SERIES 33 Three Flute End Mills
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1 Solid Carbide Tools SERIES 33 Three Flute End Mills ISO 9001 Certified
2 Using the latest in engineering design and grinding capabilities, Series 33 High Perfmance End Mills are ideal f aggressive ramping, pocketing, and slotting in difficult to machine materials such as Stainless Steel, Titanium, and Inconel. Designed f applications challenged by heavy chip evacuation, this 3-Flute design offers increased chip clearance and a reduction in harmonics. Proprietary 3-Flute design allows f me controlled chip fmation and efficient chip evacuation. Specially engineered stepped ce design provides stability f aggressive ramping and rigidity when flutes are completely engaged. Open design at the axial end accommodates material flow and load reduction during operations. Variable geometry design provides superi chatter and vibration suppression during aggressive milling. Available with KSPT Patented Jet Stream Technology f precise coolant placement. Exclusively coated with Ti-NAMITE-A, which helps to prevent edge build-up while ensuring superi wear and enhanced tool life. A B A Stepped Ce Design Increased chip space at the axial end of the tool f aggressive slotting, improved rigidity, and optimized chip fmation. B Proprietary Variable Geometry Engineered variable helix and pitch configuration offer chatter and vibration suppression.
3 THE SERIES 33 IS IDEAL FOR AGGRESSIVE RAMPING, POCKETING AND SLOTTING IN DIFFICULT TO MACHINE MATERIALS: rospace Structural Components Medical Implants Automotive Perfmance Components Stainless Steel Valves Series 33 is exclusively available with the abrasive resistant AlTiN hard coating, Ti-NAMITE-A. With excellent thermal and chemical resistance, Ti-NAMITE-A allows f dry cutting and improved perfmance of carbide. The coating has a high hardness ensuring the ultimate protection against abrasive wear and erosion. Ideal f cast iron, high temperature alloys, titanium, steels, and stainless steel applications. Hardness (HV): 3700 Oxidation Temperature: 1100 C / 2010 F Coefficient of Friction: 0.30 Thickness: 1 4 Microns (based on tool diameter) C C Symmetrical End Gashing Superi balance combined with a high level of strength and ramping capabilities.
4 CASE STUDY KYOCERA SGS Precision Tools SAVES AN END USER $263,100 ANNUALLY BY INCREASING METAL REMOVAL RATE & OPTIMIZING CYCLE TIME INDUSTRY Lift Equipment COMPONENT Hook Plate MATERIAL ASTM A514 HTSTL PLT 100 KSI PRODUCT KSPT Series 33 End Mill AlTiN Coated APPLICATION Peripheral Machining CNC INFO Haas VF7 SPINDLE CAT 50 Milling Chuck COMPETITOR 3 Flute End Mill COOLANT Water Soluble TOOL INFORMATION 1 DIA / 2 ¼ LOC / 5 OAL BACKGROUND The hook plate is a primary suppt piece of a fk lift assembly and requires precise machining tolerances. The application calls f machining.230 from the peripheral of the part at an axial depth of 1-1/2 : the A514 material used in this application is similar to The competit tool was perfming this in four rough passes followed by a single finish pass. KYOCERA SGS Precision Tools (KSPT) proposed a single roughing and finishing pass utilizing a 1 Series 33 End Mill. GOALS The primary goals of this test were to reduce cycle time, increase tool life, and decrease overall tooling cost. STRATEGY Wking with the end user to understand their needs, KSPT approached the application with a 1 three flute Series 33 End Mill, allowing f increased tool life and greater feed rates to improve cycle times. KSPT COMPETITOR TOOL DIAMETER SPEED 2500 SFM 1578 SFM FEED 54 IPM 17 IPM RADIAL CUT (AE) AXIAL CUT (AP) CYCLE TIME 7.69 seconds seconds METAL REMOVAL RATES 2.46 cubic inches.78 cubic inches COMPETITOR FEED IN INCHES KSPT CYCLE TIME/ SECONDS The KSPT Series 33 End Mill allowed f a 217% increase in feed rates and a 68% reduction in cycle time.
