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Cut-offH1~H26H1~H26
H1
KTKF Lateral side screw clamp holder H8
KTKFS (For sub spindle tooling) Lateral side screw clamp holder H10
KGD Integral Toolholder H14
KGD-S Separate Toolholder H15
KGM (For automatic lathe) Integral Toolholder H18
KGM Integral Toolholder H19
KGM-T Integral Toolholder H19
KTKB-SS / KTKB-S Blade H22
KTKTB / KTKTBF Toolblock H23
KTKH-S Integral Toolholder H24
Recommended Cutting Conditions H25
Product Lineup H2
Guide for Cut-Off H3
Summary of Cut-Off H4~H5
Cut-Off Toolholders (for small diameter cut-off) H6~H11
Alternative Toolholder Reference Table for Cut-off Toolholder H26
H1
H2
Width: 1.0~2.0 mm
Cut
-off
H
KGD
CERACUT Cut-Off(1-edge)
Product Lineup
Width: 1.5~4.0mm, 3~8mm Width: 2.0~6.0mm
CERACUT / Plunge & Turn
(2-edge)
For Small Diameter Cut-Off
Width: 0.5~2.0 mm
Toolholder (Long Shank for automatic lathe)
Cut-Off Dia.
ø5~ø12~ø16
For sub spindle tooling
Cut-Off Dia.
ø6~ø12ø14~ø16
Width: 1.6~9.6mmWidth: 2.2~5.1mm
Bolt ClampCut-Off Dia.
ø18~ø60
Toolholder TypeCut-Off Dia.
ø30~ø79
Blade typeCut-Off Dia.
ø32~ø120
■ Product Lineup
Bolt ClampCut-Off Dia.
ø12~ø50
KGD ( H14)
Width: 2.0~4.0mm Width: 2.0~4.0mm
KGD-S ( H15)
■ Cut-Off ToolsSeries Name Shape Advantage Application
For Small Diameter Cut-Off
1) Insert clamp is side screw type from lateral side
2) 2-edge Insert
3) Cut-off Diameter is prepared for two sizes from ø5~ø12 and max.ø16.
1) For cut-off and grooving of small workpieces
2) For automatic lathe, small machine
KGD
1) Insert is clamped from top side.
2) 1-edge and 2-edge inserts available
3) Integral type and separate type are available.
4) Max. Cutting Dia.: ø50
1) PM Chipbreaker…For Cut-Off
2) PH Chipbreaker… For Cut-Off (High Feed)For Grooving
CERACUT / Plunge & Turn
1) Insert is clamped from top side
2) 1-edge and 2-edge inserts available
3) Max. Cutting Dia.: ø60
1) For cut-off and grooving of small workpieces
2) For automatic lathe, small machine
3) TMR-Chipbreaker provides stable chip control up to high feed rate ranges.
CERACUT Cut-Off
1) Self-Clamping SystemTap the insert lightly with a plastic hammer to set it in the pocket.
2) 1-edge insert
3) Blade type and Integral Shank type
4) Max. Cutting Dia.: ø120
1) For cut-off and deep grooving
2) Standard chipbreaker is general cut-off type.
Feed rate : over 0.1mm/rev
P-Chipbreaker is for cut-off at low feed rates
Feed rate : 0.03~0.08mm/rev
KTKF ( H8) KTKFS ( H10)
KGM ( H18~H19) KGM-T ( H19)
KTKH-S ( H24) KTKB-S(S) ( H22)
H3
Cut
-off
H
Guide for Cut-Off
θ
TKN
TKR
TKR
TKN
TKN
(L-hand)(R-hand)TKR TKL
θ
・Angled (θ) insert can reduce the burr size when cutting off.・When using a larger lead angle (θ), cutting
resistance becomes smaller, but the feed rate should be reduced.
Wrench
Plastic Hammer Insert's back end does not contact the toolholder.
■ How to Set Up (TKN / TK&)
1. Tap the insert lightly with a plastic hammer to push it in to the extent that it can not be removed by hand. 2. Remove the insert by using the supplied wrench.
