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CoroMill® 331

Universal skiv- och planfräs

Kundexempel, Thailand

BranschAllmän verkstadsindustri
MaterialHöglegerat stål, CMC 3.11 (P3.1.Z.AN)
OperationTvåsidigt skärande skivfräs
MaskinMazak

-73 %

kostnad per komponent

+279 %

produktivitetsökning

VerktygL331.52-160S40FMN331.32-200Q40FM12.00
SkärN331.1A-08 45 08H-PL 4240N331.1A-08 45 08E-M30 1130
Dc160 (6,3)160 (6,3)
Zn1212
n, varv/min450350
vc m/min (fot/min)226 (741)176 (577)
hex mm (tum)0,017 (0,0007)0,078 (0,0031)
fz mm (tum)0,02 (0,001)0,09 (0,004)
vf, mm/min (tum/min)108 (4)375 (15)
ap mm (tum)6 (0,236)6 (0,236)
ae mm (tum)40 (1,575)40 (1,575)
VerktygsbyteskriterierSkärbrottSkärbrott
Ingreppstid (minuter)68,518
Skärlivslängd (antal komponenter)1437,5

Resultat

Den nya E-M30-geometrin ökade produktiviteten med 279 % och reducerade kostnaden per komponent avsevärt.

Kundexempel, USA

KomponentKulventil för flödesreglering (olja och gas)
MaterialM1.0.Z.AQ (316 SS)
OperationSpårfräsning
MaskinSpecialmaskin
VerktygN331.32-152T38EM0.394N331.32-152T38EM0.394
SkärN331.1A-08 45 08H-PL S30TN331.1A-08 45 08E-L50 S30T
DC152152
zn, (zeff)12 (6)12 (6)
n, varv/min11091109
vc m/min (fot/min)529 (1736)529 (1736)
hex mm (tum)0,036 (0,001)0,036 (0,001)
fz mm (tum)0,1 (0,004)0,1 (0,004)
vf, mm/min (tum/min)658 (25,9)658 (25,9)
ap mm (tum)11,5 (0,453)11,5 (0,453)
ae mm (tum)5,5 (0,217)5,5 (0,217)
Tid i ingrepp/komponent, sek.2,52,5
Skärlivslängd, komponenter210260

Resultat

När H-PL-geometrin byttes mot den nya L-50-geometrin ökade skärlivslängden med 24 % och skärförslitningen blev mycket mer tillförlitligt och förutsägbart.

Kundexempel, USA

KomponentFlygindustrin, rörkoppling
MaterialS2.0.Z.AN (Inconel 625)
OperationSatsfräsning
MaskinHorisontell dornmonterad, manuell fräsmaskin

67 %

Ökad skärlivslängd

VerktygR331.52-127T38EM
L331.52-127T38EM		R331.52-127T38EM
L331.52-127T38EM
SkärN331.1A-08 45 08H-PL S30TN331.1A-08 45 08 L50 S30T
DC127127
zn, (zeff)10 (10)10 (10)
n, varv/min142142
vc m/min (fot/min)56,7 (186)56,7 (186)
hex mm (tum)0,051 (0,002)0,051 (0,002)
fz mm (tum)0,051 (0,002)0,051 (0,002)
vf, mm/min (tum/min)72,95 (2,87)72,95 (2,87)
ap mm (tum)1,27 (0,050)1,27 (0,050)
ae mm (tum)16,26 (0,640)16,26 (0,640)
Tid i ingrepp/komponent, sek.25,0 × 3 passeringar indexerat25,0 × 3 passeringar indexerat
Skärlivslängd, komponenter120200

Resultat

Det nya L50-skäret gav överlägsen skärlivslängd och förutsägbar, tillförlitlig verktygsförslitning. Minskad vibration och bättre ytjämnhet var andra förbättringar som uppskattades.

