Tools for aluminium machining - Power-Tools

Tools for aluminium machiningThe best for aluminium machining

AluminiumAluminium - a material that has a futureParticularly in the field of transportengineering massive application oflight weight materials representsthe order of the day. The goal ofsaving fuel and other energy formscan mainly be achieved through thereduction of vehicle weights.Apart from various syntheticmaterials, the classical light metalaluminium offers the bestprerequisites for reaching thisobjective.In other application fields, too, itsnumerous favourable propertiesmake aluminium an appreciatedconstruction material for engineers.[ mill. tons]Aluminium in the automobile19992009(Prognosis EAA)Trends in the field of machiningInnovative machining strategies arecharacterised by maximum cuttingspeeds and feed rates in order toobtain the highest possible metalremoval rates.Refraining from massive use ofcooling lubricant represents animportantdemand with reference tothe environmental impact.Process safety and an increase inproductivity are the prerequisitesfor a favourable market positionand thus competitiveness.The machining properties ofaluminium are perfectly suitable forputting modern machiningconcepts into practice.Machining time [in h]conventionalHPC – High Performance CuttingTime saving withHPC machiningmachine down timesroughingfinishingHPCmachiningPrerequisites forHPC machiningHSC spindle(> 25,000 rev./min)high feed rates(> 40 m/min)high acceleration(> 2.5 – 3.0 m/sec)fast CNC controls(processing speed < 3.0 ms)balanced toolsadequate cutting materialsSource: Heidelberger Druck2

Machinability of aluminium alloysRelative machinabilityIt depends on the type of alloy whether materials are easy to machine or not.As far as machinability is concerned you can find any degree of difficulty, ranging from the easily machinedalloy stocks to the diffult to machine pure aluminium.GroupAlloy typeRelative machinabilitypureAlAl 99,95malleable aluminium alloysnonhardenedhardenedAl MnAl MgAl Mg MnAl Mg Simachining alloy stockAl Cu MgAl Cu Si MgAl Zn Mg Cu4 - 53 - 53 - 43 - 41 - 22 - 332cast aluminium alloysG - Al SiG - Al Si MgG - Al Si CuG - Al MgG - Al Mg SiG - Al Cu TiG - Al Si Cu Mg Ni32 - 322222 - 31 - very good machinability5 - bad machinabilityMachinability can be defined as the degree of difficulty that a material creates when being machined. In order toassess the machinability of a material basically 4 parameters have to be taken into consideration:cutting forcetool lifesurface qualitychip formation3

Machinability of aluminium alloys1. Cutting forceAluminium requires only approx. 30 % of the cutting force necessary forsteel materials. The influence of the material on the cutting force is expressedthrough the special cutting force K s1.1 . The rake angle of the cutting edge isof particular interest regarding the cutting force. Increasing the rake angleby one degree the cutting force is reduced by ~1.5%.Important characteristics of PLANSEE TIZIT inserts:rake angle > 25°sharp, uniform cutting edgeextra-smooth rake face2. Tool lifeThe time the cutting edge can be used until it is worn out. In the field ofaluminium machining this criterion is determined by three wear forms:cutting material:HM-K10tool life t [min]crater wearflank wearbuilt up edges andadhesion to thecutting edgeAlloysSource: WZL AachenReasons for wear:cutting speed Vc [m/min]thermal and mechanical stressdiffusion processes, frictionabrasive alloy elementstendency to sticktreatment state of the alloyImportant characteristics of PLANSEE TIZIT inserts:extremely wear resistant hard metal gradesoptimised coatingextra-smooth rake face4

3. Surface finishWith regard to surface finish you can distinguish between kinematicroughness, surface roughness and roughness caused by disturbances. Thekinematic roughness is a function of the relative movement between tooland work piece and the size of the corner radius.The surface roughness is dependent upon the properties of the alloy, thecutting data, geometry, cutting material and the surface quality of the rakeface. Disturbances, e.g. lack of stability of the machining systems, result insurface defects such as chatter marks.cut edgeroughnessImportant characteristics of PLANSEE TIZIT inserts:extra-smooth rake faceoptimised micro-geometry of the cutting edgefine grain substrates4. Chip formationBadly formed chips disturb the production process considerably. They interferewith both the work piece and the machine, and are difficult to remove themfrom the machining environment. Precisely machined surfaces showscratches; the quality of the pieces is reduced.Important characteristics of PLANSEE TIZIT inserts:unfavourablealuminium specific chip groovesreduced friction between chip and rake facefavourableDemands on tooling systems suitable for aluminium machiningadapted rake andclearance anglescontrolled chip formationsharp, uniformcutting edgessmooth rake facesdisturbance free chip flow(claws etc.)large chip pocketsHSC suitable5