5 Increased Feed Rates Increased Material Removal Increased Tool Life RESULTS The changes made to the application combined with the high perfmance geometry of the KSPT Series 33 End Mill resulted in an annual gain of production hours. In addition to meeting the goal f improved cycle times, tool life was increased from 20 to 240 parts per tool. This reduced the tooling cost per part by 91%, allowing the end user to achieve a total annual cost savings of $263,100. CYCLE TIME SAVED PER PART Seconds NUMBER OF PARTS PER YEAR 22,500 CYCLE TIME SAVED ANNUALLY Hours COST TO MACHINE PER HOUR $100 MACHINE COST SAVED ANNUALLY $10,425 TOOL LIFE IMPROVEMENT 220 Additional Parts TOOLING COST SAVED PER PART $11.23 TOOLING COST SAVED ANNUALLY $252,675 CONCLUSION KSPT was able to achieve the primary goals of cycle time reduction and decreased tooling cost by recommending a high perfmance tool f the application. This allowed f increased feed and speed rates, resulted in greater metal removal rates and drastically improved tool life. $263,100 ANNUAL COST SAVINGS 13 DAYS ADDITIONAL PRODUCTIVITY 91% REDUCTION IN TOOLING COST $300,000 $250,000 $200,000 $150,000 $100,000 $50,000 $0 NUMBER OF PARTS PER TOOL $252,675 $263,100 ANNUAL TOOLING COST SAVINGS COMPETITOR 20 PARTS COMPETITOR TOTAL ANNUAL COST SAVINGS KSPT 240 PARTS KSPT The KSPT Series 33 End Mill allowed f a 1100% increase!
6 L 2 L 1 TOLERANCES (inch) DIAMETER D 1 D 2 1/8-1/ / h6 D 1 R D 2 > 1/4-3/ / h6 > 3/ / h6 CORNER RADIUS TOLERANCES (inch) R = / Series 33 CR Fractional Cutting Diameter D 1 Length of Cut L 2 Overall Length L 1 Shank Diameter D 2 Cner Radius R Ti-NAMITE-A (AlTiN) EDP No. 1/8 3/8 2-1/2 1/ /16 9/16 2-1/2 1/ /4 3/4 2-1/2 1/ /16 13/16 2-1/2 5/ / /2 3/ /16 1-1/8 2-3/4 7/ /2 1-1/4 3-1/4 1/ /8 1-1/2 3-1/2 5/ /4 1-3/4 4 3/ / Cner Straight HAIMER Safe-Lock Regular Variable Right Spiral POS Positive Rake Angle External Coolant JetStream Flute Spacing Unequal 3 Flutes 6
7 TOLERANCES (mm) DIAMETER D 1 D 2 L 2 L ,000 / 0,030 h6 > ,000 / 0,040 h6 > ,000 / 0,050 h6 D 1 R D 2 CORNER RADIUS TOLERANCES (mm) R= +0,000 / 0,050 Cner Straight HAIMER Safe-Lock Regular Variable Right Spiral POS Positive Rake Angle External Coolant JetStream Flute Spacing Unequal 3 Flutes Cutting Diameter D 1 Length of Cut L 2 Overall Length L 1 Shank Diameter D 2 Cner Radius R Ti-NAMITE-A (AlTiN) EDP No. 3,0 9,0 57,0 6,0 0, ,0 9,0 57,0 6,0 0, ,0 12,0 57,0 6,0 0, ,0 12,0 57,0 6,0 0, ,0 15,0 57,0 6,0 0, ,0 15,0 57,0 6,0 0, ,0 18,0 57,0 6,0 0, ,0 18,0 57,0 6,0 1, ,0 18,0 57,0 6,0 1, ,0 18,0 57,0 6,0 2, ,0 20,0 