Kundexempel, Indien

KomponentHuvudstång till lok
MaterialStål CMC 2.2
OperationBearbetning av oljespår med interpolering
MaskinMazak, Nexus 5000-II
VerktygR331.35-063A25EM(Z6)R331.35-063A25EM(Z6)
SkärN331.1A-08 45 08H-NL 1025N331.1A-08 45 08E-M30 1130
DC6363
zn, (zeff)6 (3)6 (3)
n, varv/min960960
vc m/min (fot/min)190 (623)190 (623)
hex mm (tum)0,015 (0,0006)0,015 (0,0006)
fz mm (tum)0,03 (0,001)0,03 (0,001)
vf, mm/min (tum/min)58 (2,28)58 (2,28)
ap mm (tum)10 (0,394)10 (0,394)
ae mm (tum)3 (0,118)3 (0,118)
FörslitningUrflisningFlank- och värmesprickor
Skärlivslängd, komponenter816

Resultat

Längre skärlivslängd med mycket mer tillförlitlig och förutsägbar verktygsförslitning. Även ljudet förbättrades väsentligt.

Customer case, France

ComponentHousing for tractor
MaterialCast iron FGL 300 (K2.2.C.UT)
OperationSide and face milling with interpolation
MachineHMC (HSK100)
Existing insert (M-KM 1020) New insert (M30 1020)
Tool203 24 0242 R 0114203 24 0242 R 0114
Insert N331.1A-08 45 08M-KM 1020 N331.1A-08 45 08 M30 1020
DC5050
zn, (zeff)6 (6, big overlap)6 (6, big overlap)
n, rpm 15611561
vc m/min (ft/min)245 (804)245 (804)
hex mm (inch)0.21 (0.008)0.21 (0.008)
fz mm (inch)0.21 (0.008)0.21 (0.008)
vf, mm/min (in/min)1965 (77.4)1965 (77.4)
ap mm (inch)10 (0.394)10 (0.394)
ae mm (inch)14 (0.551)14 (0.551)
Time in cut / component, min 0.840.84
Tool life, components3737

Result

The new M30 insert provided more controlled and less tool wear for the same number of components and less spindle load.

Half side and face milling

ComponentGeneral engineering
MaterialCMC 01.3 (P1.3.Z.AN)
OperationHalf side and face milling
MachineHeller MCH350
+569%
Productivity

-394 HRS
Machine time
​ Competitor CoroMill®​ 331
ToolR331.32-125Q32 KM 15
Insert N331.1A-115008M-PM4230
DC mm (inch)125 (5.0)125 (5.0)
zn10 (zeff10)8 (zeff8)
n, rpm 530790
vc m/min (ft/min)208 (682)310 (1017)
hex mm (inch)0.05 (0.0020)0.12 (0.0047)
fz mm/z (in/z)0.08 (0.0031)0.18 (0.0071)
v​f, mm/min (in/min)424 (16.693)1138 (44.803)
ap mm (inch)5 (0.197)8 (0.315)
ae mm (inch)12 (0.472)15 (0.591)
Cycle time, min33.965.01
Results
Tool life, components812
Tool life, m (feet)115.12 (377.69)68.42 (224.47)
Tool life, min271.6860.12

Customer case, Russia

Industry: Automotive
Component: Connecting rod cap
Material: Cast iron (K2.1.C.UT)
Operation: Mill full slot
Machine: Special arbor-mounted automatic milling machine
Coolant: Emulsion, 7%
33%
Increased tool life
  Existing insert (M-KM 3040) New insert (M30 1020)
Insert N331.1A-08 45 08M-KM3040 N331.1A-08 45 08 M30 1020
DC 125 125
zn (zeff) 16 (8) 16 (8)
Tool overhang Arbor-mounted Arbor-mounted
n, rpm 207 207
vc, m/min (ft/min) 81.5 (267) 81.5 (267)
hex mm (inch) 0.05 (0.002) 0.05 (0.002)
fz mm (inch) 0.12 (0.005) 0.12 (0.005)
vf, mm/min (in/min) 200 (7.87) 200 (7.87)
ap mm (inch) 6.0 (0.236) 6.0 (0.236)
ae mm (inch) 15 (0.591) 15 (0.591)
Time in cut/component (sec) 20.0 20.0
Spindle load NA NA
Tool life, components 3000 4000

Result

The new insert provided an improved, safe machining process with no cracks, less sound and with no vibration.

