Carbide Modular Shrink System

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1 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. Carbide Modular Shrink System 15

2 Carbide Modular Shrink System Inserts & Holders 17 Profile Milling Program Tools Copy Milling Program Tools 18 19,21 BS Series in PC and CBN Tipped Cutting Parameters Carbide Modular Shrink System Shrink System Identification Head, Steel Measurement System enotes Type iameter Size Connection Compatability Imperial CHY 500 T1 CHY 12 T1 Shank, Carbide Measurement System enotes Type iameter Size Overall Length Connection Compatability Imperial CSS T1 CSS T1 16 CHTA or CHTAV = Taper Neck Head CHY = Straight Head for Ball Insert CHF = Straight Head for Flat Type Insert Imperial = Hundredths of an Inch = Millimeters

3 Carbide Modular Shrink System Insert Shrink Fit HEA Shrink Fit SHANK Type Code Tool Number imensions imensions Ø1 Tool Number Ø1 VB, VRBS CHTAV-0250-T CHTAV-0312-T TO, HF, FB, BS, MB,MBT, B, TOB-NF, RBT CHTA-0375-T RB, MB, MBT, BS, RBT CHY-0500-T CSS T1 CSS T FB, B, BS, HF, TO, TOB-NF CHF-0500-T BS, RB, MB, MBT, RBT FB, B, BS, HF, TO, TOB-NF CHY-0625-T CHF-0625-T CSS T2 CSS T RB, BS, MB, MBT, RBT FB, B, BS, HF, TO, TOB-NF CHTAV-0250-T T1 1 CHY-0750-T CHF-0750-T CHTA-0312-T T1 1 6 T1 CHTA-0375-T T1 1 6 CHY-0500-T1 CHF-0500-T CSS T3 CSS T3 CSS T3 T1 1 6 CHY-0625-T2 CHF-0625-T T2 T mm CHY-0750-T3 CHF-0750-T T3 T Inch Carbide Modular Shrink System Inserts & Holders Page

4 Profile Milling Program Tools Small Ball Nose & Back raft Inserts VRBS 2 L Tool Ordering Number imensions L R XRN TLN HSN escription VRBS Used for semi and finish-milling small radius or detail work, VRBS and surface milling in soft and hard steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling. VB Tool Ordering Number imensions L R XRN TLN HSN 1 R L VB-0250-R Used for semi and finish-milling small radius or detail work, VB-0312-R and surface milling in soft and hard steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling. VRBS, VB, HF Inserts HF Cutting Recommendations Inch 18 High Feed Inserts HF L Tool Ordering imensions Number L PR XRN TLN HSN escription HF Millstar HF insert is designed for High feed and High speed HF machining. It runs at high cutting speed and feed rates with shallow depth of cut. It allows the chip to flow up and out of the HF cut quickly. It allows heavy chip loads. HF HF 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 Coating Insert Type Recom. Cut speed at Max feed per tooth fz at cutting insert diameter Hrc Ae max sfm/min <41 0,014 0,019 0,023 0,028 0, % HF XRN/HSN ,012~0,016 0,017~0,021 0,021~0,025 0,026~0,030 0,035~0, ,012 0,016 0,019 0,023 0, % HF XRN/HSN ,010~0,014 0,014~0,018 0,017~0,021 0,021~0,025 0,029~0, ,009 0,013 0,016 0,019 0, % HF HSN ,007~0,011 0,011~0,015 0,014~0,018 0,017~0,021 0,023~0,027 <41 0,014 0,019 0,023 0,028 0, % HF XRN/HSN ,012~0,016 0,017~0,021 0,021~0,025 0,026~0,030 0,035~0, ,012 0,016 0,019 0,023 0, % HF XRN/HSN ,010~0,014 0,014~0,018 0,017~0,021 0,021~0,025 0,029~0, ,009 0,013 0,016 0,019 0, % HF HSN ,007~0,011 0,011~0,015 0,014~0,018 0,017~0,021 0,023~0,027 P20/1,2330 <41 0,014 0,019 0,023 0,028 0, % HF XRN/HSN ,012~0,016 0,017~0,021 0,021~0,025 0,026~0,030 0,035~0,039 P20/1, ,012 0,016 0,019 0,023 0, % HF XRN/HSN ,010~0,014 0,014~0,018 0,017~0,021 0,021~0,025 0,029~0,033 2/1,2379/ <41 0,014 0,019 0,023 0,028 0, % HF XRN/HSN ,012~0,016 0,017~0,021 0,021~0,025 0,026~0,030 0,035~0,039 SK11 2/1,2379/ ,012 0,016 0,019 0,023 0, % HF XRN/HSN ,010~0,014 0,014~0,018 0,017~0,021 0,021~0,025 0,029~0,033 SK11 2/1,2379/ 51+ 0,009 0,013 0,016 0,019 0, % HF HSN ,007~0,011 0,011~0,015 0,014~0,018 0,017~0,021 0,023~0,027 SK11 Grey Cast Iron/ <41 0,014 0,019 0,023 0,028 0, % HF XRN/HSN ,012~0,016 0,017~0,021 0,021~0,025 0,026~0,030 0,035~0,039 GG Cast Iron/GGG 41+ 0,012 0,016 0,019 0,023 0, % HF XRN/HSN ,012~0,016 0,017~0,021 0,021~0,025 0,026~0,030 Page 0,035~0,039 18

