如果您想追求更高的加工效率, 请尝试此款世界最高速的三刃钻头 Mega Muscle The World's Fastest and Most Productive -Fed Carbide Drill * * 内部调查数据 Internal Data ~3 刃钻头有以下优势 ~ 在一般 2 刃钻的

Transcription

1 硬质合金 MEGA MUSCLE 三刃钻头 Vol.❸ -1 TRS TRS-HO-10D Mega Muscle Drills 欧士机 ( 上海 ) 精密工具有限公司

2 如果您想追求更高的加工效率, 请尝试此款世界最高速的三刃钻头 Mega Muscle The World's Fastest and Most Productive -Fed Carbide Drill * * 内部调查数据 Internal Data ~3 刃钻头有以下优势 ~ 在一般 2 刃钻的 1.5 ~2 倍的高进给条件下实现高寿命 Three key concepts that differentiate the Mega Muscle Drill from two fluted drills Feed rates up to 1.5 to 2 times faster than two fluted drills extend tool life. 独特的沟槽形状使其在高进给条件下也能将切屑细小分断! Unique flute form breaks chips into small manageable pieces for easy ejection even at high feed rates! 采用最适合的边缘负角设计, 抑制在贯穿时的崩刃现象 Special negative cutting edges decrease the tendency of chipping at the corners during hole exit. 高进给! High feed rate! S50C 高精度! High precision! 加工硬化降低低減! Reduced work hardening! 120 等分刃带减轻切削加工中的震动, 抑制孔内毛刺的产生 The 120 equal spacing margins allow vibration-free hole processing and better hole tolerance. 减轻每刃进给可以抑制加工硬化, 为提高下一个工序的刀具寿命做出贡献 Less loads per flute reduces work hardening, thereby prolongs tool life of secondary operations such as tapping and reaming. 即使高进给加工也能发挥优良耐性的 WDI 涂层 WDⅠ Coating, Superior Resistance for High Feed Machining 复合多层构造 Multi-Layered Structure 抑制裂纹传播, 实现优良耐崩刃性 Prevents crack propagation and provides greater durability 涂层构造 Coating Structure 硬度 (HV) Surface Hardness 氧化开始温度 ( ) Oxidation Temperature 3,300HV 的高硬度涂层 3,300HV Coating Hardness 实现优良的耐性 Superior wear resistance WDⅠ 涂层 W DⅠ c o a ti n g 复合多层 Multi-layered 3,300 1,100 1,100 高温氧化开始温度 1,100 Oxidation Temperature 氧化起始温度高, 对应易发热的高速条件 High speed cutting condition achieved by its high oxidation temperature TiAlN 涂层 TiAlN coating 2 层 Dual layer 2,

