silver, black, strong the new force in machining. · 12 application chart ... 68 description of...

The new force in machining.

Product handbook

Milling

_ SILVER, BLACK, STRONG

Cutting tool materials with the Tiger·tec® technology brand are setting the standard in machining again and again, in terms of productivity and process stability. With the new cutting tool material Tiger·tec®Silver, the engineers at Walter have moved another great step closer to the ideal cutting tool material. Tiger·tec®Silver is ideal for dry and wet machining of steel and cast iron materials, and is at home in important key sectors: the automotive industry and rail vehicle manufacturing, power engineering, the aerospace industry, mechanical engineering and in mould and die making.

THE MACHINING AGE IS OVER. IT’S TIME TO TIGER.

CONTENTS

Milling

2 Tiger·tec®Silver

2 The new technology

6 Applications and examples

12 Application chart

14 Extract from the milling cutter range

16 Walter Select milling cutters

34 Technical information

34 Cutting data for milling

38 Feed rate specification

54 Application-specific data

68 Description of indexable insert geometry

76 Calculation Formulae

78 Problem solving

Tiger·tec®Silver

The new technology

2

Extremely smooth rake

face for excellent

tribochemical wear resistance

Extremely stable cutting

edges for high level

of process reliability Silver coloured

flank face for extremely easy wear detection during use

New Tiger, new benchmark:

100 %increase in output

Up to

3Tiger·tec®Silver

UNiqUe ThroUghoUT The worldWith its globally unique CVD coating technology, the cutting tool material Tiger·tec®Silver is forging ahead into new dimensions. In day-to-day manu-facturing, this means that increases in output of up to 100 % are possible in machining.

Other features of Tiger·tec®Silver:Enormous toughness and minimal –formation of hairline cracks thanks to optimum residual strengthGreatly reduced tribochemical –wear thanks to perfect, smooth rake facesNot susceptible to thermal stress –variations during wet and dry machining

Completely new CVD coating technology:

Combines wear resistance and –toughnessfor steel and cast iron workpieces –

Optimum friction behaviour

Resistant to tribochemical wear

Greater resistance to flank face wear

Excellent hardness to toughness ratio

-Al2O3

MT-Ti(C, N)

Substrate

Tiger·tec®Silver

The new technology

4

HIGH lEVEl Of WEAR RESISTANCE

A close-up view of the cutting edges shows it clearly: the new cutting tool material Tiger·tec®Silver can easily handle even the most difficult machin-ing conditions thanks to its new, revolutionary coating. Hairline cracks, such as those that occur at high cutting speeds, with interrupted cuts and diffi-cult cutting conditions in particular, are decisively reduced with Tiger·tec®Silver

existing

indexable inserts. In the example shown, heat treatable steel 42CrMo4 was milled twice, with the existing insert and with the new Tiger·tec®Silver. With the Tiger·tec®Silver indexable insert, the high level of wear resistance, the tough-ness and resistance to temperature reduce negative hairline crack forma-tions and chipping, and therefore costly reductions in service life.

Outstanding properties

5Tiger·tec®Silver

PRODUCT PROPERTIES:

Performance increase of up to 100 %

thanks to excellent wear behaviour –combined with extreme toughness

Excellent cutting and swarf evacuation behaviour

thanks to extremely smooth rake –faces

Resistant to deformation and oxidation wear

thanks to the new type of aluminium –oxide coating

High level of resistance to flank face wear

thanks to fine-grained, columnar, –average temperature titanium carbonitride

New dimension in the toughness to wear resistance ratio

thanks to the new type of coating –technology

BENEfITS fOR yOU:

low production costshigher cutting speeds thanks to –heat-resistant coating

High level of process reliabilityhigh level of toughness thanks to –Tiger·tec®Silver technology improved chip flow thanks to – extremely smooth rake faces

low cutting material costsexcellent wear detection thanks –to indicator coatingunused cutting edges not wasted –

Tiger·tec®Silver

Applications and examples

6

THE APPlICATION

With the new Tiger·tec®Silver technolo-gy, there is also completely new surface treatment in addition to the special coating combination. Due to the optimal residual stresses, the toughness of the wear-resistant Tiger·tec®Silver cutting

tool material increases exponentially. It is this combination of a high level of wear resistance and toughness that gives Tiger·tec®Silver superior machining performance.

PVd-Al2o3

PVd

Temperature resistance

Toughness

CVd-Al2o3 Tiger·tec®

Tiger·tec®Silver

WAlTER GRADE DESIGNATION

w K P 35 STiger·tec®Silver

Application range

Primary application ISO P

Primary application ISO KWalter

7Tiger·tec®Silver

wAK 15

wKP 25



wSP 45

wKP 25

wKP 35 STiger·tec®Silver

wKP 35 STiger·tec®Silver

MATERIAl: STEEl (ISO P)

MATERIAl: CAST IRON (ISO K)

wKK 25

Toughness

Toughness

WKP 35 S

Primary application: all steel materi-als at medium to high cutting speeds and medium to high feeds per tooth. For unfavourable conditions, e.g. wet machining, fluctuating material removal or long projection length.

Primary application: spheroidal graphite cast iron or ADI materials at low to medium cutting speeds and medium to high feeds per tooth. For unfavour-able conditions, e.g. wet machining, fluctuating material removal or aggressive interrupted cuts.

Tiger·tec®Silver

Example 1: machine frame (shoulder milling)

8

Benefits for you:high level of process stability despite –unstable weld design; holes and weld seams are also milled in some areaslower tool costs –

Cutting data:

Competitor Tiger·tec®Silvervc [m/min] 400 400fz [mm] 0.2 0.2vf [mm/min] 2425 2425ap [mm] 1.5 – 3 1.5 – 3ae [mm] 60 60

with coolant with coolantTool life quantity 1 inner surface 2 inner surfaces

Workpiece material:

St37 (1.0037), ISO P (BS879M39, EN40 Structural Steel)

Tool: F4042 / Z6 / dia. 63Indexable insert: ADMT160608R-F56Cutting tool material: WKP35S

Comparison in tool life of inner surfaces [pieces]

0 0.5 1 1.5 2

Competition

Tiger·tec®Silver

+ 100 %

2.5

Example 2: guide tracks (face milling)

9Tiger·tec®Silver

Benefits for you:reduced tool costs thanks to doubled –service lifemachine capacity increased thanks to –26 % higher feed rate

Cutting data:

existing Tiger·tec®Silvervc [m/min] 236 283fz [mm] 0.33 0.33vf [mm/min] 1584 2000ap [mm] 4 4ae [mm] 100 100

with coolant with coolantTool life [m] 18 36

Workpiece material: St52-2 (1.0570), ISO P (Unalloyed Structural Steel)

Tool: F4080 / Z8 / dia. 125Indexable insert: ODHT0605ZZN-F57Cutting tool material: WKP35S

feed rate comparison [mm/min]

00 600 1200 1800 2400

existing

Tiger·tec®Silver

+ 26 %

Tiger·tec®Silver

Example 3: form insert (pocket milling)

10

Benefits for you:a complete component can be –reliably machinedlower tool costs –

Cutting data:

existing Tiger·tec®Silvervc [m/min] 105 105fz [mm] 0.3 0.3vf [mm/min] 955 955ap [mm] 3 3ae [mm] 35 – 63 35 – 63

with coolant with coolantTool life [m] 105 143

Workpiece material: 40CrMnMo7 (1.2311), ISO P (Mould Steel)

Tensile strength: 1200 N/mm2

Tool: F4042 / Z6 / dia. 63Indexable insert: ADMT160608R-F56Cutting tool material: WKP35S

Tool life comparison [m]

0 50 100 150

existing

Tiger·tec®Silver

+ 36 %

Example 4: brake caliper (circular face milling)

11Tiger·tec®Silver

Benefits for you:reduction in CPP (cost per part) –low tool costs thanks to longer tool life –high level of process reliability –

Cutting data:

Competitor Tiger·tec®Silvervc [m/min] 160 160fz [mm] 0.215 0.215vf [mm/min] 1533 1533ap [mm] 1.5 1.5ae [mm] 25 25

without coolant without coolantTool life quantity [pieces] 800 1400

Workpiece material: GGG50 (0.7050), ISO K (Nodular Iron)

Tool: F4042R / Z7 / dia. 50Indexable insert: ADMT10T308R-F56Cutting tool material: WKP35S

Tool life quantity comparison [pieces]

0 400 800 1200 1600

Competition

Tiger·tec®Silver

+ 75 %

Walter grade designation

Standard designation

Workpiece material group Application range

Coat

ing

proc

ess

Coat

ing

com

posi

tion

Inde

xabl

e in

sert

exa

mpl

e

P M K N S H 01 10 20 30 40

Stee

l

Stai

nles

s st

eel

Cast

iron

Non

-fer

rous

m

etal

s

Mat

eria

ls w

ith

diff

icul

t cu

ttin

g pr

oper

ties

Har

d m

ater

ials

05 15 25 35 45

WKP 35 SHC – P 35 C C

CVD TiCN + Al2O3(+TiCN)

HC – K 35 C C

WKP 25HC – P 25 C C

CVD TiCN + Al2O3(+TiN)HC – K 25 C C

WAK 15 HC – K 15 C C CVD TiCN + Al2O3 (+TiN)

WSP 45

HC – S 45 C C

PVD TiAlN + Al2O3(ZrCN)HC – P 45 C C

HC – M 45 C C

WKK 25 HC – K 25 C C PVD TiAlN + Al2O3(ZrCN)

Tiger·tec®Silver

Application chart

12

HC = coated carbide C C Primary application

Walter grade designation

Standard designation

Workpiece material group Application range

Coat

ing

proc

ess

Coat

ing

com

posi

tion

Inde

xabl

e in

sert

exa

mpl

e

P M K N S H 01 10 20 30 40

Stee

l

Stai

nles

s st

eel

Cast

iron

Non

-fer

rous

m

etal

s

Mat

eria

ls w

ith

diff

icul

t cu

ttin

g pr

oper

ties

Har

d m

ater

ials

05 15 25 35 45

WKP 35 SHC – P 35 C C

CVD TiCN + Al2O3(+TiCN)

