HFM. Small Diameter Machining High Feed Tool. High Feed Mill. HFM High Feed Mill

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1 High Feed Mill Small Diameter Machining High Feed Tool Stable machining, high efficiency milling tools For small diameter machining. High Feed / High Efficiency Machining Increase productivity through improved insert she and size, high feed per tooth, and many cutting edges, for small diameter machining. High Speed / High Hardness Machining Stable tool life through the combination of the reinforced toughness on corner and suitable grades of high hardness in the area of high speed and high hardness. High efficiency machining High Feed Mill High Feed machining High speed machining high hardness machining

2 High Efficiency Milling Tool for Small Diameter Machining High Feed Mill() The need for high feed tooling has grown while the materials of molds tend to be harder. Small size tooling is required for the electronic parts and mold manufacturers to achieve high productivity. Insert However, increasing productivity has been restricted due to the absence of small size high feed tools for high hardness steel. extends the range of process to small diameter, improving productivity with more number of teeth, compared to HRM(D). Shank High Helix angle on the cutting edge reduces cutting resistance, while the negative axial rake angle of holder reduces the contact surface on workpiece, reducing wear and vibration and increasing stability. Improved grades ensure stable tool life. Ultrafine grain substrate and specialized coating layer highly improve anti-chipping and anti-wear. Modular Small diameter Extension of the range of cutting process More number of teeth brings high productivity Advantages Optimum she of cutting edge Helix angle on cutting edge lessen cutting resistance and enable high feed process Reinforced cutting edge Various mixture of grade Anti-chipping make cutting hard material easier Suitable for P, M, K, S, H Improved anti-chipping and anti-wear Code System [ Shank Type ] S 1 1 H R - 2 L 1 High Feed Mill Tool type Inscribed S : Shank circle of insert 1:4type insert Tool Dia. 1 : Ø1 Coolant type No code : None H : Thru-hole Hand R : Right L : Left No. of tooth Shank length 2 : 2teeth S : Standard type M: Middle type L : Long type Shank Dia. 1 : Ø1 [ Modular Type ] M 1 1 H R - M6 High Feed Mill Tool type M : Modular Inscribed circle of insert 1:4type insert Tool Dia. 1 : Ø1 Coolant type No code : None H : Thru-hole Hand R : Right L : Left M Dimensions [ Modular Adter ] MAT - M1-1 - S2 S - C - 17 Modular Adter M Dimensions M1 Neck length 1 : 1mm Shank Dia. S2 : Ø2 Neck type T : Ter S : straight Adtor material Unmarked : Steel C : Carbide Adtor length 17 : 17mm 2 KORLOY TECH-NEWS

3 Features Apply helix cutting edge on insert, low cutting load and reinforce toughness on corner Increased rigidity with double relief angle (11, 13), prevent interference with high feed To ply the negative axial rake angle when set up the holder, increased chipping resistance Tool life is increased with suitable C/B and grade for every material Axial rake angle - Holder Setup To set up the negative axial rake angle, increased chipping resistance No. of tooth Increased Tool life with increased flutes HRM(D) Ø2 (2 flutes) Ø2 (5 flutes) Relief angle 11, 13 double relief angle increase rigidity and prevent interference Major cutting edge Apply helix cutting edge - Improved sharpness of principle edge - Improved toughness of corner edge Application Area Good performance at machining small diameter (Ø8~Ø2) with small size and she of Application Area ( & Diameter) Application Area ( & fz) : 4type HRM(D) : 6~16type : 4type HRM(D) : 6~16type HRM(D) HRM(D) 13type 9type 16type type 13type 9type type 6type.5.5 4type 4type Ø8 ~ Ø16 ~ Ø25 ~ Ø32 ~ Ø8 ~ Ø Diameter(Ø) fz(mm/t) Usage and Features of Chip Breakers Chip Breaker Cutting edge Applications Features MF None C/B Fine finishing Titanium & Inconel machining Super hard material machining Low cutting resistance C/B, suitable for light cutting High toughness she, suitable for hard die steel cutting 3