Cutting materials suitable foraluminium machiningOverviewheat resistance and thermal stabilityoxideceramicsCBNnitrideceramicsPCDwhisker reinforcedceramicscoatedcermetscermetscoatedhard metalshard metalson WC basissub-micron gradehard metalspowder metallurgical HSS, coatedHSScutting materials suitable for aluminium machiningtoughness6

PLANSEE TIZIT gradesSm 80Powder metallurgically produced HSS withCVD carbonitride coating.For niche applications in the fields of turning andmilling when highest toughness is required.Suitable only for low and medium cutting speeds.H 216 T / H 10 T(K10 - K15)Due to its regular structure the fine grainsubstrate guarantees high cutting edge stability.Universal grades!TSM 10 (K10)High wear resistance through fineWC grains and low CO content.First choice for solid carbide tools.TSM 20 (K15 - K20)High wear resistance and good toughnessthrough fine WC grain and medium CO content.For special applications with solid carbidetools and certain insert tools.TSM 30 (K20 - K30)Good wear resistance and very good toughness.Fine WC grain and large CO content.First choice for extremely stressed solidcarbide milling tools.AMZ (K10)Substrate with extremely hard PVDcoating containing Ti Al N - Al 2 O 3 .Reduces wear and tendency to stick.First choice for high cutting speeds andalloys with tendency to stick.PKDPolycrystalline diamond (PCD segmentbrazed onto a supporting insert).First choice with abrasive Al-Si-alloys,(>18% Si) for polish turning andindustrial scale manufacturing.Coating layer system:CVD Ti(C+N) TiNCoating thickness:5 µmMicro-hardness of the coating:HV 0,05 2500Hardness:HV 1630Grain size:1 µmCO content:6 %Hardness:HV 1850Grain size:0.7 µmCO content:6 %Hardness:HV 1720Grain size:0.7 µmCO content:7.5 %Hardness:HV 1550Grain size:0.7 µmCO content:10 %Coating layer system:PVD / Ti Al NCoating thickness:3 µmMicro-hardness of the coating:HV 0,05 3600Hardness:HV ~10.000Grain size:~10 µm7

Microfinish“Microfinish“ is synonymous with a high polish surface finish and therefore represents the logical continuation ofthe advanced PLANSEE TIZIT aluminium line.Indexable inserts with “microfinish“ are perfectly suitable for the extremely high demands in aluminium machining.The indexable insert with the “P “ for the crucial plus in performance.Every aluminium alloy has special demands on an indexable insert.Problem:Solution:Chip particles get stuck in thecutting edge areaDue to the tendency to stick the timethe tool can be used is decreasedNot everything that is desired in the field ofsurface quality can be put into practiceThe shining surface keeps thecutting edge free of chip particlesTool life and wear are optimisedThe surface quality of the finished productmeets highest demandsREM photo: rake face without “microfinish“chip particles “stuck“ on the rake faceREM photo: rake face with “microfinish“the indexable insert with the “P “8

Chip formationFactors influencing chip formationWork piece materialMachinealloystype of structuretreatment statestatic and dynamic rigidityCutting materialCoolingfriction on therake facehigh volume coolantminimum quantity lubricationdry machiningCutting dataChip controlf / a p / v ccutting edge geometrychip grooveThe chip groove design is of decisive importance. In order to obtain an optimum machining result, chip grooveswhich are adapted to the alloy type or machinability group have to be applied.Chip groove -23Alloy:soft malleable aluminiumalloys(e.g. AlMn, AlMg)Parts:extrusion partsMachining methods:turning, reboringf [mm/rev]9

Chip groovesChip groove -25Alloy:cast and malleable aluminiumalloys, also with low Sicontent(e.g. G-AlSi2, AlMgSi)Parts:cast and forged partsMachining methods:turning, copy turningf [mm/rev]Chipgroove -27Alloy:cast and malleable aluminiumalloysParts:cast parts, extrusion androlled partsMachining methods:turning, reboring(same type of geometry alsofor milling, drilling, parting,grooving and thread cutting!)f [mm/rev]10

Competence in aluminium machining11

TurningMaxilock S tooling systemThe positive screw clamping guarantees a safeconnection of the insert with the tool holder. Chipevacuation is not hindered by obstructive clampingelements. Due to the neutral insert position theeffectively available rake angle is identical with therake angle of the insert.Program see special catalogue“Tool holders for turning and boring“(No. 90)Insert delivery programIndexable insertsType,ordering descriptionCCGT 060202FN-23PCCGT 060202FN-25PCCGT 060202FN-27CCGT 060204FN-23CCGT 060204FN-23PCCGT 060204FN-25PCCGT 060204FN-27CCGT 09T302FN-25PCCGT 09T302FN-27CCGT 09T304FN-23CCGT 09T304FN-23PCCGT 09T304FN-25PCCGT 09T304FN-27CCGT 09T308FN-23PCCGT 09T308FN-25PCCGT 09T308FN-27AMZH 10 TH 216 TRR RRRRRR RRRRRRRRRrRRRRRRR= standard stockr= limited stock or upon request= coated hard metal= uncoated hard metal12