3 高进给! High feed rate! 惊人的高进给 Amazingly High s 极限进给比较 Maximum feed rate Comparison Feed φ8 FCD m/min (4,000min -1 ) 可变 Variable 40mm ( 通孔 ) 水溶性 ( 外部给油 ) (External) 注 )由于其它公司产品没有内冷油孔, 所以这个测试使用外部给油 Note: Because the competitor's drills are not the coolant-through, coolant had to be fed externally during the test. A A B B 极限进给量下效率比较 Efficiency comparison during maximum feed 折损 Breakage 折损 Breakage (m/min) 实现 vf=5,092mm/min v f =5,092mm/min were achieved ( 每加工十个孔提高 0.16mm/rev 的来测试各刀具的极限 Maximum feed rate of each tool while the feed rate is increased by 0.16 mm/rev every 10 holes 每转进给量 Feed (mm/min) ,092 A A ,546 B B ,909 当加工材料为铸铁 (FCD600) 时,Mega Muscle 钻头实现了 F=5,092mm/min 的极限进给量 这是因为新槽形设计带来了更好的刚性, 这个进给率是其它公司产品的 倍 但是在这个加工事例的场合, 我们实际的推荐进给量为 0.36mm/rev, 为极限进给量的 28%, 这也是充分考虑到加工的安全性以及稳定性 When processing cast iron (FCD600) the Mega Muscle Drill achieved a feed rate up to v f =5,092mm/ min. This was achieved by combining the new point and flute design with superior rigidity. This rate is times more productive than competitor's. In this case, the actual recommended feed rate is approximately 0.36mm/rev, which is the 28% of maximum limitation of. However, as illustrated in the test, the Mega Muscle Drill has a large range of achievable feed rates. The priorities in any cutting condition should always be safety and application stability. 高精度! High precision! 不仅是速度, 更是实现了超群的孔精度 Amazing Speeds with Excellent Hole Accuracy SCM440(30HRC) 孔扩大量的比较 Hole oversize comparison in SCM440 (30HRC) Feed φ10.8 SCM440(30HRC) 70m/min (2,060min -1 ) 1,010mm/min (0.49mm/rev) 50mm ( 通孔 ) 水溶性 扩孔量的变化 Changes in amount of hole oversize 扩孔量的变 ,000 1,200 1,400 1,600 1,800 2,000 化(mm) Oversize μm 6μm 对比孔扩大量,TRS 钻头比二刃钻头小 加工中二刃钻的孔扩大量幅度最大可达到 16μm, 而 TRS 钻头则控制在 6μm 显示了超群的稳定加工 这是由于最佳刃带宽度以及三个接触点, 维持了加工时的平衡性, 实现了稳定加工 When compared to 2 fluted drills, the Mega Muscle Drill always shows a lower amount of hole expansion. The 2 fluted drills were found to have a hole expansion range of approximately 16μm, while the Mega Muscle Drill only had a 6μm variation. The high hole accuracy is possible because the 3-fluted drill has 3 stable points of contact with a hole, when compared to a 2-fluted drill only has 2 points of contact. 加工硬化降低! Reduced work hardening! 减低了之后加工工序中工具的加工负荷! Low risk for the secondary processes 碳素钢加工中的进给量与加工硬化量的对比 Comparison of the amount of work hardening vs. feed per ravolution in carbon steel. Feed φ10.8 S50C 100m/min(2,950min -1 ) 可变 Variable 25mm ( 通孔 ) 水溶性 加工硬化量比较 Work hardening rate comparison (HV0.1) 刃 (2FL) 加工硬化层深度比较 Work hardening layer depth comparison (μm) 他社 A2 枚刃 2 刃 (2FL) 每转进给量 每转进给量 这个表格是碳素钢加工中, 每转进给量从 0.22 ~0.65mm/rev 变化时, 加工硬化量与加工硬化层深度的比较 在不考虑刃数时, 随着进给量的增加, 加工硬化量随之增加, 加工硬化层深度随之上升 但是在相同的进给量下, 三刃钻头与两刃钻头相比, 加工硬化的情况大大减低 在很好的控制了加工硬化的情况下, 之后加工工序中的螺纹加工或铰削加工的负荷将会大大减轻, 提高了工具寿命, 并且实现稳定的加工 The graphs above depict the level and depth of work hardening in carbon steel between the Mega Muscle Drill and a 2-flute drill. Regardless of the number of flutes, work hardening has a tendency to increase along side with feed rate. However, it is important to note that under the same feed rate, 3-flute drills always have a lower work hardening tendency than 2-flute drills. To prolong tool life of secondary operations such as tapping and reaming, it is prominent to keep work hardening to a minimum. 2

4 Dimensions R 形横刃 R thinning 材质 Material 表面处理 Surface Treatment 超微粒子超硬合金 Micro Grain Carbide W DⅠ 涂层 WDⅠ Coating 为了实现稳定的给油, 在柄的底部有一条沟槽 The grooves are designed at the end of the shank for stable coolant supply. 在少数钻头上的涂层会有色差的情况, 但是这不妨碍钻头的性能 Drills may have some discoloration, but it does not cause any performance problems. 3D 用 For 3D Operation 单位 :mm Unit:mm 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B= 标准库存品 B = Standard stock item 下一页 3

5 上一页 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B= 标准库存品 B = Standard stock item 更多信息, 请咨询营业人员 Please contact our sales staff for more information. 可以制作不同径 长度的非标品 其他铝合金式样的非标品也能制作 Specialized drills with other diameters, lengths and for aluminum alloy are available upon request. 4

6 Dimensions R 形横刃 R thinning 材质 Material 表面处理 Surface Treatment 超微粒子超硬合金 Micro Grain Carbide W DⅠ 涂层 WDⅠ Coating 为了实现稳定的给油, 在柄的底部有一条沟槽 The grooves are designed at the end of the shank for stable coolant supply. 在少数钻头上的涂层会有色差的情况, 但是这不妨碍钻头的性能 Drills may have some discoloration, but it does not cause any performance problems. 5D 用 For 5D Operation 单位 :mm Unit:mm 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B= 标准库存品 B = Standard stock item 下一页 5

7 上一页 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B= 标准库存品 B = Standard stock item 更多信息, 请咨询营业人员 Please contact our sales staff for more information. 可以制作不同径 长度的非标品 其他铝合金式样的非标品也能制作 Specialized drills with other diameters, lengths and for aluminum alloy are available upon request. 6

