2009 Product Catalog

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Elinor Lorena Terry
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1 2009 Product Catalog

2 Index Page Profile Milling Program s SFCY Cylindrical Steel Holder - Ball SFTA Taper Steel Holder - Ball CYF Cylindrical Steel Holder - Flat TAF Taper Steel Holder - Flat TAV, CY, TA Spike-ine Cylindrical Steel CB SFCY Cylindrical Carbide Holder - Ball CB CYF Cylindrical Carbide Holder - Flat CB TAV Spike-ine Taper Carbide Holder - Ball & Flat CB TA Taper Carbide Uni- Holder - Ball & Flat SF CY/CYF Screw-on Head - Ball & Flat Solid Carbide Adaptor Inserts Cutting Parameters Calculating Speed & Feed Profile Modular Shrink System s Copy Milling Program s FM Style 1 Toroid Cylindrical End Milling Cutter FM Style 2 Toroid Taper End Milling Cutter FMA Arbor Style Milling Cutter Insert ata Cutting Parameters High Feed Indexable Milling Program s HFSC Modular Screw-on Heads HFA Shell Milling Cutters HFSS End Milling Cutters Insert ata Machining Application ata Solid Carbide End Mill Program EIS Square EIB Square - Bullnose BI Ball TOI Toroid HFI4 High Feed Four Flute Solid Carbide High Feed Cutting Parameters EIS Flute ong Series - Square EIS Flute ong Series - Square EISA 3 Flute BIA 3 Flute - Ball BI2 2 Flute - ong Series - Ball BI4 4 Flute - ong Series - Ball EIV4 4 Flute Variable - Square, 45 Chamfer BI Flute - Ball EIS2 2 Flute - Square EIS4 4 Flute - Square Millstar Metric ing System Page 1

3 Profile Milling Program s Indexable Milling Holder Identification System CB SFCY enotes Material CB = Carbide = Steel Type SFCY = Cylindrical CY = Cylindrical Spike SFTA = Taper TA = Taper Spike iameter Size Cutter Cutter iameter The Inserts Millstar inserts are fully ground precision inserts for better chip control, faster metal removal and higher surface accuracies. They are far more accurate than pressed and O.. sharpened inserts. Millstar insert radius and seat are accurate to +/ (+/ mm) of nominal radius and cut exactly as programmed. This unparalleled accuracy also eliminates redundant Z-axis pick ups and assures accurate blending. Positive ground chipbreaker or strong negative cutting edge designs guarantee outstanding cutting performance in a wide variety of ferrous and non-ferrous materials. A choice of state-of-the-art insert grades, designs and tool coatings allow for optimum speed and feed rates in wet and dry machining. Reduced machining times by 25% to 60% are not uncommon. Economical one-piece inserts with two cutting edges are cost-effective for contour milling. True radius geometry is fully CNC-ground for higher machining accuracy and greatly reduced manual finishing and polishing time. Choose from side-cutting ball nose inserts with 180 degree nose radius, and popular ball nose inserts with a cutting edge covering 230 degrees for steep wall up-and-down ramping, profiling, contour milling and blending, and for a wider range of applications compared to conventional ball nose tools. Select from a variety of flat bottom, back draft and toroid inserts for steep or straight wall milling with long extensions on hard to reach cores, cavities or fillets. Milling with small radii prevents deflection and results in superior finishes and contour accuracies. Available with or without chipbreaker and coating in a variety of corner radii and sizes. Rock Solid Insert Clamping Cutting insert clamping is highly accurate and rigid. Unique V-pocket design gives a truly positive seat for the insert and will not allow insert movement when milling with a side thrust. Sandwiched insert clamping with single locking screw is unsurpassed for rigidity. The advanced design of Millstar inserts eliminates heat-seizing of locking screws or insert movement due to costly locating screws or pins of less advanced design. Positive V-pocket seating eliminates mismatch when changing to fresh inserts. It also eliminates the need to program new length or diameter offsets. The Holders Millstar is proud to offer the largest selection of roughing and finishing ball nose, back draft, flat bottom and toroid milling cutters available from one source. Cylindrical and tapered toolholders include the longest reach profiling tools available as standard catalog items. holders are inherently balanced for high spindle speeds. Machine with confidence at the increased speeds and velocities dictated by modern high velocity machining. Super intelligent machine controls with high speed data transfer, rapid advances in cutting edge materials and coating technologies enable ever faster machining speeds and increased productivity. Millstar tools are designed to keep pace. The Millstar product line is manufactured in the USA under ISO 9001 specifications, and all tools are fully traceable. Nearly six decades of cutting tool design and manufacturing for automotive, aerospace and many other industries, as well as special design capabilities using 3- CA allow us to respond quickly to requests for special designs. Page 2

4 SFCY - Cylindrical Steel Holder, Ball Profile Milling Program s 1 2 Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code SFCY MS 12 T20 SFCY MS 12 T20 SFCY MS 12 T20 SFCY ** mm MS 12 T20 SFCY MS 16 T20 SFCY MS 16 T20 SFCY MS 20 T20 SFCY MS 20 T20 SFCY MS 20 T20 SFCY MS 20 T20 SFCY MS 25 T20 SFCY ** mm MS 25 T20 SFCY MS 25 T20 SFCY MS 25 T20 SFCY ** mm MS 25 T20 SFCY MS 32 T30 SFCY MS 32 T30 SFTA - Taper Steel Holder, Ball MB, MBT, RB-N, BS-N Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code SFTA MS 12 T20 SFTA MS 16 T20 SFTA MS 20 T20 SFTA MS 20 T20 SFTA MS 25 T20 SFTA MS 25 T20 SFTA MS 25 T20 SFTA MS 32 T30 SFTA MS 32 T30 MB, MBT, RB-N, BS-N Page 3

5 CYF - Cylindrical Steel Holder, Flat Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code CYF MS 10 T15 CYF MS 12 T20 CYF MS 12 T20 CYF ** mm MS 12 T20 CYF MS 16 T20 CYF MS 20 T20 CYF MS 20 T20 CYF ** mm MS 20 T20 CYF MS 25 T20 CYF ** mm MS 25 T20 CYF MS 25 T20 CYF MS 25 T20 CYF ** mm MS 25 T20 CYF MS 32 T30 CYF MS 32 T30 B-N, B-R, BS, FB-R, TO, TOB-NF, HF TAF - Taper Steel Holder, Flat Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code TAF MS 10 T15 TAF MS 12 T20 TAF MS 16 T20 TAF MS 20 T20 TAF MS 25 T20 TAF MS 25 T20 TAF MS 25 T20 TAF MS 32 T30 TAF MS 32 T30 ** s with smaller shank diameter than cutter diameter for full-length side clearance. B-N, B-R, BS, FB-R, TO, TOB-NF, HF Page 4

6 Profile Milling Program s 1 2 TAV, CY, TA - Spike-ine Cylindrical Steel imensions Use with Inserts Size Ø Ø1 Ø2 TAV TAV Screw Key MS06N T MS08N T7 CY MS10 T15 CY MS10 T15 TA MS10 T15 Type Code VRBS, VB, MB, MBT, RB-N, BS-N, B, BS, FB, TO, HF 1 2 CB SFCY - Cylindrical Carbide Holder, Ball imensions Use with Inserts Size Ø Ø1 Ø2 Screw Key CBCY MS10 T15 CBCY MS10 T15 CBSFCY MS12 T20 CBSFCY ** mm MS12 T20 CBSFCY MS16 T20 CBSFCY ** mm MS20 T20 CBSFCY MS20 T20 CBSFCY MS25 T20 CBSFCY ** mm MS25 T20 ** s with smaller shank diameter than cutter diameter for full-length side clearance. Page 5 Type Code MB, MBT, RB-N, BS-N

7 CB CYF - Cylindrical Carbide Holder, Flat imensions Use with Inserts Size Ø Ø1 Ø2 Screw Key CBCYF MS12 T20 CBCYF ** mm MS12 T20 CBCYF MS16 T20 CBCYF ** mm MS20 T20 CBCYF MS20 T20 CBCYF MS25 T20 CBCYF ** mm MS25 T20 Type Code B-N, B-R, BS, FB-R, TO, TOB-NF, HF X 1 2 CB TAV - Spike-ine Taper Carbide, Ball & Flat imensions Use with Inserts Size Ø Ø1 Ø2 X Screw Key CBTAV * taper (3 /side) MS06N T7 CBTAV T* taper (3 /side) MS06N T7 CBTAV * taper (3 /side) MS08N T7 Type Code VRBS, VB X 1 2 CB TA - Taper Carbide Uni- Holder, Ball & Flat imensions Use with Inserts Size Ø Ø1 Ø2 CBTA taper X Screw Key 6 (3 /side) MS10 T15 Type Code MB, MBT, RB-N, BS-N, B, BS, FB, TO, HF Page 6

8 Profile Milling Program s SF CY - Screw-on Head, Ball 2 CYF - Screw-on Head, Flat Solid Carbide Adaptor 2 1 G1 G1 1 Size Ø iameter 1 iameter 2 Thread G1 Fits Ø SFCY 0375-SC-M M /10+12mm SFCY 0500-SC-M M /12mm SFCY 0625-SC-M M /16mm SFCY 0750-SC-M M /20mm SFCY 1000-SC-M M /25mm Use with Inserts Type Code MB, MBT, RB-N, BS-N 2 G1 1 Size Ø iameter 1 iameter 2 Thread G1 Fits Ø CYF 0375-SC-M M /10+12mm CYF 0500-SC-M M /12mm CYF 0625-SC-M M /16mm CYF 0750-SC-M M /20mm CYF 1000-SC-M M /25mm Use with Inserts Type Code B-N, B-R, BS, FB-R, TO, TOB-NF, HF Size Ø1 imensions Ø2 Thread G1 Screw Key CY SC-M M6 MS12 T20 CY SC-M M8 MS16 T20 CY SC-M M10 MS20 T20 CY SC-M M12 MS25 T20 Page 7

9 The Inserts Small Ball Nose & Back raft Inserts VRBS 2 VB 1 R imensions Grade R XRN TN escription VRBS Used for rough to finish-milling small radius or detail work, and surface milling in VRBS soft and herd steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling. VB Used for rough to finish-milling small radius or detail work, and surface milling in VB soft and herd steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling High Feed Inserts HF imensions Grade PR XRN TN escription HF Millstar HF insert is designed for High HF feed and High speed machining. It runs at high cutting speed and feed rates with HF shallow depth of cut. It allows the chip HF to flow up and out of the cut quickly. It HF allows heavy chip loads. Cutting Recommendations for High Feed Inserts Work Material USA/W.-Nr./ JIS H13/1.2344/ SK61 H13/1.2344/ SK61 H13/1.2344/ SK61 A2/1,2363/ SK12 A2/1,2363/ SK12 A2/1,2363/ SK12 Material Hardness Cutting epth at iameter ap max Cutting Width Cut speed at Max feed per tooth fz at cutting insert diameter Coating Insert Type Hrc Ae max Recom. sfm/min < % HF XRN/ ~ ~ ~ ~ ~ % HF XRN/ ~ ~ ~ ~ ~ % HF ~ ~ ~ ~ ~.04 < % HF XRN/ ~ ~ ~ ~ ~ % HF XRN/ ~ ~ ~ ~ ~ % HF ~ ~ ~ ~ ~.04 P20/1,2330 < % HF XRN/ ~ ~ ~ ~ ~.04 P20/1, % HF XRN/ ~ ~ ~ ~ ~.04 2/1,2379/ SK11 2/1,2379/ SK11 2/1,2379/ SK11 Grey Cast Iron/GG Cast Iron/ GGG Titanium (6A 4V) < % HF XRN/ ~ ~ ~ ~ ~ % HF XRN/ ~ ~ ~ ~ ~ % HF ~ ~ ~ ~ ~.04 < % HF XRN/ ~ ~ ~ ~ ~ % HF XRN/ ~ ~ ~ ~ ~ % HF XRN/ ~ ~ ~ ~ ~.04 Page 8