4 Performance Test Recommended grades have been plied according to workpiece - Better performance than competitors under high feed rate High speed machining Workpiece X155CrVMo12-1 (HRC4~45) Insert LPM(E)W42 R Recommended grade PC255(1 st ), PC251(2 nd ) Cutting speed, vc(mm/min) Competitor B Competitor A Velocity 8% and feed rate 1% increased fz(mm/t) Workpiece X155CrVMo12-1 (Over HRC6) Insert LPM(E)W42 R Recommended grade PC255(1 st ), PC251(2 nd ) Cutting speed, vc(mm/min) Competitor B Competitor C Velocity 25% and feed rate 25% increased fz(mm/t) High Helix and advanced technology have been plied to edge geometary. - Better performance than competitors under high feed rate Workpiece (Improved) (HRC3~4) Insert LPMT42 R-MF Recommended grade (1 st ), PC251(2 nd ) Cutting speed, vc(mm/min) Competitor A High feed machining Feed rate 13% increased Workpiece TiAl6V4 (HRC4~45) Insert LPMT42 R-MF Recommended grade (1 st ), PC54(2 nd ) Cutting speed, vc(mm/min) Competitor A Feed rate 25% increased Competitor B fz(mm/t) fz(mm/t) New Grades;PC255 and PC251 are the 1 st recommendation for high hardened Grade PC255 PC251 PC54 Hardness Over HRC45 HRC35~5 HRC2~4 Under HRC37 Interrupted cutting 3 4 High hardness machining [ Recommended grades according to interruption ] P Mild steel, P Alloy steel Carbon steel PC54 P Pre-hardened steel PC251 5 P Alloy tool steel PC255 6 Hardness(HRC) Interrupted cutting M Stainless steel 2 PC54 3 S HRSA 4 5 Hardness(HRC) [ Recommended grades according to velocity ] Cutting speed, vc(m/min) P Mild steel, P Alloy steel Carbon steel PC P Pre-hardened steel PC251 P Alloy tool steel M Stainless 18 steel PC PC Hardness(HRC) 5 Cutting speed, vc(m/min) S HRSA 4 5 Hardness(HRC) 4 KORLOY TECH-NEWS

5 Performance Test Effective machining Chip removal rate Q(cm 3 /min) HRMD Ø1 Ø12 Ø16 Ø2 Ø25 Cutting Dia. (Ø) [ Machining center ] BT4 and under, recommended BT5 and above, HRM(D) recommended [ Chip removal rate Q(cm 3 /min) ] Ø8~Ø2, recommende Ø2 and above, HRM(D) recommended Recommended Cutting Conditions Recommended chip breaker : First Second Workpiece Workpiece KOR (KS) USA (AISI) GER (DIN) HB (HRC) Mild steel SM2C 12 C22 12~18 Carbon steel SM45C 145 C45 2 Grade PC54 () PC54 () vc (m/min) Cutting conditions fz (mm/t) ae Chip breaker MF None C/B 1~22.5~1. ~.5.7D~.1D - 1~2.5~1. ~.5.7D~.1D - Alloy steel SCM CrMo4 27(28) 1~2.5~1. ~.5.7D~.1D - KP4M P2 (Improved) (Improved) 3(32) (PC251) 1~18.5~.9 ~.4.7D~.1D NIMAX P21 (Improved) - 37(4) (PC251) 1~18.5~.9 ~.4.7D~.1D P Pre-hardened steel CENA1 NAK8 P21 (Improved) P21 (Improved) - 37(4) (PC251) - 4(43) 1~18.5~.9 ~.4.7D~.1D 1~16.5~.7 ~.4.7D~.1D - 1~18.5~.9 ~.4.7D~.1D - Alloy tool steel STAVAX 42 X3Cr13 51(52) STD11 STD61 STD11 (Cold forging) D2 H13 X155CrVMo12-1 X4CrMoV5-1 - (4~5) M Stainless steel STS X5CrNiMo Under 27 K S Gray cast iron, Ductile cast iron HRSA PC251 () PC251 (PC255) 8~15.3~.6 ~.4.7D~.1D - 8~13.3~.55 ~.3.7D~.1D - D2 X155CrVMo (6) PC255 3~75.3~.5 ~.2.7D~.1D - GCD GGG4.3 Tensile Strength Over 45Mpa Fe series Incoloy91 N991 - (WS ) Ni or Co series Inconel718 N7718 NiCr19FeNbMo (WS ) - (25~35) - (35~45) PC54 () 7~15.5~.7 ~.5.7D~.1D - 13~22.6~.8 ~.5.7D~.1D - (PC54) (PC54) 3~1.3~.5 ~.3.4D~.7D 2~5.3~.6 ~.3.4D~.7D Titanium Ti-6Al-4V R564 TiAl6V4 - (4~45) 3~5.4~1. ~.3.7D~.1D - 5