8 TRS-HO-10D Dimensions R 形横刃 R thinning 材质 Material 表面处理 Surface Treatment 超微粒子超硬合金 Micro Grain Carbide W DⅠ 涂层 WDⅠ Coating 为了实现稳定的给油, 在柄的底部有一条沟槽 The grooves are designed at the end of the shank for stable coolant supply. 在少数钻头上的涂层会有色差的情况, 但是这不妨碍钻头的性能 Drills may have some discoloration, but it does not cause any performance problems. 10 D 用 For 10D Operation 单位 :mm Unit:mm 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock 商品记号 EDP No. Dc 刃长 l 全长 L 柄径 Ds 库存 Stock B B B B B B B B B B B B B B B B= 标准库存品 B = Standard stock item 更多信息, 请咨询营业人员 Please contact our sales staff for more information. 可以制作不同径 长度的非标品 其他铝合金式样的非标品也能制作 Specialized drills with other diameters, lengths and for aluminum alloy are available upon request. 7

9 切削条件表 Recommended Conditions, 加工材料 软钢 低炭素钢 Mild Steel Low Carbon Steel S S S 1 0 C ~150HB 500N/mm2 炭素钢 Carbon Steel S35C S50C ~210HB ~710N/mm2 合金钢 Alloy Steel S C M S C r S N C M 16~28HRC 710~900N/mm m/min m/min 60 90m/min Drill Dia. (mm) SPEED FEED SPEED FEED SPEED FEED 5 6, , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , 加工材料 合金钢 Alloy Steel S C M S C r S N C M 28~35HRC 900~1,100N/mm 2 1. 此切削条件基础表适用于水溶性冷却加工 2. 请使用稀释 20 倍以下的优质水溶性切削油 3. 使用油性或者稀释倍率超过 20 倍时, 请下调 30% 4. 装夹钻头时, 请使用无损伤, 无油污的弹簧夹头, 并将径向跳动控制在 0.02mm 以下 5. 工件夹持必须做到无变形, 无振动 6. 油污堵塞会造成折损, 因此供油装置请务必安装过滤网 铸铁 Cast Iron FC N/mm 2 球墨铸铁 Ductile Cast Iron FCD450 FCD N/mm m/min m/min m/min Drill Dia. (mm) SPEED FEED SPEED FEED SPEED FEED 5 4, , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , The indicated speeds and feeds are for drilling with water-soluble oil. 2. Suitable cutting fluid is water-emulsifiable high density oil (less than 20 times dilution). 3. When using non-water soluble oil or water-emulsifiable (over 20 times dilution), reduce drilling speed by 30%. 4. When inserting a drill into the machine, use a collet that does not have any scratches or dust located within internal bore. Also, minimize runout to under 0.02mm. 5. Fasten the work material to reduce the possibility of work deformation, deflection of machined surface, or vibration. 6. A clogged oil hole can lead to breakage. Make sure that a filter is attached to the oil feeder. 8

10 切削条件表 Recommended Conditions TRS-HO-10D 加工材料 软钢 低炭素钢 Mild Steel Low Carbon Steel S S S 1 0 C ~150HB 500N/mm2 炭素钢 Carbon Steel S35C S50C ~210HB ~710N/mm2 合金钢 Alloy Steel S C M S C r S N C M 16~28HRC 710~900N/mm m/min m/min m/min Drill Dia. (mm) Speed Feed Speed Feed Speed Feed 5 6, , , , , , , , , , , , , , , , , , , , , , , , 加工材料 铸铁 Cast Iron FC N/mm 2 球墨铸铁 Ductile Cast Iron FCD450 FCD N/mm m/min m/min Drill Dia. (mm) Speed Feed 1. 这张切削条件表是使用水溶性切削油以及 50ml/h 程度的 MQL 2. 请使用稀释 20 倍以下的优质水溶性切削油 3. 使用油性或者稀释倍率超过 20 倍时, 请下调 30% 4. 装夹钻头时, 请使用无损伤, 无油污的弹簧夹头, 并将径向跳动控制在 0.02mm 以下 5. 工件夹持必须做到无变形, 无振动 6. 油污堵塞会造成折损, 因此供油装置请务必安装过滤网 7. 请参照 TRS-HO-10D 的推荐加工方法 进行导向孔加工 Speed Feed 5 6, , , , , , , , , , , , , , , , The indicated speeds and feeds are for drilling with water-soluble oil or MQL(approx.50ml/hour). 2. Suitable cutting fluid is water-soluble high density oil(less than 20 times dilution). 3. When using non-water soluble oil or water-emulsifiable (over 20 times dilution), reduce drilling speed by 30%. 4. When inserting a drill into the machine, use a collet that does not have any scratches or dust located within internal bore. Also, minimize runout to under 0.02mm. 5. Fasten the work material to reduce the possibility of work deformation, deflection of machined surface, or vibration. 6. A clogged oil hole can lead to breakage. Make sure that a filter is attached to the oil feeder. 7. Make a guide hole before using TRS-HO-10D in accordance with "Tips for using TRS-HO-10D" (p. 10). 9