10 The Inserts Flat Bottom, Back raft, Toroid B-N B-R R XRN TN escription /32,1/16 B 0625 N /32,1/16,5/32 B 0750 N /32,1/16,1/8 Precision ground with 7º back taper. Used for milling of cores, cavities, filets with straight or very steep walls of harder materials. B 1000 N /32,1/16,1/8 B 1250 N /32,1/16,1/8 R XRN TN escription B 0375 R /32,1/16 B 0500 R /32,1/16,1/8 Precision ground with positive ground chip-breaker and 7º back taper. Used for milling of cores, cavities, filets with straight or very steep walls of softer materials. B 0500 N R The Inserts1/32,1/16,1/ B 0625 R /32,1/16 B 0750 R /32,1/16,1/8 B 1000 R /32,1/16,1/ B 1250 R BS FB-R R TO R TOB-NF R Page 9 Grade B 0375 N R imensions R 1/32,1/16,1/8 XRN TN escription BS / BS ,1/32,1/ BS /32,1/ BS /32,1/16,1/ BS /32,1/16,1/ Precision ground with unique crossover design between flat bottom FB and back draft B inserts. Allows straight walls with a larger step down than B. Allows higher cutting speeds and feeds. R XRN TN escription FB 0250 R FB 0312 R FB 0375 R /32 FB 0500 R /32,1/16,1/8 Precision ground with positive ground chip-breaker. Flat bottom inserts for shoulder milling, fillet finishing and long reach angular wall finishing of softer materials. FB 0625 R /32,1/16 FB 0750 R /32,1/16,1/8 FB 1000 R /32,1/16,1/8 FB 1250 R /32,1/16,1/8 R XRN TN escription TO TO TO TO TO Precision ground large corner radius & back taper for spiral and packet milling. Milling of pre-hard and hardened flat surfaces at higher speeds than tools with smaller corner radii. Good choice for HS milling of Aluminum. TO R XRN TN TOB 0500-NF TOB 0625-NF TOB 0750-NF TOB 1000-NF escription Millstar inserts designed for high seed high feed roughing of Aluminum, but also has the versatility to be used for fine finishing as well.

11 BS-N S imensions Grade S XRN TN Ball Nose Inserts escription BS 0375 N Sidecutting, non-chipbreaker. Side cutting BS 0500 N insert used in cavity and core profiling, for blending of fillets on medium and hard BS 0625 N materials. BS 0750 N BS 1000 N BS 1250 N MB XRN TN escription MB Unique cutting edge allows performance in all MB operations in material below 42 HRc; in semi, & finishing operations above. Significant benefits MB in heat-treated intricate geometries. Insert MB MB geometry allows smoother cutting motiondiminishing heat build up & tool deflection, MB reduces vibration caused by cutting action. MBT XRN TN escription MBT Precision ground, harder grade, for semi-finish MBT and finish milling. Excellent choice for unattended finish milling at small depth and high MBT speeds and feed rates. MBT MBT MBT RB-N XRN TN escription RB 0375 N Precision ground, non-chipbreaker. Best choice RB 0500 N for cavity, core and profile milling of pre-hard and fully hard die/mold steels, cast steels and RB 0625 N cast iron. Strongest cutting edge design. RB 0750 N RB 1000 N RB 1250 N Insert Coatings NA Non-coated grade. The lowest cost choice. May be used at normal speeds, or lower speeds on older machines, for all purpose milling. May be resharpened or altered. XRN Multi-layer hybrid coating of AlTiCrN. This coating has very good heat resistance and also a low friction coefficient. The XRN coating is designed for use in HSM of un-heat treated softer materials such as Titanium, Inconel, Stainless Steels and other gummy materials that require the use of liquid coolant. TCN Titanium Carbo-Nitride PV multi layer coating. Higher hardness and toughness than TIN. Choose on heavy cuts or high feeds and speeds, preferably with coolant. Excellent crater and wear resistance. Useful on abrasive and gummy materials (cast iron, brass, aluminum alloys) and on stainless steels and highly alloyed materials, including nickel and chrome based alloys. Millstar s new coating is a multi-layer hybrid Nano coating. This new coating has very good heat resistance and high hardness. The coating is designed for use in HSM of Heat Treated materials up to 72 HRc Customers using our new coating are seeing average tool life increases of 3-4 times more than the competition. life increases as much as 10 times have been documented. ATiN-EXAON (TN) Titanium Aluminum Nitride advanced PV coating. A special, improved ATiN coating approaching surface hardness of CBN on a tough substrate. Recommended for tough and hard metal machining applications. When high cutting temperatures are encountered the coating acts as a heat barrier, protecting the cutting edge. This allows for aggressive, high speed and dry milling so often encountered in today s die and mold machining. Use on tool, die and higher alloy steels, especially at hardness over 40 HRc. Also appropriate for all stainless steels (300, 400 and PH series), nickel alloys, titanium, nodular and gray cast iron. Also useful in machining carbon graphite. M iamond coating. Custom coating for cutting non-ferrous, non-metallic and very abrasive materials at highly elevated speeds. Use on copper, bronze, brass, aluminum-silicon alloys, carbon graphite, solid and fiber-reinforced plastics, ceramics and composite materials. Custom tool coatings for specific applications are available by request. Page 10

12 Choosing Cutting Parameters Cutting Conditions for Using Steel Holders WORKING MATERIA HARNESS GRAE SFM FEE fn (inch/rev) Ap Max Ae Max INSERT IAMETER (inch) mm mm ow Alloy Steel (1.7225) HB TN /10 /40 Alloy & ie Steel (1.2311, P20, ME2/3/5) 32-42HRC TN /8 /35 Steel (1.2344, ) 42-52HRC TN /6 /30 Stainless Steel (1.4301, ) HB XRN,TCN,TN /10 /40 Gray Cast Iron (GG25-GG30) HB TN /10 /50 Nodular Cast Iron (GGG60-GGG70) HB TN /15 /50 Copper Alloy HB XRN /10 /40 Aluminum Alloys HB XRN /10 /50 Graphite TN /20 /50 Ni & Co Based Alloy HB XRN, /8 /30 Titanium Alloy (Annealed) <350HB XRN, /8 /33 Titanium Alloy (Sol. Treated/Aged) <380HB XRN, /8 /35 Cutting Conditions for Using Carbide Holders WORKING MATERIA HARNESS GRAE SFM FEE fn (inch/rev) Ap Max Ae Max INSERT IAMETER (inch) mm mm ow Alloy Steel (1.7225) HB TN /10 /50 Alloy & ie Steel (1.2311, P20, ME2/3/5) 32-42HRC TN /8 /40 Steel (1.2344, ) 42-52HRC TN /6 /35 Stainless Steel (1.4301, ) HB XRN,TCN,TN /10 /50 Gray Cast Iron (GG25-GG30) HB TN , /10 /40 Nodular Cast Iron (GGG60-GGG70) HB TN /10 /40 Copper Alloy HB XRN /10 /40 Aluminum Alloys HB XRN /10 /40 Graphite TN /20 /40 Ni & Co Based Alloy HB XRN, /8 /50 Titanium Alloy (Annealed) <350HB XRN, /8 /50 Titanium Alloy (Sol. Treated/Aged) <380HB XRN, /8 /50 Harden Steel (1.2344, ) 45-55HRC, TN /8 /35 Page 11

13 Calculating Cutting Speed and Feed 1. Find the Cutting Speed Vc (m/min) & Feed fn (mm/n -1 ) Find Vc and fn range in Table 1 or Table 2 on opposite page. Choose the average value for Vc and the lower value for feed in the range. 2. Compute the w In order to compute the RPM value of the spindle it is necessary to determine the w which is the effective engaged tool diameter. The w depends on the geometry of the inserts (ball nose or toroid) and the relative position of the tool against the working piece surface. Example calculation is of w is presented to the right. 3. Calculate Spindle Speed N(n/min) Use the formula: N = (V c * 1,000)/π * w Table 3 - WORKING IAMETER FOR BA NOSE TOOS Ø epth of cut w Working iameter (inch) Actual effective cutting diameter Table 4 - WORKING IAMETER FOR TOROI TOOS Insert iameter epth of cut w Working iameter (inch) Actual cutting diameter of toroid inserts Calculate the Table Feed V f (m/min) Use the formula: V f = N * f n * K f. K f is the feed rate multiplier coefficient taking inconsideration that chip load is less than theoretical value. Take the value of K f from Table 5 or Table 6. Table 5 - FEE RATE MUTIPIER FOR BA NOSE INSERTS Insert iameter epth of cut FEERATE MUTIPIER FACTORS (for Working iameters w) Table 6 - FEE RATE MUTIPIER FOR TOROI TOOS Insert iameter epth of cut FEERATE MUTIPIER FACTORS (inch) (for Toroid Working iameters w) Page 12

14 Shrink Fit System Carbide Modular Shrink System Millstar s Carbide Modular Shrink System offers versatility, strength and accuracy. The carbide shank offers strength and rigidity and the shrink tolerances offer better accuracy than screw on type systems. These tools are designed for high speed machining and hard metal machining and will allow for better tool life as well as better surface finishes T1 1 CHTAV-0250-T CHTAV-0312-T1 T1 1 T T1 1 CHTA-0375-T T1 1 CHY-0500-T1 CHF-0500-T T2 T2 1 CHY-0625-T2 / CHF-0625-T T3 T3 1 CHY-0750-T3 / CHF-0750-T3 Page 13

15 Shrink Fit head Insert Type Shrink Fit imensions imensions Code Ø1 VB, VRBS CHTAV-0250-T CHTAV-0312-T TO, HF, FB, BS, MB,MBT, B, TOB-NF CHTAV-0375-T RB, MB, MBT, BS CHY-0500-T FB, B, BS, HF, TO, TOBNF CHF-0500-T BS, RB, MB, MBT CHY-0625-T FB, B, BS, HF, TO, TOBNF CHF-0625-T RB, BS, MB, MBT CHY-0750-T FB, B, BS, HF, TO, TOBNF CHF-0750-T Ø1 CSS T1 CSS T CSS T2 CSS T CSS T3 CSS T3 CSS T mm Page 14

16 Copy Milling Program s High Performance Milling from Heavy Roughing to Fine Finishing Millstar face mills are equally useful on newer high velocity machines and older slower equipment and will optimize milling performance of all your machine tools. The hardened tool bodies can be run at aggressive spindle speed and feed rates, when used with Millstar s precision ground, strong and thick, round inserts with proven hard, high performance TN tool coating. The tools provide for precision finish results, minimal tool deflection and run-out. Excellent milling results can be achieved in roughing, semi finishing and fine finishing in Z-level, profiling or raster cuts, as well as in linear or circular interpolation milling or ramping. The tools may be used with coolant, but we recommend dry, mist or MQ (minimum quantity lubrication) milling with strong air blast when high speed or hard machining steel, particularly in the higher hardness range (> 45HRc / 425 HBN). Please refer to FAQs (frequently asked questions) about milling on our web site Milling Cutters Identification System Modular FMA 2000 / FM 1000 / Page 15

17 Toroid Taper End Milling Cutters Toroid Cylindrical End Milling Cutters S2 S2 S1 S imensions Ø Ø1 Ø2 Z Screw Key Face Clamp Insert Code FM 1000/ FMIS-1 T15 FMIS2 FMI-12T3 FM 1250/ FMIS-1 T15 FMIS2 FMI-12T3 FM 1500/ FMIS-1 T15 FMIS2 FMI-12T3 Arbor Style Milling Cutters S1 S2 1 Key Width 2 imensions Ø Ø1 Z Key Width 2 Insert Screw Face Clamp Screw Key Insert Code FMA 2000/ FMIS-1 FMIS-2 T15 FMI-12T3 FMA 2500/ FMIS-1 FMIS-2 T15 FMI-12T3 FMA 3000/ FMIS-1 FMIS-2 T15 FMI-12T3 Page 16

