Tools for aluminium machining

The best for aluminium machining

Aluminium

Aluminium - a material that has a future

Aluminium in the automobile
Particularly in the field of transport engineering massive application of light weight materials represents the order of the day. The goal of saving fuel and other energy forms can mainly be achieved through the reduction of vehicle weights. Apart from various synthetic materials, the classical light metal aluminium offers the best prerequisites for reaching this objective. In other application fields, too, its numerous favourable properties make aluminium an appreciated construction material for engineers.

[ mill. tons]

1999

2009 (Prognosis EAA)

Trends in the field of machining

Innovative machining strategies are characterised by maximum cutting speeds and feed rates in order to obtain the highest possible metal removal rates. Refraining from massive use of cooling lubricant represents an importantdemand with reference to the environmental impact. Process safety and an increase in productivity are the prerequisites for a favourable market position and thus competitiveness. The machining properties of aluminium are perfectly suitable for putting modern machining concepts into practice.

HPC High Performance Cutting

Time saving with HPC machining Prerequisites for HPC machining
conventional HPC machining HSC 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 tools adequate cutting materials

Machining time [in h]

machine down times roughing finishing

Source: Heidelberger Druck

Machinability of aluminium alloys

Relative machinability
It 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 machined alloy stocks to the diffult to machine pure aluminium.

Group
pure Al

Alloy type

Relative machinability

Al 99,9

non hardened

malleable aluminium alloys

Al Mn Al Mg Al Mg Mn

4-5 3-5 3-4

Al Mg Si machining alloy stock Al Cu Mg Al Cu Si Mg Al Zn Mg Cu

3-4 1-2 2-3 3 2

cast aluminium alloys

hardened

G - Al Si G - Al Si Mg G - Al Si Cu G - Al Mg G - Al Mg Si G - Al Cu Ti G - Al Si Cu Mg Ni

3 2-3 2 2 2 2 2-3

1 - very good machinability 5 - bad machinability

Machinability can be defined as the degree of difficulty that a material creates when being machined. In order to assess the machinability of a material basically 4 parameters have to be taken into consideration: cutting force tool life surface quality chip formation

Machinability of aluminium alloys

1. Cutting force
Aluminium requires only approx. 30 % of the cutting force necessary for steel materials. The influence of the material on the cutting force is expressed through the special cutting force Ks1.1 . The rake angle of the cutting edge is of particular interest regarding the cutting force. Increasing the rake angle by one degree the cutting force is reduced by ~1.5%.

Important characteristics of PLANSEE TIZIT inserts: rake angle > 25 sharp, uniform cutting edge extra-smooth rake face

2. Tool life
cutting material: HM-K10

The time the cutting edge can be used until it is worn out. In the field of aluminium machining this criterion is determined by three wear forms:

tool life t [min]

crater wear

flank wear

built up edges and adhesion to the cutting edge

Alloys

cutting speed Vc [m/min]

Reasons for wear:

thermal and mechanical stress diffusion processes, friction abrasive alloy elements tendency to stick treatment state of the alloy

Important characteristics of PLANSEE TIZIT inserts: extremely wear resistant hard metal grades optimised coating extra-smooth rake face

Source: WZL Aachen

3. Surface finish
With regard to surface finish you can distinguish between kinematic roughness, surface roughness and roughness caused by disturbances. The kinematic roughness is a function of the relative movement between tool and work piece and the size of the corner radius. The surface roughness is dependent upon the properties of the alloy, the cutting data, geometry, cutting material and the surface quality of the rake face. Disturbances, e.g. lack of stability of the machining systems, result in surface defects such as chatter marks.

cut edge roughness

Important characteristics of PLANSEE TIZIT inserts: extra-smooth rake face optimised micro-geometry of the cutting edge fine grain substrates

4. Chip formation
Badly formed chips disturb the production process considerably. They interfere with both the work piece and the machine, and are difficult to remove them from the machining environment. Precisely machined surfaces show scratches; the quality of the pieces is reduced. unfavourable Important characteristics of PLANSEE TIZIT inserts: aluminium specific chip grooves reduced friction between chip and rake face favourable

Demands on tooling systems suitable for aluminium machining

adapted rake and clearance angles controlled chip formation

sharp, uniform cutting edges smooth rake faces

disturbance free chip flow (claws etc.) large chip pockets HSC suitable

Cutting materials suitable for aluminium machining

Overview

heat resistance and thermal stability

PCD CBN

oxide whisker reinforced ceramics ceramics coated cermets nitride ceramics cermets coated hard metals sub-micron grade hard metals

hard metals on WC basis

powder metallurgical HSS, coated

HSS

toughness
cutting materials suitable for aluminium machining

PLANSEE TIZIT grades

Sm 80
Powder metallurgically produced HSS with CVD carbonitride coating. For niche applications in the fields of turning and milling when highest toughness is required. Suitable only for low and medium cutting speeds.

