451491 Milling

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Always the next big thing.

The Premier Range

MillingProducts

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Trusted Metalwo

rking Products

ALWAYS THE NE

XT BIG THING

The Premier Ran

ge

Holemaking

Trusted Metalworking Products

ALWAYS THE NEXT BIG THING

The Premier Range

Turning

Featuring the exclusiveXOMT insert geometry

Order EDP #451477

Featuring the patentedCT insert profiling geometry and the patented ZrCN coatingfor improved toughness

Order EDP #451481

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Milling

Table of Contents

1

Page

Technical Section

Grade descriptions ...................................... 2-3

Milling formulas ............................................ 4-5

Circular & Helical Interpolation .................... 6-7

Milling Cutters & Inserts

M28 Ball Nose Cutters .................................... 8

Inserts for M28 Cutters .................................. 9

M30 Helical Cutters ........................................10

Inserts for M30 Cutters ..................................11

M100 Copy Mill Cutters ............................12-13

Inserts for M100 Cutters ................................13

M100 Face Mill & Threaded-Shank Cutters ..14

Inserts for M100 Cutters ................................15

M660 42 Face Mill Cutters ............................16

Inserts for M660 Cutters ................................17

M680 Plus Long Length, Square Shoulder, &

Slot Mill Cutters (AONT style) ........................18

Inserts for M680 Plus Cutters

(XPHT, XDHT style)........................................19

M680 Threaded Shank & Regular Length

Square Shoulder Slot Mill Cutters ................ 20

Inserts for M680 Cutters................................ 21

M680 Square Shoulder & Slot Mill

Cutters Continued .................................... 22-23

Inserts for M680 Cutters................................ 23

M680 Square Shoulder & Slot Mill

Cutters Continued.......................................... 24

Inserts for M680 Cutters................................ 25

M680 Square Shoulder & Slot Mill

Cutters Continued.......................................... 26

Inserts for M680 Cutters................................ 27

M690 Square Shoulder Mill Cutters .............. 28

Inserts for M690 Cutters................................ 29

Notes ........................................................ 30-32

Decimal Equivalent Chart .... Inside Back Cover

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Technical Section

2

CV

D C

oat

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grade designation

Coated carbide grade:- CVD-TiC-TiCN-TiN coating.- Light and general machining.- For machining austenitic stainless steel

as well as nodular cast iron.

Coated carbide grade:- MT-CVD-TiN-TiCN-Al203-TiN coating.- Light and general machining.- For machining all types of steel

and nodular cast iron.

Coated carbide grade:- CVD-TiN-TiCN-Al203 multi-layer coating.- General and heavy machining.- For machining all types of steel

and nodular cast iron.- For use in unfavorable conditions.

Coated carbide grade:- CVD-TiN-TiCN-TiN multi-layer coating.- General and heavy machining.- For machining all types of steel

and nodular cast iron.- Use with lubricant recommended- Extremely tough grade, resistant

to changes in temperature.

ISO513 01 05 10 15 20 25 30 35 40 45 50

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ISO513 01 05 10 15 20 25 30 35 40 45 50type

grade description

TN2510

TN25M

TN7525

TN7535

TN450

Coated carbide grade:- MT-CVD-TiN-TiCN composite coating.- Light and general machining.- Machining of hardened steel, stellite

and cast iron up to 64 HRC.- Very good wear resistance.

Coated micro-grain grade:- MT-CVD-TiN-TiCN-Al2O3 coating.- Light machining.- For machining all types of cast iron.- For use with very high cutting speed.

TN5505

Coated micro-grain grade:- MT-CVD-TiN-TiCN-Al2O3 coating.- Light and general machining.- For machining all types of cast iron.- Balanced toughness/wear ratio.

TN5515

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Milling

3

grade designation

Uncoated carbide grade:- General and heavy machining.- For machining steel, cast steel, and stainless steel.- For use in unfavorable conditions with low cutting

speeds.

Uncoated carbide grade:- Light and general machining.- For machining cast iron, all non-ferrous metals

and non-metals.

Uncoated carbide grade:- Ultra-fine grain grade with excellent

wear resistance.- Light and general machining.- For machining Al alloys (up to 12% Si),

Mg alloys, non metals and cast iron.

Uncoated carbide grade:- General and heavy machining.- For machining cast iron, non-ferrous metals,

and titanium alloys.

ISO513 01 05 10 15 20 25 30 35 40 45 50

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ISO513 01 05 10 15 20 25 30 35 40 45 50type

grade description

TTM

TTR

THM

THM-U

THR

Uncoated carbide grade:- Balanced toughness/wear ratio.- General machining.- For machining all types of steel.

Uncoated cermet grade:- Light and general machining.- Use at very high cutting speeds.- Use dry or with air cooling.

TTI25

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M stainless steel

K cast iron

N non-ferrous

S high-temperature alloys

H hardened materials

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Milling Technical Section

Cutting Ratios and Undeformed Chip Thickness in Milling

4

Valid for ae < 0.3 d1

Valid for ap < 0.3 d1

Valid for ap < 0.3

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Milling Technical Section

5

Up Milling / Down Milling with Square Shoulder and Side Face Mills

Up Milling / Down Milling with Face Mills

Up Milling - Non rigid setups and high strength square work materials.

Up Milling

Down Milling

Down Milling - To be preferred if permitted by machine (play-free table feed)

Down Milling

Up Milling

Maximum Chip Thickness hm

Approximate Formula s = cos (1-ae )R

hm = maximum chip thickness = fz x sin (cos-1 (1-ae )

R

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Milling Technical Section

Circular and Helical Interpolation

6

Plunge milling by helical interpolation employing inserts with corner radii and end concavity.

Minimum and maximum milling cutter size calculations:

Optimum axial advance per helical rotation

ap = R

Vfi = effective axial feed rate at cutter centerline = fz x D1/DMaximum depth of cut when ap < 0.5 x dOptimum depth of cut when ap = 0.25 x d x cos-1

Minimum Cutter Diameter: (to plunge from solid)

D(min) > 0.5 x D1 + R

Maximum Cutter Diameter:

D(max) < 0.667 x D1 + R

Program Feed Calculations: rpm = 3.8197 x sfm/D Example:M100 face mill (dimensions in inches)

fz = effective feed per toothVfi = fz x (D1 - D/D1)

Circular interpolation is a milling operation in which the axis of the cutter moves in a circle at a fixed distance from the axis of the cut being generated in a single plane. Coordinate Z remains constant whilecoordinates X & Y are constantly changing so as to generate a circle.

Helical interpolation is a circular interpolation except that the Z axischanges, increases or decreases, at a constant rate for one or more 360arcs. X & Y coordinates are constantly changing, while Z axis is changingat a fixed rate. A machine with 3 axis control is required.

The most frequent use of helical interpolation in machining is when thread milling or plunge milling to generate an internal bore or an externaldiameter. Programming requires differentiating between feed, the rate atwhich the cutter axis advances, and effective feed, the advance per inserton the workpiece. The machine feed (programmed feed) is greater onexternal milling and less on internal boring applications.

LegendD1 = Bore diameter of workpiece to be generated

D = Cutter diameter

R = Radius of insert

ap = Feed per 360 helical interpolation

T = Number of cutting inserts in cutter

sfm = Recommended surface velocity in feet/minute

rpm = Cutter revolutions per minute

fz = Effective feed per tooth

Vfi = Feed rate at cutter centerline = programmed feed rate

D1 = 8, D = 4, d = 0.6299, T = 8,fz = 0.008, Vfi = 0.004

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Milling Technical Section

7