18 Copy Milling Program s Insert ata imensions S 1 TN 1 FMI /10mm FMI-12T /12mm S FMI /16mm Cutting Conditions ata RECOMMENE CUTTING SPEE AN Ap WORKING MATERIA HARNESS GRAE SFM Ap Max Roughing Ap Max Medium Ap Max ight ow Alloy Steel(1.7225) HB, TN Alloy & ie Steel(1.2311, P20, ME2/3/5) 32-42HRC, TN Steel (1.2344, ) 42-52HRC, TN Stainless Steel (1.4301, ) HB, TN Gray Cast Iron (GG25-GG30) HB, TN Nodular Cast Iron (GGG60-GGG70) HB, TN Copper Alloy HB TN Aluminum Alloys HB TN Ni & Co Based Alloy HB, TN Titanium Alloy (Annealed) <350HB, TN RECOMMENE FEE fz (mm/tooth) OPERATION IGHT ROUGH Ap IC o The fz indicated above is for an overhang of 3x. The values are calculated based on the recommended thickness of the chip hm. IGHT: Ae up to 25% of the iameter of the. ROUGH: Ae up to 75% of the iameter of the. Page 17

19 Verify the Surface Roughness & Working iameter Verify the Surface Roughness (R th ) 1. ecreasing the A e and feed by half will improve surface roughness by 4 times. 2. Using f z = A e in most cases is the best option. Working iameter ( w ) In order to compute the RPM value of the spindle it is necessary to determine the w which is the effective engaged tool diameter. The w depends on the geometry of the inserts (ball nose or toroid) and of the relative position of the tool against the working piece surface. A formula is presented. Page 18

20 Milling Cutters Identification System High Feed Indexable Milling Program s Modular HFSC - Modular Screw-On Heads imensions Ø Z Thread G1 Screw Clamp Key Use with Inserts HFSC-1000/ M10 HFIS-1 - T8 HFCI 09T HFSC-1250/ M12 HFIS-1 - T8 HFCI 09T HFSC-1500/ M16 HFIS-2 HFIC-1 T15 HFCI CAM R Page 19

21 HFA - Shell Milling Cutters 1 S1 C1 S2 imensions Ø Ø1 Z Screw S1 Screw S2 Clamp C1 Key Use with Inserts HFA-1500/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI HFA-2000/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI HFA-2500/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI HFA-3000/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI HFA-4000/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI CAM R HFSS - End Milling Cutters imensions Ø Ø1 Z Screw Clamp C1 Key Use with Inserts HFSS HFIS-1 - T8 HFCI 09T HFSS HFIS-1 - T8 HFCI 09T HFSS HFIS-1 - T8 HFCI 09T HFSS HFIS-1 - T8 HFCI 09T HFSS HFIS-2 HFIC-1 T15 HFCI HFSS HFIS-2 HFIC-1 T15 HFCI CAM R Page 20

22 High Feed Indexable Milling Program s Insert ata imensions Grade CAM S 1 XRN R T HFCI 09T3 9,525 3,97 4, HFCI ,700 4,76 3, Machining Application ata imensions Helical Interpolation Ø Øh Ap F Øh min Øh max HFSC-1000/ mm HFSC-1250/ mm HFSC-1500/ mm HFSS mm HFSS mm HFSS mm HFSS mm HFSS mm HFSS mm HFA-1500/ mm HFA-2000/ mm HFA-2500/ mm HFA-3000/ mm HFA-4000/ mm For Slant Milling or Helical Interpolation decrease the recommended feed by 30%. In case of Helical Interpolation do not exceed the max Ap/revolution. For Plunging use 50% of recommended feed only. For insert HFCI 09T3 the max Ae is: For insert HFCI 1204 the max Ae is: The Values of n and Vf in the tables on the following pages are computed. In the application, use the closest (up side) speed from the range of the machine tool. The cutting parameters have to be adjusted accordingly to the rigidity of the machine-tool and working piece. In case of hard steel alloy of HRC decrease by 30% the Ap, Vc and feed. Page 21

23 Cutting Conditions ata Cutter Insert Grade HFSC 1000/3 HFSC 1250/4 HFSC 1500/4 HFCI 09T3 HFCI 09T3 HFCI 1204 XRN XRN XRN Work Piece Material Alloy Steel <32HRC Alloy Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Alloy Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Alloy Steel 32-42HRC Steel 42-52HRC Cast Iron Overhang n Vc Vf fz Ap Ae RPM sfm Max RPM inch/tooth inch inch < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <1 > <1 < < < <1 > <1 < < < <1 > <1 < < < <1 > <1 Page 22

24 Cutting Conditions ata Cutter Insert Grade HFSS HFSS HFSS HFSS HFSS HFSS HFCI 09T3 HFCI 09T3 HFCI 1204 XRN XRN XRN Work Piece Material Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Overhang n Vc Vf fz Ap Ae RPM sfm Max RPM inch/tooth inch inch < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <.75 > <.75 < < < <1 > <1 < < < <1 > <1 < < < <1 > <1 < < < <1 > <1 Page 23

25 Cutter Insert Grade HFA 1500/4 HFA 2000/5 HFA 2500/6 HFCI 1204 HFCI 1204 HFCI 1204 XRN XRN XRN Work Piece Material Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Overhang n Vc Vf fz Ap Ae RPM sfm Max RPM inch/tooth inch inch < < < <1 > <1 < < < <1 > <1 < < < <1 > <1 < < < <1 > <1 < < < <1.375 > <1.375 < < < <1.375 > <1.375 < < < <1.375 > <1.375 < < < <1.375 > <1.375 < < < <1.8 > <1.8 < < < <1.8 > <1.8 < < < <1.8 > <1.8 < < < <1.8 > <1.8 Page 24

26 Solid Carbide End Mill Program s Hi-Tech for Hi-Tech Applications in Your Industry Millstar s new High Performance and ultra-precise solid carbide end mills were specifically designed for High Speed, High Velocity and Hard Steel milling. esigned with specially selected premium sub-micron carbide substrate, special tool geometry and proprietary heat-defying EXAON tool coating, these tools are beating the best products the competition has to offer. They are made in the United States, and are competitively priced. Please note just some of the benefits to users: Square nose tools Series EMS / EIS with sharp corner or square nose tools Series EIB / EMB with corner radius, all with medium-high helix and strong cutting edges and tool body, work extremely well in materials up to 65HRc as well as in softer materials. Ball nose tools Series BI / BM are designed with two flutes and special nose geometry for true High Speed and Hard Material milling up to 68 HRc. Ball nose tools are the most aggressive tools for these applications. We will be glad to share our proven approach to improving your machining results. The Toroid Series TOM with large corner radius and slight back taper is a Millstar innovative addition. It is very useful in I.. and O.. Z-level and spiral milling at constant tool pressure, pocket milling, and milling of pre-hard and hardened flat surfaces at higher speeds than tools with smaller or sharp corner radii. Extended Reach ball nose tools Series BMN and extended reach square nose tools Series EMR are useful tools specifically designed for long reach milling of extrusion dies, deep cavities and cores, deep rib milling and similar applications. The reduced flute length and neck diameter assure constant cutting pressure and minimal tool deflection. Millstar s Hi-Tech Cutting s are ideal choices for accurately and aggressively machining products in many industries. Here are some examples Mold and die making: injection molds, glass molds, forging dies, extrusion dies. Aerospace: engine, landing gear and tail hook components, structural components, blisks, airfoil machining and forging dies, helicopter rotor components. Power generating: turbine blades and other components. Medical: hip and knee replacement joints, surgical instruments, medical device molds. Automotive: stamping dies, wheel and tire molds, ball joints, cam shaft machining, racing engine details, bumper and other injection molds, die cast dies, forging dies for crank and cam shafts, connecting rods, steering knuckles and yokes, and many other forged components. Consumer products: molds for cake forms and baking dishes, cell phones, lawn chairs, trash cans, toys, bottles, recyclable cutlery and dishes, jewelry, golf clubs, safety helmets, computer and accessory housings and much more. Call on Millstar application specialists or visit our web site for more product information and expert application assistance. Page 25

27 Ultra Precision End Mills EIS - Square End Exalon (AlTiN) Coated No. Cutter iameter tol. +0 / 0.01 Corner Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper Overall EIS-.020-EX / (1/4) / side EIS-.031-EX / (1/32) / (1/4) / side EIS-.062-EX / (1/16) / (1/4) / side EIS-.093-EX / (3/32) / (1/4) / side EIS-.125-EX / (1/8) / (1/4) / side EIS-.187-EX / (3/16) / (1/4) / side EIS-.250-EX / (1/4) / (1/4) EIS-.312-EX / (5/16) / (5/16) EIS-.375-EX / (3/8) / (3/8) EIS-.437-EX / (7/16) / (7/16) EIS-.500-EX / (1/2) / (1/2) EIB - Square End Bull Nose w/corner Radius Exalon (AlTiN) Coated No. Cutter iameter tol. +0 / 0.01 Corner Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper Overall EIB EX / (1/16) / (1/4) / side EIB EX / (3/32) / (1/4) / side EIB EX / (1/8) / (1/4) / side EIB EX / (1/8) / (1/4) / side EIB EX / (3/16) / (1/4) / side EIB EX / (1/4) / (1/4) EIB EX / (1/4) / (1/4) EIB EX / (5/16) / (5/16) EIB EX / (3/8) / (3/8) EIB EX / (7/16) / (7/16) EIB EX / (1/2) / (1/2) Page 26

28 Ultra Precision End Mills BI - Ball Nose Exalon (AlTiN) Coated No. Cutter iameter tol. +0 / 0.01 Ball Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper Overall BI.020 EX / (1/4) / side BI.031 EX / (1/32) / (1/4) / side BI.062 EX / (1/16) / (1/4) / side BI.090 EX / (1/4) / side BI.093 EX / (3/32) / (1/4) / side BI.125 EX / (1/8) / (1/4) / side BI.187 EX / (3/16) / (1/4) / side BI.250 EX / (1/4) / (1/4) BI.312 EX / (5/16) / (5/16) BI.375 EX / (3/8) / (3/8) BI.375 EX / (3/8) / (3/8) BI.437 EX / (7/16) / (7/16) BI.500 EX / (1/2) / (1/2) TOI - Toroid Exalon (AlTiN) Coated No. Cutter iameter tol. +0 / 0.01 Corner Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper Overall TOI.125 EX / (1/8) / (1/4) / TOI.250 EX / (1/4) / (1/4) / TOI.375 EX / (3/8) / (3/8) / TOI.500 EX / 1/2) / (1/2) / All tools backdraft 3 Page 27

29 High Feed End Mills HFI4 - High Feed Four Flute Solid Carbide No. iameter Programmable Radius iameter iameter of Cut Overall Step Over Ae epth of Cut Ap Feed per Tooth Fz HFI HFI HFI HFI After the part number, please indicate XRN or when ordering. HFI Cutting Conditions Work Material Material Hardness Cutting epth at iameter ap max Cutting Width Coating type Recom. Cut speed at Max Feed per Tooth Fz at cutting insert diameter USA/W.-Nr./JIS Hrc Ae max Coating SFM H13/1.2344/SK61 < % XRN/ H13/1.2344/SK % XRN/ H13/1.2344/SK % A2/1,2363/SK12 < % XRN/ A2/1,2363/SK % XRN/ A2/1,2363/SK % P20/1,2330 < % XRN/ P20/1, % XRN/ /1,2379/SK11 < % XRN/ /1,2379/SK % XRN/ /1,2379/SK % Grey Cast Iron/GG < % XRN/ Cast Iron/GGG % XRN/ Titanium (6A 4V) % XRN/ Page 28