5 Copy Milling Program Tools Flat Bottom, Back raft, Toroid B-N Tool Ordering Number For 1/8 use ordering # 08 Example: Page 19 1/2 BS-0500N-04-HSN imensions L R XRN TLN HSN escription R B-0375-N /32,1/16 Precision ground with 7º back taper. Used for B-0500-N /32,1/16 milling of cores, cavities, L B-0625-N /32,1/16 fillets with straight or very steep walls of harder B-0750-N /32,1/16,1/8 materials. B-1000-N /32,1/16,1/8 B-1250-N /32,1/16,1/8 B-R Number L R XRN TLN HSN escription R B-0375-R /32 Precision ground with positive ground B-0500-R /32,1/16,1/8 chip-breaker and 7º back L B-0625-R /32,1/16 taper. Used for milling of cores, cavities, fillets B-0750-R /32,1/16,1/8 with straight or very B-1000-R /32,1/16,1/8 steep walls of softer materials. B-1250-R /32,1/16,1/8 BS Number L R XRN TLN HSN escription BS-0375-N /32,1/ Precision ground with unique crossover design between BS-0500-N ,1/32,1/ flat bottom FB and back draft BS-0625-N /32,1/ B inserts. Allows straight walls with a larger step down BS-0750-N /32,1/16,1/ than B. Allows higher BS-1000-N /32,1/16,1/ cutting speeds and feeds. BS-1250-N / FB-R Number L R XRN TLN HSN escription R FB-0375-R /32 Precision ground with positive ground FB-0500-R /32,1/16,1/8 chip-breaker. Flat bottom L FB-0625-R /32,1/16 inserts for shoulder milling, fillet finishing and long FB-0750-R /32,1/16,1/8 reach angular wall FB-1000-R /32,1/16,1/8 finishing of softer materials. FB-1250-R /32,1/16,1/8 TO Number L R XRN TLN HSN escription R TO Precision ground large corner radius & back TO taper for spiral and pocket L milling. Milling of pre-hard TO and hardened flat surfaces at higher speeds than tools TO with smaller corner radii. TO Good choice for HS milling of Aluminum. TO TOB-NF Number L R XRN TLN HSN escription R TOB-0500-NF Millstar inserts designed for high seed high feed TOB-0625-NF roughing of Aluminum, but L TOB-0750-NF also has the versatility to be used for fine finishing TOB-1000-NF as well. Radius Ordering Numbers: For.015 use ordering #.015 For 1/32 use ordering # 02 1/16 use ordering # 04 NA Non-coated grade. XRN Multi-layer hybrid coating of AlCrN. 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. HSN Millstar s new coating is a multi-layer hybrid Nano coating. This new coating has very good heat resistance and high hardness. The HSN coating is designed for use in HSM of Heat Treated materials up to 72 HRc. ALTiN-EXALON (TLN) Titanium Aluminum Nitride advanced PV coating. A special, improved ALTiN coating approaching surface hardness of CBN on a tough substrate. Recommended for tough and hard metal machining applications. M iamond coating. Custom coating for cutting nonferrous, 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. Flat Bottom, Back raft & Toroid Inch Inserts Inch 19