6 Cutting Performance Edge in good she [ ] [ Competitor ] Carbon steel [C45(DIN) / 145(AISI) / SM45C(KS), HB2] Workpiece Mold Cutting conditions vc(m/min) = 15, fz(mm/t) =.6, =.4, ae = 5, dry Tools Insert LPMT421R-MF () Holder S11HR-2S1 Chip removal rate Q(cm 3 /min) : 11.5 Cutting time(min) : 3 Competitor Chip removal volume(cm 3 ) 344.8cm cm 3 1% more Wear-resistance & anti-chipping increased due to helix cutting edge when machining carbon steel Edge in good she [ ] [ Competitor ] Pre-hardened steel [P21(Improved) (AISI) / NAK8(KS), HRC4~41] Workpiece Mold Cutting conditions vc(m/min) = 1, fz(mm/t) = 1.26, =.3, ae = 1, dry Tools Insert LPMT421R-MF () Holder S116HR-4S16 Chip removal rate Q(cm 3 /min) : 15 Cutting time(min) : 3.29 Competitor Chip removal volume(cm 3 ) 33.2cm cm 3 5% more Anti-chipping in high feed increased due to optimized cutting edge when machining pre-hardened steel Edge in good she [ ] [ Competitor ] Pre-hardened steel [X3Cr13(DIN) / 42(AISI) / STAVAX(KS), HRC5~51] Workpiece Mold Cutting conditions vc(m/min) = 2, fz(mm/t) =.6, =.3, ae = 1, dry Tools Insert LPMT421R-MF (PC251) Holder S116HR-4S16 Chip removal rate Q(cm 3 /min) : 14.3 Cutting time(min) : 1.26 Competitor Chip removal volume(cm 3 ) 12.8cm 3 18cm 3 4% more Wear-resistance increased comparing to competitors when machining pre-hardened steel 6 KORLOY TECH-NEWS

7 Cutting Performance Edge in good she [ ] [ Competitor ] Alloy tool steel [X155CrVMo12-1(DIN) / D2(AISI) / STD11(KS), HRC4~45] Workpiece Mold Cutting conditions vc(m/min) = 8, fz(mm/t) =.5, =.3, ae = 1, dry Tools Insert LPMW421R (PC251) Holder S116HR-4S16 Chip removal rate Q(cm 3 /min) : 4.8 Cutting time(min) : 25 Competitor Chip removal volume(cm 3 ) 1cm 3 12cm 3 2% more Anti-breakage increased due to optimized she and grade when machining alloy tool steel Edge in good she [ ] [ Competitor ] Alloy tool steel [X155CrVMo12-1(DIN) / D2(AISI) / STD11(KS), HRC6] Workpiece Mold Cutting conditions vc(m/min) = 75, fz(mm/t) =.4, =.15, ae = 5, dry Tools Insert LPMW421R (PC255) Holder S11HR-2S1 Chip removal rate Q(cm 3 /min) : 1.4 Cutting time(min) : 7.85 Competitor Chip removal volume(cm 3 ) 8.4cm 3 11cm 3 3% more Wear-resistance increased due to optimized she and grade when machining alloy tool steel Edge in good she [ ] [ Competitor ] HRSA [TiAl6V4(DIN) / R564(AISI) / Ti-6Al-4V(KS), HRC48] Workpiece Aviation parts Cutting conditions vc(m/min) = 5, fz(mm/t) = 1.2, =.3, ae = 1, wet Tools Insert LPMT421R-MF () Holder S116HR-4S16 Chip removal rate Q(cm 3 /min) : 7.2 Cutting time(min) : 1.5 Competitor Chip removal volume(cm 3 ) 6.3cm cm 3 2% more Wear-resistance increased due to optimized she of cutting edge when machining HRSA 7