Insert delivery programIndexable insertsType,ordering descriptionCCGT 120402FN-25PCCGT 120402FN-27CCGT 120404FN-25PCCGT 120404FN-27CCGT 120408FN-25PCCGT 120408FN-27CNGM 190612FN-27AMZH 10 TH 216 TRRR RRRRRRRRDCGT 070202FN-25PDCGT 070202FN-27DCGT 070204FN-23DCGT 070204FN-23PDCGT 070204FN-25PDCGT 070204FN-27DCGT 11T302FN-25PDCGT 11T302FN-27DCGT 11T304FN-23PDCGT 11T304FN-25PDCGT 11T304FN-27DCGT 11T308FN-23PDCGT 11T308FN-25PDCGT 11T308FN-27R RRRRRR RRRRRRRR RRRRR RRR= coated hard metal= uncoated hard metal13

TurningInsert delivery programIndexable insertsType,ordering descriptionRCGT 0602MOFN-27RCGT 0803MOFN-27RCGT 1003MOFN-27RCGT 1204MOFN-27AMZH 10 TH 216 TRRRRRRSCGT 09T304FN-27SCGT 09T308FN-27SCGT 09T308FN-27SCGT 120408FN-25PSCGT 120408FN-27RRRR RRRTCGT 110204FN-27TCGT 16T302FN-27TCGT 16T304FN-27TCGT 16T308EN-27RRRR= coated hard metal= uncoated hard metal14

Insert delivery programIndexable inserts-DType,ordering descriptionVCGT 110302FN-25PVCGT 110302FN-27VCGT 110304FN-25PVCGT 110304FN-27VCGT 110308FN-27VCGT 160404FN-25PVCGT 160404FN-27VCGT 160408FN-25PVCGT 160408FN-27VCGT 160412FN-25VCGT 160412FN-25PVCGT 160412FN-27VCGT 220530EN-27VCGT 220530FN-25PVCGT 220530FN-27VCUW 160408FN-DVCUW 160412FN-DVCUW 220530FN-DVPGT 220516FN-25PVPGT 220516FN-27VPUW 220516FN-DAMZH 10 TH 216 TPKDRRRRRR RRRR RRRRR RRRRR RRRRRRRR= coated hard metal= uncoated hard metal= hard metal with PCD segment15

MSSParting & grooving / threadingMSS stands for consistent modularity. Through thechange of modules the system can be adapted to therespective machining method.Flexibility, precision, stability and good economyrepresent the main characteristics of thisPLANSEE TIZIT innovation.Program see special catalogue“MSS - The modular parting,grooving and threading system“(No. 148)Insert delivery programIndexable insertsType,ordering descriptionAMZH 216 TTSM 20PKDApplicationGX16-1E2.00N0.20-27PGX16-2E3.00N0.30-27PGX16-2R1.50N-27PGX16-3E4.00N0.40-27PGX16-3R2.00N-27PGX16-3R2.50N-27PGX16-4E6.00N0.50-27PRRRRRRRR-D= coated hard metal= uncoated hard metal= hard metal with PCD-segmentGX24-4R3.00N-25P-FGX24-4R3.00N-27PGX24-4R3.00N-DGX24-5R4.00N-25P-FGX24-5R4.00N-27GX24-5R4.00N-27-FGX24-5R4.00N-27PGX24-5R4.00N-27P-FGX24-5R4.00N-35P-FGX24-5R4.00N-DGX 16 - 1 E 2.00 N 0.20 - 27PRRRRRRRRRRRRRchip groove codecorner radiusorientationparting and grooving widthinsert shapewidth classinsert sizeinsert system16

Insert delivery programIndexable insertsType,ordering descriptionAMZH 216 TTSM 20ApplicationFX 2.2N0.10-27PFX 3.1N0.15-27PFX 4.1N0.15-27PRRRFX 3.1 N 0.15 - 27Pchip groove codecorner radiusorientationparting and groving widthinsert systemTC16-1 E 0,5 ISO-27PTC16-1 E 0,75 ISO-27PTC16-1 E 1,0 ISO-27PTC16-1 E 1,25 ISO-27PTC16-1 E 1,5 ISO-27PTC16-2 E 1,75 ISO-27PTC16-2 E 2,0 ISO-27PTC16-2 E 2,5 ISO-27PTC16-2 E 3,0 ISO-27PTC16-1 I 1,0 ISO-27PTC16-1 I 1,5 ISO-27PTC16-2 I 2,0 ISO-27PTC16-2 I 3,0 ISO-27PTC16-1 EI 19 W-27PTC16-2 EI 14 W-27PTC16-2 EI 11 W-27PTC16-1 EI-A60-27PTC16-2 EI-G60-27PTC16-2 EI-AG60-27PTC16-3 EI-N60-27PRRRRRRRRRRRRRRRRRRRRturningmilling= coated hard metal= uncoated hard metalTC 16 - 2 I 2,0 ISO - 27Pchip groove codethread standardpitchinsert shapewidth classinsert sizeinsert system17