HC – K 35 C C

WKP 25HC – P 25 C C

CVD TiCN + Al2O3(+TiN)HC – K 25 C C

WAK 15 HC – K 15 C C CVD TiCN + Al2O3 (+TiN)

WSP 45

HC – S 45 C C

PVD TiAlN + Al2O3(ZrCN)HC – P 45 C C

HC – M 45 C C

WKK 25 HC – K 25 C C PVD TiAlN + Al2O3(ZrCN)


HC = coated carbide C C Primary application

Extract from the milling cutter range

14

Pocket milling: f 4042

Trimming: f 4238

Plunging: f 4030

Slot milling: f 4253

Shoulder milling: f 4042

Circular interpolation milling: f 4081

Slot milling: f 4042R


face milling: f 4033

Copy milling: f 4030

Shoulder milling: f 4041

face milling: f 4045

Walter Select milling cutters

face milling

16

Machining

Lead angle κ 45° 75° 88° 45°

Face mill f 4033 f 4047 f 4048 f 4045

Xtra·tec® Xtra·tec® Xtra·tec® Xtra·tec®

Dia. range [mm] 40 – 200 40 – 200 40 – 200 63 – 200

Ordering information* E. page 194 E. page 198 E. page 200 F. Page 153

P Steel C C C C C C

K Cast iron C C C C C C C C

Basic shape of indexable insert

Indexable insert typesSN . X 1205 . .SN . X 1606 . .

SN . X 1205 . . SN . X 1205 . .XNHF 0705 . .XNHF 0906 . .

Max. cut depths [mm] 6.5 + 9 8 10 4 + 6

Number of cutting edges per indexable insert 8 8 8 14

* G. = Complete catalogue 2007 E. = Catalogue supplement 2009 F. = Innovation flyer 2010


Machining

Lead angle κ 45° 75° 88° 45°

Face mill f 4033 f 4047 f 4048 f 4045


Dia. range [mm] 40 – 200 40 – 200 40 – 200 63 – 200

Ordering information* E. page 194 E. page 198 E. page 200 F. Page 153

P Steel C C C C C C




SN . X 1205 . . SN . X 1205 . .XNHF 0705 . .XNHF 0906 . .

Max. cut depths [mm] 6.5 + 9 8 10 4 + 6


C C

Primary application

C

Additional

application


face milling

18

Machining

Lead angle κ 43° 0–15° 0–21°

Face mill f 4080 f 2330 f 4030

Xtra·tec® Xtra·tec®

Dia. range [mm] 32 – 170 20 – 85 25 – 63

Ordering information* F. Page 155, G. page 510 E. page 192 F. Page 152

P Steel C C C C C C

K Cast iron C C C C C C


Indexable insert typesOD . . 0504 . .OD . . 0605 . .

P 2633 .P 26379

P 23696 – 1.0

Max. cut depths [mm] 3 / 8 + 4 / 10 1 + 1.5 + 2 1

Number of cutting edges per indexable insert 8 3 6



Machining

Lead angle κ 43° 0–15° 0–21°

Face mill f 4080 f 2330 f 4030


Dia. range [mm] 32 – 170 20 – 85 25 – 63


P Steel C C C C C C




P 2633 .P 26379

P 23696 – 1.0

Max. cut depths [mm] 3 / 8 + 4 / 10 1 + 1.5 + 2 1


C C

Primary application

C

Additional

application

20


face milling

Machining

Roughing ▲ ▲ ▲ ▲

Finish milling ▲ ▲

Shoulder milling ▲ ▲

Shoulder milling (finishing) ▲ ▲

Plunging ▲ ▲ ▲

Circular interpolation milling ▲ ▲ ▲

Pocket milling ▲ ▲ ▲

Lead angle κ 45° / 75° / 88° 90° 90° 0 – 15° 43° / 45° –

Face mill f 2010 f 2010

Dia. range [mm] 80 – 315 80 – 315 80 – 315 70 – 305 80 – 315 74 – 309

Ordering information* E. page 186, F. Page 159 G. page 472 G. page 468 G. page 452 G. page 454 G. page 474

P Steel C C C C C C C C C C C C

K Cast iron C C C C C C C C C C C C



LNGX 1307 . .AD . . 1204 . .AD . . 1606 . .

P 2633 . – R25P 26379 – R25

OD . . 0605 . . RO . X 1605 . .

Max. cut depths [mm] 6.5 + 8 + 9 + 10 13 11.7 + 15 2 4 / 10 8

Number of cutting edges per indexable insert 8 4 2 3 8 6



Machining

Roughing ▲ ▲ ▲ ▲

Finish milling ▲ ▲

Shoulder milling ▲ ▲

Shoulder milling (finishing) ▲ ▲

Plunging ▲ ▲ ▲

Circular interpolation milling ▲ ▲ ▲

Pocket milling ▲ ▲ ▲

Lead angle κ 45° / 75° / 88° 90° 90° 0 – 15° 43° / 45° –

Face mill f 2010 f 2010

Dia. range [mm] 80 – 315 80 – 315 80 – 315 70 – 305 80 – 315 74 – 309

Ordering information* E. page 186, F. Page 159 G. page 472 G. page 468 G. page 452 G. page 454 G. page 474

P Steel C C C C C C C C C C C C

K Cast iron C C C C C C C C C C C C



LNGX 1307 . .AD . . 1204 . .AD . . 1606 . .

P 2633 . – R25P 26379 – R25

OD . . 0605 . . RO . X 1605 . .

Max. cut depths [mm] 6.5 + 8 + 9 + 10 13 11.7 + 15 2 4 / 10 8

Number of cutting edges per indexable insert 8 4 2 3 8 6

C C

Primary application

C

Additional

application


Shoulder milling

22

Machining

Lead angle κ 90° 90° 90°

Shoulder milling cutter f 4041 f 4042R f 4042

Xtra·tec® Xtra·tec® Xtra·tec®

Dia. range [mm] 40 – 160 16 – 63 10 – 160

Ordering information* G. page 520 E. page 204, F. Page 158 E. page 202

P Steel C C C C C C



Indexable insert types LNGX 1307 . . AD . T 10T3 . .AD . T 0803 . . AD . T 1204 . .AD . T 1606 . . AD . T 1807 . .

Max. cut depths [mm] 13 10 8 + 11.7 + 15 + 16




Machining


Shoulder milling cutter f 4041 f 4042R f 4042


Dia. range [mm] 40 – 160 16 – 63 10 – 160


P Steel C C C C C C



Indexable insert types LNGX 1307 . . AD . T 10T3 . .AD . T 0803 . . AD . T 1204 . .AD . T 1606 . . AD . T 1807 . .

Max. cut depths [mm] 13 10 8 + 11.7 + 15 + 16


C C

Primary application

C

Additional

application


Shoulder milling

24

Machining

Lead angle κ 90° 90° 90° 90°

Shoulder milling cutter f 4038 f 4138 f 4238 f 4338


Dia. range [mm] 20 – 32 32 – 80 40 – 80 63 – 125

Ordering information* E. page 216 G. page 556,F. Page 156 G. page 558, F. Page 156 F. Page 156

P Steel C C C C C C C C



Indexable insert types AD . T 0803 . . AD . T 1204 . . AD . T 1606 . . AD . T 1807 . .

Max. cut depths [mm] 37 76 112 124




Machining

Lead angle κ 90° 90° 90° 90°

Shoulder milling cutter f 4038 f 4138 f 4238 f 4338


Dia. range [mm] 20 – 32 32 – 80 40 – 80 63 – 125

Ordering information* E. page 216 G. page 556,F. Page 156 G. page 558, F. Page 156 F. Page 156

P Steel C C C C C C C C



Indexable insert types AD . T 0803 . . AD . T 1204 . . AD . T 1606 . . AD . T 1807 . .

Max. cut depths [mm] 37 76 112 124


C C

Primary application

C

Additional

application


Slot milling

26

Machining


Slot mill f 4053 f 4153 f 4253

Dia. range [mm] 80 – 160 80 – 200 100 – 315

Ordering information* E. page 218, F. Page 157 E. page 220, F. Page 157 E. page 222, F. Page 157

P Steel C C C C C C



Indexable insert types LN.X 070204 . .LN . . 0803 . . LN . . 0804 . .

LN . . 1005 . .LN . . 0804 . . LN . . 1005 . .LN . . 1206 . . LN . . 1608 . .

Max. cutting width across teeth [mm]

4 6 + 8 + 10 12 + 14 + 16 + 20 + 25

Number of cutting edges per indexable insert 2 + 2 2 + 2 2 + 2


Xtra·tec®


Machining


Slot mill f 4053 f 4153 f 4253

Dia. range [mm] 80 – 160 80 – 200 100 – 315

Ordering information* E. page 218, F. Page 157 E. page 220, F. Page 157 E. page 222, F. Page 157

P Steel C C C C C C



Indexable insert types LN.X 070204 . .LN . . 0803 . . LN . . 0804 . .

LN . . 1005 . .LN . . 0804 . . LN . . 1005 . .LN . . 1206 . . LN . . 1608 . .

Max. cutting width across teeth [mm]

4 6 + 8 + 10 12 + 14 + 16 + 20 + 25

Number of cutting edges per indexable insert 2 + 2 2 + 2 2 + 2

C C

Primary application

C

Additional

application



Copy milling

28

Machining

Copy mill f 2334

Dia. range [mm] 25 – 160

Ordering information* G. page 590

P Steel C C

K Cast iron C C


Indexable insert types RO . X . .