Oil groove finishing

Industry Automotive engine
Component: Connecting rod
Material: CrMo steel forging
Operation: Oil groove finishing
Machine: Vertical M/C
Coolant: Emulsion, 8%
  Existing insert (M-PM 4320) New insert (M30 4230)
Tool N331.32-080S27EM(Z6) N331.32-080S27EM(Z6)
Insert N331.1A-084508M-PM 4230 UVM3667-PMD-009  M30 4230
DC 80 (3.15) 80 (3.15)
zn 6 6
n, rpm 600 600
vc, m/min (ft/min) 150 (492) 150 (492)
fz mm (inch) 0.056 (0.002) 0.056 (0.002)
vf, mm/min (in/min) 100 (3.94) 100 (3.94)
ap mm (inch) 12 (0.472) 12 (0.472)
ae mm (inch) 2 pass 3+2.5 2 pass 3+2.5
Average flank wear, mm (inch) Less than 0.1 mm (0.004), even Less than 0.1 mm (0.004), even
Tool life (components) 15 components 15 components

Result

Existing M-PM shows slightly vibration-affected surface quality within specification. M30 however, shows good surface quality without vibration. M30 also proved much more light-cutting than the existing M-PM geometry.

Full slotting with interpolation

ComponentValve body (oil and gas)
MaterialCMC 02.2 (P2.5.Z.HT)
OperationFull slotting with interpolation
MachineHYUNDAI03
+195%
Productivity

-500 HRS
Machine time
​ Competitor CoroMill® 331
ToolTMR331.35-520743
Insert L331.1A-08 45 30H-WL 1030
DC mm (inch)80 (3.15)86 (3.4)
zeff44
n, rpm 500650
vc m/min (ft/min)175 (574)175 (574)
fz mm/z (in/z)0.1 (0.0039)0.2 (0.0079)
vf, mm/min (in/min)200 (7.874)520 (20.472)
ap mm (inch)1 (0.039)10 (0.394)
ae mm (inch)80 (3.150)60 (2.362)
Cycle time, min3010
Results
Tool life, components44
Tool life, m (feet)12 (39.37)20.8 (68.24)
Tool life, min12040

Boss milling

ComponentTurbine support case
MaterialCMC 20.22 (S2.0.Z.AG)
OperationBoss milling (interpolation)
MachineChiron
+166%
Productivity

-382 HRS
Machine time
Competitor CoroMill®331
ToolR331.35-050A20CM060
Insert N331.1A-043505H-PL S30T
DC mm (inch)50 (2.0)50 (2.0)
zn4 (zeff2)6 (zeff3)
n, rpm 255255
vc m/min (ft/min)40 (131)40 (131)
hex mm (inch)0.01 (0.0004)0.02 (0.0008)
fz mm/z (in/z)0.01 (0.0004)0.02 (0.0008)
vf, mm/min (in/min)7 (0.276)18 (0.709)
ap mm (inch)1 (0.039)1 (0.039)
ae mm (inch)6 (0.236)6 (0.236)
Cycle time, min346118
Results
Tool life, components0.090.25
Tool life, m (feet)0.04 (0.131)0.11 (0.361)
Tool life, min29.529.41

Deep grooving

ComponentAircraft frame
MaterialCMC 23.22 (S4.3.Z.AG)
OperationDeep grooving
MachineGidding & Lewis
+826%
Productivity

-76 HRS
Machine time
Competitor CoroMill® 331
ToolN331.32-203T51FMB
Insert R331.1A-084530H-WL 1030
DC mm (inch)203 (8.0)203 (8.0)
zn18 (zeff6)16 (zeff8)
n, rpm 7372
vc m/min (ft/min)46 (151)46 (151)
fz mm/z (in/z)0.051 (0.002)0.127 (0.005)
vf, mm/min (in/min)22.25 (0.876)72.77 (2.865)
ap mm (inch)7.62 (0.300)13.46 (0.530)
ae mm (inch)12.7 (0.500)12.7 (0.500)
Cycle time, min37.56.5
Results
Tool life, components0.58
Tool life, m (feet)0.42 (1.37)3.78 (12.41)
Tool life, min18.7552

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