30 Ultra Precision End Mills EIS Flute ong Series Endmill, Square End No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EIS /8 XX EIS /16 XX EIS /4 XX EIS /16 XX EIS /8 XX EIS /16 XX EIS /2 XX EIS /8 XX EIS /4 XX EIS XX EIS Flute ong Series Endmill, Square End No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EIS /8 XX EIS /16 XX EIS /4 XX EIS /16 XX EIS /8 XX EIS /16 XX EIS /2 XX EIS /8 XX EIS /4 XX EIS XX AlumiSTAR EISA - 3 Flute Endmill, 45 - Aluminum No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EISA /8 XX EISA /16 XX EISA /4 XX EISA /16 XX EISA /8 XX EISA /16 XX EISA /2 XX EISA /8 XX EISA /4 XX EISA XX Page 29

31 Ultra Precision End Mills AlumiSTAR BIA - 3 Flute Endmill, Ballnose 45 - Aluminum No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () BIA / BIA / BIA / BIA / BIA / BIA / BIA / BIA / BIA / BIA No. BI2-2 Flute ong Series Endmill, Ballnose Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () BI / BI / BI / BI / BI / BI / BI / BI / BI / BI No. BI4-4 Flute Endmill ong Series, Ballnose Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () BI / BI / BI / BI / BI / BI / BI / BI / BI / BI Page 30

Ultra Precision End Mills EIV4-4 Flute Variable Fluted Endmill, Square End w/45 Chamfer No. Cutter iameter tol. +0 / 0.015 Corner Radius (R1) iameter (1) Cutting () () EIV4-0125- 1/8 XX 0.125 0.500 1.

32 Ultra Precision End Mills EIV4-4 Flute Variable Fluted Endmill, Square End w/45 Chamfer No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EIV /8 XX EIV /16 XX EIV /4 XX EIV /16 XX EIV /8 XX EIV /16 XX EIV /2 XX EIV /8 XX EIV /4 XX EIV XX BI Flute Endmill, Ballnose No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () BI / BI / BI / BI / BI / BI / BI / EIS2-2 Flute Endmill, Square End No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () Nose Taper Per Side EIS /32 XX eg EIS /16 XX eg EIS /32 XX eg EIS /8 XX EIS /16 XX EIS /4 XX EIS /16 XX EIS /8 XX EIS /16 XX EIS /2 XX EIS /8 XX EIS /4 XX EIS /8 XX EIS XX Page 31

No. Cutter iameter tol. +0 / 0.015 EIS4-4 Flute Endmill, Square End Corner Radius (R1) iameter (1) Cutting () () Nose Taper Per Side EIS4-031- 1/32 XX 0.125 0.094 1.500 7.5 eg EIS4-062- 1/16 XX 0.

33 No. Cutter iameter tol. +0 / EIS4-4 Flute Endmill, Square End Corner Radius (R1) iameter (1) Cutting () () Nose Taper Per Side EIS /32 XX eg EIS /16 XX eg EIS /32 XX eg EIS /8 XX EIS /16 XX EIS /4 XX EIS /16 XX EIS /8 XX EIS /16 XX EIS /2 XX EIS /8 XX EIS /4 XX EIS /8 XX Page 32

34 Index - Metric Page Profile Milling Program s SFCY Cylindrical Steel Holder - Ball SFTA Taper Steel Holder - Ball CYF Cylindrical Steel Holder - Flat TAF Taper Steel Holder - Flat TAV, CY, TA Spike-ine Cylindrical Steel CYMK Morse Steel Holder - Ball CYFMK Morse Steel Holder - Flat CB SFCY Cylindrical Carbide Holder - Ball CB CYF Cylindrical Carbide Holder - Flat CB TAV Spike-ine Taper Carbide Holder - Ball & Flat CB CYV Spike-ine Taper Carbide Holder - Ball & Flat CB CY Cylindrical Carbide Uni- Holder - Ball & Flat CB TA Taper Carbide Uni- Holder - Ball & Flat SF CY/CYF Screw-on Head - Ball & Flat Solid Carbide Adaptor Inserts Cutting Parameters Calculating Speed & Feed Profile Modular Shrink System s Copy Milling Program s FM Style 1 Toroid Cylindrical End Milling Cutter FM Style 2 Toroid Taper End Milling Cutter FMA Arbor Style Milling Cutter Insert ata Cutting Parameters High Feed Indexable Milling Program s HFSC Modular Screw-on Heads HFA Shell Milling Cutters HFSS End Milling Cutters Insert ata Machining Application ata Solid Carbide End Mills Program s EMS Square EMB Square - Bullnose BM Ball TOM Toroid BMN Ball - Extended Reach Taper EMR Square End Bull Nose w/corner Radius, Extended Reach Taper HFM4 High Feed Four Flute Solid Carbide High Feed Cutting Parameters EMS Flute ong Series - Square EMS Flute ong Series - Square AP2 2 Flute Aluminum AP3 3 Flute Aluminum EMSA 3 Flute BMA 3 Flute - Ball BM2 2 Flute - ong Series - Ball BM4 4 Flute - ong Series - Ball EMV4 4 Flute Variable - Square, 45 Chamfer BM Flute - Ball EMS2 2 Flute - Square EMS4 4 Flute - Square Page 33

35 Profile Milling Program s Indexable Milling Holder Identification System CB SFCY enotes Material CB = Carbide = Steel Type SFCY = Cylindrical CY = Cylindrical Spike SFTA = Taper TA = Taper Spike iameter Size Cutter Cutter iameter The Inserts Millstar inserts are fully ground precision inserts for better chip control, faster metal removal and higher surface accuracies. They are far more accurate than pressed and O.. sharpened inserts. Millstar insert radius and seat are accurate to +/ (+/ mm) of nominal radius and cut exactly as programmed. This unparalleled accuracy also eliminates redundant Z-axis pick ups and assures accurate blending. Positive ground chipbreaker or strong negative cutting edge designs guarantee outstanding cutting performance in a wide variety of ferrous and non-ferrous materials. A choice of state-of-the-art insert grades, designs and tool coatings allow for optimum speed and feed rates in wet and dry machining. Reduced machining times by 25% to 60% are not uncommon. Economical one-piece inserts with two cutting edges are cost-effective for contour milling. True radius geometry is fully CNC-ground for higher machining accuracy and greatly reduced manual finishing and polishing time. Choose from side-cutting ball nose inserts with 180 degree nose radius, and popular ball nose inserts with a cutting edge covering 230 degrees for steep wall up-and-down ramping, profiling, contour milling and blending, and for a wider range of applications compared to conventional ball nose tools. Select from a variety of flat bottom, back draft and toroid inserts for steep or straight wall milling with long extensions on hard to reach cores, cavities or fillets. Milling with small radii prevents deflection and results in superior finishes and contour accuracies. Available with or without chipbreaker and coating in a variety of corner radii and sizes. Rock Solid Insert Clamping Cutting insert clamping is highly accurate and rigid. Unique V-pocket design gives a truly positive seat for the insert and will not allow insert movement when milling with a side thrust. Sandwiched insert clamping with single locking screw is unsurpassed for rigidity. The advanced design of Millstar inserts eliminates heat-seizing of locking screws or insert movement due to costly locating screws or pins of less advanced design. Positive V-pocket seating eliminates mismatch when changing to fresh inserts. It also eliminates the need to program new length or diameter offsets. The Holders Millstar is proud to offer the largest selection of roughing and finishing ball nose, back draft, flat bottom and toroid milling cutters available from one source. Cylindrical and tapered toolholders include the longest reach profiling tools available as standard catalog items. holders are inherently balanced for high spindle speeds. Machine with confidence at the increased speeds and velocities dictated by modern high velocity machining. Super intelligent machine controls with high speed data transfer, rapid advances in cutting edge materials and coating technologies enable ever faster machining speeds and increased productivity. Millstar tools are designed to keep pace. The Millstar product line is manufactured in the USA under ISO 9001 specifications, and all tools are fully traceable. Nearly six decades of cutting tool design and manufacturing for automotive, aerospace and many other industries, as well as special design capabilities using 3- CA allow us to respond quickly to requests for special designs. Page 34

36 SFCY - Cylindrical Steel Holder, Ball Profile Milling Program s 1 2 Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code SFCY , MS12 T20 SFCY , MS12 T20 SFCY , MS16 T20 SFCY , MS16 T20 SFCY , MS20 T20 SFCY , MS20 T20 SFCY , MS25 T20 SFCY , MS25 T20 SFCY , MS25 T20 SFCY , MS25 T20 SFCY 30/ / , MS32 T30 SFCY 30/ / , MS32 T30 SFCY 30/ / , MS32 T30 MB, MBT, RB-N, BS-N SFTA - Taper Steel Holder, Ball Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code SFTA , MS12 T20 SFTA , MS16 T20 SFTA , MS20 T20 SFTA , MS25 T20 SFTA , MS25 T20 SFTA 30/ / , MS32 T30 SFTA 30/ / , MS32 T30 MB, MBT, RB-N, BS-N Page 35

37 CYF - Cylindrical Steel Holder, Flat Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code CYF , MS10 T15 CYF , MS12 T20 CYF , MS12 T20 CYF , MS16 T20 CYF , MS20 T20 CYF , MS20 T20 CYF , MS25 T20 CYF , MS25 T20 CYF 30/ / , MS32 T30 CYF 30/ / , MS32 T30 B-N, B-R, BS, FB-R, TO, TOB-NF, HF 2 TAF - Taper Steel Holder, Flat 1 6 Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code TAF , MS10 T15 TAF , MS12 T20 TAF , MS16 T20 TAF , MS20 T20 TAF , MS25 T20 TAF , MS25 T20 TAF 30/ / , MS32 T30 B-N, B-R, BS, FB-R, TO, TOB-NF, HF Page 36

38 Profile Milling Program s TAV, CY, TA - Spike-ine Cylindrical Steel Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code TAV , MS06N T7 TAV , MS08N T7 CY , MS10 T15 CY , MS10 T15 TA , MS10 T15 TA , MS10 T15 VRBS, VB, MB, MBT, RB-N, BS-N, B, BS, FB, TO, HF CYMK - Morse Steel Holder, Ball Size Ø Ø1 imensions Use with Inserts MORSE Screw Key Type Code CYMK , MK2 MS12 T20 CYMK , MK2 MS16 T20 CYMK , MK2 MS20 T20 CYMK , MK3 MS25 T20 CYMK , MK4 MS25 T20 MB, MBT, RB-N, BS-N Page 37

39 CYFMK - Morse Steel Holder, Flat Size Ø Ø1 imensions Use with Inserts MORSE Screw Key Type Code CYFMK , MK2 MS12 T20 CYFMK , MK2 MS16 T20 CYFMK , MK2 MS20 T20 CYFMK , MK3 MS25 T20 CYFMK , MK4 MS25 T20 B-N, B-R, BS, FB-R, TO, TOB-NF, HF CB SFCY - Cylindrical Carbide Holder, Ball 1 2 Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code CBSFCY , MS12 T20 CBSFCY , MS16 T20 CBSFCY , MS20 T20 CBSFCY , MS25 T20 CBSFCY 30/ / , MS32 T30 MB, MBT, RB-N, BS-N Page 38