Max. cut depths [mm] 4 – 10

Number of cutting edges per indexable insert 4 – 8


Circular interpolation milling


C C

Primary application

C

Additional

application

Machining

Lead angle κ 45° / 90°

Circular interpolation mill f 4081

Xtra·tec®

Dia. range [mm] 36 – 85

Ordering information* F. Page 155

P Steel C C

K Cast iron C C



Max. cut depths [mm] 3 + 4

Number of cutting edges per indexable insert 2 – 4

30



Machining

Lead angle κ 43° 0–15° 0–21°

Circular interpolation mill f 4080 f 2330 f 4030


Dia. range [mm] 32 – 170 20 – 85 25 – 63


P Steel C C C C C C




P 2633 .P 26379

P 23696 – 1.0

Max. cut depths [mm] 3 / 8 + 4 / 10 1 + 1.5 + 2 1

Number of cutting edges per indexable insert 2 – 4 3 6



Machining

Lead angle κ 43° 0–15° 0–21°

Circular interpolation mill f 4080 f 2330 f 4030


Dia. range [mm] 32 – 170 20 – 85 25 – 63


P Steel C C C C C C




P 2633 .P 26379

P 23696 – 1.0

Max. cut depths [mm] 3 / 8 + 4 / 10 1 + 1.5 + 2 1


C C

Primary application

C

Additional

application

32




Machining

Lead angle κ 90° 90°

Circular interpolation mill f 2334 f 4042R f 4042


Dia. range [mm] 25 – 160 16 – 63 10 – 160


P Steel C C C C C C



Indexable insert types RO . X . . AD . T 10T3 . .AD . T 0803 . . AD . T 1204 . .AD . T 1606 . . AD . T 1807 . .

Max. cut depths [mm] 4 – 10 10 8 + 11.7 + 15 + 16



C C

Primary application

C

Additional

application

Machining

Lead angle κ 90° 90°

Circular interpolation mill f 2334 f 4042R f 4042


Dia. range [mm] 25 – 160 16 – 63 10 – 160


P Steel C C C C C C



Indexable insert types RO . X . . AD . T 10T3 . .AD . T 0803 . . AD . T 1204 . .AD . T 1606 . . AD . T 1807 . .

Max. cut depths [mm] 4 – 10 10 8 + 11.7 + 15 + 16


Technical Information

Cutting data for milling

34

Mat

eria

l gro

up

Workpiece material Brin

ell h

ardn

ess

HB

Mac

hini

ng g

roup

2

Roughing with surface/shoulder milling cutters

Roughing with porcupine cutters

Roughing with side and face mills

WKP 35 S WKP 35 S WKP 35 S

ae / DC3 ae / DC

3 ae / DC

1/11/2 1/5 1/1

1/2 1/5 central 1/5 1/10

P

Unalloyed steel 1

approx. 0.15 % C annealed 125 1 250 300 195 250 195 250 275


approx. 0.45 % C heat treated 250 3 195 220 150 185 150 185 285



Low-alloy steel 1

annealed 180 6 220 270 170 215 170 215 235

heat treated 275 7 180 210 135 155 130 165 165

heat treated 300 8 170 190 130 145 125 145 150

heat treated 350 9 130 150 90 105 90 100 105

High-alloyed steel and high-alloyed tool steel 1

annealed 200 10 130 160 100 120 100 120 130

hardened and tempered 325 11 80 90 60 70 60 75 75

Stainless steel 1ferritic / martensitic, annealed 200 12 140 160 105 120 105 130 130

martensitic, heat treated 240 13 100 120 70 95 70 95 105

K

Grey cast ironpearlitic/ferritic 180 15 300 330 160 180 160 180 190

pearlitic (martensitic) 260 16 170 200 120 140 120 140 150

Grey cast iron with spheroidal graphite

ferritic 160 17 200 220 140 150 140 150 160

pearlitic 250 18 140 160 110 120 110 120 130

Malleable cast ironferritic 130 19 210 240 150 170 150 170 180

pearlitic 230 20 150 180 130 140 130 140 150


Mat

eria

l gro

up


ell h

ardn

ess

HB

Mac

hini

ng g

roup

2

Roughing with surface/shoulder milling cutters

Roughing with porcupine cutters

Roughing with side and face mills

WKP 35 S WKP 35 S WKP 35 S

ae / DC3 ae / DC

3 ae / DC

1/11/2 1/5 1/1

1/2 1/5 central 1/5 1/10

P

Unalloyed steel 1






Low-alloy steel 1

annealed 180 6 220 270 170 215 170 215 235

heat treated 275 7 180 210 135 155 130 165 165

heat treated 300 8 170 190 130 145 125 145 150

heat treated 350 9 130 150 90 105 90 100 105


annealed 200 10 130 160 100 120 100 120 130

hardened and tempered 325 11 80 90 60 70 60 75 75

Stainless steel 1ferritic / martensitic, annealed 200 12 140 160 105 120 105 130 130

martensitic, heat treated 240 13 100 120 70 95 70 95 105

K

Grey cast ironpearlitic/ferritic 180 15 300 330 160 180 160 180 190

pearlitic (martensitic) 260 16 170 200 120 140 120 140 150


ferritic 160 17 200 220 140 150 140 150 160

pearlitic 250 18 140 160 110 120 110 120 130

Malleable cast ironferritic 130 19 210 240 150 170 150 170 180

pearlitic 230 20 150 180 130 140 130 140 150

1 and cast steel2 The arrangement of the machining group can be found in the complete catalogue 2007,

from page 7913 ae / DC = 1/10, vC = 10 % higher than 1/5


Cutting data for milling

36

Mat

eria

l gro

up


ell h

ardn

ess

HB

Mac

hini

ng g

roup

2

Roughing with copy milling cutters Circular interpolation milling

WKP 35 S WKP 35 S

ae / DC ae / DC3

1/1 1/5 1/10 1/1 1/5

P

Unalloyed steel 1

approx. 0.15 % C annealed 125 1 240 300 300 220 270


approx. 0.45 % C heat treated 250 3 185 240 240 180 200



Low-alloy steel 1

annealed 180 6 165 210 230 200 240

heat treated 275 7 155 195 215 160 190

heat treated 300 8 145 180 200 150 170

heat treated 350 9 120 155 170 110 130


annealed 200 10 110 145 160 120 140

hardened and tempered 325 11 75 100 100 80 90

Stainless steel 1ferritic / martensitic, annealed 200 12 120 155 170 120 140

martensitic, heat treated 240 13 110 145 155 90 100

K

Grey cast ironpearlitic/ferritic 180 15 240 280 300 270 297

pearlitic (martensitic) 260 16 190 230 250 153 180


ferritic 160 17 240 280 300 180 198

pearlitic 250 18 190 230 250 126 144

Malleable cast ironferritic 130 19 250 290 310 189 216

pearlitic 230 20 200 240 260 135 162


Mat

eria

l gro

up


ell h

ardn

ess

HB

Mac

hini

ng g

roup

2

Roughing with copy milling cutters Circular interpolation milling

WKP 35 S WKP 35 S

ae / DC ae / DC3

1/1 1/5 1/10 1/1 1/5

P

Unalloyed steel 1






Low-alloy steel 1

annealed 180 6 165 210 230 200 240

heat treated 275 7 155 195 215 160 190

heat treated 300 8 145 180 200 150 170

heat treated 350 9 120 155 170 110 130


annealed 200 10 110 145 160 120 140

hardened and tempered 325 11 75 100 100 80 90

Stainless steel 1ferritic / martensitic, annealed 200 12 120 155 170 120 140

martensitic, heat treated 240 13 110 145 155 90 100

K

Grey cast ironpearlitic/ferritic 180 15 240 280 300 270 297

pearlitic (martensitic) 260 16 190 230 250 153 180


ferritic 160 17 240 280 300 180 198

pearlitic 250 18 190 230 250 126 144

Malleable cast ironferritic 130 19 250 290 310 189 216

pearlitic 230 20 200 240 260 135 162

1 and cast steel2 The arrangement of the machining group can be found in the complete catalogue 2007,

from page 7913 ae / DC = 1/10, vC = 10 % higher than 1/5

38


Determining the feed

Cutter types

Feed per tooth fzo for ae = Dc ap = ap max = Lc

f 2010 / f 2330 Face milling

f 2330 Plunging

f 4030 Face milling

f 4030 Plunging

Lead angle κ 0 – 15° 0 – 15° 0 – 21° 0 – 21°

fzo = [mm] fzo = [mm] fzo = [mm] fzo = [mm]

Tool dia. or dia. range [mm] 20 – 25 32 – 85 52 – 315 20 – 25 32 – 85 52–315 25 – 63 25 – 63

max. depths of cut ap max = Lc [mm] ap max = 1 ap max = 1.5 ap max = 2 ae max = 7 ae max = 10 ae max = 15 apmax = 1 aemax = 10

P

Unalloyed steel* 1.2 1.6 2.0 0.18 0.25 0.30 1.2 0.18

Low-alloyed steel* 1.0 1.4 1.8 0.16 0.22 0.25 1.0 0.16

High-alloyed steel and tool steel* 0.7 1.0 1.2 0.12 0.16 0.22 0.7 0.12

Stainless steel*, martensitic 0.5 0.6 0.8 0.10 0.12 0.15 0.5 0.10

KGrey cast iron 1.2 1.6 2.0 0.18 0.25 0.30 1.2 0.18

Cast iron with spheroidal graphite 1.0 1.4 1.8 0.16 0.22 0.28 1.0 0.16

Malleable cast iron 1.0 1.4 1.8 0.16 0.22 0.28 1.0 0.16

Indexable insert typesP 2633 . –

R 10P 2633 . –

R 14P 2633 . –

R 25

P 2633 . – P 26379 –

R 10

P 2633 . – P 26379 –

R 14

P 2633 . – P 26379 –

R 25

P 23696 – R 14

P 23696 – R 14

Correction factor Kae

for the feed per tooth dependent on the ratio cut width ae to cutter diameter Dc

ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0

1/5 1.4 1.4 1.3 1.4

1/10 1.8 1.8 1.8 1.8

1/20

1/50

Correction factor Kap

for the feed per tooth dependent on the depth of cut ap

ap = 0.5 1.3 1.4 1.5 1.3

1.0 1.0 1.2 1.4 1.0

1.5 1.0 1.2

2.0 1.0

Correctionfactor K

1<(L : Dc)≤2 1.4 1.4 1.4 1.0 1.0 1.0 1.0

2<(L : Dc)≤4 1.0 1.0 1.0 0.7 0.7 0.7 0.7

4<(L : Dc)≤6 0.7 0.7 0.7 0.5 0.5 0.5 0.5

fz = fzo · Kae · Kap · K

Dc

L

Dc ap max

* and cast steel


face mill: f 2010, f 2330, f4030

Cutter types


f 2010 / f 2330 Face milling

f 2330 Plunging

f 4030 Face milling

f 4030 Plunging


Lead angle κ 0 – 15° 0 – 15° 0 – 21° 0 – 21°


Tool dia. or dia. range [mm] 20 – 25 32 – 85 52 – 315 20 – 25 32 – 85 52–315 25 – 63 25 – 63

max. depths of cut ap max = Lc [mm] ap max = 1 ap max = 1.5 ap max = 2 ae max = 7 ae max = 10 ae max = 15 apmax = 1 aemax = 10

