High-Precision Cutterfor Finishing Applications

MFF

High-Precision Cutter for Finishing Applications

MFF

NEW

Innovative Finishing Technology with Increased Efficiency
Enhanced Cutter Design for a Better Finishing Solution
Molded Wiper Insert Design
High Feed Rates (f = Max 5.0 mm/rev) and High-Quality Surface Finish (0.8 μm Ra) *Adjustable Cutting Edge Height for Improved Usability*User evaluation

High-Precision Cutter for Finishing Applications

MFF

Cutter Body Design Provides Excellent Reliability
Molded Wiper Inserts Increases Machining Efficiency

1Our Solution for Finish Machining

MFF was made to solve the problems in machining.
Designed with a unique insert combination of semi-finishing and finishing, the MFF drastically improves productivity by reducing quality issues.
Semi-finishing Insert
To flatten ruggedness when roughing

SOLUTION
Increase feed to f = 5.0 mm/rev
Achieved 0.8 μm Ra surface finish
No grinding requiredAchieved 5 μm flatness
The above is the result of a field test. Actual results will depend on
machining environment, workpiece rigidity, machine, etc.
For more details, see case studies on page 3 and 4.

Finishing Insert
Provides excellent surface finish
Adjustable cutting edge and a single insert eliminates runout

MFF

Machining Solutions
Can be used on a wide variety or parts andworkpieces

Part Name
Plate / Frame / Case
Cylinder Pump / Rail
Turbine Housing
Casing / Mold Base1

Workpiece

Industry

SS400 / FC250 / FCD600
Ni-resist Cast Iron
SKD 61 equivalent (Mold Steel)Carburized and hardened steel (60 HRC)

Industrial Machining
Machine Tools
Shipbuilding / Automotive
Construction MachineryMolds

Molded Wiper Insert for High-Quality
Surface Finish2PR1525

PV60M

Utilizes Kyocera's unique molded insert technology for high feed rates and excellent surface finish
MEGACOAT NANO Cermet PV60M
For high-speed machining
Recommended Vc = ~ 350 m/min

Low cutting force withspecial edge preparation

Wiper edge

Micro-honing
Good sharpness

Large S-curve shape developed forhigher feed rates

High-quality surface finish

Molded TT Chipbreaker

Edge Temperature Simulation Comparison (Internal Evaluation)

MFF

Conventional tool

After 2 sec machining

InsertInsert

HighReduces chip clogging
High feed machining

LowWorkpiece

WorkpieceComprehensive Machining Solutions

From Roughing to Finishing Machining Improvements (Internal Evaluation)

Combine with Kyocera's MFH high feed cutter to improve quality and efficiency
4 sec tool change included

Conventional

General Use Cutter

MFH Harrier

Roughing

125 Sec

Finishing

Cutting TimeMFF

SOLUTION

37 Sec70 %DOWN

High Feed Cutter

Cutting Conditions
Conventional ø200 (6 inserts)
Vc = 200 m/min
Roughing : Vf = 286 mm/min (fz = 0.15 mm/t), ap = 1.2 mm
Finishing : Vf = 230 mm/min (fz = 0.12 mm/t), ap = 0.3 mm
SOLUTION
Roughing: MFH Harrier ø 63 (6 inserts)
Vc = 200 m/min
Vf = 7,300 mm/min (fz = 1.2 mm/t), ap = 0.7 mm
Finishing: MFF ø 200 (2 inserts)
Vc = 300 m/min
Vf = 2,400 mm/min (f = 5.0 mm/rev), ap = 0.1 mm

Surface Finish Quality after Machining
SOLUTION

Excellent Surface Finish (0.27 μm Ra)

Conventional Machining

Cloudy Surface Finish (1.01 μm Ra)

2

The MFF provides
excellent finishingsolutions*User evaluation

SOLUTION 1

1.7 times increase in efficiency at f = 5.0 mm/rev with a 0.8 μm Ra surface finish

Plate (SS400)

1.7 times Machining Ef f iciency

SOLUTION

MFF

Vf =

ø 200 2 inserts
Conventional

Required surface finish: 0.8 μm Ra

SOLUTION 2

2,600 mm/min

0.8μmRa or less

Vc = 330 m/min, f = 5.0 mm/rev, ap = 0.1 mm, Dry

1,500 mm/min

Competitor A

Vf =ø 200 2 inserts

Vc = 220 m/min, f = 4.3 mm/rev, ap = 0.1 mm, Dry

The conventional cutter was not able to feed faster than f = 4.3 mm/rev as surface finish deteriorated.
The MFF showed good surface finish of 0.8 μmRa or less even at f = 5.0 mm/rev.
Increasing the cutting speed increased machining eﬃciency by 1.7 times.