40 CB CYF - Cylindrical Carbide Holder, Flat Profile Milling Program s Size Ø Ø1 imensions Ø2 Use with Inserts Screw Key Type Code CBCYF , MS12 T20 CBCYF , MS16 T20 CBCYF , MS20 T20 CBCYF , MS25 T20 B-N, B-R, BS, FB-R, TO, TOB-NF, HF CB TAV - Spike-ine Taper Carbide, Ball & Flat X 1 2 Size Ø Ø1 imensions Ø2 Use with Inserts X Screw Key Type Code CBTAV , ,5º MS06N T7 CBTAV , º MS06N T7 CBTAV T , º MS06N T7 CBTAV , ,5º MS08N T7 CBTAV , º MS08N T7 VRBS, VB Page 39

41 3 X 1 2 CB CYV - Spike ine Taper Carbide, Ball & Flat imensions Use with Inserts Size Ø Ø1 Ø2 3 Shaft X Screw Key CBCYV , MS06N T7 CBCYV , MS08N T7 Type Code VRBS, VB CB CY - Cylindrical Carbide Uni- Holder, Ball & Flat 1 2 imensions Use with Inserts Size Ø Ø1 Ø2 Screw Key CBCYV , MS06N T7 CBCYV , MS08N T7 CBCY , MS10 T15 Type Code VRBS, VB MB, MBT, RB-N, BS-N, B, BS, FB, TO, HF X 1 2 CB TA - Taper Carbide Uni- Holder, Ball & Flat imensions Use with Inserts Size Ø Ø1 Ø2 X Screw Key CBTA , MS10 T15 Type Code MB, MBT, RB-N, BS-N, B, BS, FB, TO, HF Page 40

42 Profile Milling Program s SF CY - Screw-on Head, Ball 2 CYF - Screw-on Head, Flat Solid Carbide Adaptor 2 1 G1 G1 1 Size Ø iameter 1 iameter 2 Thread G1 Screw Key SFCY 10-SC-M ,5 M MS10 T15 SFCY 12-SC-M ,5 M MS12 T20 SFCY 16-SC-M ,5 M MS16 T20 SFCY 20-SC-M ,5 M MS20 T20 SFCY 25-SC-M ,5 M MS25 T20 SFCY 32-SC-M ,5 M MS32 T30 Use with Inserts Type Code MB, MBT, RB-N, BS-N 2 G1 1 Size Ø iameter 1 iameter 2 Thread G1 Screw Key CYF 10-SC-M ,5 M MS10 T15 CYF 12-SC-M ,5 M MS12 T20 CYF 16-SC-M ,5 M MS16 T20 CYF 20-SC-M ,5 M MS20 T20 CYF 25-SC-M ,5 M MS25 T20 CYF 32-SC-M ,5 M MS32 T30 Use with Inserts Type Code B-N, B-R, BS, FB-R, TO, TOB-NF, HF Size Ø1 imensions Ø2 Thread G1 Screw Key CY SC-M6 10 6, M6 MS10 T15 CY SC-M6 12 6, M6 MS12 T20 CY SC-M8 16 8, M8 MS16 T20 CY SC-M , M10 MS20 T20 CY SC-M , M12 MS25 T20 CY SC-M , M16 MS32 T30 Page 41

43 The Inserts Small Ball Nose & Back raft Inserts VRBS 2 VB 1 R imensions Grade R XRN TN escription VRBS 6 6 8,10 3 Used for rough to finish-milling small radius or detail work, and surface milling in VRBS 8 8 4,50 4 soft and herd steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling. VB ,6 0,4 Used for rough to finish-milling small radius or detail work, and surface milling in VB ,4 soft and herd steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling High Feed Inserts HF imensions Grade PR XRN TN escription HF ,00 Millstar HF insert is designed for High HF ,43 feed and High speed machining. It runs at high cutting speed and feed rates with HF ,94 shallow depth of cut. It allows the chip HF ,26 to flow up and out of the cut quickly. It HF ,82 allows heavy chip loads. Cutting Recommendations for High Feed Inserts Work Material USA/W.-Nr./ JIS H13/1.2344/ SK61 H13/1.2344/ SK61 H13/1.2344/ SK61 A2/1,2363/ SK12 A2/1,2363/ SK12 A2/1,2363/ SK12 Material Hardness Cutting epth at iameter ap max Cutting Width Cut speed at Max feed per tooth fz at cutting insert diameter Coating Insert Type Hrc Ae max Recom. sfm/min < % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, % HF ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 < % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, % HF ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 P20/1,2330 < % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 P20/1, % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 2/1,2379/ SK11 2/1,2379/ SK11 2/1,2379/ SK11 Grey Cast Iron/GG Cast Iron/ GGG Titanium (6A 4V) < % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, % HF ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 < % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, % HF XRN/ ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 Page 42

44 The Inserts Flat Bottom, Back raft, Toroid B-N B-R R BS FB-R R TO R TOB-NF R XRN TN escription 8,5 0,5/0,8/1 B 16 N 16 11,55 0,5/1/1,3/2/3 B 20 N 20 13,35 0,5/1/1,6/2/3 Precision ground with 7º back taper. Used for milling of cores, cavities, filets with straight or very steep walls of harder materials. B 25 N 25 19,95 1/2 B 30 N 30 23,35 1/2,6 B 32 N 32 8,5 1,0/2,6 R XRN TN escription B 10 R 10 8,5 0,5/0,8/1 Precision ground with positive ground chip-breaker and 7º back taper. Used for milling of cores, cavities, filets with straight or very steep walls of softer materials. B 12 N R Grade 10 B 10 N R imensions The Inserts 12 9,95 0,5/1/2 B 12 R 12 9,95 0,5/1 B 16 R 16 11,55 0,5/1/1,3 B 20 R 20 13,35 0,5/1/1,6 B 25 R 25 19,95 1/2 B 32 R 32 23,35 2,6 R XRN TN escription BS 10 N 10 8,5 0,8/1,0 3 Precision ground with unique crossover design between flat bottom FB and back draft B inserts. Allows straight walls with a larger step down than B. Allows higher cutting speeds and feeds. BS 12 N 12 9, BS 16 N 16 11,55 1/1,3 3 BS 20 N 20 13,35 1/1,6 3 BS 25 N 25 19,95 1/2 3 R XRN TN escription FB 10 R 10 8,5 0,8 FB 12 R 12 9,15 1 Precision ground with positive ground chip-breaker. Flat bottom inserts for shoulder milling, fillet finishing and long reach angular wall finishing of softer materials. FB 16 R 16 10,65 0,5/1,3 FB 20 R 20 12,25 1,6 FB 25 R 25 16,35 2 FB 32 R 32 21,3 2,6 R XRN TN escription TO ,65 3 TO ,20 3 TO ,25 4 Precision ground large corner radius & back taper for spiral and packet milling. Milling of pre-hard and hardened flat surfaces at higher speeds than tools with smaller corner radii. Good choice for HS milling of Aluminum. TO ,15 5 TO ,25 6 TO ,15 7,5 TO ,95 8 R XRN TN escription TOB 12-NF 12 9,2 3 TOB 16-NF 16 11,25 3 Millstar inserts designed for high seed high feed roughing of Aluminum, but also has the versatility to be used for fine finishing as well. TOB 20-NF 20 13,15 3 TOB 25-NF 25 18,25 3 Insert Coatings NA Non-coated grade. The lowest cost choice. May be used at XRN Multi-layer hybrid coating of AlTiCrN. This coating has very normal speeds, or lower speeds on older machines, for all purpose milling. May be resharpened or altered. Page 43 good heat resistance and also a low friction coefficient. The XRN coating is designed for use in HSM of un-heat treated softer materials such as Titanium, Inconel, Stainless Steels and other gummy materials that require the use of liquid coolant.

45 BS-N S imensions Grade S XRN TN Ball Nose Inserts escription BS 10 N 10 9,50 3,65 Sidecutting, non-chipbreaker. Side cutting BS 12 N 12 8,80 2,90 insert used in cavity and core profiling, for blending of fillets on medium and hard BS 16 N 16 10,70 2,85 materials. BS 20 N 20 12,75 2,85 BS 25 N 25 17,20 4,85 BS 30 N 30 20,00 5,10 BS 32 N 32 21,00 5,30 MB XRN TN escription MB ,65 Unique cutting edge allows performance in all MB ,20 operations in material below 42 HRc; in semi, & finishing operations above. Significant benefits MB ,25 in heat-treated intricate geometries. Insert MB ,15 MB ,25 geometry allows smoother cutting motiondiminishing heat build up & tool deflection, MB ,15 reduces vibration caused by cutting action. MB ,95 MBT XRN TN escription MBT ,65 Precision ground, harder grade, for semi-finish MBT ,20 and finish milling. Excellent choice for unattended finish milling at small depth and high MBT ,25 speeds and feed rates. MBT ,15 MBT ,25 MBT ,15 MBT ,95 RB-N XRN TN escription RB 10 N 10 9,50 Precision ground, non-chipbreaker. Best choice RB 12 N 12 9,20 for cavity, core and profile milling of pre-hard and fully hard die/mold steels, cast steels and RB 14 N 14 9,45 cast iron. Strongest cutting edge design. RB 16 N 16 11,25 RB 20 N 20 13,15 RB 22 N 22 17,45 RB 25 N 25 18,25 RB 30 N 30 22,15 RB 32 N 32 21,95 TCN Titanium Carbo-Nitride PV multi layer coating. Higher hardness and toughness than TIN. Choose on heavy cuts or high feeds and speeds, preferably with coolant. Excellent crater and wear resistance. Useful on abrasive and gummy materials (cast iron, brass, aluminum alloys) and on stainless steels and highly alloyed materials, including nickel and chrome based alloys. Millstar s new coating is a multi-layer hybrid Nano coating. This new coating has very good heat resistance and high hardness. The coating is designed for use in HSM of Heat Treated materials up to 72 HRc Customers using our new coating are seeing average tool life increases of 3-4 times more than the competition. life increases as much as 10 times have been documented. ATiN-EXAON (TN) Titanium Aluminum Nitride advanced PV coating. A special, improved ATiN coating approaching surface hardness of CBN on a tough substrate. Recommended for tough and hard metal machining applications. When high cutting temperatures are encountered the coating acts as a heat barrier, protecting the cutting edge. This allows for aggressive, high speed and dry milling so often encountered in today s die and mold machining. Use on tool, die and higher alloy steels, especially at hardness over 40 HRc. Also appropriate for all stainless steels (300, 400 and PH series), nickel alloys, titanium, nodular and gray cast iron. Also useful in machining carbon graphite. M iamond coating. Custom coating for cutting non-ferrous, non-metallic and very abrasive materials at highly elevated speeds. Use on copper, bronze, brass, aluminum-silicon alloys, carbon graphite, solid and fiber-reinforced plastics, ceramics and composite materials. Page 44