P

Unalloyed steel* 1.2 1.6 2.0 0.18 0.25 0.30 1.2 0.18



Stainless steel*, martensitic 0.5 0.6 0.8 0.10 0.12 0.15 0.5 0.10

KGrey cast iron 1.2 1.6 2.0 0.18 0.25 0.30 1.2 0.18



Indexable insert typesP 2633 . –

R 10P 2633 . –

R 14P 2633 . –

R 25

P 2633 . – P 26379 –

R 10

P 2633 . – P 26379 –

R 14

P 2633 . – P 26379 –

R 25

P 23696 – R 14

P 23696 – R 14



ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0

1/5 1.4 1.4 1.3 1.4

1/10 1.8 1.8 1.8 1.8

1/20

1/50



ap = 0.5 1.3 1.4 1.5 1.3

1.0 1.0 1.2 1.4 1.0

1.5 1.0 1.2

2.0 1.0

Correctionfactor K

1<(L : Dc)≤2 1.4 1.4 1.4 1.0 1.0 1.0 1.0

2<(L : Dc)≤4 1.0 1.0 1.0 0.7 0.7 0.7 0.7

4<(L : Dc)≤6 0.7 0.7 0.7 0.5 0.5 0.5 0.5


40



Cutter types


f 2010 / f 4080 f 4081 f 2010 / f 4033 f 4045


Lead angle κ 43° 45° 45° 45°


Tool dia. or dia. range [mm] 32–125 50–315 36–85 52–85 40–315 50–315 63–200 80–200

max. depths of cut ap max = Lc [mm] 3 /8 4 / 10 3 /8 4 / 10 6 9 4 6

P

Unalloyed steel* 0.45 0.50 0.40 0.45 0.25 0.40

Low-alloyed steel* 0.40 0.45 0.36 0.40 0.20 0.35

High-alloyed steel and tool steel* 0.30 0.35 0.27 0.32 0.20 0.30

Stainless steel,* martensitic 0.20 0.25 0.18 0.22 0.15 0.20

KGrey cast iron 0.45 0.50 0.40 0.45 0.30 0.50 0.30 0.50



Indexable insert typesOD . .

0504 . .OD . . 0605

OD . . 0504 . .with

corner radius

OD . . 0605. .with

corner radius

SN . X 120512SN . X 120520

SN . X 1205 ANNSN . X 1606 XNHF 0705 XNHF 0906


for the feed per tooth dependent on the ratio cut width ae to cutting diameter Dc

ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

1/5 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

1/10 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

1/20 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3

1/50



ap = 1 1.0 1.0 1.0 1.0

2 1.0 1.0 1.0 1.0

3 1.0 1.0 1.0 1.0

4 0.6 1.0 1.0 1.0

6 0.6 0.6 0.6 1.0

8 0.6 0.6 0.6 0.6

ap max = Lc 0.6 0.6 0.6 0.6


Dc ap max

* and cast steel


face mill: f 2010, f 4080, f 4081, f 4033, f 4045

Cutter types


f 2010 / f 4080 f 4081 f 2010 / f 4033 f 4045


Lead angle κ 43° 45° 45° 45°


Tool dia. or dia. range [mm] 32–125 50–315 36–85 52–85 40–315 50–315 63–200 80–200

max. depths of cut ap max = Lc [mm] 3 /8 4 / 10 3 /8 4 / 10 6 9 4 6

P

Unalloyed steel* 0.45 0.50 0.40 0.45 0.25 0.40




KGrey cast iron 0.45 0.50 0.40 0.45 0.30 0.50 0.30 0.50



Indexable insert typesOD . .

0504 . .OD . . 0605

OD . . 0504 . .with

corner radius

OD . . 0605. .with

corner radius

SN . X 120512SN . X 120520

SN . X 1205 ANNSN . X 1606 XNHF 0705 XNHF 0906


for the feed per tooth dependent on the ratio cut width ae to cutting diameter Dc

ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

1/5 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

1/10 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

1/20 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3

1/50



ap = 1 1.0 1.0 1.0 1.0

2 1.0 1.0 1.0 1.0

3 1.0 1.0 1.0 1.0

4 0.6 1.0 1.0 1.0

6 0.6 0.6 0.6 1.0

8 0.6 0.6 0.6 0.6

ap max = Lc 0.6 0.6 0.6 0.6




42

Cutter types


f 2010 / f 4047 f 2010 / f 4048 f 2010 / f 4041 f 2010 / f 4042 / f 4042R


Lead angle κ 75° 88° 90° 90°


Tool dia. or dia. range [mm] 63 – 315 63 – 315 40 – 315 10 – 50 16 – 32 25 – 315 40 –315 50 – 160

max. depths of cut ap max = Lc [mm] 8 10 13 8 10 11.7 15 16.7

P

Unalloyed steel* 0.22 0.20 0.20 0.15 0.18 0.20 0.25 0.30



Stainless steel,* martensitic 0.14 0.13 0.12 0.08 0.10 0.12 0.15 0.18

KGrey cast iron 0.25 0.22 0.25 0.15 0.20 0.25 0.30 0.40



Indexable insert typesSN . X 120512SN . X 120520

SN . X 1205 ENN

SN . X 120512SN . X 120520

SN . X 1205 ZNNLNGX 1307

AD . . 0803

AD . . 10T3

AD . . 1204

AD . . 1606

AD . . 1807



ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

1/5 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

1/10 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

1/20 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3

1/50

fz = fzo · Kae

Dc ap max

* and cast steel

face and shoulder mill: f 2010, f 4047, f 4048, f 4041, f 4042, f 4042R


Cutter types


f 2010 / f 4047 f 2010 / f 4048 f 2010 / f 4041 f 2010 / f 4042 / f 4042R


Lead angle κ 75° 88° 90° 90°


Tool dia. or dia. range [mm] 63 – 315 63 – 315 40 – 315 10 – 50 16 – 32 25 – 315 40 –315 50 – 160

max. depths of cut ap max = Lc [mm] 8 10 13 8 10 11.7 15 16.7

P

Unalloyed steel* 0.22 0.20 0.20 0.15 0.18 0.20 0.25 0.30



Stainless steel,* martensitic 0.14 0.13 0.12 0.08 0.10 0.12 0.15 0.18

KGrey cast iron 0.25 0.22 0.25 0.15 0.20 0.25 0.30 0.40



Indexable insert typesSN . X 120512SN . X 120520

SN . X 1205 ENN

SN . X 120512SN . X 120520

SN . X 1205 ZNNLNGX 1307

AD . . 0803

AD . . 10T3

AD . . 1204

AD . . 1606

AD . . 1807



ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

1/5 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

1/10 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

1/20 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3

1/50

fz = fzo · Kae



44

Cutter types


f 2010 / f 4038 f 4138 f 4238 f 4338

Xtra·tec®

Lead angle κ 90° 90° 90° 90°


Tool dia. or dia. range [mm] 20 – 32 32 – 80 40 – 80 63 – 125

max. depths of cut ap max = Lc [mm] 15 – 37 33 – 76 29 – 112 31 – 124

P

Unalloyed steel* 0.15 0.20 0.25 0.25

Low-alloyed steel* 0.10 0.15 0.20 0.20

High-alloyed steel and tool steel* 0.10 0.15 0.18 0.18

Stainless steel,* martensitic 0.08 0.12 0.12 0.12

KGrey cast iron 0.15 0.25 0.28 0.28

Cast iron with spheroidal graphite 0.12 0.20 0.22 0.22

Malleable cast iron 0.12 0.20 0.22 0.22

Indexable insert types AD . . 0803 AD . . 1204 AD . . 1606 AD . . 1807



ae / Dc = 1/1–1/2 1.0 1 1.0 1 1.0 1 1.0 1

1/5 1.1 1.1 1.1 1.1

1/10 1.2 1.2 1.2 1.2

1/20 1.3 1.3 1.3 1.3

1/50 1.5 1.5 1.5 1.5



ap = 1 1.0 1.0 1.0 1.0

2 1.0 1.0 1.0 1.0

3 1.0 1.0 1.0 1.0

4 1.0 1.0 1.0 1.0

6 0.8 0.8 0.8 0.8

8 0.7 0.7 0.7 0.7

ap max = Lc 0.5 2 0.5 2 0.5 2 0.5 2


* and cast steel

Dc

Lc

Shoulder mill: f 4038, f 4138, f 4238, f 4338


Cutter types


f 2010 / f 4038 f 4138 f 4238 f 4338


Lead angle κ 90° 90° 90° 90°


Tool dia. or dia. range [mm] 20 – 32 32 – 80 40 – 80 63 – 125

max. depths of cut ap max = Lc [mm] 15 – 37 33 – 76 29 – 112 31 – 124

P

Unalloyed steel* 0.15 0.20 0.25 0.25

Low-alloyed steel* 0.10 0.15 0.20 0.20

High-alloyed steel and tool steel* 0.10 0.15 0.18 0.18

Stainless steel,* martensitic 0.08 0.12 0.12 0.12

KGrey cast iron 0.15 0.25 0.28 0.28

Cast iron with spheroidal graphite 0.12 0.20 0.22 0.22

Malleable cast iron 0.12 0.20 0.22 0.22

Indexable insert types AD . . 0803 AD . . 1204 AD . . 1606 AD . . 1807



ae / Dc = 1/1–1/2 1.0 1 1.0 1 1.0 1 1.0 1

1/5 1.1 1.1 1.1 1.1

1/10 1.2 1.2 1.2 1.2

1/20 1.3 1.3 1.3 1.3

1/50 1.5 1.5 1.5 1.5



ap = 1 1.0 1.0 1.0 1.0

2 1.0 1.0 1.0 1.0

3 1.0 1.0 1.0 1.0

4 1.0 1.0 1.0 1.0

6 0.8 0.8 0.8 0.8

8 0.7 0.7 0.7 0.7

ap max = Lc 0.5 2 0.5 2 0.5 2 0.5 2


1 only possible if ap < 0.5 x DC · 2 only possible if ae/DC < 1/5



46

Cutter types

Feed per tooth fzo for plungingcentral positioning

f 4053 f 4153 f 4253



fzo = [mm] fzo = [mm] fzo = [mm]

