P711A

1

DRILLINGTOOLS

MILLINGTOOLS

DFC4JC

DFCJRT

PCD

MCS

STAW

PCD drills, CVD diamond coated drills, cemented carbide drills with optimized cutting geometry for composite materials reduce burr formation and delamination.

Diamond coated end mills which have high wear resistance and extreme sharpness can provide stable cutting with composite materials.

Cutting tool life is usually extremely short because of the high strength of

carbon fi ber. Additionally, delamination and burring easily occurs during

cutting. The accumulated layer structure of CFRP (carbon fi ber reinforced

plastics) has high specifi c strength and there is an expanding application

area especially in the aerospace industry. Mitsubishi Materials cutting

tools achieve a long tool life and high quality machining due to an original

coating technology in combination with an optimized tool geometry.

2

DRILLING TOOLS

MCS

Superior sharpness for high quality CFRP drilling.

Drill for CFRP machining

Unique coolant hole geometry

New tool grade DD2010

Special wavy cutting edge

Back clearance

Proprietary CVD diamond coating

TRI Cooling technology (PAT.P) based on a new concept improves chip removal when machining CFRP/aluminum, CFRP/titanium stacks.(Coolant holes with TRI Cooling technology on drills larger than &6mm)

The newly developed DD2010 CVD diamond coated carbide material achieves outstanding abrasion resistance and smoothness, with proprietary fi ne multilayer diamond crystal control technology.NOTE: Uncoated carbide grade TF15 is

recommended for CFRP/titanium stacks.

The low resistance and extremely sharp wavy cutting edge reduces burrs with CFRP, CFRP/aluminum stacks and CFRP/titanium stacks.

Large back clearance for smooth ejection of chips from the center.

yCVD diamond coating surface comparison

DD2010 Conventional

MCS drills achieve good hole accuracy and long tool life by adopting the use of a fi ne multilayer CVD diamond coating and carbide grade TF15 on the cutting edges. A specialized cutting geometry allows effi cient machining of holes in laminated CFRP and stacked layers of CFRP/aluminum, CFRP/titanium. A unique through coolant hole shape also improves chip removal when machining and results in higher hole accuracy.

WSTAR drill series

3

DRILLING TOOLS

.00197

.00157

.00118

.00079

.00039

0

-.00039

-.00079

-.00118

-.00157

-.00197

.00197

.00157

.00118

.00079

.00039

0

-.00039

-.00079

-.00118

-.00157

-.00197

.00197

.00157

.00118

.00079

.00039

0

-.00039

-.00079

-.00118

-.00157

-.001975050 100100 150150 200200 250250 300300

1 50 100 150 200 2500 7.874 15.748 23.622 31.496

4995 4995

CFRP

.197"

CFRP

.197"

.512"

With TRI Cooling technology, the MCS drill improves hole accuracy compared with earlier types.

1. Drilling of CFRP/aluminum stacks with an air blast.

CUTTING PERFORMANCE An original coolant hole shape

Conventional

2. High effi ciency machining of laminated CFRP and aluminum alloy with a CNC machine.Oversize (inch)

Upper side of CFRPBottom side of CFRPAluminum alloy

Feed of the main spindle (inch/min)

About 8 times effi ciency

Oversize (inch) Oversize (inch)

No.of holes

No.of holes

No.of holes

Upper side of CFRP Upper side of CFRP

Bottom side of CFRP Bottom side of CFRPAluminum alloy Aluminum alloy

Drill Diameter &.251" &.251"

Work Material

CFRP(Passenger airline component)

CFRP/aluminum stacks(Passenger airline component)

Spindle Speed (min-1)Cutting Speed (SFM) 328 328Feed (IPR) .0016 .0016

Coolant Air blow Air blowMachine Machining center Machining center

Results

Bottom side of CFRP Bottom side of aluminum alloy

MCS(DD2010)

MCS(DD2010)

ConventionalDrill A

for CFRP

ConventionalDrill A

for CFRP

ConventionalDrill B

for CFRPor

Aluminum alloy

ConventionalDrill B

for CFRPor

Aluminum alloy

Earlier types of drills produced large burrs but with the MCS(DD2010) drill burrs are vastly reduced.