Coating layer system: CVD Ti(C+N) TiN Coating thickness: 5 m Micro-hardness of the coating: HV0,05 2500 Hardness: HV 1630 Grain size: 1 m CO content: 6% Hardness: HV 1850 Grain size: 0.7 m CO content: 6% Hardness: HV 1720 Grain size: 0.7 m CO content: 7.5 % Hardness: HV 1550 Grain size: 0.7 m CO content: 10 % Coating layer system: PVD / Ti Al N Coating thickness: 3 m Micro-hardness of the coating: HV0,05 3600 Hardness: HV ~10.000 Grain size: ~10 m

H 216 T / H 10 T
(K10 - K15)
Due to its regular structure the fine grain substrate guarantees high cutting edge stability. Universal grades!

TSM 10 (K10)
High wear resistance through fine WC grains and low CO content. First choice for solid carbide tools.

TSM 20 (K15 - K20)

High wear resistance and good toughness through fine WC grain and medium CO content. For special applications with solid carbide tools 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 solid carbide milling tools.

AMZ (K10)
Substrate with extremely hard PVD coating containing Ti Al N - Al2O3. Reduces wear and tendency to stick. First choice for high cutting speeds and alloys with tendency to stick.

PKD
Polycrystalline diamond (PCD segment brazed onto a supporting insert). First choice with abrasive Al-Si-alloys, (>18% Si) for polish turning and industrial scale manufacturing.

Microfinish
Microfinish is synonymous with a high polish surface finish and therefore represents the logical continuation of the 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:
Chip particles get stuck in the cutting edge area Due to the tendency to stick the time the tool can be used is decreased Not everything that is desired in the field of surface quality can be put into practice

Solution:
The shining surface keeps the cutting edge free of chip particles Tool life and wear are optimised The surface quality of the finished product meets highest demands

REM photo: rake face without microfinish chip particles stuck on the rake face

REM photo: rake face with microfinish the indexable insert with the P

Chip formation
Factors influencing chip formation
Work piece material
alloys type of structure treatment state

Machine
static and dynamic rigidity

Cutting material
friction on the rake face

Cooling
high volume coolant minimum quantity lubrication dry machining

Cutting data
f / ap / vc

Chip control
cutting edge geometry chip groove

The chip groove design is of decisive importance. In order to obtain an optimum machining result, chip grooves which are adapted to the alloy type or machinability group have to be applied.

Chip groove -23

Alloy: soft malleable aluminium alloys (e.g. AlMn, AlMg) Parts: extrusion parts Machining methods: turning, reboring

f [mm/rev]

Chip grooves
Chip groove -25

Alloy: cast and malleable aluminium alloys, also with low Si content (e.g. G-AlSi2, AlMgSi) Parts: cast and forged parts Machining methods: turning, copy turning

f [mm/rev]

Chipgroove -27

Alloy: cast and malleable aluminium alloys Parts: cast parts, extrusion and rolled parts Machining methods: turning, reboring (same type of geometry also for milling, drilling, parting, grooving and thread cutting!)

f [mm/rev]

10

Competence in aluminium machining

11

Turning

Maxilock S tooling system

The positive screw clamping guarantees a safe connection of the insert with the tool holder. Chip evacuation is not hindered by obstructive clamping elements. Due to the neutral insert position the effectively available rake angle is identical with the rake angle of the insert.

Program see special catalogue Tool holders for turning and boring (No. 90)

Insert delivery program

AMZ H 10 T H 216 T

Indexable inserts

Type, ordering description CCGT 060202FN-23P CCGT 060202FN-25P CCGT 060202FN-27 CCGT 060204FN-23 CCGT 060204FN-23P CCGT 060204FN-25P CCGT 060204FN-27 CCGT 09T302FN-25P CCGT 09T302FN-27 CCGT 09T304FN-23 CCGT 09T304FN-23P CCGT 09T304FN-25P CCGT 09T304FN-27 CCGT 09T308FN-23P CCGT 09T308FN-25P CCGT 09T308FN-27

R R R R R R R R R R R R R R r R R R R R R R R R

R= standard stock r= limited stock or upon request

= coated hard metal = uncoated hard metal

12

Insert delivery program

Type, ordering description CCGT 120402FN-25P CCGT 120402FN-27 CCGT 120404FN-25P CCGT 120404FN-27 CCGT 120408FN-25P CCGT 120408FN-27 CNGM 190612FN-27