Tool dia. or dia. range [mm] 80–160 80 – 200 80 – 200 80 – 200 100 – 200 100 – 200 125 – 200 160 – 250 160 – 315

max. depths of cut ap max = Lc [mm] 4 6 8 10 12 14 16 20 25

P

Unalloyed steel* 0.11 0.12 0.13 0.14 0.15 0.15 0.20 0.20 0.23

Low-alloyed steel* 0.09 0.10 0.12 0.12 0.13 0.13 0.17 0.17 0.20

High-alloyed steel and tool steel* 0.09 0.10 0.12 0.12 0.13 0.13 0.17 0.17 0.20

Stainless steel,* martensitic 0.05 0.05 0.07 0.07 0.08 0.08 0.10 0.10 0.13

KGrey cast iron 0.12 0.13 0.15 0.15 0.18 0.18 0.23 0.23 0.23

Cast iron with spheroidal graphite 0.11 0.12 0.13 0.13 0.15 0.15 0.20 0.20 0.20

Malleable cast iron 0.11 0.12 0.13 0.13 0.15 0.15 0.20 0.20 0.20

Indexable insert types LN . X0702 LN . . 0803 LN . . 0804 LN . . 1005 LN . . 0804 LN . . 0804 LN . . 1005 LN . . 1206 LN . . 1608



ae / Dc =

central 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

1/3 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

1/5 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8

1/10 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

1/20 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3

1/50 5.8 5.8 5.8 5.8 5.8 5.8 5.8 5.8 5.8

fz = fzo · Kae

* and cast steel

Side and face mills: f 4053, f 4153, f 4253


Cutter types

Feed per tooth fzo for plungingcentral positioning

f 4053 f 4153 f 4253




Tool dia. or dia. range [mm] 80–160 80 – 200 80 – 200 80 – 200 100 – 200 100 – 200 125 – 200 160 – 250 160 – 315

max. depths of cut ap max = Lc [mm] 4 6 8 10 12 14 16 20 25

P

Unalloyed steel* 0.11 0.12 0.13 0.14 0.15 0.15 0.20 0.20 0.23

Low-alloyed steel* 0.09 0.10 0.12 0.12 0.13 0.13 0.17 0.17 0.20

High-alloyed steel and tool steel* 0.09 0.10 0.12 0.12 0.13 0.13 0.17 0.17 0.20

Stainless steel,* martensitic 0.05 0.05 0.07 0.07 0.08 0.08 0.10 0.10 0.13

KGrey cast iron 0.12 0.13 0.15 0.15 0.18 0.18 0.23 0.23 0.23

Cast iron with spheroidal graphite 0.11 0.12 0.13 0.13 0.15 0.15 0.20 0.20 0.20

Malleable cast iron 0.11 0.12 0.13 0.13 0.15 0.15 0.20 0.20 0.20

Indexable insert types LN . X0702 LN . . 0803 LN . . 0804 LN . . 1005 LN . . 0804 LN . . 0804 LN . . 1005 LN . . 1206 LN . . 1608



ae / Dc =

central 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

1/3 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

1/5 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8

1/10 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

1/20 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3

1/50 5.8 5.8 5.8 5.8 5.8 5.8 5.8 5.8 5.8

fz = fzo · Kae

Please note: The feed per tooth fz should not exceed 0.6 mm.


Determining the feed of copy mills: f 2010, f 2334

48

Cutter types


f 2010 / f 2334

Tool dia. or dia. range [mm] 25 / 32 32 / 66 40–80 52–250 63–160

max. depths of cut ap max = Lc [mm] 4 5 6 8 10

P

Unalloyed steel* 0.11 0.17 0.22 0.28 0.33

Low-alloyed steel* 0.09 0.13 0.15 0.22 0.28

High-alloyed steel and tool steel* 0.09 0.13 0.15 0.22 0.28

Stainless steel,* martensitic 0.07 0.09 0.11 0.13 0.17

KGrey cast iron 0.13 0.22 0.28 0.33 0.39

Cast iron with spheroidal graphite 0.11 0.17 0.22 0.28 0.33

Malleable cast iron 0.11 0.17 0.22 0.28 0.33

Indexable insert types RO . X 0803

RO . X 10T3

RO . X 1204

RO . X 1605

RO . X 2006



ae / Dc = 1/1–1/2 1.0 1.0 1.2 1.2 1.2

1/5 1.2 1.2 1.4 1.4 1.4

1/10 1.5 1.5 1.6 1.6 1.6

1/20 1.8 1.8 1.8 1.8 1.8

1/50 2.0 2.0 2.0 2.0 2.0



ap = 1 1.4 1.5 1.6 1.8 2.0

2 1.1 1.2 1.3 1.4 1.5

4 1.0 1.0 1.1 1.2 1.5

5 1.0 1.0 1.1 1.2

6 1.0 1.1

8 1.1

10 1.0


* and cast steel

Dc

Lc

Circular interpolation mill: f 4081


Cutter types

Feed per tooth fzo for ae = Da ap = ap max = Lc

f 4081

Xtra·tec®

Lead angle κ 45°

fzo = [mm]

Tool dia. or dia. range [mm] 36 - 85 52 - 85

max. depths of cut ap max = Lc [mm] 3 4

P

Unalloyed steel* 0.40 0.45

Low-alloyed steel* 0.36 0.40

High-alloyed steel and tool steel* 0.27 0.32

Stainless steel,* martensitic 0.18 0.22

KGrey cast iron 0.40 0.45

Cast iron with spheroidal graphite 0.32 0.36

Malleable cast iron 0.32 0.36

Indexable insert types OD . . 0504 . . OD . . 0605 . .



ae / Dc = 1/1–1/2 1.0 1.0

1/5 1.1 1.1

1/10 1.2 1.2

1/20 1.3 1.3

1/50

fz = fzo · Kae

* and cast steel

Da

Lc



50

Cutter types


f 4080 f 2330 f 4030


Lead angle κ 43° 0 – 15° 0 – 21°


Tool dia. or dia. range [mm] 32 - 125 50 - 170 20 - 25 32 - 85 52 - 85 25 - 63

max. depths of cut ap max = Lc [mm] 3 4 1 1.5 2 1

P

Unalloyed steel* 0.40 0.45 1.00 1.40 1.80 1.40




KGrey cast iron 0.40 0.45 0.90 1.25 1.60 1.30

Cast iron with spheroidal graphite 0.32 0.36 0.90 1.25 1.60 1.30

Malleable cast iron 0.32 0.36 1.00 1.40 1.80 1.40

Indexable insert types OD . . 0504 . . OD . . 0605 . . P2633.-R10P26379–R10

P2633.-R14P26379–R14

P2633.-R25P26379–R25

P23696-1.0



ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0 1.0 1.0

1/5 1.1 1.1 1.4 1.4 1.4 1.4

1/10 1.2 1.2 1.8 1.8 1.8 1.8

1/20 1.3 1.3

1/50

fz = fzo · Kae

* and cast steel

Da

Lc

Circular interpolation mills: f 4080, f 2330, f 4030


Cutter types


f 4080 f 2330 f 4030


Lead angle κ 43° 0 – 15° 0 – 21°


Tool dia. or dia. range [mm] 32 - 125 50 - 170 20 - 25 32 - 85 52 - 85 25 - 63

max. depths of cut ap max = Lc [mm] 3 4 1 1.5 2 1

P

Unalloyed steel* 0.40 0.45 1.00 1.40 1.80 1.40




KGrey cast iron 0.40 0.45 0.90 1.25 1.60 1.30

Cast iron with spheroidal graphite 0.32 0.36 0.90 1.25 1.60 1.30

Malleable cast iron 0.32 0.36 1.00 1.40 1.80 1.40

Indexable insert types OD . . 0504 . . OD . . 0605 . . P2633.-R10P26379–R10

P2633.-R14P26379–R14

P2633.-R25P26379–R25

P23696-1.0



ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0 1.0 1.0

1/5 1.1 1.1 1.4 1.4 1.4 1.4

1/10 1.2 1.2 1.8 1.8 1.8 1.8

1/20 1.3 1.3

1/50

fz = fzo · Kae



52

Cutter types


f 2334 f 4042

Xtra·tec®

Lead angle κ 90°

fzo = [mm] fzo = [mm]

Tool dia. or dia. range [mm] 25 - 32 32 - 66 40 - 80 52 - 141 63 - 160 10 - 50 16 - 63 25 - 80 40 - 160 50 - 160

max. depths of cut ap max = Lc [mm] 4 5 6 8 10 8 10 11.7 15 16.7

P

Unalloyed steel* 0.11 0.17 0.22 0.28 0.33 0.13 0.16 0.18 0.22 0.27

Low-alloyed steel* 0.09 0.13 0.15 0.22 0.28 0.09 0.10 0.13 0.16 0.20

High-alloyed steel and tool steel* 0.09 0.13 0.15 0.22 0.28 0.09 0.10 0.13 0.16 0.20

Stainless steel,* martensitic 0.07 0.09 0.11 0.13 0.17 0.07 0.09 0.10 0.13 0.16

KGrey cast iron 0.13 0.22 0.28 0.33 0.39 0.13 0.18 0.22 0.27 0.36

Cast iron with spheroidal graphite 0.11 0.17 0.22 0.28 0.33 0.10 0.13 0.18 0.22 0.27

Malleable cast iron 0.11 0.17 0.22 0.28 0.33 0.10 0.13 0.18 0.22 0.27

Indexable insert types RO . X0803 . . RO . X10T3 . . RO . X1204 . . RO . X1605 . . RO . X2006 . . AD . . T0803 . . AD . . T10T3 . . AD . . 1204 . . AD.T1606 . . AD.T1807 . .



ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

1/5 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

1/10 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

1/20 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3

1/50

fz = fzo · Kae

* and cast steel

Da

Lc

Circular interpolation mills: f 2334, f 4042


Cutter types


f 2334 f 4042

Xtra·tec®

Lead angle κ 90°

fzo = [mm] fzo = [mm]

Tool dia. or dia. range [mm] 25 - 32 32 - 66 40 - 80 52 - 141 63 - 160 10 - 50 16 - 63 25 - 80 40 - 160 50 - 160

max. depths of cut ap max = Lc [mm] 4 5 6 8 10 8 10 11.7 15 16.7

P

Unalloyed steel* 0.11 0.17 0.22 0.28 0.33 0.13 0.16 0.18 0.22 0.27

Low-alloyed steel* 0.09 0.13 0.15 0.22 0.28 0.09 0.10 0.13 0.16 0.20

High-alloyed steel and tool steel* 0.09 0.13 0.15 0.22 0.28 0.09 0.10 0.13 0.16 0.20

Stainless steel,* martensitic 0.07 0.09 0.11 0.13 0.17 0.07 0.09 0.10 0.13 0.16

KGrey cast iron 0.13 0.22 0.28 0.33 0.39 0.13 0.18 0.22 0.27 0.36

Cast iron with spheroidal graphite 0.11 0.17 0.22 0.28 0.33 0.10 0.13 0.18 0.22 0.27

Malleable cast iron 0.11 0.17 0.22 0.28 0.33 0.10 0.13 0.18 0.22 0.27

Indexable insert types RO . X0803 . . RO . X10T3 . . RO . X1204 . . RO . X1605 . . RO . X2006 . . AD . . T0803 . . AD . . T10T3 . . AD . . 1204 . . AD.T1606 . . AD.T1807 . .



ae / Dc = 1/1–1/2 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

1/5 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

1/10 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

1/20 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3 1.3

1/50

fz = fzo · Kae


Application-specific data

54

fACE MIllING (f 4080 ONly)Maximum cut depth ap [mm]

OD . . 0504 . . OD . . 0605 . .

ap1 3 4ap2 8 10

ap2ap1

CIRCUlAR INTERPOlATION INTO SOlID MATERIAlRange of diameters for milling of bore in one pass [mm]

Da [mm]

Indexable insertOD . . 050408 OD . . 060508

D0 min [mm]

D0 max [mm]

fmax [mm]

D0 min [mm]

D0 max [mm]

fmax [mm]

32 40.4 64 4.540 56.4 80 4.550 76.4 100 4.5 69.5 100 5.852 80.4 104 4.5 73.5 104 5.858 92.4 116 4.560 89.5 120 5.863 102.4 126 4.5 95.5 126 5.866 108.4 132 4.5 101.5 132 5.871 118.4 142 4.573 115.5 146 5.880 136.4 160 4.5 129.5 160 5.888 152.4 176 4.590 149.5 180 5.8

100 176.4 200 4.5 169.5 200 5.8108 192.4 216 4.5110 189.5 220 5.8125 226.4 250 4.5 219.5 250 5.8133 242.4 266 4.5135 239.5 270 5.8160 289.5 320 5.8170 309.5 340 5.8

f

D0

Da

f/2

f

D0

Da

f/2

f 4080 f 4081

Octagon cutters f 4080 / f 4081


INClINED PlUNGINGMax. feed angle E [°]

Da [mm] OD . . 0504 . . OD . . 0605 . . Da [mm] OD . . 0504 . . OD . . 0605 . .

32 14.0 88 2.440 8.3 90 4.050 5.5 9.6 100 2.0 3.152 5.1 8.9 108 2.058 4.6 110 3.160 7.7 125 1.5 2.363 3.8 6.2 133 1.566 3.5 5.8 135 2.371 3.2 160 1.773 5.4 170 1.780 2.7 4.3

E°

Da

Da

Tmax

VERTICAl PlUNGINGMax. plunging depth Tmax [mm]

OD . . 0504 . . OD . . 0605 . .

Tmax 2.8 4.0

Note: Please use the F 4081 with indexable inserts with corner radii only, e.g. ODHT060508...

ap



56

fACE MIllINGMaximum cut depth ap [mm]

P 2633 . – R 10P 26379 – R10

P 2633 . – R 14P 26379 – R14

P 2633 . – R 25P 26379 – R25

ap max 1 1.5 2

INClINED PlUNGINGMaximum feed angle E [°]

Da [mm] P 2633 . – R 10P 26379 – R10

P 2633 . – R 14P 26379 – R14

P 2633 . – R 25P 26379 – R25

20 4.025 2.332 2.535 2.040 1.542 1.452 1.2 2.366 0.9 1.485 0.6 1.0

E°

Da

PlUNGINGMaximum milling depth ae [mm]

P 2633 . – R 10P 26379 – R10

P 2633 . – R 14P 26379 – R14

P 2633 . – R 25P 26379 – R25

ap max 7 10.3 15 ae max

High-performance mill f 2330


CIRCUlAR INTERPOlATION INTO SOlID MATERIAlRange of diameters for milling of a hole in one pass [mm]

Da [mm]

Indexable insert

P 2633 . – R 10 P 26379 – R10*

P 2633 . – R 14 P 26379 – R14*

P 2633 . – R 25 P 26379 – R25*

D0 min [mm]

D0 max [mm]

D0 min [mm]

D0 max [mm]

D0 min [mm]

D0 max [mm]

20 24.2 4025 34.2 5032 41.8 6435 47.8 7040 57.8 8042 61.8 8452 81.8 104 70.4 102.666 109.8 132 98.4 130.685 147.8 170 136.4 168.6

D0

Da

ap max (f)

ap max2

Indexable insert R r rt k kr X

P 2633 . – R 10 10.0 0.8 2.0 4.0 1.8 0.5P 2633 . – R 14 14.0 1.2 2.5 5.5 2.6 0.8P 2633 . – R 25 25.0 2.0 3.0 8.0 3.4 0.9

Programming the theoretical tool radius “rt” results in a maximum deviation from the final contour as shown. The minimal difference (only in the corners) is corrected by the subsequent tools during the remaining machining operations.

k

Rrt

X kr

rPROGRAMMING INfORMATION

*Special geometry for circular interpolation milling (see Description of geometry, page 68)



58

ap

E°

Da

ae max


P 23696 – 1.0

ap1 1.0

INClINED PlUNGINGMax. feed angle E [°]

Da [mm] P 23696 – 1.0

25 10.532 8.035 7.040 5.542 5.050 3.852 3.563 2.5

PlUNGINGMaximum milling depth ae [mm]

Da [mm] P 23696 – 1.0

25 8.532 1035 1040 1042 1050 1052 1063 10

High-performance mill f 4030


D0

Da

ap max (f)

ap max2

CIRCUlAR INTERPOlATION INTO SOlID MATERIAlRange of diameters for milling of bore in one pass [mm]

Da

[mm]

P 23696 – 1.0

D0 min[mm] D0 max[mm]

25 33 5032 44 6435 50 7040 59 8042 63 8450 78 10052 82 10463 104 126

Indexable insert R r rt k kr X

P 23696–1.0 14.0 1.2 2.0 5.8 2.1 0.6

Programming the theoretical tool radius “rt” results in a maximum deviation from the final contour as shown. The minimal difference (only in the corners) is corrected by the subsequent tools during the remaining machining operations.

k

Rrt

X kr

r

PROGRAMMING INfORMATION



60

INClINED PlUNGING AND CIRCUlAR INTERPOlATION MIllING INTO SOlID MATERIAlPlunging with shoulder mill F 4042 / F 4042R

AD . . 080304a max = 8 mm

AD . . 10T308 a max = 10 mm

Mill dia. DC

[mm]

Plunging angle

Emax [ ° ]

D0 min

[mm]

D0 max

[mm]

a0

[mm]

Plunging angle

Emax [ ° ]

D0 min

[mm]

D0 max

[mm]

a0

[mm]

10 12.1 15 20 0.75

12 9.9 17 24 0.8

16 13.7 21 32 2.0 6.6 20 32 0.9

20 8.9 29 40 1.9 2.9 28 40 0.6

25 5.6 39 50 1.7 2 38 50 0.6

32 3.8 53 64 1.6 1.4 52 64 0.6

40 2.8 69 80 1.6 1.1 68 80 0.6

50 2.2 89 100 1.6 0.8 88 100 0.6

63 0.6 114 126 0.6

INClINED PlUNGING AND CIRCUlAR INTERPOlATION MIllING INTO SOlID MATERIAlPlunging with shoulder milling cutter F 4042

AD . . 120408a max = 11 mm

AD . . 160608a max = 15 mm

Mill dia. DC

[mm]

Plunging angle

Emax [ ° ]

D0 min

[mm]

D0 max

[mm]

a0

[mm]

Plunging angle

Emax [ ° ]

D0 min

[mm]

D0 max

[mm]

a0

[mm]

