Technological Features FREUD

Freud products are superior tools because they are made using the most advanced technology, with premium quality materials and highly qualified staff. EUROPEAN NORM EN 847-1 For 2002, the standard cutterhead programme has been re-designed and renewed, based on the new european norm UNI EN 847-1, to eliminate and reduce dangers that may derive from these tools. In the case of manual feed, the kick-back effect is greatly reduced and easily controlled by the operator, in case of physical contact with the tool, serious injury to the operator is minimized. Tools that conform to these norms have “MEC” or “MAN” incisioned on to them and are to be used respectively on machines with mechanical or manual feed. The fundamental modifications carried out on our tools are the following • to reduce the risk of injury, our tools are constructed with a “closed form” and an anti kick-back device with limited projection; • pins have been added to stop each single component of the group, from rotating individually; • large openings for better chip distribution have been revisioned and deflectors for inserts are forseen. TECHNICAL FEATURES OF TRADITIONAL CUTTERHEADS Freud’s exclusive HW used to construct each cutter, is produced according to the kind of work which the tool will undergo, in order to obtain the best duration and quality finish possible. Special instruments guarantee precision and therefore perfect replacement of the knives we produce without the need to modify the cutterhead even after prolonged use. The most characteristic angles of a cutterhead are: hook angle (α): depends on the type of material to be cut. wedge angle (β): this angle is a direct consequence of angles α and γ. clearance angle (γ): depends on the material to be cut and the thickness of the cutting edge. shear angle (ä): necessary to obtain a better penetration into the material to be cut and a gradual removal of the chips. When the tools have different diameters, this angle allows the hook angle to remain constant. The work piece finish is given by the surface roughness and depends on many factors: the feed rate, the tool’s RPM, if the tool cuts against or with the feed and the tool’s general geometry such as the hook, wedge and shear angles. The tool’s diameter also influences the work piece finish. If the feed rate and the tool’s RPM are the same, the pitch (P) will also be the same, therefore the depth and the surface roughness (h) is reduced as the diameter of the tool increases. The tool cuts "with the feed" when the rotation and feed direction are the same, the tool cuts "against the feed" when the rotation and feed direction are opposite. During the removal of the chips, two areas can be distinguished: A and B: area A is where the material is compressed if the rotation is "against the feed"; area B is where the tool penetrates the material and removes the chips. Every tool is designed by our research and development department based on the clients specific needs and the same technology is applied to manufacturing machines that, combined with highly specialised workers, allow precision levels never reached before in the woodworking field. Every tool is balanced to remove vibrations caused by bizarre distribution of the tool’s mass, harmful during the woodworking process. Three balancing operations are done: first on the single tool, second on the set and finally, the third, on the entire group of tools that will be fitted on the same spindle. The final tuning operation is done in the testing room and consists of simulating actual working conditions: each set is used to cut a wood sample of the requested profile. All of these testing phases allow FREUD to supply the Client with a product that is ready for use and immediately operational, allowing added savings for the Client . ADVANTAGES OF PERFORMANCE SYSTEM CUTTERHEADS Performance system knives are constructed in hard metal, which Freud produces in 6 grades of hardness, second to the material to be worked: soft and hardwoods, heavy, abrasive, chipboard, melamine, laminated, M.D.F. etc. It is possible to use HW with a high grade of hardness, so as to permit a superior hold of 30% more with respect to the HW used for brazed cutting edges destined to work very abrasive materials. Other than being a solution that practically substitutes brazed cutters, thanks to the interchangeability of the profiles on the same tool and the duration of the tool itself, there is a notable advantage and convenience when working on overhead CNC router machines, where machine stoppages can result costly: infact the changing of a used or damaged knife does not require the dismounting of the cutterhead from the machine, since it is sufficient to loosen the screw that holds it in place. Instead a brazed cutter must be completely changed and a substitute available to avoid time wastage. Freud has an entire range of tools with performance, standard or personalized knives for manual or overhead CNC router machines. The performance system results advantageous, even when confronted to traditional cutterheads, thanks to the easiness of sharpening, low operational cost and the need of no particular machinery (the use of a flat grinding wheel or surface grinding machine is sufficient) or specialized personnel. Even after sharpening, performance knives maintain their original profile and the tool’s cutting diameter, considering maximum loses of 0,15÷0,20 mm. Suggestions for correct sharpening on surface gr inding machine or flat grinding machine: 1) Fix support TA01M or TA02M onto the surface grinding machine or flat grinding machine. 