- --
-
○ Fig.3
○ Fig.4
■ Tool Selection CERACUT / Plunge & Turn For Small Dia. Cut-Off CERACUT Cut-Off
Insert
Toolholder
1. Insert1-edge Insert … For Larger Dia. Workpiece (Max.ø120)2-edge Insert … For Smaller Dia. Workpiece
Cost per corner is reduced
1. Use a suitable toolholder (blade) for the workpiece dia.2. Use a more rigid toolholder (blade).3. Use a back clamp toolholder if there is no space for clamping tools from top side (Automatic Lathe).
2. Use a neutral angle insert if there is no limit to the finished shape.
3. Use angled insert to reduce the size of the remaining boss.
4. Use sharp-cornered lead-angled Insert to make the remaining boss much smaller when machining small parts and thin parts. 5. Use the minimum width insert suitable for the machining operation.
TKF...STKF...NBTKFS...S
-
○
GMM
-
GMM-&
○○○
○○
Fig.2
GMM-&Fig.2
-
○ ○
○○
○
TKF...DR
TKF...DR
○
-
TKN
TK&
-
-
○○○
Fig.1
■ Caution
○: Applicable : Not Applicable
●Do not rework the insert and toolholder (blade) to prevent damage.
3. Constant spindle revolution is recommended to obtain stable tool life.
1. Set the cutting edge height 0.1-0.2mm above the center height.2. Always apply sufficient coolant to the cutting edge.
●Overuse of insert and toolholder (blade) may cause insert breakage and toolholder (blade) damage.
●Clean the insert pocket well with compressed air when replacing insert.
4. Cut-off as close to the chuck as possible5. Decrease the feed rate from 1/2 to 1/3 at the near center to prevent chipping.
Inserts are sold in 10 piece boxes. ● : Std. Item □ : Check Availability
MEGACOAT
PVDCoated Carbide
・ Lead angle shows the angle when installed in toolholder.・ As Fig.1 of H8 shows, the cutting diameter of the insert is indicated when the top of the cutting edge progresses 1mm from the center.
Edge Shape
Ref.
Page
for T
oolh
olde
r
H7
Cut
-off
H
Classification of usage P Carbon Steel / Alloy Steel Q
・ Lead angle shows the angle when installed in toolholder.・ As Fig.1 of H8 shows, the cutting diameter of the insert is indicated when the top of the cutting edge progresses 1mm from the center.
1) When using Main Spindle only Workpiece maximum øD1 (Fig.1)=øDmax Even if the cutting edge runs beyond the center line, the insert does not
contact the workpiece, since the workpiece falls off. ( The clearance between the insert and the workpiece is 0.2mm)
Cut
-off
H
■ KTKF (For small diameter cut-off)
only for above shapeKTKF&1616JX-..
only for right shapeKTKF&1010JX-..
2˚ 1˚
L2 2
h
L1
H1
φDma
x
F1 B
1˚
F1
10
T T
*Clamp Screw can be operated from both front and back sides.
*
● Right-hand shown R-hand Insert for R-hand Toolholder.
● Light-hand shown L-hand Insert for L-hand Toolholder.
Fig.2
<Goose-neck Holder>
L1
T
BH1
H1 h
F1
T F1
8
1°
1°
Fig.1
KTKFL1620JX-12only for above shape
H6,H7
• Dimension T shows the distance from the Toolholder to the cutting edge. H6,H7 for the actual cutting diameter. Note: Cutting diameter of -12 type toolholder( øDmax ) depends on the insert grooving width.
2) When using both Main and Sub spindles In this case, when the cutting edge runs beyond the center line, the insert will
contact the workpiece, since the workpiece does not fall off. Therefore the programmed distance beyond the center must be considered. e.g. When the cutting edge is programmed to run 1mm beyond the center.
Workpiece maximum, øD2 (Fig.4) = [øDmax - 1mm×2] (mm)( The clearance between the insert and the workpiece is 0.2mm)
■ When using TKF-AS type
Fig.5 Example of the pass of KTKF toolholder + TKF-AS insert
■ Longitudinal Turning / Grooving(1-Edge insert)
Handed Insert shows R-hand.
