Rhino-Feed Cutting Tool Reference & Technical Info

Operating Instructions

Operating Instructions for Mini-Feed Inserts

Operating Instructions for Mini-Feed InsertsMini-feed inserts have the smallest IC (inscribed circle) and smallest cross section. It is suggested to run a good common-sense combination of feed and DOC with these inserts. When running a light DOC, the higher end of the feed range is acceptable. When running heavier DOC, use the lower to middle feed ranges. Index inserts promptly upon visible wear to avoid breakage.

If cutting at .025" DOC and trying for a .007" chip thickness, multiply .007" x 4 = .028" FPT.

Compensated FPT:
Dapra's mini-feed inserts have a 4x chip thinning factor. The compensated FPT recommendation of .012-.032" represents an actual chip thickness of .003-.008".

Operating Instructions for Mid-Feed Inserts

Operating Instructions for Mid-Feed InsertsMid-feed inserts have a stronger cross-section than the mini-feed, but are smaller than the heavy-feed. These are great general-purpose inserts best suited for lighterduty (40-taper, linear ways, etc.) machines. Run faster feeds with lighter DOC in most situations. In heavier DOC, run the lower to middle area of the feed ranges.

If cutting at .030" DOC and trying for a .010" chip thickness, multiply .010" x 5 = .050" FPT.

Compensated FPT:
Dapra's mid-feed inserts have a 5x chip thinning factor. The compensated FPT recommendation of .020-.060" ("T") and .015-.050" ("D") represents an actual chip thickness of .004-.012" and .003-.010", respectively.

Operating Instructions for Heavy-Feed Inserts

Operating Instructions for Heavy-Feed InsertsHeavy-feed inserts have the strongest cross-section of the RHINO-FEED line. Heavy-feed inserts are suitable for heavier DOC and larger machines (50-taper, box ways, etc). For optimum performance, use good combinations of heavier DOC with light-to-middle FPT, or lighter DOC with heavier FPT.

If cutting at .030" DOC and trying for a .010" chip thickness, multiply .010" x 5 = .050" FPT.

Compensated FPT:
Dapra's heavy-feed inserts have a 5x chip thinning factor. The compensated FPT recommendation of .025-.070" ("T") and .020-.055" ("D") represents an actual chip thickness of .005-.014" and .004-.011", respectively.

Application Information

Application Information for Rhino-Feed CuttersRecommendations

Technical Considerations

Safety

Modern metal cutting techniques involve the potential use of very high operating parameters (speeds, feeds, depths of cut, etc.). This creates the potential for flying chips and debris, and can also create tool breakage due to a variety of causes. As such, any metal cutting operation should be executed in a completely enclosed (shielded) environment to protect against injury from flying objects. Dapra does not assume responsibility for any loss, damage or expense incurred in any use or handling of our products after purchase.

Grinding produces hazardous dust. To avoid adverse health effects, use adequate ventilation and read material safety data sheet first.

Hole Diameter Calculation

Hole Diameter CalculationHelical Interpolation for Larger Diameter Hole Making

Larger diameter hole making can be quick and easy when a RHINO-FEED Cutter is used in combination with helical interpolation. This technique resembles thread milling in that all three axes (X, Y and Z) are in motion simultaneously. It differs from thread milling in that the tool is introduced into the material without a start hole of any kind. The tool simply is positioned at the inside diameter of the hole to begin its helix from there, achieving complete material removal from the hole by ramping down to the final depth. This smooth operation tends to avoid the high horsepower consumption characteristic of large diameter hole making. This quick and easy process offers the added advantage of allowing many different hole sizes to be generated with the same diameter tool. Hole size variation is all in the programming.

For more information on how helical interpolation can improve your manufacturing efficiency, contact your Dapra Applications Specialist.