DrillingMaxidrillTested and tried short hole drill system with trigoninserts. The special insert position corresponds to aPLANSEE TIZIT patent and ensures compensatedradial forces. This prevents the drill reliably fromrunning off centre.Maxidrill – first choice for drilling through-holes andblind holes without flat bottom∅ range 14 – 53 mmProgram see special catalogue“ Tools and indexable insertsfor drilling into full material“ (No. 149)Insert delivery programIndexable insertsType,ordering descriptionU 17 TApplicationWCGT 030204FNWCGT 050304FNWCGT 060304FNWCGT 07T304FNRRRR= uncoated hard metalPLANSEE TIZIT tipRods for solid carbide drillsProgram see special catalogue“Hard metal for precision tools“ (No. 147)18

Drilling / turningEcoCutThe unique multi-function tool for unbelievableincrease in productivity.A PLANSEE TIZIT patent. Drilling of blind holes withflat bottom, step bores, turning of plane surfaces andexternal profiles with only one tool.∅ range 6 – 32 mmProgram see special catalogue“EcoCut Drilling and turningwith only one tool“ (No. 143)Insert delivery programIndexable insertsType,ordering descriptionH 216 TApplicationXCET 040104FR-27PXCET 040104FL-27PRRXCET 050204FN-27PXCET 060204FN-27PXCET 070304FN-27PXCET 080304FN-27PXCET 09T304FN-27PXCET 10T304FN-27PXCET 130404FN-27PXCET 170508FN-27PRRRRRRRR= uncoated hard metal19

MillingA 260 systemThe cartridge milling tool with the new dimensionconcerning the number of variations and flexibility.a standard basic body for all cartridge styles!three adjustment possibilites for axial run outpossibility to combine roughing and finishingcartridge∅ range 80 – 400 mmProgram see special catalogue“ Tools and inserts for milling“(No. 126)Delivery program - cartridges and insertsCartridgeInsertsType,ordering descriptionH 10 TH 216 TSm 80Application78 18 018SPEX 1204EETRRwiper insert78 18 028 RPMT 120400ENRRPHT 120400FNR78 18 029 SEHT 1204AEFN-27RSEHT 1204AEFN-27PR78 18 031 SDHT 1204AEFN-27rS...SDHT 1204AEFN-27PRSDHT 1204AEFN-RRSDHW 1204AEFNrX...SDHW 1204AEFN-RXDHW 1204AEFNRR20

Delivery program - cartridges and insertsCartridgeInsertsType,ordering description78 18 032 SDHT 1504AEFN-27RSDHW 1504AEFNRH 10 TH 216 TApplication78 18 036 LDHT 120404FR-27PLDHT 120408FR-27PLDHT 120425FR-27PLDHT 120440FR-27PRRRR78 18 039 SDHT 120508FR-27PRSDHT 120525FR-27PR78 18 041 SDHT 0903AEFN-27PRS...X...XDHW 0903AEFNR78 18 042 APHT 100304FR-27PRAPHT 100308FR-27PR78 18 051 LDFT 150408FR-27PRLDFT 150408FR-PR= Goldmaster coated HSS= uncoated hard metalR= standard stockr= limited stock or upon request21

MillingA 270 / C 270 / C 272 systemsShell end and end mill cutter program with45° approach angle. close, normal and course pitch internal coolant supply finishing insert for insert size 09 and 12 face milling, chamfering, circularreboring and plunging ∅ range 16 – 160 mmProgram see special catalogue“Tools and inserts for milling“(No. 126)Insert delivery programInsertsType,ordering descriptionH 10 TH 216 TSm 80Application09SDHT 0903AEFN-27PRS...XDHW 0903AEFNRX...S...X...12SDHT 1204AEFN-27SDHT 1204AEFN-27PSDHT 1204AEFN-RSDHW 1204AEFNSDHW 1204AEFN-RrrRRRXDHW 1204AEFNSDHT 1504AEFN-27SDHW 1504AEFNRRR= goldmaster coated HSS= uncoated hard metal22

A 251 / C 251 systemsShell end and end mill cutter program withbutton inserts.positive insert indexinginternal coolant supplyface milling, milling of clearance faces withparticularly high feed rates∅ range 20 – 125 mmProgram see special catalogue“Maximill A251 / C251“ (No. 153)Insert delivery programInsertsType,ordering descriptionH 216 TApplicationRDHX 0501MOFNRRDHX 0802MOFNRRPHX 10T3MOFN-27PRRPHX 1204MOFN-27PRRPHX 1605MOFN-27PR= uncoated hard metal23