+0-0.05
*Lead angle shows the angle when installed in toolholder.
*Please use PCD Insert for traverse machining.
Grooving(Traversing is possible)
φ
ε
ε
φ
S
θ
Traversing / Grooving
h H1
φDma
x
h H1
φDma
x
1
KTKF Toolholder
KTKF Toolholder
Fig.6 When a TKF-AS insert is attached (The cutting edge is 1 mm lower than the center line.)
Fig.7 When a TKF-NB insert is attached
+0-0.05
H
θ
S±0.03
rεW
rε φd
T
B
D/2
Note1) The cutting edge of the TKF..-AS will be 1 mm lower than the center line when attached to the KTKF toolholder (See Fig.6). Adjust the height by making NC lathe parameter settings or inserting a plate.2) If the 1 mm adjustment is not possible,
use the TKF. . -NB (See Fig.7).
● : Std. Item
App
licab
le T
oolh
olde
r
No.
of C
orne
rs
The KTKF holder can be used as a multi-functional
tool for non-ferrous metals and non metals when
combined with a TKF-AS insert (See Fig.5).
CBN & PCD Tools are sold in 1 piece boxes.
Cut
-off
H
H10
Cut-Off Toolholders (for sub spindle tooling)
1 øDsm
ax
Main spindle
Sub spindle
1
Main spindle
øDsm
ax Sub spindle
Fig.1 Fig.2
● As Fig.1 shows, use KTKFL (L-hand) for the distance between main spindle and sub spindle.● As Fig.2 shows, KTKFS is recommended for small diameters and for the short distance between the main spindle and sub
• As Fig.2 of H8 shows, the cutting diameter of the insert is indicated when the top of the cutting edge progresses 1mm from the center. • Lead angle shows the angle when installed in toolholder.
■ How to use small diameter cut-off tool• Both Right-handed and Left-handed types are applicable to gang tool post.• Basically the Left-handed type is used for cut-off operations using a sub-spindle.
• When machining workpiece with small diameter, use KTKFS to reduce overhang distance from the main spindle.
R-hand
Mai
n S
pind
le <Recommendation>Use insert with lead angle
to remove boss.
・Not using sub spindle・Cut-off operation near main spindle side
KTKFR type
KTKFSL (L-hand)
<How to select>L-hand
・Short workpiece and less rigidity・Cut-off operation near sub spindle side
L3 dimension ・Sub Spindle Dia.
ø40→22(A type)ø50→26(B type)
A
B
Mai
n S
pind
le
Sub
spi
ndle
L3
L-hand
<Recommendation>Use insert without
lead angle.
・Using sub spindle・Cut-off operation near sub spindle side
KTKFL type
Mai
n S
pind
le
Sub
spi
ndle
A
B
KTKFSR (R-hand)
<How to select>R-hand
・Long workpiece and more rigidity・Cut-off operation near main spindle side
L3 dimension ・Sub Spindle Dia.
ø40→22(A type)ø50→26(B type)
Mai
n S
pind
le
Sub
spi
ndle
L3
Inserts are sold in 10 piece boxes.
H
Cut
-off
● : Std. Item □ : Check Availability
H12
⑧Chipbreaker SymbolPM : Cut-OffPH : Groove and Cut-off
Note) 1. Using the PM chipbreaker (for cut-off) for grooving cannot create a fl at bottom (See the right fi gure).
Cut
-off
H
● : Std. ItemInserts are sold in 10 piece boxes.
Groove bottom created by PM chipbreaker
③No. of edge(blank) : 2-edge S : 1-edge
⑤ Insert Length20 : 20mm
⑦Corner-R(rε)0.20 : 0.2mm
0.25 : 0.25mm0.30 : 0.3mm
②AccuracyM : Class M
④Width20 : 2mm30 : 3mm40 : 4mm
⑥Hand of Tool R : R-hand N : Neutral
G D M 30 6DPM-①Series
Newly groovingGD series
-S 20 R 025⑨Lead Angle
Without Indication : 0° 6D : 6°
◆ Indication of Description
Cut-Off Inserts
■ GDM / GDMS
Handed Insert shows R-hand.