46 Choosing Cutting Parameters Cutting Conditions for Using Steel Holders WORKING MATERIA HARNESS GRAE ow Alloy Steel (1.7225) Alloy & ie Steel (1.2311, P20, ME2/3/5) Steel (1.2344, ) Stainless Steel (1.4301, ) Gray Cast Iron (GG25-GG30) Nodular Cast Iron (GGG60-GGG70) Vc m/min FEE fn (mm/rev) INSERT IAMETER (mm) HB TN ,2 0,3 0,4 0,4 0,5 0,5 0,6 0,6 0,6 /15 / HRC TN ,15 0,25 0,3 0,4 0,4 0,4 0,5 0,5 0,5 /20 / HRC TN ,15 0,25 0,3 0,4 0,5 0,5 0,6 0,6 0,6 /20 / HB XRN,TCN, TN Ap Max mm Ae Max mm ,15 0,25 0,3 0,4 0,4 0,4 0,5 0,5 0,5 /20 / HB TN ,2 0,3 0,4 0,5 0,6 0,6 0,7 0,7 0,7 /10 / HB TN ,2 0,3 0,4 0,5 0,6 0,6 0,7 0,7 0,7 /15 /15 Copper Alloy HB XRN ,25 0,4 0,5 0,6 0,7 0,7 0,8 0,8 0,8 /10 /10 Aluminum Alloys HB XRN ,25 0,4 0,5 0,6 0,7 0,7 0,8 0,8 0,8 /6 /6 Graphite TN ,3 0,5 0,6 0,7 0,8 0,8 0,9 0,9 0,9 /5 /5 Ni & Co Based Alloy HB XRN, ,15 0,2 0,3 0,4 0,4 0,5 0,5 0,6 0,6 /30 /30 Titanium Alloy (Annealed) <350HB XRN, ,15 0,2 0,25 0,35 0,35 0,4 0,45 0,5 0,5 /33 /33 Titanium Alloy (Sol. Treated/Aged) <380HB XRN, ,1 0,15 0,2 0,3 0,3 0,35 0,4 0,45 0,45 /35 /35 Harden Steel (1.2344, ) 45-55HRC, TN ,15 0,25 0,3 0,4 0,5 0,5 0,6 0,6 0,6 /30 /30 Cutting Conditions for Using Carbide Holders WORKING MATERIA HARNESS GRAE ow Alloy Steel (1.7225) Alloy & ie Steel (1.2311, P20, ME2/3/5) Steel (1.2344, ) Stainless Steel (1.4301, ) Gray Cast Iron (GG25-GG30) Nodular Cast Iron (GGG60-GGG70) Vc m/min FEE fn (mm/rev) INSERT IAMETER (mm) Ap Max mm HB TN ,3 0,4 0,4 0,5 0,6 0,6 0,7 0,7 0,7 0,1-0,3 / HRC TN ,25 0,3 0,3 0,4 0,5 0,5 0,6 0,6 0,6 0,1-0,2 / HRC TN ,25 0,3 0,3 0,4 0,5 0,5 0,6 0,6 0,6 0,1-0,2 / HB XRN,TCN, TN Ae Max mm ,25 0,3 0,4 0,5 0,6 0,65 0,7 0,8 0,8 0,1-0,2 / HB TN ,35 0,45 0,5 0,5 0,6 0,7 0,8 1,0 1,0 0,1-0,3 / HB TN ,3 0,4 0,4 0,5 0,6 0,6 0,7 0,8 0,8 0,1-0,3 /15 Copper Alloy HB XRN ,3 0,4 0,4 0,5 0,6 0,6 0,7 0,7 0,7 0,1-0,5 /40 Aluminum Alloys HB XRN ,3 0,4 0,5 0,6 0,7 0,7 0,8 0,8 0,8 0,1-0,5 /40 Graphite TN ,3 0,5 0,6 0,7 0,8 0,8 0,9 0,9 0,9 0,1-0,5 /40 Ni & Co Based Alloy HB XRN, ,25 0,3 0,4 0,4 0,5 0,6 0,6 0,7 0,7 /30 /50 Titanium Alloy (Annealed) <350HB XRN, ,15 0,2 0,25 0,35 0,35 0,4 0,45 0,5 0,5 /33 /50 Titanium Alloy (Sol. Treated/Aged) <380HB XRN, ,1 0,15 0,2 0,3 0,3 0,35 0,4 0,45 0,45 /35 /50 Harden Steel (1.2344, ) 45-55HRC, TN ,2 0,25 0,3 0,4 0,5 0,5 0,6 0,6 0,6 0,1-0,2 /30 Page 45

47 Calculating Cutting Speed and Feed 1. Find the Cutting Speed Vc (m/min) & Feed fn (mm/n -1 ) Find Vc and fn range in Table 1 or Table 2 on opposite page. Choose the average value for Vc and the lower value for feed in the range. 2. Compute the w In order to compute the RPM value of the spindle it is necessary to determine the w which is the effective engaged tool diameter. The w depends on the geometry of the inserts (ball nose or toroid) and the relative position of the tool against the working piece surface. Example calculation is of w is presented to the right. 3. Calculate Spindle Speed N(n/min) Use the formula: N = (V c * 1,000)/π * w Table 3 - WORKING IAMETER FOR BA NOSE TOOS (TIP CUTTING) Ø Ap 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,5 2 2,5 3 3, ,5 2,2 2,6 3 3,3 3,6 3,9 4,1 4,3 4,5 5,2 5,7 5,9 6,0 8 1,8 2,5 3 3,5 3,9 4,2 4,5 4,8 5,1 5,3 6,2 6,9 7,4 7, ,8 3,4 3,9 4,4 4,7 5,1 5,4 5,7 6,0 7,1 8,0 8,7 9,2 9,5 12 2,2 3,1 3,7 4,3 4,8 5,2 5,6 6,0 6,3 6,6 7,9 8,9 9,7 10,4 10,9 11,3 11,8 14 2,4 3,3 4,1 4,7 5,2 5,7 6,1 6,5 6,9 7,2 8,7 9,8 10,7 11,5 12,1 12,6 13,4 13,9 16 2,5 3,6 4,3 5 5,6 6,1 6,5 7,0 7,4 7,7 9,3 10,6 11,6 12,5 13,2 13,9 14,8 15,5 15,9 20 2,8 4 4,9 5,6 6,2 6,8 7,4 7,8 8,3 8,7 10,5 12,0 13,2 14,3 15,2 16,0 17,3 18,3 19,1 25 4,5 5,4 6,3 7,0 7,7 8,2 8,8 9,3 9,8 11,9 13,6 15,0 16,2 17,3 18,3 20,0 21,4 22, ,9 7,7 8,4 9,1 9,7 10,2 10,8 13,1 15,0 16,6 18,0 19,3 20,4 22,4 24,0 25,4 32 7,1 7,9 8,7 9,4 10,0 10,6 11,1 13,5 15,5 17,2 18, ,2 23,2 25,0 26,5 Table 4 - WORKING IAMETER FOR TOROI TOOS (tip cutting) Insert iameter 0,1 0,2 0,3 0,4 0,5 0,6 0,7 epth of Cut w Working iameter (metric) Actual cutting diameter of toroid inserts Calculate the Table Feed V f (m/min) Use the formula: V f = N * f n * K f. K f is the feed rate multiplier coefficient taking inconsideration that chip load is less than theoretical value. Take the value of K f from Table 5 or Table 6. Table 5 - FEE RATE MUTIPIER FOR BA NOSE INSERTS Insert iameter epth of Cut FEERATE MUTIPIER FACTORS (for working diameters w) Table 6 - FEE RATE MUTIPIER FOR TOROI TOOS Insert iameter epth of Cut FEERATE MUTIPIER FACTORS (for Toroid working diameters w) Page 46

48 Shrink Fit System Carbide Modular Shrink System Millstar s Carbide Modular Shrink System offers versatility, strength and accuracy. The carbide shank offers strength and rigidity and the shrink tolerances offer better accuracy than screw on type systems. These tools are designed for high speed machining and hard metal machining and will allow for better tool life as well as better surface finishes. 7,97 6 T1 1 CHTAV-06-T1 7,67 6 CHTAV-08-T1 T1 1 T1 1 10,43 6 T1 1 CHTA-10-T1 11,05 T1 1 CHY-12-T1 CHF-12-T1 13,97 T2 T2 1 CHY-16-T2 / CHF-16-T2 17,14 T3 T3 1 CHY-20-T3 / CHF-20-T3 Page 47

Shrink Fit head Insert Type Shrink Fit imensions imensions Code Ø1 VB, VRBS CHTAV-06-T1 11,7 43,2 22,3 CHTAV-08-T1 11,7 43,2 20,9 TO, HF, FB, BS, MB,MBT, B, TOB-NF CHTAV-10-T1 11,7 43,2 21,5 RB, MB,

49 Shrink Fit head Insert Type Shrink Fit imensions imensions Code Ø1 VB, VRBS CHTAV-06-T1 11,7 43,2 22,3 CHTAV-08-T1 11,7 43,2 20,9 TO, HF, FB, BS, MB,MBT, B, TOB-NF CHTAV-10-T1 11,7 43,2 21,5 RB, MB, MBT, BS CHY-12-T1 11,7 43,2 21,5 FB, B, BS, HF, TO, TOBNF CHF-12-T1 11,7 43,2 21,5 BS, RB, MB, MBT CHY-16-T2 14,0 38,2 FB, B, BS, HF, TO, TOBNF CHF-16-T2 14,0 38,2 RB, BS, MB, MBT CHY-20-T3 17,1 48,3 FB, B, BS, HF, TO, TOBNF CHF-20-T3 17,1 48,3 Ø1 CSS T1 CSS T ,60 124,40 15,24 15,24 CSS T2 CSS T ,80 180,80 16,51 16,51 CSS T3 CSS T3 CSS T ,50 172, ,78 17,78 17,78 Page 48

Copy Milling Program s High Performance Milling from Heavy Roughing to Fine Finishing Millstar face mills are equally useful on newer high velocity machines and older slower equipment and will

50 Copy Milling Program s High Performance Milling from Heavy Roughing to Fine Finishing Millstar face mills are equally useful on newer high velocity machines and older slower equipment and will optimize milling performance of all your machine tools. The hardened tool bodies can be run at aggressive spindle speed and feed rates, when used with Millstar s precision ground, strong and thick, round inserts with proven hard, high performance TN tool coating. The tools provide for precision finish results, minimal tool deflection and run-out. Excellent milling results can be achieved in roughing, semi finishing and fine finishing in Z-level, profiling or raster cuts, as well as in linear or circular interpolation milling or ramping. The tools may be used with coolant, but we recommend dry, mist or MQ (minimum quantity lubrication) milling with strong air blast when high speed or hard machining steel, particularly in the higher hardness range (> 45HRc / 425 HBN). Please refer to FAQs (frequently asked questions) about milling on our web site Milling Cutters Identification System Modular Page 49

51 Toroid Taper End Milling Cutters Toroid Cylindrical End Milling Cutters S2 S2 S1 S imensions Ø Ø1 Ø2 Z Screw Key Face Clamp Insert Code FM 32/ FMIS-1 T15 FMIS2 FMI-12T3 FM 40/ FMIS-1 T15 FMIS2 FMI-12T3 FM 42/ FMIS-1 T15 FMIS2 FMI-12T3 FM 32/ FMIS-1 T15 FMIS2 FMI-12T3 FM 40/ FMIS-1 T15 FMIS2 FMI-12T3 imensions Ø Ø1 Ø2 Z Screw Key Face Clamp Insert Code FM 25/ FMIS-1 T15 FMIS2 FMI-12T3 FM 32/ FMIS-1 T15 FMIS2 FMI-12T3 Arbor Style Milling Cutters S1 S2 1 Key Width 2 imensions Ø Ø1 Z Key Width 2 Insert Screw Face Clamp Screw Key Insert Code FMA 50/ FMIS-1 FMIS-2 T15 FMI-12T3 FMA 52/ FMIS-1 FMIS-2 T15 FMI-12T3 FMA 63/ FMIS-1 FMIS-2 T15 FMI-12T3 FMA 52/ FMIS-1 FMIS-2 T15 FMI-12T3 FMA 63/ FMIS-1 FMIS-2 T15 FMI-12T3 FMA 52/ FMIS-1 FMIS-2 T15 FMI-1604 FMA 63/ FMIS-1 FMIS-2 T15 FMI-1604 Page 50