Work materialDrillThicknessMachineCutting speedFeedInternal air blow

: CFRP/aluminum stacks: & .251": .512" (CFRP) + .197" (Aluminum alloy) : Machining center: 197 SFM: .0012 IPR

Work materialDrillThicknessMachineInternal air blow

[MCS]Cutting speedFeed

[Conventional]Cutting speedFeed

: CFRP/aluminum stacks: & .251": .512" (CFRP) + .197" (Aluminum alloy) : Machining center

: 328 SFM: .0059 IPR

: 197 SFM: .0012 IPR

Aluminum alloy (A7075)

Cutting

Condit

ions

Burrs

Burrs

MCS drill can obtain high effi ciency machining, nearly eight times more than conventional drilling. High hole accuracy is maintained.

MCS

Conventional

MCS (DD2010)

MCS (DD2010)

4

MCS

DRILLING TOOLS

L3

L2

L1

øD4(

h6)

øD1(

h8)

øD

øDc

1(h8

)

øD4(

h6)

0– 0.018

0– 0.022

0– 0.027

0– 0.033

0– 0.008

0– 0.009

0– 0.011

0– 0.013

DD20

10

TF15

(inch) (mm) L3 L2 L1 D4

.1719 4.366 3 s MCS01719X3DB 23 28 65 6

.1915 4.864 3 s 01915X3DB 27 28 65 6

.2510 6.375 3 s 02510X3DB 33 41 78 8

.3125 7.938 3 s 03125X3DB 40 41 78 8

.3760 9.550 3 s 03760X3DB 45 46 87 10

.3765 9.563 3 s 03765X3DB 45 46 87 10

.4380 11.125 3 s 04380X3DB 53 54 100 12

.5010 12.725 3 s 05010X3DB 58 59 105 14

Drill for CFRP machining

(Note) MCS drills are suitable for use with shrink fi t holders.

RECOMMENDED CUTTING CONDITIONS

3<D<6 6<D<10 10<D<18 18<D<20

D1 Tolerance(mm)

D4 Tolerance(mm)

Drill Dia.D1 Hole Depth

(l/d)Coolant

(Int./Ext.)

Stock

Order Number

Dimensions (mm)Flute

LengthNeck

LengthOverallLength

Shank Dia.

Int.Int.Int.Int.Int.Int.Int.Int.

MCr rrrr XrD rrr

MCr rrrr Xrrrr XrD rrr

For non stocked sizes please enter details into the r below.Please contact us for details of any geometry that is not mentioned.

*Recommended carbide grade TF15 for CFRP/titanium stacks.

Size range of drill dia. : &3mm-&20mmSize range of shank dia. : &3mm -&20mmFor cutting dia D1 - Please indicate with 4 digitsE.g. &3mm - 0300For shank dia D4 - Please use 3 digitsE.g. &12mm - 120

*For inch sizes please convert to metric(1"= 25.4mm)

Order number of straight type

Order number of stepped type

CoolantS : Int.E :Ext.

CoolantS : Int.E :Ext.

Hole Depth (l/d)Size range : 2-5

Hole Depth (l/d)Size range : 2-5

Shank Dia. &D4Size range : 030-200

Shank Dia. &D4Size range : 030-200

Stepped Drill Dia. &Dc

Drill Dia. &D1Size range : 0300-2000

*Minimum diameter with internal coolant is &4mm (&.1575").

Drill Dia. &D1Size range : 0300-2000

*Minimum diameter with internal coolant is &4mm (&.1575").

s:Inventory maintained in Japan.