11 WD WDO WD / WDO Carbide Drill Series TRS-HO-10D 的推荐加工方法 Tips for using TRS-HO-10D 1WDO-PLT, WDO-3D, 导向孔加工 Make a pilot hole with WDO-PLT, WDO-3D or 2 以静止或低将深孔钻插入 Insert the extra long drill into a pilot hole with zero or low revolution. D 导向孔加工用工具请选择比 TRS-HO-10D 的直径 (D)+0.02~0.08mm 的钻头, 推荐在加工时在导向孔尽量加深 The size of the drill for pilot hole should be mm larger than TRS-HO-10D. TRS-HO-10D(D) D+0.02~0.08mm 3 加速至规定后开始加工 Increase the revolution to the designated speed and start drilling D~3D 若 WDO-PLT 标准品没有适合的, 也可使用同样直径的 钻头或者是 WDO-3D 的钻头 If the suitable size of WDO-PLT is not available among the recommended drills, the same diameter drill of WDO-3D or is recommended. 弯曲部加工时, 在定位孔加工前请先用 FX-ZDS 沉孔加工铣刀进行如图所示的沉孔加工 When working on a curved surface, use the FX-ZDS (end mill for counterboring) to counterbore a pilot hole. 4 加工后, 拔出钻头时, 在钻头离开孔底后, 请降低将其拔出 When pulling the drill out from the hole, reduce the speed after releasing the drill from the bottom of the hole. 加工时请务必使用内冷 Internal coolant supply must be used during the process. 对 TRS-HO-10D 导向孔加工推荐钻 Recommended pilot hole drills for TRS-HO-10D WDO-PLT WDO-3D 硬质合金钻头系列 WD/WDO 系列 WDO-PLT, WDO-3D 的详细情况请翻阅 WDI 涂层硬质合金内冷 WDO 钻头系列 Please refer to the WD/WDO Carbide Drill Series catalog for additional information. 欧士机 ( 上海 ) 精密工具有限公司 10

12 加工事例 Processing Data 曲轴 碳素钢 加工中 法兰盘油孔底孔加工 Maching process of mounting holes on a crankshaft flywheel (carbon steel) φ10.8 S50C 100m/min 2,950min-1 1,600 1,542孔 (holes) 可继续加工 800 1, mm/min 0.19mm/rev 1,480mm/min 0.5mm/rev 24mm 盲孔 水溶性 1.5倍工具寿命 1.5 times the tool life 1,020孔 (holes) 2.7倍效率 2.7 times the productivity Blind 产品相比 耐久达到1.5 倍以上 实现约2.7倍的高效率加工 抑制加工硬化 后序加工如螺纹加工使用的刀具寿命也能得到延长 大幅降低每个工件加工所需的成本 With the ability to control work hardening, the Mega Muscle Drill was able to achieve 1.5 times the tool life and 1.7 times the productivity versus the competition. Moreover, it was able to extend tool life for secondary process of tapping, thus reducing the overall tooling and cost per unit. 碳素钢的高速加工 High feed machining in carbon steel φ10.3 S50C 1,000 1,480mm/min 0.48mm/rev 可继续加工 Through 水溶性 异常 1,600孔 (holes) Abnormal wear 5,200孔 (holes) 32mm 通孔 崩刃 397孔 (holes) Breakage 工具比较 扩孔量的变化 wear comparison Changes in amount of hole oversize Oversize 他社品 扩孔量的变化 6,000 5,200孔 (holes) 100m/min 3,090min-1 5,000 4,000 2,000 3,000 (mm) μm μm ,200 2,400 3,600 4,800 5,200 在0.48mm/rev 的高进给量下 产品耐久十分不稳定 但 TRS 钻头能够稳 定加工 5200 孔 切削长 166m 孔扩大量与 15μm 相比 TR S 钻头可以实 现6μm 的稳定加工 Because of the high feed rate of 0.48mm/rev, the competitor's drill showed a large variation in hole size. However, the Mega Muscle Drill was able to achieve 5,200 holes (cutting length of 166m) with stable hole sizes. The competitor's hole expansion ranged up to 15μm, while the Mega Muscle Drill achieved 6μm. 11