25 8.5 36 50 2.3

32 5.6 50 64 2.2

40 3.9 66 80 2.1 5.9 62 80 2.9

50 2.7 86 100 1.9 3.9 82 100 2.6

63 2.0 112 126 1.9 2.6 108 126 2.3

80 1.5 146 160 1.9 1.9 142 160 2.3

100 1.5 182 200 2.3

120 1.2 232 250 2.3

160 0.9 302 320 2.3

Shoulder mills f 4042, f 4042R


E

a1

Ea2 ≤ amaxa0

a1

Ea0 an

L

an

L

INClINED PlUNGING AND CIRCUlAR INTER- POlATION MIllING INTO SOlID MATERIAl

Plunging with shoulder milling cutter F 4042

AD . . 180712a max = 16 mm

Mill dia. DC

[mm]

Plunging angle

Emax [ ° ]

D0 min

[mm]

D0 max

[mm]

a0

[mm]

50 2.9 74 100 1.7

63 2.1 100 126 1.7

80 1.5 134 160 1.7

100 1.2 174 200 1.7

120 0.9 224 250 1.7

160 0.7 294 320 1.7

Explanation of letter symbols

a0 [mm] amount by which the tool is to be lifted off at the end of plunging before starting the next plunging operation

an [mm] cut depth

amax [mm] max. tool cut depth

E [°] feed angle

L [mm] groove length without radius

n Number of inclined plunging operations

Groove depth after plunging:

an = n · L · tan E – (n–1) · a0

Groove depth after 2 plunging operations:

a2 = 2 · L · tan E – a0

Number of inclined plunging operations:

n = (an – a0)

(L · tan Emax – a0)

Feed angle:

tan E = [an + (n–1) · a0]

(n · L)



62

CIRCUlAR fACE MIllINGMax. axial feed per tool revolution

(“thread pitch”) f [mm]

machined hole dia.D0 [mm]

AD . . 080304DC [mm]

10 12 16 20 25 32 40 50

15 3.420 6.7 4.430 8.0 8.0 8.0 4.940 8.0 8.0 8.0 8.0 4.750 8.0 8.0 8.0 8.0 7.860 8.0 8.0 8.0 8.0 8.0 5.880 8.0 8.0 8.0 8.0 8.0 8.0 6.2

100 8.0 8.0 8.0 8.0 8.0 8.0 8.0 6.0120 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0150 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0180 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0200 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0250 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0

CIRCUlAR fACE MIllINGMax. axial feed per tool revolution



AD . . 10T308DC [mm]

16 20 25 32 40 50 63

1520 1.530 5.1 1.640 8.7 3.2 1.650 10.0 4.8 2.760 10.0 6.4 3.8 2.180 10.0 9.5 6.0 3.7 2.4

100 10.0 10.0 8.2 5.2 3.6 2.2120 10.0 10.0 10.0 6.8 4.8 3.1 1.9150 10.0 10.0 10.0 9.1 6.6 4.4 2.9180 10.0 10.0 10.0 10.0 8.4 5.7 3.8200 10.0 10.0 10.0 10.0 9.7 6.6 4.5250 10.0 10.0 10.0 10.0 10.0 8.8 6.2

Shoulder mills f 4042, f 4042R (continued)


f

D0

DC

f/2

CIRCUlAR INTERPOlATION MIllINGMax. axial feed per tool revolution (“thread pitch”) f [mm]


AD . . 120408DC [mm]

AD . . 160608DC [mm]

25 32 40 50 63 80 40 50 63 80 100 125 160

40 7.050 11.0 5.560 11.0 8.680 11.0 11.0 8.7 13.1

100 11.0 11.0 11.0 7.4 15.0 10.8120 11.0 11.0 11.0 10.3 6.4 15.0 15.0 8.1150 11.0 11.0 11.0 11.0 9.7 3.4 15.0 15.0 12.4 7.5180 11.0 11.0 11.0 11.0 11.0 5.9 15.0 15.0 15.0 10.7200 11.0 11.0 11.0 11.0 11.0 8.5 15.0 15.0 15.0 12.8 8.2250 11.0 11.0 11.0 11.0 11.0 10.2 15.0 15.0 15.0 15.0 12.3 8.0300 11.0 11.0 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0 11.2350 11.0 11.0 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0 14.4 9.3400 15.0 15.0 15.0 15.0 15.0 15.0 11.7450 15.0 15.0 15.0 15.0 15.0 15.0 14.2500 15.0 15.0 15.0 15.0 15.0 15.0 15.0

CIRCUlAR INTERPOlATION MIllINGMax. axial feed per tool revolution



AD . . 180712DC [mm]

50 63 80 100 125 160

80 4.8100 7.9 4.2120 11.1 6.5150 15.9 10.0 5.9180 16.0 13.4 8.4 5.1200 16.0 15.7 10.1 6.4250 16.0 16.0 14.3 9.6 6.1300 16.0 16.0 16.0 12.8 8.6 5.2350 16.0 16.0 16.0 16.0 11.1 7.1400 16.0 16.0 16.0 16.0 13.5 8.9450 16.0 16.0 16.0 16.0 16.0 10.8500 16.0 16.0 16.0 16.0 16.0 12.6



64

f

D0

Da

d

tR

f/2

ar

apmax

d

CIRCUlAR INTERPOlATION INTO SOlID MATERIAlRange of diameters for milling of a hole in one pass [mm]

Da

[mm]

Insert diameter d [mm]

d = 8 d = 10 d = 12 d = 16 d = 20

D0 min

[mm]D0 max

[mm]D0 min

[mm]D0 max

[mm]D0 min

[mm]D0 max

[mm]D0 min

[mm]D0 max

[mm]D0 min

[mm]D0 max

[mm]

25 34.6 5032 48.4 64 45 6440 61 80 57.4 8050 81.4 100 77.2 10052 85 104 81.2 104 75.4 10463 102.4 126 103.2 126 97.6 12666 113 132 109.4 132 103.4 132 97 13280 137.8 160 131.4 160 124.8 16096 163.4 192

100 171.4 200 164.8 200116 203.4 232125 221.4 250 214.8 250141 253.4 282160 284.8 320



d = 8 d = 10 d = 12 d = 16 d = 20

apmax [mm] 4.0 5.0 6.0 8.0 10.0

Round insert cutter f 2334


f

D0

Da

d

tR

f/2

ar

CIRCUlAR INTERPOlATION INTO SOlID MATERIAlGroove depth on the hole wall tR [mm]

axial feed rate per revolution

f [mm]


d = 8 d = 10 d = 12 d = 16 d = 20

1 0.031 0.025 0.02 0.015 0.012 0.127 0.010 0.08 0.06 0.053 0.292 0.230 0.19 0.14 0.114 0.536 0.417 0.34 0.25 0.205 0.878 0.670 0.54 0.40 0.326 (1.000) 0.80 0.58 0.467 (1.429) (1.12) 0.81 0.638 (1.53) (1.07) 0.84

ar max 1.25 1.5 2.0 3.0 4.5



66

VERTICAl PlUNGINGMaximum plunging depth Tmax [mm]

Indexable insert diameter d [mm]

d = 8 d = 10 d = 12 d = 16 d = 20

Tmax [mm] 2.4 2.6 3.1 1.2 1.6

Dad

E°

apmax

INClINED PlUNGINGMaximum feed angle E [°]

Da

[mm]

Indexable insert diameter d [mm]

d = 8 d = 10 d = 12 d = 16 d = 20

25 10.532 6.8 8.640 5.8 7.950 4.0 5.452 3.9 5.3 6.163 3.0 3.4 4.466 2.8 3.4 4.1 5.380 2.6 3.1 3.996 2.4

100 2.3 2.8116 1.9125 1.7 2.1141 1.5160 1.5

ap max [mm] 6.9 8.8 10.5 1.9

d

Tmax

0 15 30 45 60 70 90

1

0

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

d=20

d=16

d=12

d=10

d=8

Da

vf

Ez°

apz

d

Round insert cutter f 2334 (continued)

UP MIllING Of STEEP SURfACESF 2334: Maximum plunging depth Tmax [mm]



Description of indexable insert geometry

68

Geo

met

ry

exam

ple

Remarks on application area

CutMain cutting edge

Workpiece material group

suita

ble

tool

fa

mili

es

P M K N S H

P 26335 – The easy-cutting one

for good machining ‡conditionslow cutting forces ‡medium feed rates ‡

C C C C C C C C

f 2010f 2330

P 26337 – The stable one

for unfavourable ‡machining conditionsmaximum cutting edge ‡stabilityhigh feed rates ‡

0°

C C C C C C

P 26339 – The universal one

for medium machining ‡conditions universal application for ‡most materials

Cutting edge0°

C C C C C C C C

Main cutting edge

10°

P 26379 – The special one

for circular interpolation ‡milling universal application for ‡most materialstrailing edge version ‡

Cutting edge0°

C C C C C C C C

Main cutting edge

10°

C C Primary applicationC Additional application

P = Steel M = Stainless steelK = Cast ironN = Non-ferrous metalsS = Materials with difficult cutting propertiesH = Hard materials

10°

face mills and circular interpolation mills


Geo

met

ry

exam

ple




suita

ble

tool

fa

mili

es

P M K N S H

P 23696-1 – The universal one

for medium to ‡ unfavourable machining conditions universal application for ‡most materials

20°

C C C C C C C C

F 4030

OD . .

A27 – The stable onefor unfavourable ‡ machining conditionsmaximum cutting edge ‡stabilityhigh feed rates ‡

0°

C C C C

f 2010f 4080f 4081

A57 – The special onefor medium machining ‡conditionspredominantly for cast ‡iron machining

0°

C C C

D57 – The universal onefor medium machining ‡conditions universal application for ‡most materials

10°

C C C C C C C C

F57 – The easy-cutting one


16°

C C C C C C C C

G88 – The sharp onefor machining aluminium ‡low cutting forces ‡sharp cutting edges ‡

20°

C C



Description of indexable insert geometry

70



Geo

met

ry

exam

ple




suita

ble

tool

fa

mili

es

P M K N S H

SN . X . .

