End Mill Series - Mitsubishi Materials

1 Update B075G. End Mill Series Newly developed "Impact Miracle Coating". Single phase nano crystal coating technology for higher film hardness and heat resistance. Miracle end mills for increased cutting speeds, efficiency and tool life when milling high hardness Materials . Solid carbide end mills using a combination of Impact Miracle coating, new micro-grain cemented carbide and optimized geometry. a For hardened steels over 60 HRC, pre-hardened steels through to general steels. a For high-speed & high efficiency machining. a For unstable applications with long overhang machining through to precision machining. New end mill Series covering a wide range of machining applications. Coating y Features a All Impact Miracle end mills are coated using the latest Single phase nano crystal coating technology for higher film hardness and heat resistance. Cemented Carbide Geometry Characteristics of Impact Miracle coating (Al,Ti,Si)N (Al,Ti)N.

2 New coating, cemented carbide and geometry. Hardness 3700HV 3200HV 2800HV New generation of IMPACT MIRACLE end mills ! Adhesion 100N 80N 80N. Oxidation temperature 1300 C 1100 C 840 C. Friction coefficient a Improved cutting edge geometry. The superior chipping resistance allows higher speeds for reliable milling of high hardness Materials . a For reduced friction resistance and high quality surface finishes! When machining die casting mould steel tool life was doubled when compared to the conventional product. End mill VF-2SB R3. Workpiece DH31S (52 HRC). VF-2SB. Revolution 16,000min-1 (284m/min) Feed rate 1,600mm/min ( ). 2mm Machining method Climb cut, Air blow Conventional Cutting length: 120m Cutting length: 60m 0 20 40 60 80 100 120. Cutting length (m). VF-2SB Conventional Excellent cutting performance even when machining pre-hardened steels ! Cutting length: 1200m End mill VF-2 XLB Workpiece NAK80 (43 HRC).

3 VF-2 XLB. Revolution 20,000min-1 (68m/min). Feed rate 2,000mm/min ( ) Machining method Water soluble coolant Competitor 1. IMPACT MIRACLE END MILL. VF-2 SSB Ball nose, Short cut length, 2 flute, For hardened Materials 12 different sizes available. VF-2SB Ball nose, Short cut length, 2 flute, For hardened Materials 36 different sizes available. VF-2 XLB Ball nose, Long cut length, 2 flute, For hardened Materials 198 different sizes available. VF-2 SDB Ball nose, Short cut length, 2 flute, Strong geometry type 14 different sizes available. VF-2 SDBL Ball nose, Short cut length, 2 flute, Strong geometry type, Long shank 11 different sizes available. VF-3XB Ball nose, 3 flute, Taper neck, For hardened Materials 89 different sizes available. VF-SD 1- 12mm End mill, Short cut length, 4/6 flute, For hardened Materials 12 different sizes available. VF-MD 1- 25mm End mill, Medium cut length, 4/6 flute, For hardened Materials 18 different sizes available.

4 VF-SDRB 3- 12mm Corner radius, Short cut length, 6 flute, For hardened Materials 13 different sizes available. VF-MDRB 3- 20mm Corner Radius, Medium cut length, 6 flute, For hardened Materials 21 different sizes available. Higher feed rates and 4 times longer tool life compared to competitor end mills ! VF-2 SDB No End mill VF-2 SDB R3. Damage Workpiece SKD61(52 HRC) -1. Revolution 16,000min Competitor A Chipping Feed rate 9,600mm/min ( ). Competitor B Chipping Machining method Air blow 0. 1 2 Overhang 3 4. Cutting length (m) 21mm 2. IMPACT MIRACLE END MILL. <Geometry>. Powder high speed steel machining Tool life doubled compared to competitors end mills when machining hardened steels over 65 HRC. VF-2SB. <Depth of cut> <Result>. ting Cut gth 250 n le m 50. VF-2SB. Cutting length (m). 200. Conventional 150 VF-2SB. 100. End mill VF-2SB R1. 50. Workpiece Powder high speed steel 0. Revolution 8,000min-1 (18m/min).

5 Feed rate 1,260mm/min ( ) High speed steel Powder high speed steel Conventional Machining method Climb cut, Air blow <Geometry>. High speed steel machining Triple tool life compared to competitors end mills when pocket machining hardened steels ! VF-2SB. <Depth of cut> <Result>. 5times VF-2SB. ap ae 12 times Cutting length: 30m End mill VF-2SB R1. Workpiece SKH51 (65 HRC) Chipping Revolution 20,000min-1 (126m/min) Competitor Feed rate 6,000mm/min ( ). Cutting length: 10m Machining method Up and down cut milling, Air blow <Geometry>. Machining of hardened steels Triple tool life compared to competitors end mills when machining at large depths of cut. VF-2SB. <Depth of cut> <Result>. 8mm VF-2SB. Cutting length: 30m End mill VF-2SB R10. Workpiece SKD11 (60 HRC). Competitor Revolution 1,200min-1 (74m/min). Feed rate 240mm/min ( ) Cutting length: 10m Machining method Climb cut, Air blow 3. <Geometry>.

