High-efficiency Multi-edge Cutter for Cast Iron

High-efficiency, multi-edge cast iron machining cutter

MFK• Reduces chattering, achieving a superior surface finish

• 10-cornered pentagonal inserts for stable and economical machining

• Two special insert structures reduce cutting force and improve edge strength

• Multi-edge design is ideal for high-efficiency and high-feed cast iron machining

Reduces chattering and maintains sharpness even using negative type of insert

New CVD-grade CA420M for longer tool life

Wiper insert for finishing is available

Milling MFK

1

MFKMulti-edge cutter achieves high-efficiency cast iron machining10-cornered pentagonal inserts for stable and economical machining

MFK Competitor ASharp cutting prevents

burr formation

Superior design of the MFK reduces cutting forceReducing chattering as well as achieving better surface finish

Two special insert structures reduce cutting force and improve edge strength

Low cutting force with helical cutting edge designPOINT 1 Fractures reduced by the

double-edge constructionPOINT 2

■Surface finish comparison ■Burr comparison

Cutting ConditionsWorkpiece: FCD600, Dry, VC=180m/min, fZ=0.3mm/t, ap×ae=3×78mm

Cutting Conditions

Workpiece: FCD450 with 4 bores

Vc=300m/min fz=0.5mm/t ap=2.0mm Wet

Cutting ConditionsWorkpiece: FCD600, Dry, f125

Vc=180m/min, fz=0.3mm/t, ap×ae=3.0×62mm

• Cutting Force Comparison

Reduces impact load when cutter engage with workpiece

• Fracture Resistance Comparison

Two points

MFK Type

Resultant force in radial direction Resultant force in axial direction

3000

2500

2000

1500

1000

500

0

[N] [N]

Cut

ting

Forc

e

Cut

ting

Forc

e

1000

800

600

400

200

0

7% DOWN 16% DOWN

Competitor C MFK Type Competitor D0 5 10

Cutting Time (min)

CA42

0MPR

1510

（C

VD）

（C

VD）

Competitor E

Competitor F

MFK Type

15 20 25

MFK Type

Competitor B

Cutting direction

BurrRough surface resulting from chattering

Second main cutting edge

First main cutting edge

A.R. Max. +15°

2

■ Insert grade lineup

Comes in fine-pitch type and extra fine-pitch typeChoose most suitable cutter for your application

CRIOS Technology is Kyocera's original CVD coating technologyConventional

Conventional

Kyocera's unique crystal control technology and advanced film adhesion lead CVD coating to the next stage

Advanced CVD coating revolutionizes common practice

Longer tool life Prevents film peeling Controls chipping

Carbide substrate

TiCN layer

Control α-Al2O3 crystal growth to improve wear resistance

and fracture resistance

Optimized interface improves film adhesion by 40%

High aspect ratio TiCN layer improves film strength and

fracture resistance

■ Holder lineup for various applications

■ An abundant lineup of chipbreakers for a wide variety of applications

■ New milling CVD-grade CA420M provides long tool life and stable machining

■ Wear resistance comparison

General use: GM Chipbreaker

Finishing: GL ChipbreakerGround

Strong edge: GH Chipbreaker

Wiper edge: W ChipbreakerGround

0 10 20 30 40 50

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0

Cutting Time (min)

Fracture

Wea

r （m

m）

CA420MCompetitor G

Cutting ConditionsWorkpiece: FCD450, Dry

Vc=200m/min, fz=0.3mm/t, ap×ae=2.0×80

Fine-pitch (Example : f125 12 inserts)

• Recommended for low rigidity workpiece

• Handles a wide range of machining applications

Extra Fine-pitch (Example : f125 18 inserts)

• Recommended for high rigidity workpiece

• For high-efficiency machining

CA420M Long tool life

(1st recommendation)

PR1510 Stable machining

PR1525 Fracture resistance

3

MFK

■ MFK Face Mill

Fig.1 Fig.2

Fig.3 Fig.4

φ C φ D1φ D

S

G

φ d4

φ d3b

aE

φ d

H

φ D1φ D

S

φ d1

φ d

b

aE

H

φ D1φ Dφ d2

φ d1

φ dφ D2 φ D2

b

aE

S

H

φ D1

φ DC1C

S

φ d6

φ d5

φ d4

φ d3

G

b

aE

φ d

H

φ d1

φ d1

70

70

7070

φ D2 φ D2

Rake Angle (°)

Description A.R. R.R.

