Super Radius Mill TD4N Type, Modular Type

Brand :

HITACHI TOOL

Caution

Product Description

[Features]
· In addition to high efficiency, low resistance, and economical 4-corner specification, this reduces the uncut remnants that were assumed to be normal for high-feed tools.
· Reduces the load on the next process.

Product features and specifications

Drawing

Recommended cutting conditions

Product features and specifications

Basic specifications and features of the product

● Reduces uncut remnants on work materials

The cutting edge shape was reviewed for TD4N so that uncut remnants are reduced.

Tool shape definition is difficult to be created in CAM for the complicated cutting edge shapes of high-feed tools, and in many cases the tools are used with the definition for a simple R radius tool. The differences between this definition and the actual tool shape result in uncut remnants that cannot be seen on CAM and need more work in the next process.

Alpha high feed radius mill TD4N modular type programming R

● Chip breakers for different applications and economical 4-corner-use inserts

The front and back of the insert can be used, allowing the use of 4 corners with a single insert. The large rake angle of the insert provides higher cutting force reduction compared to general positive-shaped inserts.

Alpha high feed radius mill TD4N modular type corner identification mark

·Features of insert chip breaker

C chip breaker
Corresponds to the high feed inserts (EDNW, EPNW, WDNW, SDNW), and is resistant to cutting chip jamming, vibrations and crater wear.

Alpha high feed radius mill TD4N modular type C chip breaker image

B chip breaker
Suitable for work materials that require sharpness such as stainless steel, and can reduce cutting forces.

Alpha high feed radius mill TD4N modular type B chip breaker image

·Comparison of cutting forces

Alpha high feed radius mill TD4N modular type cutting force comparison graph

·Enlarged cross section of the cutting edge

Alpha high feed radius mill TD4N modular enlarged cross section of cutting edge

Positive rake angle

● Easy-to-use large tip diameter

The TD4N has a larger tip diameter to reduce the generation of uncut remnants that tend to leave on the bottom surface of machined areas. The cutting width (ae) can be set to a large value, effectively improving machining efficiency.

Alpha high feed radius mill TD4N modular type Tip diameter diagram and corner machining surface photograph

● High cutting chip discharge capability

It reduces the occurrence of sudden troubles due to cutting chip jamming. It enables further improvements in machining efficiency.

Alpha high feed radius mill TD4N modular type cutting chips from tools with small chip gullets

When cutting chips were not discharged successfully, a jamming between the tool and the wall occurred, causing sudden damage such as chipping.

Alpha high feed radius mill TD4N modular type cutting chips when in use of TD4N

The large chip gullet and controlling the cutting chip discharge direction provide good cutting chip discharge capability.

AJ coating series

Uses a new composition of AlTi-based film with a high AI content.
High abrasion resistance, chipping resistance and heat resistance.

·Grade for machining pre-hardened steel or hardened steel JP4120

Micro-grain cemented carbide with well-balanced abrasion resistance and toughness and the new "AJ coating" have improved abrasion resistance and chipping resistance.
It is highly versatile and provides high abrasion resistance and chipping resistance in cutting of steels in the range of 30 to 50 HRC.

·Grade for processing stainless steel materials JM4160
A micro-grain cemented carbide base material with excellent toughness and the new "AJ coating" have improved abrasion resistance and chipping resistance for cutting stainless steel materials.
The "AJ coating" with high chip-weld resistance has reduced the chip welding of work materials that occurs in machining stainless steel-based materials.

·General purpose for steel JS4045
A coating film with high heat resistance has reduced the crater wear that occurs in high efficiency milling.
A highly heat resistant cemented carbide base material reduces the progression of wear and provides high tool lifespan.
Especially in dry type machining, it has a long lifespan.

Performance/test information

(1) Reduced machining time

·Intermittent machining

·Cutting edge condition after 30 min of cutting

Alpha high feed radius mill TD4N modular type intermittent machining photo

Work material: pre-hardened steel (40HRC)
Tools to use: TD4N2032S-5 (ø32, 5 flutes)
ENMU0603EN-B (JP4120)
Cutting conditions: vc = 100 m/min
vf = 9,000 mm/min (fz = 1.8 mm/t)
ap × ae = 0.6 × 20 mm
Air blow

90-minute machining time reduced to approx. 30 minutes

(2) Improved tool lifespan

·Pocketing

Alpha high feed radius mill TD4N modular type pocket machining diagram

·Cutting edge condition after 100 minutes of cutting

Alpha high feed radius mill TD4N modular type pocket machining photo

Work material: carbon steel
Tools to use: TD4N2020S-3 (ø20, 3 flutes)
ENMU0603EN-B (JP4120)
Cutting conditions: vc = 140 m/min
vf = 5,000 mm/min (fz = 0.75 mm/t)
ap × ae = 0.8 × 10 mm
Water soluble cutting fluid