H
L
M rε
rεW±0
.031.5°
1.5°
M
L W±0
.03
1.5°
1.5°
H
rε
Ref.
Page
for T
oolh
olde
r
Cut
-off
Gro
ovin
g an
d C
ut-o
ff
Tolerance
H13
C45 (S45CF) 〈Result〉・The cutting edge of KGD Cut-off PM Chipbreaker (PR1225) shows good condition even after processing the same number of workpiece as Competitor L.・Longer product life can be expected.(Competitor L suffered from chipping of cutting blade).
◆ Caution(Cut-Off)1.Be sure to perform wet processing. Apply enough coolant to the cutting edge.2.Keep a constant rate during processing so that optimal product life will be achieved.3.Cut off as close to the chuck as possible.4.Lower the feed rate to 1/2 to 1/3 at the near center to prevent impact caused by cutting.
250pcs/edge Chipping occurred
250 pcs/edge Can be extended
■ Case Studies (Cut-Off)
3~4
2
0.1 0.2 0.3
WidthWidth
(mm)
PH ChipbreakerPH Chipbreaker
f (mm/rev)f (mm/rev)Feed RateFeed Rate
(Carbon Steel S50C))
2~4
0.1 0.2 0.3
PM Chipbreaker (Carbon Steel S50C))
f (mm/rev)f (mm/rev)Feed RateFeed Rate
WidthWidth
(mm)
◆ Example of feed
For General Use
PM
High feed rate
PH
High
Low
Cutti
ngRe
sista
nce
LargeSmall Feed Rate
[■ in the graph indicates the center value of feed (f)]
Note)1. Dimension T : Maximum depth to which processing can be made. (If the dimension T is 20 mm or more, the maximumgroove-depth made by the 2-edged insert will be 18 mm.)
Note) 1. In case of normal mounting position, the toolholder body may interfere with the tool presetter. 2. To olholder description and blade description are printed on the toolholder body. (Unit description is not indicated.)
KGD-S : R-hand Blade for R-hand Toolholder, L-hand Blade for L-hand Toolholder.Combination of the optional toolholder (KGD..-C) and blade (KGD..T..-C) (both separately sold) can make up the corresponding assembly part. Make sure of the “hand of toolholder” and “hand of blade”.
3. Dimension T: Maximum depth to which processing can be made. (If the dimension T is 20 mm or more, the maximum depth of groove made by the 2-edge insert will be 18 mm.)
4. Recommended tightening torque of clamp bolt for insert: 6.5N•m (Groove width 2 - 6 mm)
Recommended Cutting Conditions H13
Wid
th
(mm
)
Avai
labl
e G
roov
ing
D
epth
(mm
)
Sha
nk A
ngle
H16
Cut
-off
H
Cut-Off Inserts
Classification of usage P Carbon Steel / Alloy Steel ○ P Q P Q
• Sharp Edge Spec. can reduce cutting resistance by 40% compared to chamfer edge.
Series Advantage
GMM-MT Specific chipbreaker for cut-off operations requiring sharp cutting performance.Minimizes the Boss.
GMM-NB Cutting edge is flat with no chipbreaker.Good performance for brass, etc.
GMM-TKStable design with chipbreaker for cut-off.Large corner-R.2-edge for economical performance.
GMN-TKSame chipbreaker geometry as GMM-TK.1-edge.Wide application range.
GMN (Std.) Mainly for deep grooving, but available for groove widening and turning due to projection near side cutting edge.1-edge and wide application range. Available for cut-off applications.
● TMR-Chipbreaker enables stable chip control also for high feed rates.
Good chip control even when cutting speed (spindle revolution) is increased.
● Workpiece Surface RoughnessTMR-Chipbreaker provides good surface roughness on the workpiece end face at high feed rate ranges.
