Section H 25-26

WaveMill WEX Series ■ WEX Type Series Application Range (Shoulder Milling)

■ WEX1000

Number of Teeth

0.6

Number of Teeth Number of Teeth

Number of Teeth

WEX3000

Maximum Depth of Cut APMX Maximum Depth of Cut APMX

WEX1000E Standard Type APMX = 6.0mm WEX1000E Standard Type APMX = 6.0mm

WEX1000EL Long Type APMX = 6.0mm WEX1000EL Long Type APMX = 6.0mm

WEX2000E Standard Type APMX = 10.0mm WEX2000E Standard Type APMX = 10.0mm

Maximum Depth of Cut APMX

0.4

WEX1000E Standard Type APMX = 6.0mm

WEX1000EL Long Type APMX = 6.0mm

WEX2000E Standard Type APMX = 10.0mm

Cutter Dia. ø10mm ø12mm ø14mm ø16mm Cutter Dia. ø10mm ø12mm ø14mm ø16mm

WEX2000

Q Q Q 1 2 1 2

2 3 3 4 2 3 4

2 2 3 3 2 3

Cutter Dia. ø10mm ø12mm ø14mm ø16mm

Q Q

2 3 3 4

2 2 3 3

0.2

WEX1000

0.12 0 (1) Shoulder milling precision High-precision cutting edges provide very small step marks Ŷ Cutting Performance (1) Shoulder milling precision High-precision cutting edges provide very small step marks (less than half that of competitors' products) High-precision cutting edges provide very small step marks (less than half that of competitors' products) (1) Shoulder milling precision (less than half that of competitors' products) Ŷ Cutting Performance 0.004 0.008 Ŷ Cutting Performance

0.012 0.016 Squareness of Machined Shoulder Squareness of Machined Shoulder

1 2

1.0

0.94”

Feed Rate per Tooth f z (IPT)

1.0 0.8

0.94”

Squareness of Machined Shoulder

1st Step Depth of Cut (0.315”) 1st Step Depth of Cut (0.315”) 2nd Step Depth of Cut (0.315”) 2nd Step Depth of Cut (0.315”) 3rd Step Depth of Cut (0.315”) 3rd Step Depth of Cut (0.315”)

1.0

0.94”

0.8 0.6

Cutting Conditions Part Material: A36 Tool: Cutting Conditions Part Material: A36 Tool: Insert:

0.63”

0.8

WEX3032E (ø32)

0.63”

1st Step Depth of Cut (0.315”)

0.6 0.4

WEX3032E (ø32) AXMT170508PEER-G Cutting Conditions Part Material: A36 Tool: Insert: Grade: ACP200 Cutting Speed: v c =492 SFM Feed Rate: f z =0.006 IPT ( v f =26.57 IPM) Cutting Width: a e =0.197” Depth of Cut: a p =0.315” x 3 times Dry Grade: ACP200 Cutting Speed: v c =492 SFM Feed Rate: f z =0.006 IPT ( v f =26.57 IPM) Cutting Width: a e =0.197” Depth of Cut: a p =0.315” x 3 times Dry AXMT170508PEER-G Insert:

0.63”

0.32”

0.6

WEX3032E Competitor's Product Conventional Tool WEX3032E Competitor's Product Conventional Tool WEX3032E Competitor's Product Conventional Tool

0.4 0.2

WEX3032E (ø32)

0.32”

2nd Step Depth of Cut (0.315”)

0.4

AXMT170508PEER-G

0.2

0.32”

Grade: ACP200 Cutting Speed: v c =492 SFM Feed Rate: f z =0.006 IPT ( v f =26.57 IPM) Cutting Width: a e =0.197” Depth of Cut: a p =0.315” x 3 times Dry

0”

-50

-100

100

Cutting width 0.197”

Deviation (μm)

0.2

0”

3rd Step Depth of Cut (0.315”)

-50

-100

100

Cutting width 0.197”

Deviation (μm)

0”

(2) Cutting force (2) Cutting force

(3) Fracture resistance (3) Fracture resistance

-50

-100

100

Cutting width 0.197”

Deviation (μm)

Cutting force (principal force) is approximately 15% lower than conventional tools Lower resistance Cutting force (principal force) is approximately 15% lower than conventional tools

Huge increase in fracture resistance with improved cutting edge strength Huge increase in fracture resistance with improved cutting edge strength No Breakage (3) Fracture resistance Huge Increase No Breakage Huge increase in fracture resistance with improved cutting edge strength 40 40

(2) Cutting force

Principal Force Feed Force Back force (+) Back force (–) Principal Force Feed Force Back force (+) Back force (–)

6.0

Lower resistance Cutting force (principal force) is approximately 15% lower than conventional tools

Huge Increase

Breakage

6.0

Lower resistance

No Breakage

Breakage

4.0 6.0

Breakage Huge Increase

Principal Force Feed Force Back force (+) Back force (–)

Breakage

4.0

2.0

Breakage

Breakage Breakage

Breakage

4.0

16 8

2.0

Breakage

0.0 -1.0 0.0 -1.0 2.0 0.0 -1.0

Breakage

WEX Type (G Type) WEX Type (G Type) WEX Type (G Type)

Conventional Tool Standard Type Conventional Tool Standard Type Conventional Tool Standard Type

WEX Type (G Type) WEX Type (G Type)