Damage improved without major chipping

(3) High efficiency milling under weak clamping rigidity

·Low clamping rigidity

Work material: general structural steel
Tools to use: TD4N2032S-5 (ø32, 5 flutes)
ENMU0603EN-C (JS4045)
Cutting conditions: vc = 200 m/min
vf = 8,000 mm/min (fz = 0.8 mm/t)
ap × ae = 0.5 × 20 mm
Water soluble cutting fluid

Good with little wear even after 200 machining cycles

Drawing

Supports center through holes

Recommended cutting conditions

Recommended cutting condition table

This cutting condition describes the rotational speed, feed rate, and cutting amount for each work material (general steel, steel alloy, heat-treated steel, high-hardness steel, stainless steel, aluminum, cast iron, etc.) based on the manufacturer's recommended conditions.
Optimal machining conditions vary depending on the machining environment (machine tools, tool holder, etc.); therefore, please check the machining conditions (machined surface, chattering, etc.) and make corrections during use.

* The red indicates the primary recommended insert grade.

Alpha high feed radius mill TD4N modular type standard cutting conditions table

Alpha high feed radius mill TD4N modular type supplementary drawing for cutting conditions

Precautions for cutting conditions

(1) Use an appropriate coolant according to the work material and machining shape.
(2) This cutting conditions table gives an indication of the cutting conditions for shoulder milling.
In actual machining, please adjust the parameters according to the machining shape, purposes, machine used, etc.
In particular, when the cutting chip discharge or vibrations is a problem in machining with or close to groove cutting, please adjust the cutting conditions as follows.

Reduce the depth of the cut ap to 50 to 70%.
Reduce the rotational speed n and table rate Vf to 50 to 70%.

(3) Please note that the GX coating and JS coating do not cause a reaction to energized touch sensors.
(4) Be sure to remove cutting chips by air blower etc., to prevent tool damage due to chip clogging.
(5) Replace the insert as soon as possible to prevent damage due to excessive use.
(6) The following equation can be used to determine the cutting chip discharge per unit time Q:
Q (cm3/min) = ap (mm) × ae (mm) × Vf (mm/min)/1,000 Do not set values higher than the maximum value.

Compatible work material

Carbon steel / steel alloy < 30HRC
Steel alloy / tool steel 30 to 40HRC
Pre-hardened steel / steel alloy 40 to 50HRC
Stainless steel SUS
Cast iron FC, FCD

● Regarding Inclined cutting and helical machining diameter

Alpha high feed radius mill TD4N modular type incision example table

The cutting depth per rotation should be set up to ap = 1 mm or less.

Alpha high feed radius mill TD4N modular type incision example diagram

[Cautions]
(1) It is recommended that the tool to be used after thoroughly removing cutting chips and checking for not abnormal vibrations.
(2) The inclined angle θ should be set within the ranges listed above. It is recommended to use at 0.5° or less.
(3) For hole diameters outside the ranges listed above, a pilot hole should be drilled before machining.

● Precautions for creating a machining program

·In CAM, define the tool shape as the corner radius shape of R2.0.
·For the axial-direction cutting depth ap, use 1.0 mm or less.

Alpha high feed radius mill TD4N modular type machining program reference table

Alpha high feed radius mill TD4N modular type machining program reference drawing

Cautions/prohibitions

The data in the figures and tables are examples of test results and are not guaranteed values.

Safety precautions
1. Precautions for handling

When removing the tool from the case (packing), please take care not to injure yourself by dropping the tool on your feet or the tips of your bare fingers.
When setting the insert and actually using it, be careful not to touch the cutting edge directly with your bare hands.

2. Precautions for installation

When using the insert, set it firmly, and mount it on the arbor etc., securely.
If abnormal vibrations or other problems occur during use, stop the machine immediately and remove the cause of the vibration.

3. Precautions for use

Check the dimensions and direction of rotation of the cutting tool or work material in advance.
Please use the values in the standard cutting conditions table as a guide for starting a new work. If the cutting depth is large or the rigidity of the machine used is small, adjust the parameters appropriately according to the properties of the workpiece.
The insert is made of a rigid material. It may be damaged and scattered during use. Cutting chips may also be scattered. These flying fragments may cause cuts, burns, or eye injuries to operators. Install a safety cover around the tool and wear protective glasses or other protective gears while using the tool for securing the operation under a safety environment.
Do not use the tool in areas where there is a risk of ignition or explosion.
Do not use water-insoluble cutting oil as it may cause a fire.
Do not use or modify the tool for any purpose other than its intended purpose.