Indexable inserts

DCGT 070202FN-25P DCGT 070202FN-27 DCGT 070204FN-23 DCGT 070204FN-23P DCGT 070204FN-25P DCGT 070204FN-27 DCGT 11T302FN-25P DCGT 11T302FN-27 DCGT 11T304FN-23P DCGT 11T304FN-25P DCGT 11T304FN-27 DCGT 11T308FN-23P DCGT 11T308FN-25P DCGT 11T308FN-27

= coated hard metal = uncoated hard metal

AMZ H 10 T H 216 T

R R R R R R R R R R R

R R R R R R R R R R R R R R R R R R R R R R R

13

Turning

Insert delivery program

Type, ordering description RCGT 0602MOFN-27 RCGT 0803MOFN-27 RCGT 1003MOFN-27 RCGT 1204MOFN-27

Indexable inserts

SCGT 09T304FN-27 SCGT 09T308FN-27 SCGT 09T308FN-27 SCGT 120408FN-25P SCGT 120408FN-27

TCGT 110204FN-27 TCGT 16T302FN-27 TCGT 16T304FN-27 TCGT 16T308EN-27

= coated hard metal = uncoated hard metal

14

AMZ H 10 T H 216 T

R RR RR R

R R R R R R R

R R R R

Insert delivery program

Type, ordering description VCGT 110302FN-25P VCGT 110302FN-27 VCGT 110304FN-25P VCGT 110304FN-27 VCGT 110308FN-27 VCGT 160404FN-25P VCGT 160404FN-27 VCGT 160408FN-25P VCGT 160408FN-27 VCGT 160412FN-25 VCGT 160412FN-25P VCGT 160412FN-27 VCGT 220530EN-27 VCGT 220530FN-25P VCGT 220530FN-27 VCUW 160408FN-D VCUW 160412FN-D VCUW 220530FN-D VPGT 220516FN-25P VPGT 220516FN-27 VPUW 220516FN-D

Indexable inserts

-D

= coated hard metal = uncoated hard metal = hard metal with PCD segment

AMZ H 10 T H 216 T PKD

R R R R R R R R R R R R R R R R R R R R R R R R R R R R

15

MSS

Parting & grooving / threading

MSS stands for consistent modularity. Through the change of modules the system can be adapted to the respective machining method. Flexibility, precision, stability and good economy represent the main characteristics of this PLANSEE TIZIT innovation.

Program see special catalogue MSS - The modular parting, grooving and threading system (No. 148)

Insert delivery program

AMZ H 216 T TSM 20 PKD

Indexable inserts

Type, ordering description GX16-1E2.00N0.20-27P GX16-2E3.00N0.30-27P GX16-2R1.50N-27P GX16-3E4.00N0.40-27P GX16-3R2.00N-27P GX16-3R2.50N-27P GX16-4E6.00N0.50-27P GX24-4R3.00N-25P-F GX24-4R3.00N-27P GX24-4R3.00N-D GX24-5R4.00N-25P-F GX24-5R4.00N-27 GX24-5R4.00N-27-F GX24-5R4.00N-27P GX24-5R4.00N-27P-F GX24-5R4.00N-35P-F GX24-5R4.00N-D

Application

R R R R R R R R R R R R R R R R R R R R R
chip groove code corner radius orientation parting and grooving width insert shape width class insert size insert system

-D

= coated hard metal = uncoated hard metal = hard metal with PCD-segment

GX 16 - 1 E 2.00 N 0.20 - 27P

16

Insert delivery program

AMZ H 216 T TSM 20

Indexable inserts

Type, ordering description FX 2.2N0.10-27P FX 3.1N0.15-27P FX 4.1N0.15-27P

Application

R R R
chip groove code corner radius orientation parting and groving width insert system

FX 3.1 N 0.15 - 27P

TC16-1 E 0,5 ISO-27P TC16-1 E 0,75 ISO-27P TC16-1 E 1,0 ISO-27P TC16-1 E 1,25 ISO-27P TC16-1 E 1,5 ISO-27P TC16-2 E 1,75 ISO-27P TC16-2 E 2,0 ISO-27P TC16-2 E 2,5 ISO-27P TC16-2 E 3,0 ISO-27P TC16-1 I 1,0 ISO-27P TC16-1 I 1,5 ISO-27P TC16-2 I 2,0 ISO-27P TC16-2 I 3,0 ISO-27P TC16-1 EI 19 W-27P TC16-2 EI 14 W-27P TC16-2 EI 11 W-27P TC16-1 EI-A60-27P TC16-2 EI-G60-27P TC16-2 EI-AG60-27P TC16-3 EI-N60-27P

R R R R R R R R R R R R R R R R R R R R

turning

milling

= coated hard metal = uncoated hard metal

TC 16 - 2 I 2,0 ISO - 27P

chip groove code thread standard pitch insert shape width class insert size insert system