8 α α Ramping and Helical cutting Ramping Helical cutting Lmin Hmax Hmax Hmin Hmin α α dmax dmax α dmax α dmax α Lmin = tan α Lmin : Min. inclination cutting length α : Max. ramping angle : Depth of cut = Tool Dia. = Tool path = Hmin, max - Hmin(Min diameter, mm) = Hmax(Max diameter, mm) = 2-2 Designation Tool Dia. Depth of cut Max ramping angle α( ) Ramping Lmin Max diameter Hmax Helical cutting Max pitch dmax Min diameter Hmin Max pitch dmax S11HR 1.4~ S111HR 11.4~ S112HR 12.4~ S113HR 13.4~ S114HR 14.4~ S115HR 15.4~ S116HR 16.4~ S117HR 17.4~ S118HR 18.4~ S119HR 19.4~ S12HR 2.4~ S121HR 21.4~ M125HR 25.4~ M126HR 26.4~ M13HR 3.4~ M132HR 32.4~ M133HR 33.4~ Adjust feed to under 7% of recommended cutting condition when ramping & helical cutting In helical ramping, max. cutting depth(dmax) per 1 helical revolution of cutter should not exceed max. cutting depth() as per insert size In ramping, max. cutting depth per 1 ramping process of cutter should not exceed max. depth of cut as per used insert size 8 KORLOY TECH-NEWS

9 Corner R programming Corner R programming Insert Ov er cu t Uncut R.31 R R1.5 LPMT422R-MF LPMW422R LPEW422R Uncut Over Cut Nose R Max. R1.(Standard) LPMT421R-MF LPMW421R LPEW421R Corner R programming Cutting conditions 1. R R(Standard) When using CNC program, overcut & uncut occurs on the corner processing site if entering the correct program corner R value for each insert To prevent overcut, you will need to complete a CNC program considering the above overcut Insert LPMT 421R-MF LPMT421R-MFDepth of cut Dimensions PC255 PC251 Usage PC54 Designation Coated - l 6.4 d 4.2 Fine finishing 422R-MF LPMW 421R High hardness material machining 422R LPEW 421R High hardness material machining 422R t r d1 Configuration LPMT421R-MF LPMW421R 2.6LPMT421R-MF 1..4 LPMW421R 2.6LPMT422R-MF.5 LPMT421R-MF LPMW421R LPMT421R-MF LPMT422R-MF 2.6LPMW421R 1..4 LPMW422R LPMT422R-MF LPMW421R LPMT421R-MF 2.6LPMW422R.5 LPMT422R-MF LPMW422R LPMT422R-MF 2.6LPMW421R 1..4 LPMW422R LPMW422R.5 LPMT422R-MF LPMW422R Parts Specification ~Ø1 Ø11~Ø33 Screw Wrench FTKA184 FTKA1842 TW6S-A 9