MillingA 490 systemShell end milling cutters with 90° approach angle.four efficient cutting edges!integrated face chamfereconomic, robustclose pitch, integral coolant supplyface and shoulder milling,milling of 90° grooves∅ range 50 – 125 mmProgram see special catalogue“Tools and inserts for milling“(No. 126)Insert delivery programInsertsType,ordering descriptionH 216 TApplicationSDHT 120508FR-27PSDHT 120525FR-27PRR= uncoated hard metal24

A 210 / C 210 / C 212 / A 244 / C 244 systemsShell end and end mill cutters with 90° approachangle.one insert form and sizefor all milling cutters!complete family forshoulder and slot millinginternal coolant supplyexceptionally quiet machining,low power consumption∅ range 16 – 125 mmProgram see special catalogue“Tools and inserts for milling“(No. 126)Insert delivery programInsertsType,ordering descriptionH 216 TApplicationAPHT 100304FR-27PAPHT 100308FR-27PRR= uncoated hard metal25

MillingA 241 / C 241 systemsShell end and end mill cutterswith 90° approach angle.robust constructiondepth of cut up to 14 mminternal coolant supply∅ range 16 – 125 mmProgram see special catalogue“Tools and inserts for milling“(No. 126)Insert delivery programInsertsType,ordering descriptionH 216 TSm 80ApplicationLDFT 150408FR-27PLDFT 150408FR-PLDHT 15T3PD-FRRRR= goldmaster coated HSS= uncoated hard metal26

Helimax systemEnd mills manufactured from solid carbide and endmills with brazed helical carbide strip.E110 suitable for drillinglong and precisely ground peripheral cuttingedge for optimal finishing (milling)HSC suitablehigh rigidity, precise radial run outfine grain grade∅ range 2 – 40 mmProgram see special catalogue“Tools and inserts for milling“(No. 126)Delivery programToolType,ordering descriptionTSM 30ApplicationE110.02.R.02-ALE110.03.R.02-ALE110.04.R.02-ALE110.05.R.02-ALE110.06.R.02-ALE110.08.R.02-ALE110.10.R.02-ALE110.12.R.02-ALE110.16.R.02-ALE110.20.R.02-ALE110.25.R.02-ALE110.32.R.02-ALE110.40.R.02-ALRRRRRRRRRRRRR= uncoated hard metalR112.02.R.02-ALR112.03.R.02-ALR112.04.R.02-ALR112.05.R.02-ALR112.06.R.02-ALR112.08.R.02-ALR112.10.R.02-ALR112.12.R.02-ALR112.16.R.02-ALR112.20.R.02-ALRRRRRRRRRR27

MillingHSC-12 systemShell end and end mill cutter programwith 90° approach angle.patented positive insert clampingbalanceableinternal coolant supply∅ range 16 – 100 mma p max 10 mm; v c max 5000 m/minProgram see special catalogue“Tools and inserts for milling“(No. 126)Insert delivery programInsertsType,ordering descriptionH 216 TApplicationLDHT 120404FR-27PLDHT 120408FR-27PLDHT 120425FR-27PLDHT 120440FR-27PRRRR= uncoated hard metal28

HSV systemShell end and end mill programwith 90° approach angle. robust V-formed insert with R 3.0 large chip pockets (only 2 cutting edges) well-suited for plunging ∅ range 40 – 100 mm a p max 15 mmProgram see special catalogue“Tools and inserts for milling“(No. 126)Insert delivery programInsertsType,ordering descriptionH 10 TH 216 TApplication...T...XVCGT 220530FN-27MVCGT 220530FN-27MPVCGX 220530FN-27MPrRRR= standard stockr= limited stock or upon request= uncoated hard metal29

MillingHSX systemShell end and end mill cutter programwith 90° approach angle. cutting edge lengths 20 and 23 mm corner radius R 4.0 and R 5.0 well-suited for plunging large chip pocket ∅ range 25 – 80 mm a p max 23 mmProgram see special catalogue“ Tools and inserts for machiningaluminium components“ (No. 170)Insert delivery programInsertsType,ordering descriptionH 216 TApplicationXDHT 200450FR-27PXDHT 230440FR-27PRR= uncoated hard metal30

HSC-HP systemShell end and end mill cutter programwith 90° approach angle.positive insert clampingfor the upper HSC rangecentrifugal force test for all milling cutterswell-suited for plunging∅ range 25 – 63 mmProgram see special catalogue“ Tools and inserts foraluminium component machining“(No. 170)Insert delivery programInsertsType,ordering descriptionH 216 TApplication= uncoated hard metalXDHX 190402FR-27PXDHX 190404FR-27PXDHX 190408FR-27PXDHX 190420FR-27PXDHX 190425FR-27PXDHX 190432FR-27PXDHX 190440FR-27PXDHX 190450FR-27PRRRRRRRR31