13 扩孔量的变1 2 3 合金钢的高进给加工 High feed operation in alloy steel φ10.5 SCM440 生材 80m/min(2,430min -1 ) 1,140mm/min(0.47mm/rev) 50mm( 通孔 ) 水溶性 500 1,000 1,500 2,000 2,500 3,000 1,075 孔 (holes) 1,000 孔 (holes) 2,600 孔 (holes) 2,200 孔 (holes) 崩刃 Breakage 崩刃 Breakage 工具比较 wear comparison 扩孔量的变化 Changes in amount of hole oversize μm μm 0.03 化(mm) Oversize 他社品 ,000 1,400 1,800 2,200 2, mm/rev 的高进给加工下, 贯穿时发生崩刃 但是 TRS 在加工 2200 孔 ( 切削长 110m) 时正常 使得每台零部件刀具费用稳定 孔扩大量作比较, 产品的 25μm, 而 TRS 钻头可以实现 11μm 稳定的孔精度 At a high feed drilling rate of 0.47mm/rev, the competitor's drill suffered unstable hole accuracy as well as poor tool life. In contrast, the Mega Muscle Drill exceeded 2,200 holes (cutting length of 110m) with normal wear, thus capable of reducing the overall cost per unit. In terms of hole expansion, the competitor tool was found to have a large variation of up to 25µm, while the Mega Muscle Drill had only up to 11µm. 30HRC 合金钢的高进给加工 High feed machining in 30HRC alloy steel 500 1,000 1,500 2,000 2,500 3,000 φ10.8 SCM440(30HRC) 70m/min(2,060min -1 ) 1,010mm/min(0.49mm/rev) 50mm( 通孔 ) 水溶性 进给在 0.49mm/rev 的条件下, 产品早期异常折损 相对的,TRS 钻头可稳定加工 1700 孔 ( 切削长 85m) 后正常, 并且确保在研磨次数及研磨费用, 使每台零部件的道具费用相对稳定 工具比较 wear comparison 2,000 孔 (holes) 1,700 孔 (holes) 174 孔 (holes) 300 孔 (holes) 崩刃 Breakage 异常 Abnormal wear At a high feed drilling rate of 0.49mm/rev, the competitor drill displayed abnormal wear and early breakage. In contrast, the Mega Muscle Drill experienced normal wear after drilling 1,700 holes, thus allowing more regrinds and tool life per drill, thereby reducing overall manufacturing cost. 12

14 加工事例 Processing Data 30HRC 合金钢的高耐久 高效率 高精度加工 Machining of high durability, precision and long tool life in 30HRC alloy steel 1,000 2,000 3,000 4,000 φ6.8 SCM440(30HRC) 70m/min(3,280min -1 ) 4,000 孔 (holes) 3,440 孔 (holes) 1,120mm/min(0.34mm/rev) 34mm( 盲孔 ) (Blind) 水溶性 134 孔 (holes) 393 孔 (holes) 崩刃 Breakage 崩刃 Breakage 0.24mm/rev 的高进给条件下, 产品的刃尖刚性不足, 两把都折损了 相对的,TRS 钻头加工了 3440 孔 ( 切削长 117m) 且正常 孔扩大量控制在 5μm 以内 At a high feed drilling rate of 0.34mm/ rev, the competitor s 2-flute drill failed with early tool breakage. The Mega Muscle Drill, on the other hand, was able to machine 3,440 holes (cutting length of 117m) with normal wear. 工具比较 wear comparison 扩孔量的变化 Changes in amount of hole oversize 扩孔量的变1 2 3 化(mm) Oversize μm 5μm 800 1,000 2,000 3,000 4,000 软钢的稳定加工 Stable operation in mild steel φ ,000 1,500 2,000 2,500 SS m/min(3,030min -1 ) 第一次 No.1 2,400 孔 (holes) 可继续加工 1,430mm/min(0.47mm/rev) 50mm( 通孔 ) 水溶性 第二次 No.2 2,400 孔 (holes) 可继续加工 每转进给即使 0.47mm/rev,TRS 钻头也能稳定加工 2400 孔 ( 切削长 m) 以上 一般用钢考虑到切屑分断性不同请适当调整 The Mega Muscle Drill achieved over 2,400 holes (cutting length of 120m), at a feed rate of 0.47mm/rev. It is recommended to adjust the cutting speed accordingly in order to form proper chip shape. 加工 2400 孔时刃尖照片 after 2,400 holes 13

