre

Grade 17 grey cast iron

Face Milling – Fly Cutting

0.2 mm

CNMA 120412T DE DR-50

800 m/min (2670 ft/min) cutting without coolant

0.1 mm/rev (0.004”/rev)

Must be better than 0.8 Ra (32 Cla)

Average 300 minutes contact

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Compressor Body

Makino Horizontal Machining Centre

Grade 17 grey cast iron

Boring – Interrupted cutting (figure of 8 bores)

0.25 mm

TCMW 16T307T CE DR-50

800 m/min (2670 ft/min) cutting without coolant

0.1 mm/rev (0.004”/rev)

Must be better than 0.8 Ra (32 Cla)

Average 300 minutes contact

Consistent squareness, roundness and surface finish

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Printing press frame

Segen Boring machine

Grade 17 grey cast iron

Boring

0.25 mm

TCMW 16T308T CE DR-50

800 m/min (2670 ft/min) cutting without coolant

0.1 mm/rev (0.004”/rev)

Must be better than 0.8 Ra (32 Cla)

Average 300 minutes contact

Consistent squareness, roundness and surface finish

PLEASE NOTE THAT OUR PRODUCT RANGE AND SITE ARE CURRENTLY UNDER REVIEW

for more information please contact -

Sales and Technical Enquiries

HARDENED STEEL – FINISHING DR-450

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Selector Shaft End Bracket

Case Hardened EN8

Mazak Quickturn 8 2 axis CNC Lathe

Boring – Interrupted Cut (20 mm diameter 36 mm deep)

0.2 mm

TBMN 060106T DR-450

150 m/min

0.08 mm/rev

Must be better than 0.8 Ra (32 Cla)

800 parts

Tool life more consistent than DR-50

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Gear

Case Hardened EN36B

Takisawa TF20 2 axis CNC Lathe

Facing across drilled and tapped holes

0.25 mm

CNMA 120408T CE DR-450

140 m/min

0.1 mm/rev

Not important

100 parts

Work holding not rigid enough for DR-50

Component:

Machine Tool:

Material:

Operation:

Depth of Cut:

Insert:

Surface Speed:

Feed Rate:

Surface Finish:

Tool Life:

Comments:

Transmission Component

Case hardened EN36B

Mazak AJV Machining Centre

Boring Dowel holes in Flange face

0.1 mm

EPMW 040204T CE DR-450

100 m/min

0.04 mm/rev

Not important

180 holes - Dia. 8mm, 10 mm deep

Achieves Jig Grinding tolerances in boring cycle time