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

    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

 

      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

 

 

 

 

 

 

 

© David Richards Engineering 2008