15 无中心定位的加工 ( 特殊品 ) Machining operation without centering (Special) 加工工程 Process 每个部件上的孔数 Holes per Part 每个部件需要的加工时间 Cycle Time per Part 寿命 ( 孔 ) Life TRS-HO-8D( 特殊品 ) (Special) 无 90 中心定位 No Centering 钻削加工 Drilling 80m/min (1,590min -1 ) 1,020mm/min (0.64mm/rev) 92 秒 (sec) φ16 FC250 钻削加工 Drilling 有 90 中心定位 Centering 中心定位加工 Centering 90m/min 80m/min (1,790min -1 ) (2,120min -1 ) 540mm/min 630mm/min (0.3mm/rev) (0.3mm/rev) 105mm( 通孔 ) 1,080 孔 (Holes) 15 孔 (Holes) 水溶性 6mm 175 秒 (sec) 8.5 秒 (sec) 秒 (sec) 1,080 孔 (Holes) TRS-HO-8D ( 非标品 ) (Special) TRS-HO-8D ( 非标品 ) (Special) ,080 孔 (holes) 1,080 孔 (holes) mm/min 1,080 孔加工后的刃尖比较 after drilling 1,080 holes TRS-HO-8D Feed 1,020mm/min 800 效率 Efficiency Ratio 1.98 倍以上 more than 1.98 times 800 1,000 1,000 1,200 可继续加工 1,200 钻削加工 (112m) 需要的时间 *Drilling time until fixed cutting distance (112m) 以往的加工, 为了防止孔偏移而是先用中心钻定位 TRS 钻头可以再未定位的情况下直接加工 削减了工序的同时, 将提高到 1.88 倍 加工效率与工序削减结合起来, 提高了 1.98 倍 另外, 钻头的耐久性较以往换刀时间 (1080 孔 ) 可继续加工 Center drilling with a 2-flute drill is a common machining practice for securing higher hole accuracy. With the introduction of the Mega Muscle Drill, center drilling can be eliminated. Moreover, the Mega Muscle Drill has almost doubled the feed rate and overall productivity. 气缸盖缸盖螺栓的铸铁加工 Hole processing of bolt holes on a cylinder head m/min (1,820min -1 ) φ14 FC m/min (2,270min -1 ) 486 孔 (holes) 346 孔 (holes) 效率比 Efficiency Ratio 2.2 倍 2.2 times 可继续加工 1,270mm/min (0.7mm/rev) 105mm( 通孔 ) 570mm/min (0.25mm/rev) 以延长寿命为目的降低, 设定每转进给量为产品的 2.8 倍 其结果是产品的 2.2 倍效率及寿命, 并实现加工时间缩减一半 水溶性 The machining parameters have been adjusted to extend tool life. Although the cutting speed has been reduced in comparison to the competitor tool, the cutting feed had been increased by 2.8 times. As a result, the Mega Muscle Drill s overall tool life was increased by 2.2 times while cycle time was reduced by half. 14

16 加工事例 Processing Data 球墨铸铁建筑零部件加工 Processing construction machining part in ductile cast iron TRS-HO-8D( 特殊品 ) (Special) 80m/min (1,410min -1 ) 1,020mm/min (0.72mm/rev) φ18 FCD mm( 通孔 ) 水溶性 立式加工中心 Vertical Machining Center 56m/min (990min -1 ) 200mm/min (0.2mm/rev) TRS-HO-8D ( 特殊品 ) (Special) 他社品 孔 (holes) 300 孔 (holes) 能率比 5.1 倍 Efficiency Ratio 5.1 times 可继续加工 Breakage 产品相比约 1.4 倍, 每转进给 3.6 倍的条件下加工, 结果寿命是 A 产品的 1.4 倍以上, 综合效率为 5.1 倍, 每个工件加工时间缩短 2 分 40 秒 刃尖比较照片 The Mega Muscle Drill was machining at 1.4 times the cutting speed and 3.6 times the feed rate versus the competitor tool. It was able to achieve 1.4 times the tool life while increasing productivity by 5.1 times. Cycle time per part had been reduced by 2 minutes and 40 seconds. 机械部件加工 (SS400) 寿命及效率得到大幅提升! Excellent durability and efficiency in SS400 drilling TRS-HO-10D 100m/min (3,350min -1 ) 1,500mm/min (0.45mm/rev) φ9.5 SS400 75m/min (2,510min -1 ) 900mm/min (0.36mm/rev) 100mm( 通孔 ) 水溶性 TRS-HO-10D 38m 30m 切削长 (m)drilling Length 效率比 1.6 倍以上 more than 1.6 times the productivity 耐久比 1.25 倍以上 more than 1.25 times the tool life 可继续加工 二刃钻头相比效率提高了 1.6 倍以上, 耐久提高了 1.25 倍以上 针对易发生切屑阻塞的软钢材料效果非常理想 一般用钢加工时, 因其切屑分断型不同, 请适当调节 切屑的情况 Chips In comparison to the competitor's 2-flute drill, the Mega Muscle Drill was able to achieve more than 1.6 times the efficiency and 1.25 the tool life. When machining materials that are prone to creating bellow-shaped chips, please adjust the cutting speed accordingly in order to maintain proper chip shape. 15