Workmaterial CFRP CFRP/Aluminum stacks CFRP/Titanium

(Ti-6Al-4V etc.) stacksGrade DD2010 TF15

Dia. D1(inch)

Cutting Speed(SFM)

Feed(IPR)

Cutting Speed(SFM)

Feed(IPR)

Cutting Speed(SFM)

Feed(IPR)

.118<D1<.197 280(165–395)

.0015(.001– .003)

180(130–230)

.0015(.001– .0025)

25(10–40)

.001(.0008– .0015)

.197<D1<.315 310(200–425)

.002(.001– .003)

210(165–260)

.002(.001– .003)

25(10–40)

.001(.0008– .0015)

.315<D1<.433 310(200–425)

.003(.0015– .005)

210(165–260)

.0025(.0015– .003)

35(15–50)

.0015(.001– .002)

.433<D1<.787 330(200–490)

.004(.002– .006)

230(165–330)

.003(.002– .004)

35(15–50)

.0015(.001– .002)

1) Cutting condtions shown left are for when using internal coolant. (mist or air)

2) When dri l l ing CFRP/aluminum stacks with external coolant reduce the cutting conditions by 30%.

Recommended grade

CFRP CFRP/Aluminum stacks

CFRP/Titanium stacks

DD2010 DD2010 TF15

5

STAW

PCD

DRILLING TOOLS

STAW drills (special order) decrease burr formation and delaminationwhen machining due to a CVD diamond coating and an optimized geometry.

Long tool life and high quality drilling is achievable.

PCD drills (special order) with optimized geometry andPCD (sintered diamond) decreases burrs and delamination.Long tool life and high quality drilling is achievable.

yCutting Performance

PCD Drill (Special)

CVD diamond coated insert (Special insert)

CFRP

CFRP

Titanium alloy.1968".3937"

.433"

(Photo: 120 holes machined)Further use is possible because of small wear.

(Photo: 25 holes machined)Further use is possible because of small wear.

(Photo: 20 holes machined)Further use is possible because of small wear.

Drill & .2510"Work material CFRP/Titanium stacks

Thickness .3937" (CFRP) + .1968" (Titanium alloy) Cutting conditions 33 SFM (n500min-1), .0020 IPR, Internal mist

Machine Machining center

yCutting PerformanceDrill & .4331" (insert grade: DD2010)

Work material CFRP/aluminum stacksThickness .984" (CFRP) + .197" (Aluminum alloy)

Cutting conditions 262 SFM (n2546min-1), .0020 IPR, Int. air blowMachine Machining center

Drill & .3937" (insert grade: DD2010)Work material CFRP

Thickness .4331"Cutting conditions 262 SFM (n2546min-1), .0020 IPR, Dry

Machine Machining center

CFRP

Aluminum alloy.197"

.984"

6

DFC4JC

DFCJRT

MILLING TOOLS

1970

.0118

.0079

.0039

0394 591

DFC Series

CVD diamond coating with outstanding abrasion resistance and superior sharpness for

high quality CFRP machining.

CVD diamond coated end mill for CFRP machining

The low resistance cutting edge with low helix angle reduces delamination and burrs when machining CFRP.

The cross-nick type cutting edge allows high effi ciency machining due to lower cutting resistance and reduced temperatures.

For fi nishing (First recommendation)

For effi cient machining

Geometry for CFRP machining

yCVD diamond coating surface comparison

New coating grade Conventional

Proprietary CVD diamond coating

The newly developed CVD diamond coated carbide material achieves outstanding abrasion resistance and smoothness due to a proprietary fi ne multilayer diamond crystal control technology.

yLong tool life

Cutting length (inch)

Flan

k w

ear (

inch

)

DFC4JC

Conventional

DFC4JC

yExcellent surface fi nish

Conventional

Cutting directionCutting direction

Less burrs Burrs

DFC4JC DFCJRT

End mill DFC4JCD1000(ø .3937")

Work material

CFRP(Thick: .2362")

Revolution 6000min-1

(617 SFM)

Feed rate 29.5 inch/min(.0012 inch/tooth)

Coolant mode Air blow

End mill DFC4JCD1000(ø .3937")

Work material

CFRP(Thick: .2087")

Revolution 6400min-1

(656 SFM)

Feed rate 31.5 inch/min(.0012 inch/tooth)

Coolant mode Air blow

DFC4JC

DFCJRT

MILLING TOOLS

DFCUWC

apL1 øD

4(h6

)