2) Fix the knives with the screws that are supplied. 3) Procede with the sharpening of the entire set of knives. Use of abundant cooling liquid during sharpening is recommended. Use diamond grinding wheels  with the following characteristics: D6A2-C100-D54. On request, sharpening can be carried out at our premisses by simply sending us the complete set of knives and indicating on the order the code OPTAFF AA9. INSERTS AND SPURS The triangular spur is a component produced in HW to give the cutting edge a long life, used on cutterheads and on Performance tools to give a better finish on rebates. The width of the cutting surface (22 mm) and the position of the spur (positive hook angle) guarantees a perfect finish without leaving a trace (the length of the rebate is less than the length of the spur). Another important characteristic is the size of the chip discharge area in front of the spur: this allows excellent chip discharge and therefore the spur is more efficient . The rounding and bevelling inserts are used to remove sharp angles from the work piece. These inserts give a better quality finish allowing various wood coatings to deposit more uniformly. Inserts with a shear angle allow a better finish when the wood is cut across the grain. Inserts and their seats are manufactured with extreme precision and this allows them to be replaced without the need of spacing rings. The new and patented NSR ADJUSTABLE INSERT SYSTEM is the only one that allows adjustments without the need of measuring instruments. This particular system allows the inserts to be adjusted with precision of a hundredth of a millimetre on the entire length of the tool. The indelible reference marks are etched with extreme precision by lasers and allow a rapid and simple repositioning of the insert . shows the components. The inserts have a positive hook angle and a shear angle that allows an excellent finish on any type of material. The same seat can be fitted with rounding inserts (R= 1,5 - 2 - 3 mm) or bevelling inserts (3 mm x 45°). The rounding spur combines the characteristics of a rounding insert and a spur. With a single operation, the rebate is internally and externally rounded and finished. These solid carbide inserts are manufactured with various rebate depths to satisfy clients needs. Extremely good finish is guaranteed by the inserts shear - hook angle combination. In the same seats, different inserts can be fitted so that the same tool can cut rebates of different depths. Tools must be used and handled by experienced and trained personnel, in possesion of the necessary understanding. The maximum speed marked on the tool shall not be exceeded. Where stated, the speed range must be respected. Tools and tool bodies must be locked correctly, so they do not loosen during operation. When mounting tools, insure that locking reacts against the body and the cutting edges are not in contact with each other (Fig. 34) or with any other locking elements. Screws and nuts shall be tightened using the appropriate spanners etc. and to the torque value provided by the manufacturer. Spanner extensions or tightening using hammer blows is strictly forbidden. Do not use reduction rings with a bore different to those specified by the constructor. Clamping surfaces must be free of dirt, grease, oil and water. Resins must be removed from tools with light alloy bodies using cleaners that do not damage the aluminium and compromise the materials mechanical features. Accurately clean the tool after every knife change. Tools compiling a set, must be repaired by experienced and fully trained personnel, with the knowledge of the design requirements and security levels to be reached . Repairing tools is allowed only in accordance to the tool manufacturer’s instructions. Particular attention is drawn to the following: • Repair shall therefore include e. g. use of parts which are in accordance with the specification of the original parts provided by the manufacturer. • Tolerances which ensure correct locking shall be maintained.  After any type of maintenence work, a tool marked “MAN” must continue to respect the requirements imposed by the norm relative to tools with manual feed. Wearing glooves increases grip and reduces the risk of injury. To avoid injury, tools must be handled with care using special appliances so as to transport them without incuring injury to the user.