MillingHSC-19 systemShell end and end mill cutter programwith 90° approach angle.for the medium HSC rangewell-suited for plunging∅ range 25-100 mmProgram see special catalogue“ Tools and inserts for aluminiumcomponent machining“ (No. 170)Insert delivery programInsertsType,ordering descriptionH 216 TApplicationXDHT 190402FR-27PXDHT 190404FR-27PXDHT 190408FR-27PXDHT 190420FR-27PXDHT 190425FR-27PXDHT 190432FR-27PXDHT 190440FR-27PXDHT 190450FR-27PRRRRRRRR= uncoated hard metal32

MillingSpecial insertsLDHTInsertsType,ordering descriptionH 10 TH216TApplicationLDHT 15T308FRROFHRInsertsType,ordering descriptionH 10 TH216TApplicationOFHR 070410FR-27PRSFANInsertsType,ordering descriptionH 10 TH216TApplicationSFAN 1203EFFRRSPKRInsertsType,ordering descriptionH 10 TH216TApplicationSPKR 1203EDFR-ALR= uncoated hard metal33

System solutionsGeneralOffering component specific systemsolutions is indispensable.In this field PLANSEE TIZIT provides the followingservices for selected customer segments:complete tool solutionsoptimised cutting materials and geometriesengineering know-how and applicationsupport at the respective companytraining courses and seminarsextensive support with regards to O.E.M. projectsconstruction and manufacture of special toolscoordination of project teams34

System solutionsProgramsee special brochure“Tools and insertsfor aluminium wheelmachining“ (No. 129)Aluminium rim machiningScrew bores / valve boresExternal machiningFront / “mirror“HubInternal machining35

System solutionsAerospaceHigh performance milling toolsfor machining aluminium componentsProgram see special catalogue“ Tools and inserts for aluminiumcomponent machining“ (No. 170)36

Standard materialsCast alloysDIN 1725-2 DIN EN 1706Alloy group Material Alloy designationAlCuAlSiMgTiAlSi7MgAlSi10MgAlSiAlSi5CuAlSi9CuAlSi(Cu)AlSiCuNiMgAlMgAlZnMgdesignationG-AlCu4TiMgG-AlCu4Ti––G-AlSi7Mg–G-AlSi10Mg–G-AlSi10Mg(Cu)G-AlSi9MgGD-AlSi10MgG-AlSi11–G-AlSi12GD-AlSi12–G-AlSi6Cu4––––GD-AlSi9Cu3–G-AlSi9Cu3––––G-AlSi12(Cu)GD-AlSi12(Cu)––G-AlMg3GD-AlMg9G-AlMg5G-AlMg5Si–number3.13713.1841––3.2371–3.2381–3.23833.23733.23823.2211–3.25813.2582–3.2151––––3.2163–3.2163––––3.25833.2982––3.35413.32923.35613.3261–numericEN AC-21000EN AC-21100EN AC-4100EN AC-42000EN AC-42100EN AC-42200EN AC-43000EN AC-43100EN AC-43200EN AC-43300EN AC-43400EN AC-44000EN AC-44100EN AC-44200EN AC-44300EN AC-44400EN AC-45000EN AC-45100EN AC-45200EN AC-45300EN AC-45400EN AC-46000EN AC-46100EN AC-46200EN AC-46300EN AC-46400EN AC-46500EN AC-46600EN AC-47000EN AC-47100EN AC-48000EN AC-51000EN AC-51100EN AC-51200EN AC-51300EN AC-51400EN AC-7100chem. symbolEN AC-Al Cu4MgTiEN AC-Al Cu4TiEN AC-Al Si2MgTiEN AC-Al Si7MgEN AC-Al Si7Mg0,3EN AC-Al Si7Mg0,6EN AC-Al Si10Mg/a)EN AC-Al Si10Mg(b)EN AC-Al Si10Mg(Cu)EN AC-Al Si9MgEN AC-Al Si10Mg(Fe)EN AC-Al Si11EN AC-Al Si12(b)EN AC-Al Si12(a)EN AC-Al Si12(Fe)EN AC-Al Si9EN AC-Al Si6Cu4EN AC-Al Si5Cu3MgEN AC-Al Si5Cu3MnEN AC-Al Si5Cu1MgEN AC-Al Si5Cu3EN AC-Al Si9Cu3(Fe)EN AC-Al Si11Cu2(Fe)EN AC-Al Si8Cu3EN AC-Al Si7Cu3MgEN AC-Al Si9Cu1MgEN AC-Al Si9Cu3(Fe)(Zn)EN AC-Al Si7Cu2EN AC-Al Si12(Cu)EN AC-AlSi12Cu1(Fe)EN AC-Al Si12CuNiMgEN AC-Al Mg3(b)EN AC-AlMg3(a)EN AC-Al Mg9EN AC-Al Mg5EN AC-Al Mg5 (Si)EN AC-Al Zn5Mg37