17

Drilling

Maxidrill
Tested and tried short hole drill system with trigon inserts. The special insert position corresponds to a PLANSEE TIZIT patent and ensures compensated radial forces. This prevents the drill reliably from running off centre. Maxidrill first choice for drilling through-holes and blind holes without flat bottom range 14 53 mm

Program see special catalogue Tools and indexable inserts for drilling into full material (No. 149)

Insert delivery program

Type, ordering description WCGT 030204FN WCGT 050304FN WCGT 060304FN WCGT 07T304FN

U 17 T

Indexable inserts

Application

R R R R

= uncoated hard metal

PLANSEE TIZIT tip Rods for solid carbide drills

Program see special catalogue Hard metal for precision tools (No. 147)

18

Drilling / turning

EcoCut
The unique multi-function tool for unbelievable increase in productivity. A PLANSEE TIZIT patent. Drilling of blind holes with flat bottom, step bores, turning of plane surfaces and external profiles with only one tool. range 6 32 mm

Program see special catalogue EcoCut Drilling and turning with only one tool (No. 143)

Insert delivery program

Type, ordering description XCET 040104FR-27P XCET 040104FL-27P

Indexable inserts

H 216 T

Application

R R

XCET 050204FN-27P XCET 060204FN-27P XCET 070304FN-27P XCET 080304FN-27P XCET 09T304FN-27P XCET 10T304FN-27P XCET 130404FN-27P XCET 170508FN-27P = uncoated hard metal

R R R R R R R R

19

Milling

A 260 system
The cartridge milling tool with the new dimension concerning the number of variations and flexibility. a standard basic body for all cartridge styles! three adjustment possibilites for axial run out possibility to combine roughing and finishing cartridge range 80 400 mm

Program see special catalogue Tools and inserts for milling (No. 126)

Delivery program - cartridges and inserts

H 10 T H 216 T Sm 80

Cartridge 78 18 018

Inserts

Type, ordering description SPEX 1204EETR

Application

wiper insert 78 18 028 RPMT 120400EN RPHT 120400FN R R

78 18 029

SEHT 1204AEFN-27 SEHT 1204AEFN-27P

R R

78 18 031
S...

X...

SDHT 1204AEFN-27 SDHT 1204AEFN-27P SDHT 1204AEFN-R SDHW 1204AEFN SDHW 1204AEFN-R XDHW 1204AEFN

r R R r R R

20

Delivery program - cartridges and inserts

H 10 T H 216 T

Cartridge 78 18 032

Inserts

Type, ordering description SDHT 1504AEFN-27 SDHW 1504AEFN

Application

R R

78 18 036

LDHT 120404FR-27P LDHT 120408FR-27P LDHT 120425FR-27P LDHT 120440FR-27P

R R R R

78 18 039

SDHT 120508FR-27P SDHT 120525FR-27P

R R

78 18 041
S...

SDHT 0903AEFN-27P

X...

XDHW 0903AEFN APHT 100304FR-27P APHT 100308FR-27P

R R R

78 18 042

78 18 051

LDFT 150408FR-27P LDFT 150408FR-P

R R

= Goldmaster coated HSS = uncoated hard metal R= standard stock r= limited stock or upon request

21

Milling

A 270 / C 270 / C 272 systems

Shell end and end mill cutter program with 45 approach angle. close, normal and course pitch internal coolant supply finishing insert for insert size 09 and 12 face milling, chamfering, circular reboring and plunging range 16 160 mm

Program see special catalogue Tools and inserts for milling (No. 126)

Insert delivery program

H 10 T H 216 T Sm 80

Inserts

Type, ordering description SDHT 0903AEFN-27P

Application

09
S...

XDHW 0903AEFN
X...

12
S...

SDHT 1204AEFN-27 SDHT 1204AEFN-27P SDHT 1204AEFN-R SDHW 1204AEFN SDHW 1204AEFN-R XDHW 1204AEFN SDHT 1504AEFN-27 SDHW 1504AEFN

r R R r R R R R

X...