63,0 8,0 0, ,0 20,0 63,0 8,0 1, ,0 20,0 63,0 8,0 1, ,0 20,0 63,0 8,0 2, ,0 27,0 72,0 10,0 0, ,0 27,0 72,0 10,0 1, ,0 27,0 72,0 10,0 1, ,0 27,0 72,0 10,0 2, ,0 27,0 72,0 10,0 2, ,0 30,0 83,0 12,0 0, ,0 30,0 83,0 12,0 1, ,0 30,0 83,0 12,0 1, ,0 30,0 83,0 12,0 2, ,0 30,0 83,0 12,0 2, ,0 30,0 83,0 12,0 3, ,0 30,0 83,0 12,0 4, ,0 38,0 92,0 16,0 1, ,0 38,0 92,0 16,0 1, ,0 38,0 92,0 16,0 2, ,0 38,0 92,0 16,0 2, ,0 38,0 92,0 16,0 3, ,0 38,0 92,0 16,0 4, ,0 46,0 104,0 20,0 1, ,0 46,0 104,0 20,0 2, ,0 46,0 104,0 20,0 2, ,0 46,0 104,0 20,0 3, ,0 46,0 104,0 20,0 4, Series 33 MCR Metric 7
8 Ap Series 33CR Fractional Hardness Vc Diameter (D 1 ) (inch) x D 1 Ap x D 1 (sfm) 1/8 1/4 3/8 1/2 5/8 3/4 1 Series 33 Speed & Feed Recommendations P H K CARBON STEELS 1018, 1040, 1080, 1090, 10L50, 1140, 1212, 12L15, 1525, 1536 ALLOY STEELS 4140, 4150, 4320, 5120, 5150, 8630, 86L20, TOOL STEELS A2, D2, H13, L2, M2, P20, S7, T15, W2 CAST IRONS (LOW & MEDIUM ALLOY) Gray, Malleable, Ductile CAST IRONS (HIGH ALLOY) Gray, Malleable, Ductile 275 Bhn 28 HRc 375 Bhn 40 HRc 375 Bhn 40 HRc 220 Bhn 19 HRc 260 Bhn 26 HRc 550 RPM ( ) Fz Feed (ipm) RPM ( ) Fz Feed (ipm) RPM ( ) Fz Feed (ipm) RPM ( ) Fz Feed (ipm) RPM ( ) Fz Feed (ipm) RPM ( ) Fz Feed (ipm) RPM ( ) Fz Feed (ipm) RPM ( ) Fz Feed (ipm) RPM ( ) Fz Feed (ipm) RPM ( ) Fz Feed (ipm) M STAINLESS STEELS (FREE MACHINING) 303, 416, 420F, 430F, 440F 275 Bhn 28 HRc 490 RPM Fz ( ) Feed (ipm) RPM Fz ( ) Feed (ipm) continued on next page 8
9 Ap Series 33CR Fractional Hardness Vc Diameter (D 1 ) (inch) x D 1 Ap x D 1 (sfm) 1/8 1/4 3/8 1/2 5/8 3/4 1 M S STAINLESS STEELS (DIFFICULT) 304, 304L, 316, 316L STAINLESS STEELS (PH) 13-8 PH, 15-5 PH, 17-4 PH, Custom 450 SUPER ALLOYS (NICKEL, COBALT, IRON BASE) Inconel 601, 617, 625, Incoloy, Monel 400 SUPER ALLOYS (NICKEL, COBALT, IRON BASE) Inconel 718, X-750, Incoloy, Waspaloy, Hastelloy, Rene TITANIUM ALLOYS Pure Titanium, Ti6Al4V, Ti6Al2Sn4Zr2Mo, Ti4Al4Mo2Sn0.5Si 275 Bhn 28 HRc 325 Bhn 35 HRc 300 Bhn 32 HRc 400 Bhn 43 HRc 350 Bhn 38 HRc 340 RPM ( ) Feed (ipm) RPM ( ) Feed (ipm) RPM ( ) Feed (ipm) RPM ( ) Feed (ipm) RPM (64-96) Fz Feed (ipm) RPM (52-78) Fz Feed (ipm) RPM (50-74) Fz Feed (ipm) RPM (39-59) Fz Feed (ipm) RPM ( ) Feed (ipm) RPM ( ) Feed (ipm) Series 33 Speed & Feed Recommendations TITANIUM ALLOYS (DIFFICULT) Ti10Al2Fe3Al, Ti5Al5V5Mo3Cr, Ti7Al4Mo, Ti3Al8V6Cr4Zr4Mo, Ti6Al6V6Sn, Ti15V3 Cr3Sn3Al 440 Bhn 47 HRc 75 RPM (60-90) Feed (ipm) RPM (48-72) Feed (ipm) Note: Bhn (Brinell) HRc (Rockwell C) rpm = Vc x 3.82 / D 1 ipm = Fz x 3 x rpm reduce speed and feed f materials harder than listed reduce feed and when finish milling (.02 x D 1 maximum) refer to the KYOCERA SGS Tool Wizard f complete technical infmation (