MFK080R-

(MAX.)+15°

-7°

MFK100R- -6°

MFK125R-

…

MFK315R--5°

Spare Parts and Applicable Inserts

Description

Spare Parts

Applicable Inserts Description

Spare Parts

Applicable Inserts

Wedge Wedge screw

Wrench Mounting Bolt

Wedge Wedge screw

Wrench Mounting Bolt

MFK 080R-11-8T

C09N W6X18N TT-15

HH16X40

PNMG1106XNEN-GMPNMG1106XNEN-GHPNEG1106XNEN-GLPNEG1106XNER-W

MFK 080R-11-8T-M

C09N W6X18N TT-15

HH12X35

PNMG1106XNEN-GMPNMG1106XNEN-GHPNEG1106XNEN-GLPNEG1106XNER-W

100R-11-10T 100R-11-10T-M HH16X40

125R-11-12T

–

125R-11-12T-M

–

160R-11-16T 160R-11-16T-M

200R-11-20T 200R-11-20T-M

250R-11-24T 250R-11-24T-M

315R-11-28T 315R-11-28T-M

MFK 080R-11-10T

C09N W6X18N TT-15

HH16X40

PNMG1106XNEN-GMPNMG1106XNEN-GHPNEG1106XNEN-GLPNEG1106XNER-W

MFK 080R-11-10T-M

C09N W6X18N TT-15

HH12X35

PNMG1106XNEN-GMPNMG1106XNEN-GHPNEG1106XNEN-GLPNEG1106XNER-W

100R-11-14T 100R-11-14T-M HH16X40

125R-11-18T

–

125R-11-18T-M

–

160R-11-22T 160R-11-22T-M

200R-11-28T 200R-11-28T-M

250R-11-36T 250R-11-36T-M315R-11-44T 315R-11-44T-M

Toolholder Dimensions

Bore Dia.