Standard materialsMalleable aluminium alloys - barsDIN 1725-1/DIN 1712-3 DIN EN 573-3MaterialAlloy designationdesignationAlCuMgPbAlCuBiPb–AlMgSiPb–AlMgSi0,5–AlMgSi1AlCuSiMnAlCuMg1AlCuMg2AlZn4,5Mg1AlZnMgCu0,5AlZnMgCu1,5Al99,5E-AlAlMg3AlMg5AlMg4,5Mnnumber3.16453.1655–3.0615–3.3206–3.23153.12553.13253.13553.43353.43453.43653.02553.02573.35353.35553.3547numericEN AW-2007EN AW-2011EN AW-2030EN AW-6012EN AW-6262EN AW-6060EN AW-6063EN AW-6082EN AW-2014EN AW-2017AEN AW-2024EN AW-7020EN AW-7022EN AW-7075EN AW-1050AEN AW-1350EN AW-5754EN AW-5019EN AW-5083chem. symbolEN AW-Al Cu4PbMgMEN AW-Al Cu6BiPbEN AW-Al Cu4PbMgEN AW-Al MgSiPbEN AW-Al Mg1SiPbEN AW-Al MgSiEN AW-Al Mg0,7SiEN AW-Al Si1MgMnEN AW-Al Cu4SiMgEN AW-Al Cu4MgSi(A)EN AW-Al Cu4Mg1EN AW-Al Zn4,5Mg1EN AW-Al Zn5Mg3CuEN AW-Al Zn5,5MgCuEN AW-Al 99,5EN AW-Eal 99,5EN AW-Al Mg3EN AW-Al Mg5EN AW-Al Mg4,5Mn0,7Attention: EN755-2 (extruded bars) and EN754-2 (drawn bars) contain numerous othermaterials and alloy variations which are less common.= hardenable materials= naturally hard materials38

Malleable aluminium alloys - insertsDIN 1725-1/DIN 1712-3 DIN EN 573-3MaterialAlloy designationdesignationnumbernumericchem. symbolAl99,5AlMg3AlMg4,5MnAlMg1SiCuAlMgSi1AlCuMg1AlCuMg2AlZn4,5Mg1AlZnMgCu0,5AlZnMgCu1,53.02553.35353.35473.32113.23153.13253.13553.43353.43453.4365EN AW-1050AEN AW-5754EN AW-5083EN AW-6061EN AW-6082EN AW-2017AEN AW-2024EN AW-7020EN AW-7022EN AW-7075EN AW-Al 99,5EN AW-Al Mg3EN AW-Al Mg4,5Mn0,7EN AW-Al Mg1SiCuEN AW-Al Si1MgMnEN AW-Al Cu4MgSi(A)EN AW-Al Cu4Mg1EN AW-Al Zn4,5Mg1EN AW-Al Zn5Mg3CuEN AW-Al Zn5,5MgCuAttention: EN 485-2 contains some other materials and alloy variations which are less common= naturally hard materials= hardenable materials39

Practical examplesHousingProblem / criteria:surface finishformation of burrsclampingResults:surface roughness R z 3.4 µmexcellently quiet machiningminimal burr formationat exit pointsWork piece:Material:Machine:Tools:housingSiluminSHWA 270.80.R.05SDHT 1204AEFN-27P H216TApplication data:V c [m/min] 500a p [mm] 3a e [mm] 32 – 45v f [mm/min] 2500f z [mm] 0.25Aluminium rimProblem / criteria:vibrationschip formationwet machiningResults:good surface qualitylong cutting edge life (80’)short machining timesWork piece:Material:Machine:Tools:aluminium rimG-AlSi12MgIMTMaxilock S and MSSVCGT 160412FN-27P H216TGX24-5R4.00N-35P-F H216TApplication data:V c [m/min] 300 – 2200a p [mm] 1.0 – 2.5f [mm/rev.] 0.25 – 0.640

Aluminium rimProblem / criteria:TIZITsurface finishfree from blow holesResults:good surface qualitylong cutting edge life(approx. 1,400 pieces)Work piece:Material:Machine:Tools:aluminium rimG-AlSi12MgOkumaUT40-SVHCR-16VCUW 160412FN-DApplication data:V c [m/min] 1800 – 2200a p [mm] 0.3f [mm/rev.] 0.2TubeProblem / criteria:dimensional accuracydeformationResults:no deformation ofthin walled work pieceWork piece:Material:Machine:Tools:tubeAlCuBiPbWasinoSDJR 2020 K11DCGT11T304-FN-27 H216TApplication data:V c [m/min] 216 – 280a p [mm] 2,0f [mm/rev.] 0,141

