DR-80/85 Application Examples

DR-80/DR-85 Application Examples

HARDENED STEEL – SEMI-FINISHING DR-80

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Machine Tool:

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Operation:

Depth of Cut:

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Surface Speed:

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Comments:

Taper roller Bearing

Mazak Quickturn 15 CNC Lathe

EN31 (100Cr6) (AISI 52100) through hardened to 58/ 60 Hrc

Boring and turning taper

0.8/ 1.0 mm (0.030/ 0/040”)

CNMA 120408T DE DR-80

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

0.15 mm/rev (0.006”/rev)

N/A

Average 40 minutes contact

Semi-finishing, rapid stock removal operation on big bearing to remove heat treatment distortion. Work holding not good Enough

for finish machining.

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Gear

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

Ajax 2 axis CNC lathe

Grooving (interrupted)

3 mm wide groove

NB3R W=3 R04 5522T DR-80

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

0.05 mm/rev (0.002”/rev)

Not important

Average 30 minutes contact

Using DR-80 because work holding and machine tool are not rigid enough to use DR-50.

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Machine Tool:

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Comments:

Forming Roll

D2 Tool Steel 60/ 62 HRc

Okuma LC30 CNC Lathe

Turning form on roll diameter

0.5mm per pass

RNMN 090300T DR-100

120 m/min (400 ft/min) cutting with coolant

0.1 mm/rev (0.004”/rev)

Must be better than 0.8 Ra (32 Cla)

30 minutes contact

Complex combination of angles and radii easily achieved.

CAST IRON – FINISHING / SEMI-FINISHING DR-80

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Operation:

Depth of Cut:

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Comments:

Vertical Machining Centre Table

Mazak AJV60/80 Vertical Machining Centre

Grey cast iron

Face Milling – Fly Cutting

0.1/ 0.15 mm

SNGN 1204ZNTN-T DR-80

1500 m/min (2670 ft/min) cutting without coolant

0.54 mm/rev (0.021”/rev)

Must be better than 0.8 Ra (32 Cla)

Average 300 minutes contact

Consistent flatness and surface finish

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Comments:

Slideway

Mazak AJV 60/80 Vertical Machining Centre

Heat treated cast iron (55/ 60 Hrc)

Semi-finish Milling

0.5/ 1.0 mm

TNMN 160312T DR-80

350m/min (1150 ft/min) cutting without coolant

0.1 mm/ tooth/rev (0.004”/ tooth/rev) - 2 inserts cutting

N/A

Average 60 minutes contact

Greatly reduced finish grinding 0.15 mm (0.006”)

Component:

Machine Tool:

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Comments:

Compressor Body

VTL

Grade 17 grey cast iron

Boring (1metre diameter x 1 metre deep)

0.5 mm (0.020”)

CNMA 120408T DE DR-80

300 m/min (1000ft/min) cutting with coolant

0.1 mm/rev (0.004”/rev)

Must be better than 0.8 Ra (32 Cla)

Average 300 minutes contact

Consistent squareness + roundness prior to finish honing operation

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Comments:

Pump part

High Chrome Iron (27%)

Webster Bennett Vertical Borer

Internal threading – Stub Achme Taper thread

Variable

Special brazed tools

80 m/min (270 ft/min) cutting without coolant

To suit pitch

N/A

1 Thread per tool

CAST IRON FINISHING - DR-85

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Machine Tool:

Material:

Operation:

Depth of Cut:

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Surface Speed:

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Surface Finish:

Tool Life:

Comments:

Fly Wheel

Grey Iron

Okuma LC30 2 axis CNC Lathe

Facing

0.2 mm

TPGN 160308T DR-85

600 m/min

0.25 mm/rev

2-3 Ra required

600 parts

Better than BN600 and BZN 6000

Component:

Machine Tool:

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Depth of Cut:

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Comments:

Cast Iron Cylinder Block

Grey Iron

Special Purpose Milling Machine

Face milling - Finishing

0.3 mm

SPKW 1204EDR

600 m/min

0.07mm / tooth

Better than 0.8 Ra

Contact time – 300 minutes