D27 – The special onefor machining cast iron ‡materialsfor sand inclusions or ‡casting skinmaximum process ‡ reliability

10°

C C C

F 2010F 4033F 4047F 4048

F27 – The stable onefor unfavourable ‡ machining conditionsmaximum cutting edge ‡stabilityhigh feed rates ‡

16°

C C C C C C

F57 – The universal onefor medium machining ‡conditions universal application for ‡most materials

16°

C C C C C C C C

F67 – The easy-cutting one


16°

C C C C C C C C

K88 – The sharp onefor machining aluminium ‡low cutting forces ‡sharp cutting edges ‡

22°

C C

face and shoulder mills



Geo

met

ry

exam

ple




suita

ble

tool

fa

mili

es

P M K N S H

XNHF . .

D27 – The stable onefor unfavourable ‡ machining conditionsmaximum cutting edge ‡stabilityhigh feed rates ‡

10°

C C C

F 4045

D57 – The universal onefor medium machining ‡conditions universal application ‡

10°

C C C

D67 – The easy-cutting one


10°

C C C

LNGX . .

L55 – The universal onefor medium machining ‡conditions universal application for ‡most materials

20°

C C C C C C C C

F 2010F 4041

L88 – The sharp onefor machining aluminium ‡low cutting forces ‡sharp cutting edges ‡

28°

C C


Description of indexable insert geometry – shoulder mills

72

Geo

met

ry

exam

ple




suita

ble

tool

fa

mili

es

P M K N S H

AD . T . .

D51 – The quiet oneantivibration geometry ‡for tools with longer ‡projection lengths

10°

C C C C C C

F2010F 4042F 4042RF 4038F 4138 F 4238F 4338

D56 – The stable onefor unfavourable machin- ‡ing conditionsmaximum cutting edge ‡stabilityhigh feed rates ‡

10°

C C C C C C

D67 – The powerful onehigh cutting edge stability ‡ for machining high-alloy ‡and high-tensile steels and Ni-based alloyshigh level of accuracy ‡

10°

C C C C C C C

F56 – The universal onefor medium machining ‡conditions universal application for ‡most materials

16°

C C C C C C C C

G56 – The easy-cutting one


20°

C C C C C C C C

G77 – The special onefor machining titanium ‡materialslow cutting forces ‡high level of accuracy ‡

20°

C C C C C

G88 – The sharp onefor machining aluminium ‡low cutting forces ‡sharp cutting edges ‡

20°

C C

Copy mill




Geo

met

ry

exam

ple




suita

ble

tool

fa

mili

es

P M K N S H

RO . X . .

A27 – The stable onefor unfavourable ‡ machining conditionsmaximum cutting edge ‡stabilityhigh feed rates ‡

0°

C C C C

F 2010F 2334

D57 – The universal onefor medium machining ‡conditions universal application for ‡most materials

10°

C C C C C C C C

D67 – The powerful onehigh cutting edge stability ‡ for machining high-alloy ‡and high-tensile steels and Ni-based alloys, e.g. Inconelhigh level of accuracy ‡

10°

C C C C C C C

G77 – The special onefor machining titanium ‡materialslow cutting forces ‡high level of accuracy ‡

20°

C C C C C


Description of side and face mill geometry

74



Geo

met

ry

exam

ple




suita

ble

tool

fa

mili

es

P M K N S H

LN . X . .

D57T – The stable onefor unfavourable ‡ machining conditionsmaximum cutting edge ‡stabilityhigh feed rates ‡

12°

C C C C

F 4053

F57T – The universal onefor medium machining ‡conditions universal application for ‡most materials

18°

C C C C C C C C

LN . U . .

B57T – The stable onefor unfavourable ‡ machining conditionsmaximum cutting edge ‡stabilityhigh feed rates ‡

6°

C C C C

F 4153F 4253

F57T – The universal onefor medium machining ‡conditions universal application for ‡most materials

16°

C C C C C C C C

Workpiece material groups


SteelRm

(N/mm2)kc 1.1

(N/mm2)mc

P

Low-carbon soft steelsLow tensile ferritic steels

<450 1350 0.21

Low-carbon free cutting steels 400 <700 1500 0.22

Normal structural steels, low to medium content of carbon (< 0.5 % C)

450 <550 1500 0.25

Normal, low-alloy steels and cast steel; tempering steel; carbon steel (> 0.5 % C); ferritic and martensitic, stainless steels

550 <700 1700 0.24

Normal tool steels; harder tempering steels; martensitic, stainless steels

700 <900 1900 0.24

Hard-to-machine tool steels, hard, high-alloyed steels and cast steel, martensitic stainless steels

900 <1200 2000 0.24

High tensile steels with difficult cutting properties; hardened steels of groups 3 – 6; martensitic, stainless steels

>1200 2900 0.22

Cast ironRm

(N/mm2)kc 1.1

(N/mm2)mc

K

Cast iron of medium hardness, grey cast iron 1150 0.22

Low-alloyed cast iron, malleable cast iron, nodular cast iron

1225 0.25

Cast iron alloy of medium hardness, malleable cast iron, GGG, average cutting properties

1350 0.28

Hard-to-machine, high-alloyed cast iron, malleable cast iron, GGG, hard to machine

1470 0.30


Calculation formulae

76

n Speed rpm

DC Drill diameter mm

ap Depth of cut mm

ae Width of cut mm

z Number of teeth

vc Cutting speed m/min

vf Feed rate mm/min

fz Feed per tooth mm

Q Metal removal rate cm3/min

Pmot Drive power kW

hm Medium chip thickness mm

kc Specific cutting force N/mm2

h Machine’s level of efficiency (0.7–0.95)

κ Lead angle °

js Engagement angle °

kc1.1* Specific cutting force for 1 mm2

Chip cross section N/mm2

mc* Increase in the kc curve

Rake angle °

*mc and kc1.1 see table on page 75

Speed

Cutting speed

Feed rate

Feed per tooth

Metal removal rate

Power requirement


fz

hm Vfφm

φs

φ1

φ2

Dc

ae

φs

φ1

φ2 = 90°

Dcae

y = ae–Dc/2

Medium chip thickness

or

as an approximation for ae/Dc < 30 %

Specific cutting force

Engagement angle

where cutter is positioned centrally

where cutter is positioned eccentrically

fORMATION Of HAIRlINE CRACKS

featureIn relation to the cutting edge, vertical small cracks that can result in chipping along the edge and fractures in the indexable insert.

CauseFormation of hairline cracks resulting from stresses caused by changes in temperature

due to an interrupted cut (brief –contact time between cutting edge and workpiece, long cooling phase)use of coolant (thermal shock) –

Remedy / measure(s)

try working without coolant –use a tougher cutting material –reduce the cutting speed –

flANK fACE WEAR

featureThe most frequently occurring type of wear, affecting the flank face.

Causecaused by abrasion between the –flank face and workpieceduring roughing, this often leads to –vibrations and increased capacity requirements. During finishing, it can lead to poor surfaces

Remedy / measure(s)

use a wear-resistant cutting material –Reduce the cutting speed –increase the feed –


Problem solving

78

CHIPS AlONG THE EDGE

featureChipping along the edges of small sections of the cutting material in the cutting edge.

Causemechanical overload leads to small –sections of the cutting material in the cutting edge breaking offmay be a result of hairline cracks –

Remedy / measure(s)

select a more stable geometry (longer –removal phase)ensure a stable machining process –use a tougher cutting material –

PlASTIC DEfORMATION

featureCutting edge deformed in some other, undefined manner.

Causeoccurs at high machining tempera- –tures in conjunction with a high mechanical load, because of “softening” and “yielding” of the cutting tool materialleads to a sudden and sharp increase –in the machining temperature and cutting force, fluctuations in dimen-sions and poor surfaces on the component, and sometimes frac-tures in the cutting edge

Remedy / measure(s)

use a wear-resistant cutting material –reduce the cutting speed –reduce feed –


80


Problem solving

Problem

Remedy / measure(s)

Cutt

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Built-up cutting edge + + ~ + –Formation of hairline cracks – +Chips on contact with the workpiece – –Machine overload – – +Rattling, vibration ~ ~ ~ ~Poor workpiece surface + – –Chipping along the cutting edge – + ~ +Deformation of the cutting edge – – +~Chip formation, accumulation of chips ~ ~Excessive crater wear – – +Excessive flank face wear – +Indexable insert fracture – + ~

+ increase– decrease, reduce~ check, optimise

Walter AG

Derendinger Str. 53, 72072 Tübingen Postfach 2049, 72010 Tübingen Germany

www.walter-tools.com

Walter GB lTD.Bromsgrove, England +44 (1527) 839 450 [email protected] Walter Kesici Takimlar Sanayi ve Ticaret limited Sirketi Istanbul, Turkey +90 (216) 528 1900 Pbx [email protected]

Walter Wuxi Co. ltd.Wuxi, Jiangsu, P.R. China +86 (510) 8241 9399 [email protected]

Walter AG Singapore Pte. ltd.+65 6773 6180, [email protected]

Walter Korea ltd.Ansan, Kyungki-do, Korea +82 (31) 3646 100 [email protected]

Walter Tools India Pvt. ltd.Pune, India +91 (20) 2714 5028 [email protected]

Walter (Thailand) Co., ltd.Bangkok, Thailand +66 (2) 687 0388, [email protected]

Walter Malaysia Sdn. Bhd.Selangor D.E., Malaysia +60 (3) 8023 7748 [email protected]

Walter Australia Pty. ltd.Victoria, Australia +61 (3) 8793 1000 [email protected]

Walter Tooling Japan K.K.Nagoya, Japan +81 (52) 723 5800 [email protected]

Walter USA, llCWaukesha (WI), USA +1 800-945-5554 [email protected]

TDM Systems Inc.Schaumburg (IL), USA +1 (847) 605 1269, [email protected]

Walter Tools S.A. de C.V.Saltillo Coahuila, Mexico +52 (55) 5365-6895 [email protected]

Walter CanadaMississauga, Canada [email protected] Pr

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