52 Copy Milling Program s Insert ata imensions S 1 TN 1 FMI ,18 3,88 FMI-12T3 12 3,97 3,9 15 S FMI ,77 5,2 Cutting Conditions ata WORKING MATERIA HARNESS GRAE RECOMMENE CUTTING SPEE AN Ap Vc m/min Ap Max Roughing Ap Max Medium Ap Max ight ow Alloy Steel (1.7225) HB 5110, TN ,5-4,5 1,0-2,5 0,1-1,0 Alloy & ie Steel (1.2311, P20, ME2/3/5) 32-42HRC 5110, TN ,5-4,0 1,0-2,5 0,1-1,0 Steel (1.2344, ) 42-52HRC 5110, TN ,0-3,5 1,0-2,5 0,1-1,0 Stainless Steel (1.4301, ) HB 5110, TN ,5-4,0 1,0-2,5 0,1-1,0 Gray Cast Iron (GG25-GG30) HB 5110, TN ,5-4,0 1,0-2,5 0,1-1,0 Nodular Cast Iron (GGG60-GGG70) HB 5110, TN ,5-4,0 1,0-2,5 0,1-1,0 Copper Alloy HB TN 350 2,5-4,5 1,0-2,5 0,1-1,0 Aluminum Alloys HB TN 400 2,5-5,0 1,0-2,5 0,1-1,0 Ni & Co Based Alloy HB 5110, TN ,0-3,0 1,0-2,5 0,1-1,0 Titanium Alloy (Annealed) <350HB 5110, TN ,0-3,0 1,0-2,5 0,1-1,0 RECOMMENE FEE fz (mm/tooth) OPERATION IGHT ROUGH Ap IC 0,3 0,5 0,7 0,8 1 1, ,3 0,23 0,2 0,18 0, ,38 0,3 0,25 0,23 0,21 0, ,45 0,35 0,3 0,27 0,23 0,21 0, ,32 0,29 0,22 0,18 0,16 0, ,42 0,38 0,3 0,28 0,24 0,20 0,18 0, ,50 0,47 0,36 0,3 0,27 0,25 0,34 0,23 The fz indicated above is for an overhang of 3x. The values are calculated based on the recommended thickness of the chip hm. IGHT: Ae up to 25% of the iameter of the. ROUGH: Ae up to 75% of the iameter of the. Page 51

53 Verify the Surface Roughness (R th ) Verify the Surface Roughness (R th ) 1. ecreasing the A e and feed by half will improve surface roughness by 4 times. 2. Using f z = A e in most cases is the best option. Page 52

54 Milling Cutters Identification System High Feed Indexable Milling Program s Modular HFSC - Modular Screw-On Heads imensions Ø Z Thread G1 Screw Clamp Key Use with Inserts HFSC-20/ M10 HFIS 1 - T8 HFCI 09T3 2,27 HFSC-25/ M12 HFIS 1 - T8 HFCI 09T3 2,27 HFSC-30/ M16 HFIS 1 - T8 HFCI 09T3 2,27 HFSC-32/ M16 HFIS 1 - T8 HFCI 09T3 2,27 HFSC-32/ M16 HFIS 2 HFIC-1 T15 HFCI ,52 HFSC-42/ M16 HFIS 2 HFIC-1 T15 HFCI ,52 CAM R Page 53

55 HFA - Shell Milling Cutters 1 S1 C1 S2 imensions Ø Ø1 Z Screw S1 Screw S2 Clamp C1 Key Use with Inserts HFA-42/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-50/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-52/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-63/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-66/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-80/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-100/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 CAM R HFSS - End Milling Cutters imensions Ø Ø1 Z Screw Clamp C1 Key Use with Inserts HFSS HFIS-1 - T8 HFCI 09T3 2,27 HFSS HFIS-1 - T8 HFCI 09T3 2,27 HFSS HFIS-1 - T8 HFCI 09T3 2,27 HFSS HFIS-1 - T8 HFCI 09T3 2,27 HFSS HFIS-1 - T8 HFCI 09T3 2,27 HFSS HFIS-1 - T8 HFCI 09T3 2,27 HFSS HFIS-2 HFIC-1 T15 HFCI ,52 HFSS HFIS-2 HFIC-1 T15 HFCI ,52 CAM R Page 54

56 High Feed Indexable Milling Program s Insert ata imensions Grade CAM S 1 XRN R T HFCI 09T3 9,525 3,97 4,4 2,27 0,52 HFCI ,700 4,76 3,4 3,52 0,64 Machining Application ata imensions Helical Interpolation Ø Øh Ap F Øh min Øh max HFSC-20/ HFSC-25/ HFSC-30/ HFSC-32/ HFSC-32/ HFSC-42/ HFSS HFSS HFSS HFSS HFSS HFSS HFSS HFSS HFSS HFA-42/ HFA-50/ HFA-52/ HFA-63/ HFA-66/ HFA-80/ HFA-100/ For Slant Milling or Helical Interpolation decrease the recommended feed by 30%. In case of Helical Interpolation do not exceed the max Ap/revolution. For Plunging use 50% of recommended feed only. For insert HFCI 09T3 the max Ae is: 5,0 For insert HFCI 1204 the max Ae is: 6,0 The Values of n and Vf in the tables on the following pages are computed. In the application, use the closest (up side) speed from the range of the machine tool. The cutting parameters have to be adjusted accordingly to the rigidity of the machine-tool and working piece. In case of hard steel alloy of HRC decrease by 30% the Ap, Vc and feed. Page 55

57 Cutting Conditions ata Cutter Insert Grade HFSC 20/2 HFSC 25/3 HFSC 30/4 HFCI 09T3 HFCI 09T3 HFCI 09T3 XRN XRN XRN Work Piece Material Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Alloy Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Alloy Steel 32-42HRC Steel 42-52HRC Cast Iron n Vc Vf fz Ap Ae Overhang RPM mm/min mm/min mm/tooth mm mm < < < <15 > <15 < < < <15 > <15 < < < <15 > <15 < < < <15 > <15 < < < <20 > <20 < < < <20 > <20 < < < <20 > <20 < < < <20 > <20 < < < <21 > <21 < < < <21 > <21 < < < <21 > <21 < < < <21 > <21 Page 56

58 Cutting Conditions ata Cutter Insert Grade HFSC 32/4 HFSC 32/3 HFSC 42/4 HFCI 09T3 HFCI 1204 HFCI 1204 XRN XRN XRN Work Piece Material Alloy Steel <32HRC Alloy Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Alloy Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Alloy Steel 32-42HRC Steel 42-52HRC Cast Iron n Vc Vf fz Ap Ae Overhang RPM mm/min mm/min mm/tooth mm mm < < < <22 > <22 < < < <22 > <22 < < < <22 > <22 < < < <22 > <22 < < < <22 > <22 < < < <22 > <22 < < < <22 > <22 < < < <22 > <22 < < < <28 > <28 < < < <28 > <28 < < < <28 > <28 < < < <28 > <28 Page 57

59 Cutter Insert Grade HFSS HFSS HFSS HFSS HFSS HFSS HFCI 09T3 HFCI 09T3 HFCI 09T3 XRN XRN XRN Work Piece Material Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron n Vc Vf fz Ap Ae Overhang RPM mm/min mm/min mm/tooth mm mm < < < <15 > <15 < < < <15 > <15 < < < <15 > <15 < < < <15 > <15 < < < <20 > <20 < < < <20 > <20 < < < <20 > <20 < < < <20 > <20 < < < <21 > <21 < < < <21 > <21 < < < <21 > <21 < < < <21 > <21 Page 58

60 Cutting Conditions ata Cutter Insert Grade HFSS HFSS HFA 42/4 HFA 50/5 HFCI 1204 HFCI 1204 HFCI 1204 XRN XRN XRN Work Piece Material Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron n Vc Vf fz Ap Ae Overhang RPM mm/min mm/min mm/tooth mm mm < < < <28 > <28 < < < <28 > <28 < < < <28 > <28 < < < <28 > <28 < < < <28 > <28 < < < <28 > <28 < < < <28 > <28 < < < <28 > <28 < < < <35 > <35 < < < <35 > <35 < < < <35 > <35 < < < <35 > <35 Page 59

61 Cutter Insert Grade HFA 52/5 HFA 63/6 HFA 66/6 HFCI 1204 HFCI 1204 HFCI 1204 XRN XRN XRN Work Piece Material Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron Alloy Steel <32HRC Steel 32-42HRC Steel 42-52HRC Cast Iron n Vc Vf fz Ap Ae Overhang RPM mm/min mm/min mm/tooth mm mm < < < <36 > <36 < < < <36 > <36 < < < <36 > <36 < < < <36 > <36 < < < <45 > <45 < < < <45 > <45 < < < <45 > <45 < < < <45 > <45 < < < <47 > <47 < < < <47 > <47 < < < <47 > <47 < < < <47 > <47 Page 60

Solid Carbide End Mill Program s Hi-Tech for Hi-Tech Applications in Your Industry Millstar s new High Performance and ultra-precise solid carbide end mills were specifically designed for High Speed,

62 Solid Carbide End Mill Program s Hi-Tech for Hi-Tech Applications in Your Industry Millstar s new High Performance and ultra-precise solid carbide end mills were specifically designed for High Speed, High Velocity and Hard Steel milling. esigned with specially selected premium sub-micron carbide substrate, special tool geometry and proprietary heat-defying EXAON tool coating, these tools are beating the best products the competition has to offer. They are made in the United States, and are competitively priced. Please note just some of the benefits to users: Square nose tools Series EMS / EIS with sharp corner or square nose tools Series EIB / EMB with corner radius, all with medium-high helix and strong cutting edges and tool body, work extremely well in materials up to 65HRc as well as in softer materials. Ball nose tools Series BI / BM are designed with two flutes and special nose geometry for true High Speed and Hard Material milling up to 68 HRc. Ball nose tools are the most aggressive tools for these applications. We will be glad to share our proven approach to improving your machining results. The Toroid Series TOM with large corner radius and slight back taper is a Millstar innovative addition. It is very useful in I.. and O.. Z-level and spiral milling at constant tool pressure, pocket milling, and milling of pre-hard and hardened flat surfaces at higher speeds than tools with smaller or sharp corner radii. Extended Reach ball nose tools Series BMN and extended reach square nose tools Series EMR are useful tools specifically designed for long reach milling of extrusion dies, deep cavities and cores, deep rib milling and similar applications. The reduced flute length and neck diameter assure constant cutting pressure and minimal tool deflection. Millstar s Hi-Tech Cutting s are ideal choices for accurately and aggressively machining products in many industries. Here are some examples Mold and die making: injection molds, glass molds, forging dies, extrusion dies. Aerospace: engine, landing gear and tail hook components, structural components, blisks, airfoil machining and forging dies, helicopter rotor components. Power generating: turbine blades and other components. Medical: hip and knee replacement joints, surgical instruments, medical device molds. Automotive: stamping dies, wheel and tire molds, ball joints, cam shaft machining, racing engine details, bumper and other injection molds, die cast dies, forging dies for crank and cam shafts, connecting rods, steering knuckles and yokes, and many other forged components. Consumer products: molds for cake forms and baking dishes, cell phones, lawn chairs, trash cans, toys, bottles, recyclable cutlery and dishes, jewelry, golf clubs, safety helmets, computer and accessory housings and much more. Call on Millstar application specialists or visit our web site for more product information and expert application assistance. Page 61

63 Ultra Precision End Mills EMS - Square End Exalon (AlTiN) Coated No. Cutter iameter tol. +0 / 0.01 Corner Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper EMS-0.5-EX ,5 1,5 7.5 / side 63 EMS-1.0-EX / side 63 EMS-1.5-EX ,5 4,5 7.5 / side 63 EMS-2.0-EX , / side 63 EMS-3.0-EX , / side 75 EMS-4.0-EX , / side 75 EMS-5.0-EX EMS-6.0-EX EMS-8.0-EX EMS-10.0-EX EMS-12.0-EX Overall EMB - Square End Bull Nose w/corner Radius Exalon (AlTiN) Coated No. Cutter iameter tol. +0 / 0.01 Corner Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper EMB EX 1 0, / side 63 EMB EX 1.5 0, ,5 4,5 7.5 / side 63 EMB EX 2 0, / side 63 EMB EX 3 0, / side 75 EMB EX 4 0, / side 75 EMB EX 5 0, / side 75 EMB EX 6 0, EMB EX EMB EX 8 0, EMB EX EMB EX Overall Page 62