Chip width < grooving width
Improved chip evacua-tion by squeezing chips
Special Curve Wall
Cut
ting
Spe
ed V
c (m
/min
)
f (mm/rev)
TMRChipbreaker
Application Range
2
4
6
8
Rou
ghne
ss R
z (μ
m)
f (mm/rev)
(Vc=200m/min)
2
4
6
8
Rou
ghne
ss R
z (μ
m)
f (mm/rev)
(Vc=200m/min)・ GMM2020R-TMR-6D ・ GMM2020-TMR
GMM2020R-TMR-6DCompetitor's Chipbreaker A
GMM2020R-TMRCompetitor's Chipbreaker A
Depression in center of cutting edge.
H18
Cut
-off
H
Cut-Off Toolholders
H3
H1
φDma
x
5°
F1
KGM&1616 A
hH3
L2
L1
H4
H2
H1
B
W
■ KGM (For automatic lathe)
● Right-hand shown
Edge Width: 1.5~4.0mm
• 4.0mm width Insert can be installed in KGM&1212H-3, but is not recommended due to the toolholder's rigidity.• Dimension T shows the distance from the Toolholder to the cutting edge.
• Dimension T shows the distance from the Toolholder to the cutting edge. See the Table (H20) for the relationship between the Grooving Depth and the Cutting Dia..• When using GMG / GMM type (2-edge) Insert, set the grooving depth under 15mm.
● ● R ●2 2.2 0.20 R ● ● R ●2.4 2.4 0.20 ● ● R ●3 3.1 0.25 R ● ● ● ●4 4.1 0.30 R ● ● ●5 5.1 0.30 ● ● ●
TK& 1.6-P2-P3-P
1.62.23.1
0.200.200.25
8°R
RRR
●●●
RRR
RRR
◆ Cut-Off Tools
CVDCoated Carbide
PVDCoated Carbide
Carb
ide
For recommended cutting conditions, see page H25
Inserts are sold in 10 piece boxes
Handed Insert shows Right-hand
Cermet
● : Std. Item □ : Check Availability R : Std. Item (R-hand Only) L : Std. Item (L-hand Only)
H22
Cut
-off
H
Cut-Off Blades
7゜
φD
150゜A
H h
W
L
hH
W
150゜
B
A
7゜
φD
L
W
KTKBRKTKB
15゜
15゜
150゜
hH
A
B
φD
A
hH
W
L
● Blade Dimensions
■ KTKB-S / KTKB-SS
Note) 1. Suffix “-SS” means silver coating.2. Releasing wrench is “LTK-5”.
* Dimension H shows virtual apex distance.
Fig.1
Fig.2 Fig.3
◆ How to install toolblock and blade.
Datum Plane
●Incorrect way
●Correct way
Datum Plane
●Incorrect Setting of Clamp Element
Inco
rrec
t Edg
e H
eigh
tE
dge
Hei
ght
If the clamp element is mounted backwards, a largegap will occur between the clamp and the toolblockand the blade may come off during cutting. Becareful when installing the clamp for safety reasons.
■ Alternative Toolholder Reference Table for Cut-off Toolholder (KTKF / KGM)
Note) The corresponding alternative toolholder may be different from the conventional toolholder in insert clamping system or insert size. Make sure of their specifications by referring to the catalog or other documents.
KGMR 1010JX-2 φ20 Processing diameter is small.KTKH& 1212M-2-150S φ30 KGM& 1212JX-2 φ25 Processing diameter is small.KTKH& 1616M-2-150S φ36 KGM& 1616JX-2 φ32 Processing diameter is small.KTKH& 1616M-3-150S φ45 KGM& 1616JX-3 φ32 Processing diameter is small.
■ Alternative Toolholder Reference Table for Cut-off Toolholder (KTKH-B / KTKH-S)
Note) The corresponding alternative toolholder may be different from the conventional toolholder in processing diameter or insert size. Make sure of their specifications by referring to the catalog or other documents.