High-Speed Cutter for Aluminum Alloys RF Type
■ General Features The RF Type 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
17,000
RF4100R
15,900
RF4160R SUMIDIA Blade (DA2200) RF4125R SUMIDIA Insert (DA1000) RF4250R Carbide Insert (H1)
c = 9,843
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
Case (ADC12)
RF4125R
13,500
f = 225
v
RF4160R
11,000
a
p = 0.004"
RF4200R
9,000
Contact Surface of Transmission Case (ADC12) Contact Surface of Cylinder Head (AC4C)
c = 9,843
v
RF4250R
7,600
f = 300
v
RF4315R
6,000
a
p = 0.06"
c = 6,562
v
f = 296
v
a
p = 0.14"
■ Recommended Cutting Conditions Si content of 12.6% or less
■ Finished Surface Roughness
· Process: Finish Milling · Machine: Vertical Machining Centre · Arbour: HSK63A · Work Material: Si 10 to 12% Al Alloy · Cutter: RF4100R 6-Flute (1 Wiper) · Grade: SUMIDIA (DA1000)
· v c = 16,372 SFM · n = 15,900 RPM · v f = 450 IPMn · f z = 0.0047 IPT · a p = 0.0197", Wiper a p = 0.0012"· Dry
Work Material
Insert Grade
Cutting Speed v
c (SFM)
Feed Rate f
z (IPT)
Hardness
ISO
Min. - Max.
Min. - Max.
DA1000 DA2200
6,560 - 16,400 0.002 - 0.008
-
Aluminum Alloy
N
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
-
Aluminum Alloy
N
660 - 1,320
0.002 - 0.008
H1
-
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
■ Structure of RF Type
● Recommended Cutting Edge Position
Cap Screw (Main Clamp) BX0620
We recommend positioning as in the figure below when mounting carbide inserts or SUMIDIA inserts (blades).
Stopper RFS
● When roughing and finishing in the same process
● When using wiper edge
Adjustment Screw RFJ
SUMIDIA Insert
Carbide Insert
Cartridges RFR,RFF,RFFH
Flat Screw (Insert Seat Screw) BFTX0509N
Wiper Insert
SUMIDIA Insert
1.0
DC 1.1
Set Screw (Sub-clamp) BTD0510
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 SUMIDIA inserts of the blades on opposite sides of the cutter.
Cover RFC
Flat Screw FBUP2-A0-8
H192
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