10 S1 (Shank) AA 13 AR : -4 RR : -14 ~ -7 L Designation L S 18HR-1S ~ HR-1M ~ HR-1L ~ HR-2S ~ HR-2M ~ HR-2L ~ HR-2S ~ HR-2M ~ HR-2L ~ HR-2S ~ HR-2M ~ HR-2L ~ HR-3S ~ HR-3M ~ HR-3L ~ HR-3S ~ HR-3M ~ HR-3L ~ HR-3S ~ HR-3M ~ HR-3L ~ HR-3S ~ HR-3M ~ HR-3L ~.5.1 Available Inserts Designation LPMW LPEW Coated Usage PC54 PC251 PC255 LPMT 421R-MF - Fine finishing 422R-MF - LPMW 421R - High hardness material machining 422R - LPEW 421R - High hardness material machining 422R - :Stock item Parts Specification Screw Wrench Ø8~Ø1 Ø11~Ø21 FTKA184 FTKA1842 TW6S-A 1 KORLOY TECH-NEWS

11 S1 (Shank) AA 13 AR : -4 RR : -6 ~ -3 L Designation L M S 115HR-4S ~ HR-4M ~ HR-4L ~ HR-4S ~ HR-4M ~ HR-4L ~ HR-4S ~ HR-4M ~.5.15 L 117HR-4L ~ HR-4S ~ HR-4M ~ HR-4L ~ HR-4S ~ HR-4M ~ HR-4L ~ HR-4S ~ HR-4M ~ HR-4L ~ HR-5S ~ HR-5M ~ HR-5L ~ HR-5S ~ HR-5M ~ HR-5L ~ Available Inserts Designation LPMW LPEW Coated Usage PC54 PC251 PC255 LPMT 421R-MF - Fine finishing 422R-MF - LPMW 421R - High hardness material machining 422R - LPEW 421R - High hardness material machining 422R - :Stock item Parts Specification Screw Wrench Ø8~Ø1 Ø11~Ø21 FTKA184 FTKA1842 TW6S-A 11

12 M (Modular) L M AA 13 AR : -4 RR : -14 ~ -3 1 L Designation 1 L M M 18HR-M M6.4~ HR-M M6.4~ HR-M M6.4~ HR-M M6B.4~ HR-M M6B.4~ HR-M M8.4~ HR-M M8.4~ HR-M M1.4~ HR-M M1.4~ HR-M M12.4~ HR-M M12.4~ HR-M M16.4~ HR-M M16.4~ HR-M M16.4~.5.18 Available Inserts Designation LPMW LPEW Coated Usage PC54 PC251 PC255 LPMT LPMW LPEW 421R-MF - Fine finishing 422R-MF - 421R - High hardness material machining 422R - 421R - High hardness material machining 422R - :Stock item Parts Specification Screw Wrench Ø8~Ø1 Ø11~Ø33 FTKA184 FTKA1842 TW6S-A 12 KORLOY TECH-NEWS

13 MAT (Steel Shank type) Fig. 1 Fig. 2 Designation 1 L M Fig MAT- M6-2-S1S M6 1 S : Straight Neck Adter T : Ter Neck Adter M6B-2-S12S M6 1 M6B-4-S12S M6 1 M8-2-S16S M8 1 M1-3-S2S M1 1 M12-3-S25S M12 1 M16-35-S32S M16 1 M6-4-S12T M6 2 M6-65-S16T M6 2 M6B-65-S16T M6 2 M6B-8-S16T M6 2 M8-4-S16T M8 2 M8-65-S16T M8 2 M8-8-S2T M8 2 M8-11-S25T M8 2 M1-5-S2T M1 2 M1-7-S2T M1 2 M1-9-S25T M1 2 M1-11-S25T M1 2 M1-13-S32T M1 2 M12-5-S25T M12 2 M12-7-S25T M12 2 M12-9-S25T M12 2 M12-11-S32T M12 2 M S4T M12 2 M16-55-S32T M16 2 M16-8-S32T M16 2 M16-12-S32T M16 2 M S4T M