= goldmaster coated HSS = uncoated hard metal

22

A 251 / C 251 systems

Shell end and end mill cutter program with button inserts. positive insert indexing internal coolant supply face milling, milling of clearance faces with particularly high feed rates range 20 125 mm

Program see special catalogue Maximill A251 / C251 (No. 153)

Insert delivery program

H 216 T

Inserts

Type, ordering description RDHX 0501MOFN

Application

RDHX 0802MOFN RPHX 10T3MOFN-27P

R R

RPHX 1204MOFN-27P

RPHX 1605MOFN-27P = uncoated hard metal

23

Milling

A 490 system
Shell end milling cutters with 90 approach angle. four efficient cutting edges! integrated face chamfer economic, robust close pitch, integral coolant supply face and shoulder milling, milling of 90 grooves range 50 125 mm

Program see special catalogue Tools and inserts for milling (No. 126)

Insert delivery program

H 216 T

Inserts

Type, ordering description SDHT 120508FR-27P SDHT 120525FR-27P

Application

R R

= uncoated hard metal

24

A 210 / C 210 / C 212 / A 244 / C 244 systems

Shell end and end mill cutters with 90 approach angle. one insert form and size for all milling cutters! complete family for shoulder and slot milling internal coolant supply exceptionally quiet machining, low power consumption range 16 125 mm

Program see special catalogue Tools and inserts for milling (No. 126)

Insert delivery program

H 216 T

Inserts

Type, ordering description APHT 100304FR-27P APHT 100308FR-27P

Application

R R

= uncoated hard metal

25

Milling

A 241 / C 241 systems

Shell end and end mill cutters with 90 approach angle. robust construction depth of cut up to 14 mm internal coolant supply range 16 125 mm

Program see special catalogue Tools and inserts for milling (No. 126)

Insert delivery program

H 216 T Sm 80

Inserts

Type, ordering description LDFT 150408FR-27P LDFT 150408FR-P LDHT 15T3PD-FR

Application

R R R

= goldmaster coated HSS = uncoated hard metal

26

Helimax system
End mills manufactured from solid carbide and end mills with brazed helical carbide strip. E110 suitable for drilling long and precisely ground peripheral cutting edge for optimal finishing (milling) HSC suitable high rigidity, precise radial run out fine grain grade range 2 40 mm

Program see special catalogue Tools and inserts for milling (No. 126)

Delivery program
TSM 30

Tool

Type, ordering description E110.02.R.02-AL E110.03.R.02-AL E110.04.R.02-AL E110.05.R.02-AL E110.06.R.02-AL E110.08.R.02-AL E110.10.R.02-AL E110.12.R.02-AL E110.16.R.02-AL E110.20.R.02-AL E110.25.R.02-AL E110.32.R.02-AL E110.40.R.02-AL R112.02.R.02-AL R112.03.R.02-AL R112.04.R.02-AL R112.05.R.02-AL R112.06.R.02-AL R112.08.R.02-AL R112.10.R.02-AL R112.12.R.02-AL R112.16.R.02-AL R112.20.R.02-AL

Application

R R R R R R R R R R R R R R R R R R R R R R R

= uncoated hard metal

27

Milling

HSC-12 system
Shell end and end mill cutter program with 90 approach angle. patented positive insert clamping balanceable internal coolant supply range 16 100 mm ap max 10 mm; vc max 5000 m/min

Program see special catalogue Tools and inserts for milling (No. 126)

Insert delivery program

H 216 T

Inserts

Type, ordering description LDHT 120404FR-27P LDHT 120408FR-27P LDHT 120425FR-27P LDHT 120440FR-27P

Application

R R R R

= uncoated hard metal

28

HSV system
Shell end and end mill program with 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 ap max 15 mm

Program see special catalogue Tools and inserts for milling (No. 126)

Insert delivery program

H 10 T H 216 T

Inserts

Type, ordering description VCGT 220530FN-27M VCGT 220530FN-27MP VCGX 220530FN-27MP

...T ...X

Application

r R R

R= standard stock r= limited stock or upon request = uncoated hard metal

29

Milling

HSX system
Shell end and end mill cutter program with 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 ap max 23 mm

Program see special catalogue Tools and inserts for machining aluminium components (No. 170)

Insert delivery program

H 216 T

Inserts

Type, ordering description XDHT 200450FR-27P XDHT 230440FR-27P

Application

R R

= uncoated hard metal

30

HSC-HP system
Shell end and end mill cutter program with 90 approach angle. positive insert clamping for the upper HSC range centrifugal force test for all milling cutters well-suited for plunging range 25 63 mm

Program see special catalogue Tools and inserts for aluminium component machining (No. 170)

Insert delivery program

H 216 T

Inserts

Type, ordering description XDHX 190402FR-27P XDHX 190404FR-27P XDHX 190408FR-27P XDHX 190420FR-27P XDHX 190425FR-27P XDHX 190432FR-27P XDHX 190440FR-27P XDHX 190450FR-27P

Application

= uncoated hard metal

R R R R R R R R

31

Milling

HSC-19 system
Shell end and end mill cutter program with 90 approach angle. for the medium HSC range well-suited for plunging range 25-100 mm

Program see special catalogue Tools and inserts for aluminium component machining (No. 170)

Insert delivery program

H 216 T

Inserts

Type, ordering description XDHT 190402FR-27P XDHT 190404FR-27P XDHT 190408FR-27P XDHT 190420FR-27P XDHT 190425FR-27P XDHT 190432FR-27P XDHT 190440FR-27P XDHT 190450FR-27P