Practical examplesScrewProblem / criteria:surface finishchip evacuationResults:good chip control clean and even cut surfaceWork piece:Material:Machine:Tools:screwG-AlSi12CuOerlikonXLCFN 3203 M31FX3,1FN-27P H216TApplication data:V c [m/min] 70 – 350a p [mm] 3.1f [mm/rev.] 0.1HousingProblem / criteria:suitable for plungingchip evacuationResults: Ergebnis:good chip controlmore economic machining comparedto HSS (only Helimax)Work piece: housingMaterial: AlCuMgMachine: Maho MC 600Tool:C-HSC-HP-25-R-02-19-ZS20 L60Application data:V c [m/min] 320a p [mm] 3.0 – 20a e [mm] 5.0 – 25v f [mm/min] 570f z [mm] 0.0742

General informationAdvantagesPLANSEE TIZIT aluminium inserts are characterised by large rake angles, sharp cutting edges,extra-smooth rake faces and wear resistant hard metal grades.With reference to practical application, these properties result in the following advantages:low cutting forceslow tolerances maintained (component stability)low burr formationclean surface at the componentgood swarf controllong tool lifeThese advantages are not only relevant for aluminium!Additional application fields for PLANSEE TIZIT aluminium inserts:RFinishing and fine finishing of:stainless steel, steelcast irontitaniummolybdenumRGeneral machining of:steelmagnesiumcopper alloysplasticsgraphitehardenedmaterialsstainlessRIn the branches:super alloyslight engineeringmedical systemswatch and clock making industrygen. mechanical engineeringcast ironRMachining of composite materials:soft and hard materialsnon ferrousmetals43

Parent companyPLANSEE TIZIT Aktiengesellschaft‘A-6600 Reutte/TirolTel.: +43 (5672) 600-0Fax:+43 (5672) 600-502 Cutting Tools+43 (5672) 600-503 Wear PartsE-Mail: tool.at@plansee.atE-Mail: wear.at@plansee.athttp://www.plansee.comAustriaPLANSEE TIZIT AktiengesellschaftA-6600 Reutte/TirolTel.: +43 (5672) 600-0Fax: +43 (5672) 600-505E-Mail: zerspanung.at@plansee.at= Sales Cutting ToolsBulgariaINSTRUMENT AGBoulevard Stoletov 157BG-5301 GabrovoTel.: +359 (66) 438-11Fax: +359 (66) 437-42E-Mail: instrument@eda.bg= Sales Cutting ToolsGermanyPLANSEE TIZIT GmbHSchützenstraße 29D-72574 Bad UrachTel.: +49 (7125) 1501-0Fax: +49 (7125) 8594E-Mail: tool.de@plansee.de= Sales Cutting ToolsFranceSociété PLANSEE TIZIT S.A.R.L.20, Rue LavoisierF-95300 PontoiseTel.: +33 (1) 3433-3180Fax: +33 (1) 3030-9339E-Mail: tool.f@plansee.at= Sales Cutting ToolsGreat BritainPLANSEE TIZIT (UK) Ltd.Cliff LaneGrappenhallWarrington WA4 3JXTel.: +44 (1925) 261-161Fax: +44 (1925) 267-933E-Mail: tool.uk@plansee.at= Sales Cutting ToolsChinaPLANSEE TIZIT Hong Kong Ltd.Room 1201-1202Hollywood Centre233 Hollywood Rd., Sheung WanHong KongTel.: (+852) 2542-1838Fax: (+852) 2854-3777E-Mail: tool.hk@plansee-hk.com= Sales Cutting ToolsIndiaSiel TIZIT Limited58, Motilal Gupta RoadBarishaIN-700 008 CalcuttaTel.: +91 (33) 447-5435Fax: +91 (33) 447-6472Telex: 021 8142 ihm inE-Mail: positiz@cal.vsnl.net.in= Sales Cutting ToolsItalyTIZIT S.p.APiazza F. Martelli, 7I-20162 MilanoTel.: +39 (02) 6441-111Fax: +39 (02) 6611-6040E-Mail: tool.i@plansee.at= Sales Cutting ToolsSpainPLANSEE TIZITVía de las Dos Castillas, 9cPortal 2, Bajo BE-28224 Pozuelo (Madrid)Tel.: +34 (91) 351-0609Fax: +34 (91) 351-2813E-Mail: tool.e@plansee.at= Sales Cutting ToolsUSASCHWARZKOPFTECHNOLOGIES Corporation115 Constitution BoulevardFranklin, MA 02038Tel.: +1 (508) 553-3800Fax: +1 (508) 553-3823E-Mail: tool.usa@stc-ma.com= Sales Cutting Tools162 / 1We reserve the right to make technical changes for product improvement.162 E 09.00