14 MAT-C (Carbide Shank type) Fig. 1 Fig. 1 Designation 1 L M Fig MAT- M6-3-S1S-C M6 1 M6-5-S1S-C M6 1 M6-8-S1S-C M6 1 M6B-3-S1S-C M6 1 M6B-5-S1S-C M6 1 M6B-8-S1S-C M6 1 M8-8-S16S-C M8 1 M8-11-S16S-C M8 1 M8-15-S16S-C M8 1 M8-1-S16S-C M8 2 M8-1-S16S-C M8 2 M8-1-S16S-C M8 2 M1-9-S2S-C M1 1 M1-11-S2S-C M1 1 M1-175-S2S-C M1 1 M1-1-S2S-C M1 2 M1-1-S2S-C M1 2 M1-1-S2S-C M1 2 M12-9-S25S-C M12 1 M12-11-S25S-C M12 1 M S25S-C M12 1 M12-15-S25S-C M12 2 M12-15-S25S-C M12 2 M12-15-S25S-C M12 2 M16-9-S32S-C M16 1 M16-12-S32S-C M16 1 M S32S-C M16 1 M16-2-S32S-C M16 2 M16-2-S32S-C M16 2 M16-2-S32S-C M KORLOY TECH-NEWS

15 BT3 / BT4 / BT5 Designation L M BT3- MAT-M M6*1. MAT-M M8*1.25 MAT-M M1*1.5 MAT-M M12*1.75 MAT-M M16* BT4- MAT-M M6*1. MAT-M M6*1. MAT-M M6*1. MAT-M M8*1.25 MAT-M M8*1.25 MAT-M M8*1.25 MAT-M M1*1.5 MAT-M M1*1.5 MAT-M M1*1.5 MAT-M M12*1.75 MAT-M M12*1.75 MAT-M M12*1.75 MAT-M M16* MAT-M M16* MAT-M M16* BT5- MAT-M M6*1. MAT-M M6*1. MAT-M M6*1. MAT-M M8*1.25 MAT-M M8*1.25 MAT-M M8*1.25 MAT-M M1*1.5 MAT-M M1*1.5 MAT-M M1*1.5 MAT-M M12*1.75 MAT-M M12*1.75 MAT-M M12*1.75 MAT-M M16* MAT-M M16* MAT-M M16* 15

16 HSK63A / HSK1A Designation L M HSK63A- MAT-M M6*1. MAT-M M6*1. MAT-M M6*1. MAT-M M8*1.25 MAT-M M8*1.25 MAT-M M8*1.25 MAT-M M1*1.5 MAT-M M1*1.5 MAT-M M1*1.5 MAT-M M12*1.75 MAT-M M12*1.75 MAT-M M12*1.75 MAT-M M16* MAT-M M16* MAT-M M16* HSK1A- MAT-M M6*1. MAT-M M6*1. MAT-M M6*1. MAT-M M8*1.25 MAT-M M8*1.25 MAT-M M8*1.25 MAT-M M1*1.5 MAT-M M1*1.5 MAT-M M1*1.5 MAT-M M12*1.75 MAT-M M12*1.75 MAT-M M12*1.75 MAT-M M16* MAT-M M16* MAT-M M16* Holystar B/D, 135, Nambusunhwan-ro, Geumcheon-gu, Seoul, 8536, Korea Tel : Fax : , Web : export@korloy.com 62 Mle Avenue, Torrance, CA 953, USA Tel : Toll Free : Fax : sales@korloy.us Plot NO.415, Sector 8, IMT Manesar, Gurgaon 12251, Haryana, INDIA Tel : Fax : sales.kip@korloy.com Gablonzer Str , 6144 Oberursel, Germany Tel : Fax : sales@korloyeurope.com Av. Aruana 28, conj.12, WLC, Alphaville, Barueri, CEP646-1, SP, Brasil Tel : vendas@korloy.com TN5-EM-2 / 21751

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