Application

R R R R R R R R

= uncoated hard metal

32

Milling Special inserts

LDHT
Type, ordering description LDHT 15T308FR

Inserts

H 10 T H216T

Application

OFHR
H 10 T H216T

Inserts

Type, ordering description OFHR 070410FR-27P

Application

SFAN
H 10 T H216T

Inserts

Type, ordering description SFAN 1203EFFR

Application

SPKR
H 10 T H216T

Inserts

Type, ordering description SPKR 1203EDFR-AL

Application

= uncoated hard metal

33

System solutions

General Offering component specific system solutions is indispensable. In this field PLANSEE TIZIT provides the following services for selected customer segments:
complete tool solutions optimised cutting materials and geometries engineering know-how and application support at the respective company training courses and seminars extensive support with regards to O.E.M. projects construction and manufacture of special tools coordination of project teams

34

System solutions

Aluminium rim machining

Program see special brochure Tools and inserts for aluminium wheel machining (No. 129)

Screw bores / valve bores External machining Front / mirror

Hub

Internal machining

35

System solutions

Aerospace

High performance milling tools

for machining aluminium components

Program see special catalogue Tools and inserts for aluminium component machining (No. 170)

36

Standard materials

Cast alloys
DIN 1725-2 Alloy group Material designation G-AlCu4TiMg G-AlCu4Ti G-AlSi7Mg G-AlSi10Mg G-AlSi10Mg(Cu) G-AlSi9Mg GD-AlSi10Mg G-AlSi11 G-AlSi12 GD-AlSi12 G-AlSi6Cu4 GD-AlSi9Cu3 G-AlSi9Cu3 G-AlSi12(Cu) GD-AlSi12(Cu) G-AlMg3 GD-AlMg9 G-AlMg5 G-AlMg5Si number 3.1371 3.1841 3.2371 3.2381 3.2383 3.2373 3.2382 3.2211 3.2581 3.2582 3.2151 3.2163 3.2163 3.2583 3.2982 3.3541 3.3292 3.3561 3.3261 numeric EN AC-21000 EN AC-21100 EN AC-4100 EN AC-42000 EN AC-42100 EN AC-42200 EN AC-43000 EN AC-43100 EN AC-43200 EN AC-43300 EN AC-43400 EN AC-44000 EN AC-44100 EN AC-44200 EN AC-44300 EN AC-44400 EN AC-45000 EN AC-45100 EN AC-45200 EN AC-45300 EN AC-45400 EN AC-46000 EN AC-46100 EN AC-46200 EN AC-46300 EN AC-46400 EN AC-46500 EN AC-46600 EN AC-47000 EN AC-47100 EN AC-48000 EN AC-51000 EN AC-51100 EN AC-51200 EN AC-51300 EN AC-51400 EN AC-7100 DIN EN 1706 Alloy designation chem. symbol EN AC-Al Cu4MgTi EN AC-Al Cu4Ti EN AC-Al Si2MgTi EN AC-Al Si7Mg EN AC-Al Si7Mg0,3 EN AC-Al Si7Mg0,6 EN AC-Al Si10Mg/a) EN AC-Al Si10Mg(b) EN AC-Al Si10Mg(Cu) EN AC-Al Si9Mg EN AC-Al Si10Mg(Fe) EN AC-Al Si11 EN AC-Al Si12(b) EN AC-Al Si12(a) EN AC-Al Si12(Fe) EN AC-Al Si9 EN AC-Al Si6Cu4 EN AC-Al Si5Cu3Mg EN AC-Al Si5Cu3Mn EN AC-Al Si5Cu1Mg EN AC-Al Si5Cu3 EN AC-Al Si9Cu3(Fe) EN AC-Al Si11Cu2(Fe) EN AC-Al Si8Cu3 EN AC-Al Si7Cu3Mg EN AC-Al Si9Cu1Mg EN AC-Al Si9Cu3(Fe)(Zn) EN AC-Al Si7Cu2 EN AC-Al Si12(Cu) EN AC-AlSi12Cu1(Fe) EN AC-Al Si12CuNiMg EN AC-Al Mg3(b) EN AC-AlMg3(a) EN AC-Al Mg9 EN AC-Al Mg5 EN AC-Al Mg5 (Si) EN AC-Al Zn5Mg