64 Ultra Precision End Mills BM - Ball Nose Exalon (AlTiN) Coated No. Cutter iameter tol. +0 / 0.01 Ball Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper BM 0.5 EX 0,5 0, ,5 7.5 / side 63 BM-0.6-EX 0,6 0, ,6 7.5 / side 63 BM-0.8-EX 0,8 0, ,8 7.5 / side 63 BM 1.0 EX 1 0, ,0 7.5 / side 63 BM 1.5 EX 1,5 0, ,5 7.5 / side 63 BM 2.0 EX 2 1, ,0 7.5 / side 63 BM 3.0 EX 3 1, ,0 7.5 / side 75 BM 4.0 EX 4 2, ,0 7.5 / side 75 BM 5.0 EX 5 2, ,0 7.5 / side 75 BM 6.0 EX 6 3, ,0 75 BM 6.0 EX- 6 3, ,0-100 BM 8.0 EX 8 4, ,0 90 BM 10.0 EX 10 5, ,0 100 BM 10.0 EX- 10 5, ,0-120 BM 12.0 EX 12 6, ,0 100 BM 12.0 EX- 12 6, ,0-120 BM 16.0 EX 16 8, ,0 100 BM 16.0 EX- 16 8, ,0 150 Overall TOM - Toroid Exalon (AlTiN) Coated No. Cutter iameter tol. +0 / 0.01 Corner Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper TOM 2.0 EX / TOM 3.0 EX / TOM 4.0 EX / TOM 6.0 EX / - 63 TOM 8.0 EX / - 75 TOM 10.0 EX / - 75 TOM 12.0 EX 12 3.O / - 90 All tools backdraft 3 Overall Page 63

65 BMN - Ball, Extended Reach Tapered Nose* Exalon (AlTiN) Coated No. Cutter iameter tol. +0 / 0.01 Corner Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper BM-2.0-EX-1.25N ,9 / 1,3 2 31,75 / (1,25") 75 BM-2.0-EX-1.80N ,9 / 1,3 2 45,70 / (1,8") 75 BM-2.5-EX-1.25N 2,5 1, ,4 / 1,3 2,5 31,75 / (1,25") 75 BM-2.5-EX-1.80N 2,5 1, ,4 / 1,3 2,5 45,70 / (1,8") 75 BM-3.0-EX-1.25N 3 1, ,9 / 1,3 3 31,75 / (1,25") 75 BM-3.0-EX-1.50N 3 1, ,9 / 1,3 3 38,1 / (1,5") 75 BM-3.0-EX-1.80N 3 1, ,9 / 1,3 3 45,70 / (1,8") 75 BM-3.0-EX-50N 3 1, ,9 / 1, / (1,95") 75 BM-4.0-EX-1.25N ,9 / 1,3 4 31,75 / (1,25") 75 BM-4.0-EX-1.80N ,9 / 1,3 4 45,70 / (1,8") 75 BM-4.0-EX-50N ,9 / 1, / (1,95") 75 BM-5.0-EX-1.25N 5 2, ,9 / 1,3 5 31,75 / (1,25") 75 BM-5.0-EX-1.80N 5 2, ,9 / 1,3 5 45,70 / (1,8") 75 BM-6.0-EX-1.25N ,9 / ,75 / (1,25") 75 BM-6.0-EX-1.50N ,9 / ,1 / (1,5") 75 BM-6.0-EX-1.80N ,9 / ,70 / (1,8") 75 BM-8.0-EX-1.25N ,9 / ,75 / (1,25") 75 * 1.3 Taper Per Side Overall EMR - Square End Bull Nose w/corner Radius, Extended Reach Tapered Nose* Exalon (AlTiN) Coated No. Cutter iameter tol. +0 /.0004 Corner Radius iameter (h6) No. of Flutes iameter Cutting Nose Taper EMR EX-1.25N 2 0, ,9 / 1,3 2 31,75 / (1,25") 75 EMR EX-1.80N 2 0, ,9 / 1,3 2 45,70 / (1,8") 75 EMR EX-50N 2 0, ,9 / 1, / (1,95") 75 EMR EX-1.25N 2,5 0, ,4 / 1,3 2,5 31,75 / (1,25") 75 EMR EX-1.80N 2,5 0, ,4 / 1,3 2,5 45,70 / (1,8") 75 EMR EX-1.25N 3 0, ,9 / 1,3 3 31,75 / (1,25") 75 EMR EX-1.80N 3 0, ,9 / 1,3 3 45,70 / (1,8") 75 EMR EX-50N 3 0, ,9 / 1, / (1,95") 75 EMR EX-1.25N 4 0, ,9 / 1,3 4 31,75 / (1,25") 75 EMR EX-1.80N 4 0, ,9 / 1,3 4 45,70 / (1,8") 75 EMR EX-50N 4 0, ,9 / 1, / (1,95") 75 EMR EX-1.25N 5 0, ,9 / 1,3 5 31,75 / (1,25") 75 EMR EX-1.80N 5 0, ,9 / 1,3 5 45,70 / (1,8") 75 EMR EX-1.25N 6 0, ,9 / ,75 / (1,25") 75 EMR EX-1.80N 6 0, ,9 / ,70 / (1,8") 75 EMR EX-1.25N 12 0, ,9 / ,75 / (1,25") 75 EMR EX-1.80N 12 0, ,9 / ,70 / (1,8") 75 * 1.3 Taper Per Side Overall Page 64

66 High Feed End Mills HFM4 - High Feed Four Flute Solid Carbide No. iameter Programmable Radius iameter iameter of Cut Overall Step Over Ae epth of Cut Ap Feed per Tooth Fz HFM HFM HFM HFM HFM HFM HFM HFM After the part number, please indicate XRN or when ordering. HFM Cutting Conditions Work Material Material Hardness Cutting epth at iameter ap max Cutting Width USA/W.-Nr./JIS Hrc Ae max H13/1.2344/SK61 < % H13/1.2344/SK % H13/1.2344/SK % A2/1,2363/SK12 < % A2/1,2363/SK % A2/1,2363/SK % P20/1,2330 < % P20/1, % 2/1,2379/SK11 < % 2/1,2379/SK % 2/1,2379/SK % Grey Cast Iron/GG < % Cast Iron/GGG % Titanium (6A 4V) % Page 65

67 Ultra Precision End Mills EMS Flute ong Series Endmill, Square End No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EMS XX EMS XX EMS XX EMS XX EMS XX EMS XX EMS XX EMS XX EMS Flute ong Series Endmill, Square End No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EMS XX EMS XX EMS XX EMS XX EMS XX EMS XX EMS XX EMS XX Coating type Recommended Cut speed at Max feed per tooth fz at cutting insert dia Coating m/minute XRN/ XRN/ XRN/ XRN/ XRN/ XRN/ XRN/ XRN/ XRN/ XRN/ XRN/ Page 66

68 Ultra Precision End Mills AlumiSTAR AP - 2 Flute Endmill - Aluminum Cutter iameter (1) Cutting () (3) iameter (3) Radius Flutes () AP NA AP NA iameter (2) AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA none none AP NA AP NA none none AP NA none none AP NA AP NA AP NA AP NA AP NA AP NA none none AP NA AP NA AP NA none none AP NA AP NA AP NA none none AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA Page 67

69 Cutter iameter (1) Cutting () AlumiSTAR AP - 3 Flute Endmill - Aluminum (3) iameter (3) Radius Flutes () AP NA AP NA AP NA iameter (2) AP NA AP NA none none AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA AP NA Page 68

Ultra Precision End Mills AlumiSTAR EMSA - 3 Flute Endmill, 45 - Aluminum No. Cutter iameter tol. +0 / 0.

70 Ultra Precision End Mills AlumiSTAR EMSA - 3 Flute Endmill, 45 - Aluminum No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EMSA-04-4 XX 4, EMSA-06-6 XX 6, EMSA-08-8 XX 8, EMSA XX 10, EMSA XX 12, EMSA XX 16, EMSA XX 20, AlumiSTAR BMA - 3 Flute Endmill, Ballnose 45 - Aluminum No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () BMA ,5 3, BMA , BMA , BMA , BMA , BMA , BMA , BMA , BM2-2 Flute ong Series Endmill, Ballnose No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () BM , BM BM BM BM BM BM BM BM4-4 Flute Endmill ong Series, Ballnose No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () BM , BM BM BM BM BM BM BM Page 69

71 EMV4-4 Flute Variable Fluted Endmill, Square End w/45 Chamfer No. Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EMV XX EMV XX EMV XX EMV XX EMV XX EMV XX EMV XX EMV XX No. BM Flute Endmill, Ballnose Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () BM ,5 3 2,25 38 BM ,00 50 BM ,50 63 BM ,00 63 BM ,50 63 BM ,00 76 No. EMS2-2 Flute Endmill, Square End Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EMS * XX 3, EMS * XX 3, EMS XX 3, EMS XX 4, EMS XX 6, EMS XX 8, EMS XX 10, EMS XX 12, EMS XX 16, EMS XX 20, No. EMS4-4 Flute Endmill, Square End Cutter iameter tol. +0 / Corner Radius (R1) iameter (1) Cutting () () EMS XX 3, EMS XX 4, EMS XX 6, EMS XX 8, EMS XX 10, EMS XX 12, EMS XX 16, EMS XX 20, Page 70

30200 Ryan Road Warren, MI 48092 1.877.MISTAR www.millstar.

Precision End Mills End Mill Expansion IMITE WARRANTY Millstar Warrants to all distributors and industrial users that the products supplied by Millstar shall be free from defects in material and

For a period of thirty days from the date of sale, Millstar will repair or replace (at no additional cost to the customer) any standard Millstar product which Millstar determines contains defects in

However, complete operating conditions and any other information requested by Millstar must accompany claims made under this Warranty. Millstar cannot issue credit or accept returns on special items.

72 30200 Ryan Road Warren, MI MISTAR Steel Holders Copy Milling & Profiling Inserts Back raft, Flat Bottom & Toroid Inserts High Feed Inserts TOB-NF for Aluminum ong Reach Solid Carbide s Shrink Fit Toroid Button Cutters Ultra Precision End Mills End Mill Expansion IMITE WARRANTY Millstar Warrants to all distributors and industrial users that the products supplied by Millstar shall be free from defects in material and workmanship. For a period of thirty days from the date of sale, Millstar will repair or replace (at no additional cost to the customer) any standard Millstar product which Millstar determines contains defects in material or workmanship. Alternately, at its sole discretion, Millstar may credit all or part of the purchase price for such product. However, complete operating conditions and any other information requested by Millstar must accompany claims made under this Warranty. Millstar cannot issue credit or accept returns on special items. EXCUSION OF OTHER WARRANTIES AN POICIES There are no warranties, express or implied, which extend beyond the warranty description on the face hereof and specifically, MISTAR AN ITS AFFIIATE COMPANIES EXCUE ANY IMPIE WARRANTY OF MERCHANTABIITY OR FITNESS FOR A PARTICUAR USE. Millstar and its affiliated companies shall have no liability or responsibility for any claim or loss arising out of design, manufacture, sale or use of its products other than to repair or replace its products as described above. IN NO EVENT SHA MISTAR OR ITS AFFIIATE COMPANIES BE IABE FOR ANY SPECIA, CONSEQUENTIA OR INCIENTA AMAGES. Any misuse or alteration of the product will void this Warranty. Millstar does not authorize any person or entity to make any representation (verbal or written) contrary to the terms of this imited Warranty or its exclusions