øD11

DFCUWC

apL1 øD

4(h6

)

øD1

h6

h6

D1 ap L1 D4 NDFC4JCD0600 6 20 70 6 4 s 1

D0800 8 30 80 8 4 s 1D1000 10 30 90 10 4 s 1D1200 12 30 100 12 4 s 1

CFRP

6 (.2362) 11000 37.48 (.3150) 8000 30.7

10 (.3937) 6400 27.612 (.4724) 5300 25.6

D1 ap L1 D4 NDFCJRTD0600 6 20 70 6 10 s 1

D0800 8 30 80 8 10 s 1D1000 10 30 90 10 12 s 1D1200 12 30 100 12 12 s 1

CFRP

6 (.2362) 11000 47.28 (.3150) 8000 39.3

10 (.3937) 6400 35.412 (.4724) 5300 33.4

End mill, Semi long cut length,4 fl ute, For CFRP

0 – -0.030 – -0.0080 – -0.0090 – -0.011

D4 = 68< D4< 10 D4 = 12

Order NumberDia. Length of Cut Overall Length Shank Dia. No. of

Flutes Stock Type

Please contact Mitsubishi Materials for geometries and through coolant types other than standard.

1) Cutting conditions may differ considerably due to the kind of CFRP, the rigidity of the machine, or the clamping and geometry of the workpiece. Please use the left table as a standard starting point.

2) When high machining accuracy is needed, or large burrs or delamination occurs. We recommend reducing the feed rate.

3) When the depth of cut is greater than 0.8D1, we recommend reducing the feed rate.

4) Please take precautions against dust.

RECOMMENDED CUTTING CONDITIONSWork material

Dia.(mm) (inch)

Revolution(min-1)

Feed rate(inch/min)

Cross-nick type end mill, Semi long cut length,For CFRP

0 – -0.0080 – -0.0090 – -0.011

D4 = 68< D4< 10 D4 = 12

Order NumberDia. Length of Cut Overall Length Shank Dia. No. of

Flutes Stock Type

Please contact Mitsubishi Materials for geometries and through coolant types other than standard.

1) Cutting conditions may differ considerably due to the kind of CFRP, the rigidity of the machine, or the clamping and geometry of the workpiece. Please use the left table as a standard starting point.

2) When high machining accuracy is needed, or large burrs or delamination occurs. We recommend reducing the feed rate.

3) When the depth of cut is greater than 0.8D1, we recommend reducing the feed rate.

4) Please take precautions against dust.

RECOMMENDED CUTTING CONDITIONSWork material

Dia.(mm) (inch)

Revolution(min-1)

Feed rate(inch/min)

Type 1

Type 1

s:Inventory maintained in Japan.

s:Inventory maintained in Japan.

EXP-11-E015Printed in U.S.A. 01/12

LOS ANGELES HEAD OFFICE11250 Slater Avenue, Fountain Valley, CA 92708TEL : 714-352-6100 FAX : 714-668-1320

CHICAGO OFFICE1314B North Plum Grove Road, Schaumburg, IL 60173TEL : 847-252-6300 FAX : 847-519-1732

TORONTO OFFICE6535, Millcreek Drive, Units, 63&64, Mississauga, Ontario L5N 2M2, CanadaTEL : 905-814-0240 FAX : 905-814-0245

MMC METAL DE MEXICO, S.A. DE C.V.Av. La Cañada No.16, Parque Industrial Bernardo Quintana,El Marques, Queretaro, CP76246, MexicoTEL : +52-442-221-6136 FAX : +52-442-221-6134

Customer Service : 800-523-0800Technical Service : 800-486-2341

For Your SafetyaDon't handle inserts and chips without gloves. aPlease machine within the recommended application range and exchange expired tools with new ones in advance of breakage. aPlease use safety covers and wear safety glasses. aWhen using compounded cutting oils, please take fire precautions. aWhen attaching inserts or spare parts, please use only the correct wrench or spanner. aWhen using rotating tools, please make a trial run to check run-out, vibration and abnormal sounds etc.

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