AlCu AlSiMgTi AlSi7Mg

AlSi10Mg

AlSi

AlSi5Cu

AlSi9Cu

AlSi(Cu) AlSiCuNiMg AlMg

AlZnMg

37

Standard materials

Malleable aluminium alloys - bars

DIN 1725-1/DIN 1712-3 Material designation AlCuMgPb AlCuBiPb AlMgSiPb AlMgSi0,5 AlMgSi1 AlCuSiMn AlCuMg1 AlCuMg2 AlZn4,5Mg1 AlZnMgCu0,5 AlZnMgCu1,5 Al99,5 E-Al AlMg3 AlMg5 AlMg4,5Mn number 3.1645 3.1655 3.0615 3.3206 3.2315 3.1255 3.1325 3.1355 3.4335 3.4345 3.4365 3.0255 3.0257 3.3535 3.3555 3.3547 numeric EN AW-2007 EN AW-2011 EN AW-2030 EN AW-6012 EN AW-6262 EN AW-6060 EN AW-6063 EN AW-6082 EN AW-2014 EN AW-2017A EN AW-2024 EN AW-7020 EN AW-7022 EN AW-7075 EN AW-1050A EN AW-1350 EN AW-5754 EN AW-5019 EN AW-5083 DIN EN 573-3 Alloy designation chem. symbol EN AW-Al Cu4PbMgM EN AW-Al Cu6BiPb EN AW-Al Cu4PbMg EN AW-Al MgSiPb EN AW-Al Mg1SiPb EN AW-Al MgSi EN AW-Al Mg0,7Si EN AW-Al Si1MgMn EN AW-Al Cu4SiMg EN AW-Al Cu4MgSi(A) EN AW-Al Cu4Mg1 EN AW-Al Zn4,5Mg1 EN AW-Al Zn5Mg3Cu EN AW-Al Zn5,5MgCu EN AW-Al 99,5 EN AW-Eal 99,5 EN AW-Al Mg3 EN AW-Al Mg5 EN AW-Al Mg4,5Mn0,7

Attention: EN755-2 (extruded bars) and EN754-2 (drawn bars) contain numerous other materials and alloy variations which are less common.

= hardenable materials = naturally hard materials

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Malleable aluminium alloys - inserts

DIN 1725-1/DIN 1712-3 Material designation Al99,5 AlMg3 AlMg4,5Mn AlMg1SiCu AlMgSi1 AlCuMg1 AlCuMg2 AlZn4,5Mg1 AlZnMgCu0,5 AlZnMgCu1,5 number 3.0255 3.3535 3.3547 3.3211 3.2315 3.1325 3.1355 3.4335 3.4345 3.4365 numeric EN AW-1050A EN AW-5754 EN AW-5083 EN AW-6061 EN AW-6082 EN AW-2017A EN AW-2024 EN AW-7020 EN AW-7022 EN AW-7075 DIN EN 573-3 Alloy designation chem. symbol EN AW-Al 99,5 EN AW-Al Mg3 EN AW-Al Mg4,5Mn0,7 EN AW-Al Mg1SiCu EN AW-Al Si1MgMn EN AW-Al Cu4MgSi(A) EN AW-Al Cu4Mg1 EN AW-Al Zn4,5Mg1 EN AW-Al Zn5Mg3Cu EN AW-Al Zn5,5MgCu

Attention: EN 485-2 contains some other materials and alloy variations which are less common

= naturally hard materials = hardenable materials

39

Practical examples

Housing
Problem / criteria:
surface finish formation of burrs clamping

Results:
surface roughness Rz 3.4 m excellently quiet machining minimal burr formation at exit points

Application data:
Work piece: Material: Machine: Tools: housing Silumin SHW A 270.80.R.05 SDHT 1204AEFN-27P H216T Vc ap ae vf fz [m/min] [mm] [mm] [mm/min] [mm] 500 3 32 45 2500 0.25

Aluminium rim
Problem / criteria:
vibrations chip formation wet machining

Results:
good surface quality long cutting edge life (80) short machining times

Application data:
Work piece: Material: Machine: Tools: aluminium rim G-AlSi12Mg IMT Maxilock S and MSS VCGT 160412FN-27P H216T GX24-5R4.00N-35P-F H216T Vc ap f [m/min] [mm] [mm/rev.] 300 2200 1.0 2.5 0.25 0.6

40

Aluminium rim
Problem / criteria:
TIZIT

surface finish free from blow holes

Results:
good surface quality long cutting edge life (approx. 1,400 pieces)

Application data:
Work piece: Material: Machine: Tools: aluminium rim G-AlSi12Mg Okuma UT40-SVHCR-16 VCUW 160412FN-D Vc ap f [m/min] [mm] [mm/rev.] 1800 2200 0.3 0.2

Tube
Problem / criteria:
dimensional accuracy deformation

Results:
no deformation of thin walled work piece

Application data:
Work piece: Material: Machine: Tools: tube AlCuBiPb Wasino SDJR 2020 K11 DCGT11T304-FN-27 H216T Vc ap f [m/min] [mm] [mm/rev.] 216 280 2,0 0,1