6 High load machining of pre-hardened steels Excellent chipping resistance compared to competitors end mills ! VF-2 SDB. ap 5times <Depth of cut> <Result>. Bottom cutting edge Gash geometry VF-2 SDB. ae 12times Cutting length: length: 15m End mill VF-2 SDB R3. Workpiece SKD61 (52 HRC). Competitor Revolution 12,000min-1 (226m/min). Feed rate 4,500mm/min ( ). Cutting length: length: 15m Machining method Air blow <Geometry>. Deep and high feed machining comparison Excellent fracture resistance even with long overhang (7D) and large depths of cut ! VF-2 SDB. <Depth of cut> <Result> Bottom cutting edge Gash geometry VF-2 SDB. Overhang 70mm Conventional A 7D. End mill VF-2 SDB R5. Workpiece SKD61(52 HRC). Revolution 6,000min-1 (188m/min). Conventional B. Feed rate 500mm/min ( ). Machining method Air blow <Geometry>. Pre-hardened steel machining Roughing on mould 1) No chipping after the 2 hour's machining.

7 2) Minimum tool wear, further machining possible. VF-2 SDB. <Depth of cut> <Result>. Bottom cutting edge Cutting edge 1 Cutting edge 2. End mill VF-2 SDB R5. Workpiece PX5 (40 HRC). Revolution 5,000min-1 (157m/min). Feed rate 2,000mm/min ( ). Machining method Non water soluble coolant 4. IMPACT MIRACLE END MILL. <Geometry>. Alloy tool steel for hot moulding Roughing on mould 1) No chipping at long overhang machining (5D). 2) Conventional end mill had chipping. VF-2 SDB. <Depth of cut> <Result>. Overhang 50mm VF-2 SDB Conventional 50mm 5D. End mill VF-2 SDB R5. Workpiece SKD61 (52 HRC). Revolution 8,000min-1 (251m/min). Feed rate 4,800mm/min ( ). Machining method Climb cut, Air blow <Geometry>. Pocket machining of hardened steels Longer tool life without chipping compared to competitors end mills ! VF-2 XLB. <Depth of cut> <Result>. Cutting length: 20m VF-2 XLB. 2 component 10times 10times Cutting length: 10m End mill VF-2 XLB R1x20.

8 Workpiece SKD11 (60 HRC) Competitor Revolution 10,000min-1 (63m/min) 1 component Feed rate 1,000mm/min ( ). Machining method Up and down cut milling, Air blow <Geometry>. Pre-hardened steel machining Long tool life compared to competitors end mills when pocket machining hardened steels ! VF-2 XLB. <Depth of cut> <Result>. VF-2 XLB Cutting length 1,000m Competitor Cutting length 700m End mill VF-2 XLB Workpiece STAVAX (52 HRC) VF-2 XLB. r Revolution 20,000min-1 (68m/min) Competitor wea Big Feed rate 4,000mm/min ( ). 0 300 500 700 1,000. Machining method Climb cut, Water soluble coolant Cutting length (m). 5. <Geometry>. Hardened steel machining Comparison with conventional 2 flute end mill, VF-3XB shows high fracture resistance. VF-3XB. <Depth of cut> <Result>. 10 groove Neck Length: 25mm 60times No Damage VF-3XB (10 groove). 9 groove 4times End mill VF-3XB x x 25 Fracture Competitor A (9 groove).

9 Workpiece SKD61 (52 HRC) (2 flute) 1 groove Fracture Competitor B (1 groove). (2 flute). Revolution 13,000min-1 ( ) 0 1 2 3 4 5 6 7 8 9. Number of slots machined 10. Feed rate 1,500mm/min ( ). Machining method Air blow <Geometry>. Hardened steel machining Feed rate increased by 60%. VF-3XB. <Depth of cut> <Result>. Previous feed rate: 1600mm/min 75times Neck Length: 30mm ( ). VF-3XB: 2,600mm/min 8times VF-3XB Conventional End mill VF-3XB R1 x x 30. Workpiece SKD61 (52 HRC). Revolution 16,000min-1 (100m/min). Feed rate 2,600mm/min ( ). Machining method Coolant mist <Geometry>. Hardened steel machining Feed rate increased by 50%. VF-3XB. <Depth of cut> <Result>. Previous feed rate: 2500mm/min 40times Neck Length: 40mm ( ). VF-3XB: 3,400mm/min 8times VF-3XB Conventional End mill VF-3XB x x 40. Workpiece SKD61(52 HRC). Revolution 14,000min-1 (131m/min). Feed rate 3,400mm/min ( ). Machining method Coolant mist 6.

10 IMPACT MIRACLE END MILL. <Geometry>. STAVAX (Copy turning). 1) 30% increase in efficiency! 2) Surface finish improved and longer tool life. VF-3XB. <Depth of cut> <Result>. Machining the bottom of the slot. End mill VF-3XB R1 x x 25. Workpiece STAVAX (40 HRC). Revolution 12,000min-1 (75m/min). Feed rate 850mm/min ( ). Machining method Climb cut, Non water soluble coolant <Geometry>. SKD61 (Rib processing). Conventional end mill : damage at the cutting edge VF3XB : damage was reduced VF-3XB. <Depth of cut> <Enlarged view> <Result>. 45mm 45mm End mill VF-3XB R2 x x 40. Workpiece SKD61 (45 HRC). Revolution 10,000min-1 (MAX 125m/min). Feed rate Roughing: 2,000mm/min ( ), Finshing: 720mm/min ( ). Machining method Water soluble coolant <Geometry>. Side machining of hardened mould steels Excellent wear resistance without fracturing at the end cutting edge ! VF-MD. <Depth of cut> <Result>. VF-MD.