High-Speed Cutter for Aluminum Alloys RF Series
■ General Features The RF cutter for aluminum alloy has a lightweight body designed for high-speed, high- performance roughing to finish milling of aluminum alloy and other non-ferrous metals.
■ Work Material ● Aluminum and aluminum alloys ● Other Non-Ferrous Metals
(
)
Not suited for cast iron or steel.
■ Features ● From Roughing to Finishing Processes: Roughing: Economical carbide insert / Finishing: High-precision SUMIDIA insert ● Strong and Lightweight Body: Special aluminum alloy body. 40% lighter than steel cutters. Hard anodizing. Improved efficiency with higher spindle speeds, lower spindle loads and shorter tool change time ● Safety Design: Prevents inserts from dislodging from cutter due to centrifugal force. (Speeds must be within max. recommended conditions) To prevent warping, wedges are not used in the cutter construction ● Easy Runout Adjustment: External setting gauge is used for easy tool presetting. High-precision cutter construction - units fitted are within 10μm runout even before setting ■ Application Examples ● Maximum Allowable Spindle Speed
H
n max (RPM)
Cutting Conditions v c = Cutting Speed (SFM) v f = Feed Rate (IPM) a p = Depth of Cut (inch)
Tool Cutting Blade (Insert Grade)
Cat. No.
Workpiece (Work Material)
Results
RF4080R RF4100R RF4125R RF4160R RF4200R RF4250R RF4315R
17,000 15,900 13,500 11,000
RF4160R SUMIDIA Blade (DA2200) RF4125R SUMIDIA Insert (DA1000) RF4250R Carbide Insert (H1)
Finished Surface Roughness: Ra=0.2μm, Number of Workpieces: 30,000 pcs (30x tool life of carbide inserts) Finished Surface Roughness: Ra=0.3μm, Number of Workpieces: 20,000 units Rough Cutting Number of Workpieces: 10,000 units
v c = 9,843 v f = 225 a p = 0.004" v c = 9,843 v f = 300 a p = 0.06" v c = 6,562 v f = 296 a p = 0.14"
Case (ADC12)
9,000 7,600 6,000
Contact Surface of Transmission Case (ADC12) Contact Surface of Cylinder Head (AC4C)
■ Finished Surface Roughness · Process: Finish Milling · Machine: Vertical Machining Centre · Arbour: HSK63A
■ Recommended Cutting Conditions Si content of 12.6% or less
· v c = 16,372 SFM · n = 15,900 RPM
Work Material
Insert Grade
Cutting Speed v c (SFM) Min. - Max.
Feed Rate f z (IPT) Min. - Max.
· v f = 450 IPMn · f z = 0.0047 IPT · a p = 0.0197", Wiper a p = 0.0012"· Dry
ISO
Hardness
· Work Material: Si 10 to 12% Al Alloy · Cutter: RF4100R 6-Flute (1 Wiper) · Grade: SUMIDIA (DA1000)
DA1000 DA2200
- -
6,560 - 16,400 0.002 - 0.008
N Aluminum Alloy
3,280 - 8,200 0.002 - 0.008
H1
Si content of over 12.6%
Rz (Highest Peak) : 0.69μm Ra: 0.092μm
DA1000 DA2200
- -
1,320 - 2,630 0.002 - 0.008
N Aluminum Alloy
■ Structure of RF
660 - 1,320
0.002 - 0.008
H1
Cap Screw (Main Clamp) BX0620
● Recommended Cutting Edge Position We recommend positioning as in the figure below when mounting carbide inserts or SUMIDIA inserts (blades). The cutting conditions above are a guide. Actual conditions will need to be adjusted according to machine rigidity, work clamp rigidity, depth of cut and other factors. Note
Stopper RFS
Adjustment Screw RFJ
Cartridges RFR,RFF,RFFH
Flat Screw (Insert Seat Screw) BFTX0509N
● When roughing and nishing in the same process
● When using wiper edge
SUMIDIA Insert
Carbide Insert
Set Screw (Sub-clamp) BTD0510
Wiper Insert
SUMIDIA Insert
1.0
DC 1.1
CAUTIONS (For more details, refer to the instruction manual included with the product) As it is possible to mix different types of inserts/blades, it is important to take note of the following. Do not mix reground and new inserts or inserts with a different regrinding amount on the same cutter. Carbide and SUMIDIA inserts must be arranged alternately. Ensure proper balance by fixing the PCD inserts of the blades on opposite sides of the cutter.
Cover RFC
Flat Screw FBUP2-A0-8
H227
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