KYOCERA DA2090MGMPR1535 Replaceable Tip Drill Insert User Manual

Introduction

This manual provides essential information and instructions for the safe and effective use of the KYOCERA DA2090MGMPR1535 Replaceable Tip Drill Insert. Designed for high-performance drilling, this carbide insert features a Megacoat finish and is optimized for steel applications, offering long tool life and stable machining. Adherence to these guidelines will ensure optimal performance and longevity of the product.

A close-up view of the KYOCERA DA2090MGMPR1535 replaceable tip drill insert, showcasing its carbide construction and Megacoat finish. The image highlights the cutting edges and the overall design of the insert.

Product Features

• Replaceable tip insert compatible with the Kyocera DRA Magic Drill system.
• Engineered for high-performance drilling specifically in steel applications.
• Facilitates easy and efficient insert replacement, minimizing downtime.
• Designed for fine chip breaking, even during deep hole drilling operations.
• Features MEGACOAT NANO PVD Grades for extended tool life and stable machining performance.

Setup and Installation

Proper installation of the drill insert is crucial for safety and optimal performance. Always wear appropriate personal protective equipment (PPE) such as safety glasses and gloves during installation.

1. Inspect Components: Before installation, carefully inspect the drill body and the new DA2090MGMPR1535 insert for any damage or defects. Ensure the seating surface on the drill body is clean and free of debris.
2. Position the Insert: Align the replaceable tip insert with the corresponding pocket on the Kyocera DRA Magic Drill body. Ensure the insert sits flush and correctly oriented.
3. Secure the Insert: Use the recommended clamping screw and torque wrench to secure the insert. Refer to the specific torque specifications provided by Kyocera for the DRA Magic Drill system to prevent over-tightening or under-tightening, which can lead to insert damage or instability.
4. Verify Stability: After tightening, gently check the insert for any movement. It should be firmly seated without any play.
5. Initial Run: Perform a brief, low-speed test run to confirm proper installation and stability before commencing full operation.

Operation Guidelines

To achieve the best results and ensure safety, follow these operational guidelines when using the KYOCERA DA2090MGMPR1535 drill insert:

• Material Compatibility: This insert is specifically designed for steel and alloy steel applications. Using it on incompatible materials may lead to premature wear or failure.
• Cutting Parameters: Always adhere to the recommended cutting speeds, feed rates, and depth of cut provided by Kyocera for the specific material and machine setup. These parameters are crucial for optimal chip breaking and tool life.
• Coolant Application: Utilize appropriate coolant/lubricant to dissipate heat, lubricate the cutting zone, and aid in chip evacuation. Ensure adequate flow to the cutting edges.
• Vibration Control: Minimize machine vibration to prevent premature insert wear and improve surface finish. Ensure the workpiece is securely clamped.
• Chip Evacuation: Monitor chip formation and evacuation. The design promotes fine chip breaking, but ensure chips are effectively removed from the hole to prevent recutting and tool damage.

Maintenance

Regular maintenance ensures the longevity and consistent performance of your KYOCERA DA2090MGMPR1535 drill insert.

• Inspection: Periodically inspect the insert for signs of wear, chipping, or damage. Replace inserts promptly when wear limits are reached to prevent catastrophic failure or damage to the drill body.
• Cleaning: After use, clean the insert and drill body to remove any accumulated chips, coolant residue, or debris. Use a soft brush and appropriate cleaning agents.
• Storage: Store unused or spare inserts in their original packaging in a dry, clean environment to protect them from corrosion and physical damage.
• Drill Body Maintenance: Regularly check the drill body for wear in the insert pocket or clamping mechanism. A worn drill body can lead to poor insert seating and reduced performance.

Troubleshooting

This section addresses common issues that may arise during the use of the drill insert and provides potential solutions.

• Issue: Premature Insert Wear
  Possible Causes: Incorrect cutting parameters (speed, feed), insufficient coolant, excessive vibration, wrong material application.
  Solution: Adjust cutting parameters according to recommendations, ensure adequate coolant flow, check machine rigidity and workpiece clamping, verify material compatibility.
• Issue: Poor Chip Evacuation / Long Chips
  Possible Causes: Incorrect feed rate, insufficient coolant pressure, worn insert.
  Solution: Increase feed rate within recommended limits, optimize coolant delivery, replace worn insert.
• Issue: Poor Hole Quality / Surface Finish
  Possible Causes: Worn insert, excessive vibration, incorrect cutting parameters, unstable setup.
  Solution: Replace insert, reduce vibration, optimize cutting parameters, ensure rigid machine and workpiece setup.
• Issue: Insert Breakage
  Possible Causes: Excessive feed rate, impact, insufficient clamping, material hardness variations.
  Solution: Reduce feed rate, ensure smooth entry/exit, verify proper insert clamping torque, check material consistency.

Technical Specifications

Warranty and Support

KYOCERA products are manufactured to high standards of quality and performance. For specific warranty information regarding the DA2090MGMPR1535 Replaceable Tip Drill Insert, please refer to the documentation provided with your purchase or visit the official Kyocera Precision Tools website. For technical support, product inquiries, or assistance with troubleshooting, please contact Kyocera customer service directly. Contact details can typically be found on the manufacturer's website or product packaging.

Manufacturer Website: www.kyocera-cuttools.com