41

Practical examples

Screw
Problem / criteria:
surface finish chip evacuation

Results:
good chip control clean and even cut surface

Application data:
Work piece: Material: Machine: Tools: screw G-AlSi12Cu Oerlikon XLCFN 3203 M31 FX3,1FN-27P H216T Vc ap f [m/min] [mm] [mm/rev.] 70 350 3.1 0.1

Housing
Problem / criteria:
suitable for plunging chip evacuation

Results: Ergebnis:
good chip control more economic machining compared to HSS (only Helimax)

Application data:
Work piece: Material: Machine: Tool: housing AlCuMg Maho MC 600 C-HSC-HP-25-R-02-19-ZS20 L60 Vc ap ae vf fz [m/min] [mm] [mm] [mm/min] [mm] 320 3.0 20 5.0 25 570 0.07

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General information

Advantages
PLANSEE 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 forces low tolerances maintained (component stability) low burr formation clean surface at the component good swarf control long tool life

These advantages are not only relevant for aluminium! Additional application fields for PLANSEE TIZIT aluminium inserts:
RFinishing and fine finishing of: stainless steel, steel cast iron titanium molybdenum

steel

ha r ma dene d ter ial s

RGeneral machining of: magnesium copper alloys plastics graphite

s es inl sta

RIn the branches:

ys llo ra pe su

light engineering medical systems watch and clock making industry gen. mechanical engineering

RMachining of composite materials: soft and hard materials

non ferrous metals

ca st iro n

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Parent company PLANSEE TIZIT Aktiengesellschaft A-6600 Reutte/Tirol Tel.: +43 (5672) 600-0 Fax: +43 (5672) 600-502 Cutting Tools +43 (5672) 600-503 Wear Parts E-Mail: tool.at@plansee.at E-Mail: wear.at@plansee.at http://www.plansee.com Austria PLANSEE TIZIT Aktiengesellschaft A-6600 Reutte/Tirol Tel.: +43 (5672) 600-0 Fax: +43 (5672) 600-505 E-Mail: zerspanung.at@plansee.at = Sales Cutting Tools Bulgaria INSTRUMENT AG Boulevard Stoletov 157 BG-5301 Gabrovo Tel.: +359 (66) 438-11 Fax: +359 (66) 437-42 E-Mail: instrument@eda.bg = Sales Cutting Tools Germany PLANSEE TIZIT GmbH Schtzenstrae 29 D-72574 Bad Urach Tel.: +49 (7125) 1501-0 Fax: +49 (7125) 8594 E-Mail: tool.de@plansee.de = Sales Cutting Tools France Socit PLANSEE TIZIT S.A.R.L. 20, Rue Lavoisier F-95300 Pontoise Tel.: +33 (1) 3433-3180 Fax: +33 (1) 3030-9339 E-Mail: tool.f@plansee.at = Sales Cutting Tools Great Britain PLANSEE TIZIT (UK) Ltd. Cliff Lane Grappenhall Warrington WA4 3JX Tel.: +44 (1925) 261-161 Fax: +44 (1925) 267-933 E-Mail: tool.uk@plansee.at = Sales Cutting Tools

China PLANSEE TIZIT Hong Kong Ltd. Room 1201-1202 Hollywood Centre 233 Hollywood Rd., Sheung Wan Hong Kong Tel.: (+852) 2542-1838 Fax: (+852) 2854-3777 E-Mail: tool.hk@plansee-hk.com = Sales Cutting Tools India Siel TIZIT Limited 58, Motilal Gupta Road Barisha IN-700 008 Calcutta Tel.: +91 (33) 447-5435 Fax: +91 (33) 447-6472 Telex: 021 8142 ihm in E-Mail: positiz@cal.vsnl.net.in = Sales Cutting Tools Italy TIZIT S.p.A Piazza F. Martelli, 7 I-20162 Milano Tel.: +39 (02) 6441-111 Fax: +39 (02) 6611-6040 E-Mail: tool.i@plansee.at = Sales Cutting Tools Spain PLANSEE TIZIT Va de las Dos Castillas, 9c Portal 2, Bajo B E-28224 Pozuelo (Madrid) Tel.: +34 (91) 351-0609 Fax: +34 (91) 351-2813 E-Mail: tool.e@plansee.at = Sales Cutting Tools USA SCHWARZKOPF TECHNOLOGIES Corporation 115 Constitution Boulevard Franklin, MA 02038 Tel.: +1 (508) 553-3800 Fax: +1 (508) 553-3823 E-Mail: tool.usa@stc-ma.com = Sales Cutting Tools

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We reserve the right to make technical changes for product improvement.