Mini-Feed
(R2 – 8mm IC)
Holder Minimum Hole Dia.
HFEM050-150-R2-1 .65"
HFEM050-250-R2-1 .65"
HFEM063-200-R2-1 .78"
HFEM063-300-R2-1 .78"
HFEM075-MOD-R2-2 1.09"
HFEM075-200-R2-2 1.09"
HFEM075-300-R2-2 1.09"
HFEM100-250-R2-3 1.58"
HFEM100-450-R2-3 1.58"
HFEM100-MOD-R2-3 1.58"
Mid-Feed
(R3 – 10mm IC)
Holder Minimum Hole Dia.
HFEM100-250-R3-2 1.375"
HFEM100-450-R3-2 1.375"
HFEM100-MOD-R3-2 1.375"
HFEM125-300-R3-3 1.875"
HFEM125-500-R3-3 1.875"
HFEM125-MOD-R3-3 1.875"
HFEM150-350-R3-3 2.375"
HFEM150-550-R3-3 2.375"
HFEM150-MOD-R3-3 2.375"
HFSM200-075-R3-5 3.375"
HFSM300-100-R3-6C 5.375"
Heavy-Feed
(R4 – 12mm IC)
          Holder           Minimum Hole Dia.
HFEM125-300-R4-2 1.75"
HFEM125-500-R4-2 1.75"
HFEM150-350-R4-3 2.25"
HFEM150-550-R4-3 2.25"
HFSM200-075-R4-4 3.25"
HFSM200-075-R4-5 3.25"
HFSM250-100-R4-5 4.25"
HFSM300-100-R4-6 5.25"
HFSM400-150-R4-8 7.25"
HFSM500-150-R4-8 9.25"
HFSM600-200-R4-9 11.25"

 

Maximum Hole Dia.* = Tool Dia. x 2

* Not generally recommended. At this diameter, the center tip is at its maximum. It is suggested that you stay slightly under this number.


Recommended Cutting Speeds & Feeds for Rhino-Feed Cutting Tools

Rhino-Feed Recommended Cutting Speeds

Click here or on the chart above for a larger version (opens in a new window).

The best choice for each material is shown in bold text.

The parameters provided are suggested operating parameters. Actual speeds and feeds will depend on many variables, such as rigidity, workpiece hardness, tool extension, machine accuracy, Depth of Cut, etc. Start at the middle of the SFM range and the low end of the FPT range. Next, increase FPT to optimize productivity and tool life. Higher SFM will provide higher output but may reduce tool life. Try different combinations to find the parameters that best suit your needs.

This chart is also part of our Rhino-Feed catalog PDF.

Insert Grade Selection

Rhino-Feed Insert Grade Selection
Shock & Wear Resistance Uncoated (Base Grade) with Coating Description Specifications
TOUGHEST
Shock Resistance
DMK30 Moderate wear resistance/high shock resistance. Recommended for interrupted or unstable steel, most 300 series stainless steel, high-temperature alloys and cast iron applications. ANSI C1-C2, ISO K25-K40, M25-M35
NEW DMK30-TCI High-performance medium- to high-temperature grade. Outstanding wear resistance in steels, irons and stainless steels. Best suited for materials < 44 Rc.
DMK30-GLH Premium high-temperature coating. Best resistance to heat for high-shock applications. Excellent for tough stainless steels, high-temperature alloys and many tool steels.
MEDIUM
Shock and Wear
DMK25 Micro-grain carbide providing higher wear resistance and good shock resistance for applications in tough stainless steels, high-temperature alloys, irons and many tool steels. ANSI C2-C3, ISO K15-K30, M15-M30
  DMK25-GLH Premium high-temperature coating. Outstanding performance and wear resistance in high-heat applications involving tough stainless steels, high-temperature alloys and many tool steels.
MEDIUM
Shock and Wear
DMP25 High wear resistance/moderate shock resistance. Recommended for most steel and ductile iron applications. ANSI C5-C6, ISO P25-P40
NEW DMP25-TCI High-performance medium- to high-temperature grade. Outstanding wear resistance in steels and ductile. Best suited for materials < 44 Rc.
DMP25-GLH Premium high-temperature grade. Unbeatable performance and wear resistance in high-heat applications such as higher-speed machining in steels (< 44 Rc) and ductile irons.
NEWHARDEST
Wear Resistance
DMK15 Highest wear resistance with reduced shock absorption capabilities. Micro-grain carbide provides excellent edge strength. Suitable for all materials under stable conditions. ANSI C2-C3 ISO K15-K25, M15-M25
  DMK15-TCI High-performance medium- to high-temperature grade. Great for higher-speed grey iron applications and lighter cuts in steels or ductile iron.
DMK15-GLH Premium high-temperature grade for optimum wear resistance in cast irons and steel hard milling > 44 Rc.

DMK30-HP is a good first choice for most applications.

Additional coatings available on request. Contact Dapra for details.

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