10 Ap Series 33MCR Metric Hardness Vc Diameter (D 1 ) (mm) x D 1 Ap x D 1 (m/min) Series 33 Speed & Feed Recommendations P H K CARBON STEELS 1018, 1040, 1080, 1090, 10L50, 1140, 1212, 12L15, 1525, 1536 ALLOY STEELS 4140, 4150, 4320, 5120, 5150, 8630, 86L20, TOOL STEELS A2, D2, H13, L2, M2, P20, S7, T15, W2 CAST IRONS (LOW & MEDIUM ALLOY) Gray, Malleable, Ductile CAST IRONS (HIGH ALLOY) Gray, Malleable, Ductile 275 Bhn 28 HRc 375 Bhn 40 HRc 375 Bhn 40 HRc 220 Bhn 19 HRc 260 Bhn 26 HRc 168 RPM ( ) Fz Feed (mm/min) RPM ( ) Fz Feed (mm/min) RPM (77-115) Fz Feed (mm/min) RPM (61-91) Fz Feed (mm/min) RPM (45-68) Fz Feed (mm/min) RPM (35-53) Fz Feed (mm/min) RPM ( ) Fz Feed (mm/min) RPM (87-130) Fz Feed (mm/min) RPM (83-124) Fz Feed (mm/min) RPM (66-99) Fz Feed (mm/min) M STAINLESS STEELS (FREE MACHINING) 303, 416, 420F, 430F, 440F 275 Bhn 28 HRc 149 RPM Fz ( ) Feed (mm/min) RPM Fz (95-143) Feed (mm/min) continued on next page 10
11 Ap Series 33MCR Metric Hardness Vc Diameter (D 1 ) (mm) x D 1 Ap x D 1 (m/min) M S STAINLESS STEELS (DIFFICULT) 304, 304L, 316, 316L STAINLESS STEELS (PH) 13-8 PH, 15-5 PH, 17-4 PH, Custom 450 SUPER ALLOYS (NICKEL, COBALT, IRON BASE) Inconel 601, 617, 625, Incoloy, Monel 400 SUPER ALLOYS (NICKEL, COBALT, IRON BASE) Inconel 718, X-750, Incoloy, Waspaloy, Hastelloy, Rene TITANIUM ALLOYS Pure Titanium, Ti6Al4V, Ti6Al2Sn4Zr2Mo, Ti4Al4Mo2Sn0.5Si 275 Bhn 28 HRc 325 Bhn 35 HRc 300 Bhn 32 HRc 400 Bhn 43 HRc 350 Bhn 38 HRc 104 RPM (83-124) Feed (mm/min) RPM (66-99) Feed (mm/min) RPM (76-113) Feed (mm/min) RPM (61-91) Feed (mm/min) RPM (20-29) Fz Feed (mm/min) RPM (16-24) Fz Feed (mm/min) RPM (15-23) Fz Feed (mm/min) RPM (12-18) Fz Feed (mm/min) RPM (52-79) Feed (mm/min) RPM (41-62) Feed (mm/min) Series 33 Speed & Feed Recommendations TITANIUM ALLOYS (DIFFICULT) Ti10Al2Fe3Al, Ti5Al5V5Mo3Cr, Ti7Al4Mo, Ti3Al8V6Cr4Zr4Mo, Ti6Al6V6Sn, Ti15V3 Cr3Sn3Al 440 Bhn 47 HRc 23 RPM (18-27) Feed (mm/min) RPM (15-22) Feed (mm/min) Note: Bhn (Brinell) HRc (Rockwell C) rpm = (Vc x 1000) / (D 1 x 3.14) mm/min = Fz x 3 x rpm reduce speed and feed f materials harder than listed reduce feed and when finish milling (.02 x D 1 maximum) refer to the KYOCERA SGS Tool Wizard f complete technical infmation (