6 BS Series in PC and CBN Tipped Back raft BS Tool Ordering Number imensions L R XRN TLN HSN escription BS-0375-N /32,1/ Precision ground with unique crossover design between BS-0500-N ,1/32,1/ flat bottom FB and back draft B inserts. Allows straight BS-0625-N /32,1/ walls with a larger step down BS-0750-N /32,1/16,1/ than B. Allows higher cutting speeds and feeds. BS-1000-N /32,1/16,1/ PC Tipped For carbon milling with longer tool life CBN Tipped For high speed machining or milling of high hardness materials with longer tool life and superior finishes. NEW! Higher cutting speeds and feeds with new Back raft Tools Back raft 20 Radius Ordering Numbers: For.015 use ordering #.015 For 1/32 use ordering # 02 1/16 use ordering # 04 For 1/8 use ordering # 08 Example: 1/2 BS-0500N-04-PC or CBN

7 Copy Milling Program Tools Ball Nose Inserts BS-N S L Tool Ordering Number imensions L S XRN TLN HSN escription BS-0375-N Sidecutting, non-chipbreaker. Side cutting insert used in BS-0500-N cavity and core profiling, for BS-0625-N blending of fillets on medium and hard materials. BS-0750-N BS-1000-N BS-1250-N MB Number L XRN TLN HSN escription MB Unique cutting edge allows performance in all operations in MB material below 42 HRc; in semi, L & finishing operations above. MB Significant benefits in chip evacuation. Insert geometry MB allows smoother cutting MB motion-diminishing heat build up & tool deflection, reduces MB vibration caused by cutting action. MBT Number L XRN TLN HSN escription MBT Precision ground, harder grade, for semi-finish and finish MBT milling. Excellent choice for L MBT unattended finish milling at small depth and high speeds MBT and feed rates. MBT MBT RB-N Number L XRN TLN HSN escription RB-0375-N Precision ground, non-chipbreaker. Best choice RB-0500-N for cavity, core and profile L RB-0625-N milling of pre-hard and fully hard die/mold steels, RB-0750-N cast steels and cast iron. RB-1000-N Strongest cutting edge design. RB-1250-N RBT RBT Number L XRN TLN HSN escription RB-0375-T Precision ground for semi-finish and finish milling. Excellent choice RB-0500-T for unattended finish milling at L RB-0625-T small depth and high speed and feed rates. RB-0750-T RB-1000-T RB-1250-T NA Non-coated grade. XRN Multi-layer hybrid coating of AlCrN. 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. HSN Millstar s new coating is a multi-layer hybrid Nano coating. This new coating has very good heat resistance and high hardness. The HSN coating is designed for use in HSM of Heat Treated materials up to 72 HRc. ALTiN-EXALON (TLN) Titanium Aluminum Nitride advanced PV coating. A special, improved ALTiN coating approaching surface hardness of CBN on a tough substrate. Recommended for tough and hard metal machining applications. M iamond coating. Custom coating for cutting nonferrous, 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. Ball Nose Inserts Inch Page 21 21