17 软钢多孔加工资源 成本削减 Consumption and Energy Cost Reduction in High Efficiency Drilling of Mild Steel 环境评价 Environmental evaluation φ8.5 S50C 2 刃 (2FL) 100m/min(3,750min -1 ) 1,420mm/min 710mm/min (0.38mm/rev)(0.19mm/rev) 2 5 m m ( 通孔 ) 水溶性 (BT40) Mega Muscle 钻头高效率加工的设计, 能够节约 1/2 的电力, 并且这可以有效的大幅降低二氧化碳的排放量 * 相较于其他二刃钻头 Due to its highly efficient design, the Mega Muscle Drill consumes one-half of the electrical power versus two-flute drills and significantly reduces the discharge of carbon dioxide! (*Compared to the competitor's two-flute drills) 2 刃 's two-flute drill 5 * 我司实绩 *Internal data kg-co kg-co 2 10,000 孔 CO2 排出量 (kg-co 2 ) CO2 Discharge Rate 削减约 50%! About 50% reduction! 生产成本比较例 Productivity Cost Comparison 工件名 : 变速箱加工材料 :FC300 Item Name : Transmission case 品名 直径 Drill Diameter 切深量 回度 Revolutions per Minute 钻头寿命 Life 以往比 Ratio φ8.5 φ % 34mm 34mm 100% 120m/min 120m/min 100% 4,500min -1 4,500min % 945mm/min 2,160mm/min 229% 5,000 孔 (Hole) 7,500 孔 (Hole) 150% 品名 可再研磨数 Number of Regrinds 每月加工孔数 Number of Holes (Monthly) 每月使用量 ( 新 + 在研磨 ) Monthly Usage (New + Regrind) 每月新品必要数 Monthly Usage (New) 每孔的加工时间 Cycle Time (per hole) 每月孔加工时间 Total Time (Monthly) 2009 年实绩 As of 2009 以往比 Ratio 8 回 (Times) 8 回 (Times) 100% 300,000 孔 (Hole) 300,000 孔 (Hole) 100% 60 根 (pc.) 40 根 (pc.) 67% 7.5 根 (pc.) 5 根 (pc.) 67% 2.16 秒 (sec.) 0.94 秒 (sec.) 44% 10,794 分 (min) 4,722 分 (min) 44% 实现 2.3 倍, 耐久 1.5 倍及高效率长寿命 高效率长寿命为削减成本贡献较大 In this example, the cutting speed was increased by 1.5 times; while tool life and efficiency were increased by 2.3 times. The total cost savings totaled to approximately 118 million yen per year (calculated by standard drill list price). 削减效果 Reduction effect 加工小时 / 年 =400 小时 / 年 Reduced electric power consumption 400 hours/year 长寿命削减刀具使用量 Long life reduces the number of tools used 工具寿命 =6 倍 life = 6 times 工具使用削减量 =180 根 ( 与二刃钻相比 ) Reduction in tool usage = 180 pieces('s two-flute drill) 一年加工时间 ( h o u r )Annual Production Time ,000 4,000 6,000 8,000 10,000 寿命 Limit 刃尖比较照片 Comparison 400 小时 (hour) 5 0 % 削減! 50% reduction! 9,600 孔 (holes) 继续可能 136 分 minutes 二刃钻 's two-flute drill 800 小时 (hour) 二刃钻 's two-flute drill 1,600 孔 (holes) 耐久比 6 倍 6 times the tool life 崩刃 Breakage 45 分 minutes φ10.8 SS400 相当 100m/min(2,950min -1 ) 1,770mm/min 885mm/min (0.6mm/rev) (0.3mm/rev) 2 5 m m( 通孔 ) 水溶性 产品加工 1600 孔后发生崩刃,TRS 钻头可以再该公司产品的 2 倍效率下, 加工 9600 孔 ( 切削长 241m) 近 6 倍效率 刃尖轻微, 可以继续加工 孔数较多的加工下, 约每年缩短加工时间 400 小时 一年刀具使用量从 215 把削减到 35 把, 约削减了 180 把 TRS 钻头是一款可以大幅削减刀具及电力费用的产品 In this example, the Mega Muscle Drill processed at feed rates twice as fast as the competition. The competitor s drill broke after machining 1,600 holes. The Mega Muscle Drill, on the other hand, was able to complete 9,600 holes (cutting length of 214m) with only normal wear, which is 6 times the tool life versus the competitor. This resulted in an annual savings of approximately 400 production hours, which is equivalent to an annual savings of 5.6 million yen for the customer. It also resulted in an annual tool consumption decrease of 180 drills per year, from a total of 215 drills to just 35 drills per year. The Mega Muscle Drill is an environmentally friend drill that is capable of reducing tool consumption and electrical power. 16