Surface finish 0.5 μm Ra. No grinding required (Fewer Processes)

Valve (FCD450)

No grinding required

SOLUTION

MFFø 160 2 inserts
ConventionalCompetitor B
ø 200 10 inserts
Required surface roughness: 1.6 μm Ra

127sec

0.5 μm Ra (no grinding)

Vc = 300 m/min, Vf = 250 mm/min (f = 0.4 mm/rev) ap = 0.1 mm, WetMachining

32 sec + Grinding 10 min

Vc = 300 m/min, Vf = 800 mm/min (f = 1.6 mm/rev) ap = 0.1 mm, Wet

Conventional tool showed cloudy finished surface, MFF provided 0.5 μm Ra with a glossy finish.
Reduced grinding process and cycle time by 80%.

3

SOLUTION 3

Improved flatness and machining efficiency tripled in interrupted mold steel

Mold (SKD61 equivalent)

Machining Ef f iciency x 3

SOLUTION

MFF

Vf =ø 200 2 inserts
Conventional

Competitor Cø 125 5 inserts
Required surface roughness: 1.6 μm Ra

SOLUTION 4Flatness Improvement

Vc = 120 m/min, f = 2.0 mm/rev, ap = 0.05 mm, Dry

Vf =210 mm/min 10 Pass

Vc = 120 m/min, f = 0.65 mm/rev, ap = 0.05 mm, Dry

The MFF left a good finished surface with no gaps among tool path seams.
Larger cutter diameter reduced the number of passes to six and improved productivity.
Desirable chip shape and size were achieved.

Flatness of 5 μm was achieved. Showed good surface finish with reduced chattering on the thin partCase (FC250)

Machining Quality Improvement

SOLUTION

MFF

Reduced Chattering and Good Finishø 100 2 inserts
ConventionalCompetitor Dø 100 8 inserts (CBN)
Required Flatness: 10 μm

380 mm/min 6 Pass

Flatness of 5 μm or less

Vc = 330 m/min, Vf = 1,600 mm/min (f = 0.1.5 mm/rev) ap = 0.1 mm, Dry

Chattering occurred in thin wall
Vc = 1,200 m/min, Vf = 2,450 mm/min (f = 0.64 mm/rev) ap = 0.1 mm, Dry

Conventional cutter needed adjustment due to chattering on the thin portion.
MFF prevent chattering. Finished surface is good and there is no gap in the tool path seams.
Flatness of 5 μm achieved.

43

Adjustable cutting edge for increased usabilityCartridge height comes pre-adjusted and should
not be necessary.
Adjustment is not required after replacing insert.

Easy-to-adjust Cutting Edge
Cutting edge height can be adjusted easily with one screw

Included adjustment wrench

Edge Adjustment
If D.O.C. is ap 0.1 ~ 0.2 mm, no adjustment is necessary (Pre-adjusted before holder is shipped).
Cutting edge adjustment is NOT required when replacing inserts.
If D.O.C. is less than 0.1 mm or if you prefer a different edge height, use the following method:
Adjusting the Cutting EdgeUse the supplied TTW-15 wrench to rotate the screw and easily adjust the cutting edge position.

Finishing Insert

Procedure
To adjust, start with the screw turned counterclockwise about two rotations (lowering the cutting edge).
Tighten the screw clockwise (raising the cutting edge) to adjust the amount of protrusion.
*Use a dial gauge to measure protrusion amount.

Precautions:
Make sure to lower the cutting edge below the desired height first (turning screw counterclockwise) andthen raise the edge up to the final height (turning screw clockwise). If cutting edge is simply lowered to thefinal edge height, chattering or loosening of the screw may occur due to backlash. Make sure themeasurement position of the cutting edge is the same machining diameter.

Do not operateStandard Cutting Edge Height

Supplied Wrench(T TW -15)

ap = 0.05 mm => protrusion against rough edge: 0.03 mm
ap = 0.10 mm ~ => protrusion against rough edge : 0.06 mm *Pre-adjusted before shipment

Applicable Inserts

Shape

MEGACOATMEGACOAT
NANO
NANO
CermetDimensions (mm)Description
ICS

D1

INSL

RE

PV60M

PR1525

LNGX 120916R-TT

9.525

6.35

4.2

12.7

1.6

MTO

MTO

LNGX 120916

9.525

6.35

4.2

12.7

1.6

MTO

MTO

IC

D1RE

For steel and stainless steel(Low cutting force)

90°

INSL

SIC

D1

RE

For Cast Iron

90°

INSL

S

MTO : Made to order

5

MFF

R.R.

-8°

Medium-Finishing Insert: -9° Finishing Insert: -20°

DCSFMSDCSFMSDCSFMS

DCB
KWW

DCB

DCB
KWW

APMX

APMX

LF

LF

CBDP

KPD

CBDP
LF
APMX

DCCB1

DCCB20°

DCCB1

DCCB3

KDP

KWW

KDP

CBDP

Rake Angle
A.R.