Conventional Tool Standard Type

Competitor's Product A General Type Competitor's Product A General Type Breakage

Breakage

Conventional Tool Standard Type

Cutting Conditions Part Material: 1050 Tool: Cutting Conditions Part Material: 1050 Tool: Insert: Grade: Cutting Conditions Part Material: 1050 Tool: Insert: Grade:

Cutting Conditions Part Material: 4140 Tool: Cutting Conditions Part Material: 4140 Tool: Insert: Grade: ACP200 WEX Type (G Type) ACP200 Cutting Conditions Part Material: 4140 Tool: Insert: Grade:

Cutting Speed: v c =656 SFM Feed Rate: f z =0.008” IPT ( v f =47 IPM) Cutting Width: a e =0.315” Depth of Cut: a p =0.40” , Dry Cutting Speed: v c =656 SFM Feed Rate: f z =0.008” IPT ( v f =47 IPM) Cutting Width: a e =0.315” Depth of Cut: a p =0.40” , Dry Cutting Speed: v c =656 SFM Feed Rate: f z =0.008” IPT ( v f =47 IPM) Cutting Width: a e =0.315” Depth of Cut: a p =0.40” , Dry

Cutting Speed: v c =328 SFM Feed Rate: Cutting Speed: v c =328 SFM Feed Rate: Cutting Width: a e =0.984” Depth of Cut: a p =0.12, Dry

Conventional Tool Standard Type

f z =0.016” IPT ( v f =49.6 IPM) f z =0.016” IPT ( v f =49.6 IPM) Competitor's Product A General Type

WEX3032E (ø32) AXMT170508PEER-G WEX3032E (ø32) AXMT170508PEER-G ACP200 WEX3032E (ø32) AXMT170508PEER-G ACP200

WEX3032E (ø32) AXMT170508PEER-G

Cutting Speed: v c =328 SFM Feed Rate:

Cutting Width: a e =0.984” Depth of Cut: a p =0.12, Dry

f z =0.016” IPT ( v f =49.6 IPM)

WEX3032E (ø32) AXMT170508PEER-G

Insert: Grade:

High rake edge signicantly reduces burrs. (5) Wall surface burrs (aluminum alloy milling) High rake edge signicantly reduces burrs. (5) Wall surface burrs (aluminum alloy milling) Burr High rake edge signicantly reduces burrs. (5) Wall surface burrs (aluminum alloy milling) Burr Cutting Width: a e =0.984” Depth of Cut: a p =0.12, Dry ACP200

ACP200

Roughness Curve (Vertical Magnication: 10,000.00x, Horizontal Magnication: 100.00x) Ra = 0.115 (4) Surface roughness (aluminum alloy milling) Ra = 0.208 Smooth surface nish free of white blemishes Roughness Curve (Vertical Magnication: 10,000.00x, Horizontal Magnication: 100.00x) (4) Surface roughness (aluminum alloy milling) Smooth surface nish free of white blemishes Roughness Curve (Vertical Magnication: 10,000.00x, Horizontal Magnication: 100.00x) Roughness Curve (Vertical Magnication: 10,000.00x, Horizontal Magnication: 100.00x) (4) Surface roughness (aluminum alloy milling) Smooth surface nish free of white blemishes

Ra = 0.115

Ra = 0.208

Roughness Curve (Vertical Magnication: 10,000.00x, Horizontal Magnication: 100.00x)

Burr

Ra = 0.115

Ra = 0.208

White blemishes

WEX Type

Competitor's Product

White blemishes

WEX Type

Competitor's Product Cutting Speed: v c =2,625 SFM Feed Rate: Cutting Speed: v c =2,625 SFM Feed Rate: Cutting Width: a e =0.197” f z =0.004” IPT ( v f =94.5” IPM) f z =0.004” IPT ( v f =94.5” IPM) a p =0.472” , Dry Depth of Cut: Competitor's Product a e =0.197” Cutting Speed: v c =2,625 SFM Feed Rate: a p =0.472” , Dry Cutting Width: Depth of Cut:

Cutting Conditions Part Material: A5052 Tool: Cutting Conditions Part Material: A5052 Tool: Insert:

White blemishes

WEX3032E (ø32) WEX Type AXET170504PEFR-S (H1)

WEX3032E (ø32)

Insert:

AXET170504PEFR-S (H1)

Cutting Conditions Part Material: A5052 Tool:

WEX Type

Competitor's Product

f z =0.004” IPT ( v f =94.5” IPM)

WEX3032E (ø32)

AXET170504PEFR-S (H1)

Insert:

a e =0.197”

WEX Type

Competitor's Product Cutting Speed: v c =2,625 SFM Feed Rate: Cutting Speed: v c =2,625 SFM Feed Rate: Cutting Width: a e =0.63” Competitor's Product f z =0.004” IPT ( v f =94.5” IPM) f z =0.004” IPT ( v f =94.5” IPM) a p =0.40” , Dry Cutting Width: Depth of Cut: Cutting Speed: v c =2,625 SFM a e =0.63” a =0.40” , Dry Depth of Cut:

Cutting Width: Depth of Cut:

Cutting Conditions Work Material: A5052 Tool: Cutting Conditions Work Material: A5052 Tool: Insert: Cutting Conditions Work Material: A5052 Insert:

a p =0.472” , Dry

WEX3032E (ø32)

WEX Type

AXET170504PEFR-S (H1)

H78

WEX3032E (ø32)

AXET170504PEFR-S (H1)

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