18 加工事例 Processing Data FCD600 的高进给加工 High feed drilling in FCD600 TRS-HO-10D Feed 1,000 2,000 3,000 φ5 FCD m/min(6,370min -1 ) 1,590mm/min 955mm/min 1,590mm/min (0.25mm/rev 5%D) (0.15mm/rev 3%D) (0.25mm/rev 5%D) 50mm( 通孔 ) 水溶性 TRS-HO-10D 5%D 3%D 5%D 1,500 孔 (holes) 900 孔 (holes) 2,000 孔 (holes) 耐久 2.2 倍 2.2 times the tool life 效率比 1.6 倍 More than 1.6 times the efficiency 耐久 1.3 倍 1.3 times the tool life 二刃钻相比, 每转进给从 0.15 提高到 0.25mm/rev, 效率为 1.6 倍, 耐久为 1.3 倍 另外, 在高进给条件下, 耐久可以实现 2.2 倍, 高效率条件下可以发挥该产品性能 加工 1500 孔后道具比较 wear comparison after drilling 1,500 holes TRS-HO-10D 3%D 3%D By increasing the feed rate to 0.25mm/rev, the Mega Muscle Drill was able to achieve 1.6 times the efficiency and 1.3 times the durability versus the competitors' 2 flute drills, which ran at 0.15mm/rev. When machining under the feed rate of 0.25mm/rev, the Mega Muscle Drill was able to achieve 2.2 times the tool life versus the competition. FCD600 的深孔加工 Deep hole drilling in ductile cast iron TRS-HO-10D ,000 φ10 FCD600 80m/min(2,550min -1 ) 1,150mm/min(0.45mm/rev) 100mm( 通孔 ) 水溶性 TRS-HO-10D 756 孔 (holes) 840 孔 (holes) 420 孔 (holes) 420 孔 (holes) 耐久比 1.8 倍以上 more than 1.8 times the tool life 加工 756 孔后刀尖照片 after drilling 756 holes 球墨铸铁深孔加工, 实现进给超过 1000mm/min 高效率条件与二刃钻相比, 实现耐久 1.8 倍以上 调节可进一步提高寿命 The Mega Muscle drill was able to achieve stable high feed deep-hole drilling in ductile cast iron at 1,150mm/min with 1.8 times the tool life versus the competitor's 2-flute drill. life can be further improved by adjusting the cutting speed. 17

19 S50C 的 MQL 加工 S50C drilling with MQL TRS-HO-10D 1,000 2,000 3,000 φ5 S50C 100m/min(6,370min -1 ) 1,590mm/min(0.25mm/rev) TRS-HO-10D 2,600 孔 (holes) 2,600 孔 (holes) 耐久比 1.6 倍以上 more than 1.6 times the tool life 可继续加工 可继续加工 50mm( 通孔 ) MQL 实现为 1590mm/min, 切削长超过 130m 的高效率加工 与产品相比可以抑制横刃, 研磨费用相对稳定, 可以削减整体成本 In comparison with other competitor tools, the Mega Muscle Drill suffered minimal wear after machining 130m of materials at a high feed rate of 1,590mm/min. With stable performance and little margin wear, the Mega Muscle Drill is able to achieve long tool life and reduce overall tooling cost. A A B B 1,800 孔 (holes) 1,400 孔 (holes) 1,800 孔 (holes) 崩刃 Chipping 火花 Spark 加工 2600 孔后刀尖照片 after drilling 2,600 holes 1,400 孔 (holes) C C 759 孔 (holes) 1,181 孔 (holes) 可继续加工 加工 1000 孔时刃带部 Margin wear after drilling 1,000 holes TRS-HO-10D A A B B C C 18

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