12 SOLUTIONS AROUND THE GLOBE KYOCERA SGS Precision Tools is an ISO-certified leader of round solid carbide cutting tool technology f the aerospace, metalwking, and automotive industries with manufacturing sites in the United States and United Kingdom. Our global netwk of Sales Representatives, Industrial Distributs, and Agents blanket the wld selling into me than 60 countries. LEADERS IN SOLID CARBIDE TOOL TECHNOLOGY Brand names such as Z-Carb, S-Carb, V-Carb, Hi-PerCarb, Multi-Carb have become synonymous with high perfmance tooling in the machining and metalwking industry. We re proud to have pioneered some of the wld s most advanced cutting technology right here on our Ntheast Ohio manufacturing campus. KSPT high perfmance end mills, drills and routers are increasing productivity and reducing cost around the wld. EXCEEDING CUSTOMER EXPECTATIONS As the wld s manufacturing needs change, so does KSPT. It s all about the science, starting with our lab inspected substrate materials to our tool designs and coatings. Our exceptional team of researchers, engineers, and machinists are dedicated to developing the absolute best and delivering the ultimate value at the spindle. Incredible batch-to-batch consistency Metallurgical lab dedicated to testing and rigous quality control ISO-certified quality procedures Patented geometries that extend tool life, reduce chatter, cut cycle times, and improve part quality even at extreme parameters Specialists in extreme and demanding product applications Comprehensive tooling services Experienced Field Sales Engineers who wk to optimize a tool f your particular application Dedicated multi-lingual customer service representatives UNITED STATES OF AMERICA KYOCERA SGS Precision Tools P.O. Box South Main Street Munroe Falls, Ohio U.S.A. customer service - US and Canada: (330) fax - US & Canada: (800) international fax: (330) webmaster@kyocera-sgstool.com web: UNITED KINGDOM KYOCERA SGS Precision Tools Europe Ltd. 10 Ashville Way Wokingham, Berkshire RG41 2PL England phone: (44) fax: (44) SalesEU@kyocera-sgstool.com web: FRANCE DOGA-KSPTE FRANCE 8, Avenue Gutenburg Maurepas France phone: +33 (0) fax: +33 (0) sgsfrance@kyocera-sgstool.com web: GERMANY KADIGO Tool Systems Walramstrasse Idstein Germany phone: +49 (0) fax: +49 (0) info@kadigo-ts.com web: KSPT PRODUCTS ARE DISTRIBUTED BY: POLAND KYOCERA SGS Precision Tools phone: SalesEU@kyocera-sgstool.com SPAIN KYOCERA SGS Precision Tools IBERICA SalesEU@kyocera-sgstool.com EASTERN EUROPE SINTCOM Sintcom Tools 95 Arsenalski Blvd Sofia, Bulgaria phone: (359) fax: (359) sintcom@sintcomtools.com RUSSIA HALTEC phone: (7) info@haltec.ru web: EDP Rev 417 KYOCERA SGS Precision Tools
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