Description StockNo. ofinserts

Dimension (mm)Drawing

Weight (kg)fD fD1 fD2 fd fd1 fd2 H E a b s fd3 fd4 fd5 fd6 fC fC1 G

Inch

Sp

ec

Fin

e-p

itch

MFK 080R-11-8T 8 80 89 7631.75 26 17

63

32 8 12.7

6.0

– –

– –

–

–

–

fig.11.76

100R-11-10T 10 100 109 96 2.98

125R-11-12T 12 125 134100

38.1 55

–

3810 15.9

fig.23.65

160R-11-16T 16 160 169 50.8 70 11 19.1 4.62

200R-11-20T 20 200 209142

47.625 110 40 14 25.4 18 26 101.6 32fig.3

7.65

250R-11-24T 24 250 259 10.73

315R-11-28T MTO 28 315 324 220 22 32 177.8 fig.4 19.71

Ext

ra F

ine-

pitc

h

MFK 080R-11-10T 10 80 89 7631.75 26 17

63

32 8 12.7

6.0

– –

– –

–

–

–

fig.11.70

100R-11-14T 14 100 109 96 2.85

125R-11-18T 18 125 134100

38.1 55

–

3810 15.9

fig.23.44

160R-11-22T 22 160 169 50.8 70 11 19.1 4.44

200R-11-28T 28 200 209142

47.625 110 40 14 25.4 18 26 101.6 32fig.3

7.40

250R-11-36T 36 250 259 10.36

315R-11-44T MTO 44 315 324 220 22 32 177.8 fig.4 19.21

Met

ric

Sp

ec

Fin

e-p

itch

MFK 080R-11-8T-M 8 80 89 76 27 20 13

63

24 7 12.4

6.0

– –

– –

–

–

–fig.1

1.87

100R-11-10T-M 10 100 109 96 32 26 17 28 8 14.4 2.99

125R-11-12T-M 12 125 134100 40

55

–

33 9 16.4 fig.23.56

160R-11-16T-M 16 160 169 70 14 20 66.7 28 4.51

200R-11-20T-M 20 200 209142

60 110 40 14 25.7 18 26 101.6 32fig.3

7.35

250R-11-24T-M 24 250 259 10.43

315R-11-28T-M MTO 28 315 324 220 22 32 177.8 fig.4 19.41

Ext

ra F

ine-

pitc

h

MFK 080R-11-10T-M 10 80 89 76 27 20 13

63

24 7 12.4

6.0

– –

– –

–

–

–fig.1

1.81

100R-11-14T-M 14 100 109 96 32 26 17 28 8 14.4 2.86

125R-11-18T-M 18 125 134100 40

55

–

33 9 16.4 fig.23.38

160R-11-22T-M 22 160 169 70 14 20 66.7 28 4.32

200R-11-28T-M 28 200 209142

60 110 40 14 25.7 18 26 101.6 32fig.3

7.10

250R-11-36T-M 36 250 259 10.07

315R-11-44T-M MTO 44 315 324 220 22 32 177.8 fig.4 18.92

: Std. Item MTO : Made To Order

4

MFK

■ Applicable Inserts

■ Recommended Conditions

■ Recommended application range

Insert DescriptionDimension (mm) CVD Coated

CarbideMEGACOAT

NANO

A T X Z CA420M PR1510 PR1525

General

A

X

Z

T

PNMG1106XNEN-GM

17.23

6.35

2.0 2.0

● ● ●

Tough edge

A

X

Z

T

PNMG1106XNEN-GH ● ● ●

Surface-finish Oriented

T

A

X

Z PNEG1106XNEN-GL 17.18 2.6 2.6 ● ● ●

Wiper insert (2-edge)

X

Z

A

T

PNEG1106XNER-W 18.02 2.0 10.0 ● ● ●

Workpiece Material Insert Grade Cutting Speed (m/min) Chipbreakersfz (mm/t) Feed per tooth

0.06 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Gray Cast IronFC

CA420M 170~230~300 GM★ ●0.25

PR1510120~180~250

GH✩ ●0.3

PR1525 GL ●0.12

Nodular Cast IronFCD

CA420M 150~200~250 GM★ ●0.2

PR1510100~150~200

GH✩ ●0.25

PR1525 GL ●0.1

NotesWhen using W type, please use together with GM or GH.If machining over fz=0.2, damage of insert corner will increase. Length of main cutting edge for W type insert is lower than that of the GM and GH.Therefore, the feed rate for the insert next to W type is double of the other inserts.

Workpiece : FC Workpiece : FCD

● : Std. Item

GL GM

W

GH

fz (mm/t)

ap (m

m)

6.0

4.0

2.0

0.1 0.2 0.3 0.4fz (mm/t)

ap (m

m)

GL

GM

W

GH6.0

4.0

2.0

0.1 0.2 0.3 0.4

CP333EN

■ Case Studies

FC300

2.2m

10m

• Bed• Vc=150m/min• fz=0.26mm/t (Vf=1,242mm/min)• ap×ae=3×100mm

• Dry• MFK160R-11-16T (16 inserts)• PNMG1106XNEN-GM (CA420M)

CA420M Chip Removal Rate = 372cc/min

4 times the efficiency!

Conventional K (8 inserts)

Chip Removal Rate = 93cc/min

CA420M improved efficiency by 4 times compared with Conventional K.

FC250

720 1,000

• Machine base• Vc=160m/min• fz=0.16mm/t (Vf=782mm/min)• ap×ae=3×100mm

• Dry• MFK125R-11-12T (12 inserts)• PNMG1106XNEN-GM (PR1510)

PR1510 Chip Removal Rate = 235cc/min

Double the efficiency!

Competitor H (12 inserts)

Chip Removal Rate = 125cc/min

Low noise and minimal vibration even when cutting speed and feed rate are increased.

FCD600

• Mold part• Vc=90m/min• fz=0.34mm/t (Vf=974mm/min)• ap×ae=2×~60mm

• Dry• MFK080R-11-8T (8 inserts)• PNMG1106XNEN-GM (PR1525)

PR1525 Machining efficiency: 3 pcs/edge

Triple the tool life!

Competitor J (8 inserts)

Machining efficiency: 1 pcs/edge

Competitor J had chipping after machining 1 piece. The PR1525 maintained its sharp edge and stable machining even after machining 3 pieces.

FC250

800 800

• Base• Vc=160m/min• fz=0.18mm/t (Vf=917mm/min)• ap×ae=3×140mm

• Dry• MFK200R-11-20T (20 inserts)• PNMG1106XNEN-GM (CA420M)

CA420M Chip Removal Rate = 385cc/min

Efficiency 2.3 times greater!

Competitor I (12 inserts)

Chip Removal Rate = 167cc/min

The CA420M improved efficiency by 2.3 times while maintaining quiet, stable machining.