0°

DC

DCCB4

DCXDC
DCX

DCCB20°

DCCB1
DC
DCX

Fig.1

Fig.2

Fig.3

DC

DCSFMSDCB

DCCB 1

DCCB 2

DCCB 3

DCCB 4LF

CBDPKDPKWW

MFF080R-SF

MTO

8067.3

60

25.4

2013-

-

50

2769.5

MFF100R-SF

MTO

10087.3

70

31.75

48-

-

-

50

32

812.7

MFF125R-SF

MTO

125112.3

87

38.1

58-

--

63

38

1015.92

APMX

Description

DCX

No. of Inserts

Dimensions (mm)StockBore dia. Inch Spec

Toolholder Dimensions

Fig.1

Fig.20.3

MFF160R-SF

MTO

160147.3

102

50.8

72

MFF200R-SF

MTO

200187.3142 47.625 110---6338

1119.1

101.6

261863401425.4

Max.
Coolant
WeightShape
Revolution
hole
(kg)
(min -1)
1.3

2,000

1.8

1,600

3.5

1,300

5.9

1,000

8.1

800

10.8*

800

1.3

2,000

1.8

1,600

3.5

1,300

5.9

1,000

7.7

800

10.5*

800

NoMetric Spec

Fig.3
MFF250R-SF

MTO

250237.3

142 47.625 110

101.626186340

1425.4

MFF080R-M-SF

MTO

80

67.3

60

272013--5024712.4

MFF100R-M-SF

MTO

10087.3

703248---

50

32814.4

MFF125R-M-SF

MTO

125112.3874055---

63

33

916.4

2Fig.1

Fig.2
0.3

MFF160R-M-SF

MTO

160147.3

1024072---

63

33

916.4

MFF200R-M-SF

MTO

200187.3

142

60

110

101.6

26

1863

40

1425.7

NoFig.3
MFF250R-M-SF

MTO

250

237.3

14260

110

101.6

26

1863

40

14

*ø250 sizes have holes for lighter weight.
Caution with Max. Revolution
Set the number of revolutions per minute within the recommended cutting speed specified by the workpiece on back cover.
Do not use the end mill or cutter at the maximum revolution or higher since the centrifugal force may cause chips and parts
to scatter even under no load.

25.7

MTO : Made to orderSurface Finish
The surface will be finished flatwithin the range ofDC shown on the right.

DCDCXPartsParts
Clamp screw

Wrench

SB-3592TR

DTM-10Fastening torque for clamp
insert 1.2 NmWedge

Cartridge

Cartridge clamp
screw

WrenchAdjusting screw

Anti-seize
compound

AD-MFF

CR-MFF

HH5X15L

TTW-15

W6X18N

P-37

6

Recommended Cutting Conditions Table

ChipbreakerTT

1st recommendation

Workpiecef (mm/rev)

Structural Steel (SS 400, etc.)

1.5 – 4.0 – 5.0

Carbon Steel (S * * C, etc.)

1.0 – 4.0 – 5.0

Alloy Steel (SCM, etc.)

1.0 – 4.0 – 5.0

Mold Steel (SKD, etc.)

1.0 – 2.0 – 4.0

Mold Steel (SKD 50 HRC ~ etc.)

0.6 – 1.0 – 1.2

Austenitic stainless steel * (SUS 304, etc.)

1.0 – 2.0 – 4.0

2nd recommendation

Depth of cut ap(mm)PV60M

PR1525230 – 280 – 350

230 – 280 – 350

200 – 250 – 350

200 – 250 – 350

200 – 250 – 350

200 – 250 – 350

0.03 – 0.1 – 0.2

120 – 200 – 250120 – 200 – 250

0.03 – 0.05 – 0.1—

50 – 70 – 80

120 – 200 – 250

120 – 200 – 250

150 – 200 – 300

150 – 200 – 300

200 – 250 – 350

200 – 250 – 350

150 – 250 – 300

150 – 250 – 300

0.03 – 0.1 – 0.3

0.03 – 0.1 – 0.2
Martensitic stainless steel * (SUS 403, etc.)

1.0 – 3.0 – 4.0

Gray Cast Iron (FC)

1.0 – 2.0 – 4.0
0.03 – 0.1 – 0.3

Standard
Nodular Cast Iron (FCD)

Recommended Insert Grade (Cutting speed Vc: m/min)

1.5 – 2.0 – 4.0*Machining with coolant is recommended for stainless steel
The number in bold font is recommended starting conditions. Adjust the cutting speed and the feed rate within the above conditions according to the actual machining situation.

Gain Excellent Surface Finish with
High-Efficiency Finishing

The information contained in this brochure is current as of April 2020.
Duplication or reproduction of any part of this brochure without approval is prohibited.
CP460 CAT/17.0T2004DNN© 2020 KYOCERA Corporation