8 Cutting Parameters / Cutting Speed & Feed Choosing Cutting Parameters/Calculating Cutting Speed and Feed INCH For Ball Nose Inserts Table 1 - Cutting Conditions for Using Steel Shank Holders Working Material Hardness SFM Feed fn (inch/rev) Insert iameter (inch) Low Alloy Steel (1.7225) HB TLN, HSN x.40 x Alloy & ie Steel (1.2311, P20, ME2/3/5) Ap Max Ae Max 32-42HRC TLN, HSN x.35 x Tool Steel (1.2344, ) 42-52HRC TLN, HSN x.30 x Stainless Steel (1.4301, ) Gray Cast Iron (GG25-GG30) Nodular Cast Iron (GGG60-GGG70) HB XRN, TLN, HSN x.40 x HB TLN, HSN x.50 x HB TLN, HSN x.50 x Copper Alloy HB XRN x.40 x Aluminum Alloys HB XRN x.50 x Graphite TLN, HSN x.50 x Ni & Co Based Alloy HB XRN, HSN x.50 x Titanium Alloy (Annealed) <350HB XRN, HSN x.33 x Titanium Alloy (Sol. Treated/Aged) <380HB XRN, HSN x.35 x Table 2 - Cutting Conditions for Using Carbide Shank Holders Working Material Hardness SFM Feed fn (inch/rev) Insert iameter (inch) Low Alloy Steel (1.7225) HB TLN, HSN x.50 x Alloy & ie Steel (1.2311, P20, ME2/3/5) Ap Max Ae Max 32-42HRC TLN, HSN x.40 x Tool Steel (1.2344, ) 42-52HRC TLN, HSN x.35 x Stainless Steel (1.4301, ) Gray Cast Iron (GG25-GG30) Nodular Cast Iron (GGG60-GGG70) HB XRN, TLN, HSN x.50 x HB TLN, HSN , x.40 x HB TLN, HSN x.40 x Copper Alloy HB XRN x.40 x Aluminum Alloys HB XRN x.40 x Graphite TLN, HSN x.40 x Ni & Co Based Alloy HB XRN, HSN x.50 x Titanium Alloy (Annealed) <350HB XRN, HSN x.50 x Titanium Alloy (Sol. Treated/Aged) <380HB XRN, HSN x.50 x Harden Steel (1.2344, ) 45-55HRC TLN, HSN x.35 x Inch 22 Page 22

9 Choosing Cutting Parameters/Calculating Cutting Speed and Feed INCH 1. Find the Cutting Speed & Feed fn Find SFM and fn range in Table 1 or Table 2 at left. Choose the average value for SFM 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 Use the formula: N = SFM x 3.82 ( w) Table 3 - Working iameter For Ball Nose Tools Ø epth of cut w Working iameter (inch) Actual effective cutting diameter Table 4 - Working iameter For Toroid Tools 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 into consideration that chip load is less than theoretical value. Take the value of K f from Table 5 or Table 6. Table 5 - Feed Rate Multiplier For Ball Nose Inserts Table 6 - Feed Rate Multiplier For Toroid Tools Insert iameter epth of cut Feedrate Multiplier Factors (for Working iameters w) Insert iameter epth of cut FEERATE MULTIPLIER FACTORS (inch) (for Toroid Working iameters w) Cutting Parameters / Cutting Speed & Feed Inch Page 23 23

10 Verify 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. Surface Roughness Step-Over Surface Roughness Feed ir Inch 24 Page 24

11 Feed & Speed Calculations Nomenclature = w z Vc n Vf f cutter/insert diameter = effective cutter diameter = number of teeth = cutting speed = number of revolutions per minute = feed rate, or table feed = feed per revolution fz = feed per tooth Fzcor = feed/tooth, chip thinning corrected CF = centerline feed, helical interpolation x = multiplier symbol (inch) = multiplier symbol (metric) ap = axial depth of cut ae R SFM RPM IPM π = width of cut, step-over = insert radius = surface feet per minute = revolutions per minute = inch per minute, feed rate = circle, circumference:dia. ratio Rth,ae = theoretical surface roughness in step-over direction Rth,fz = theoretical surface roughness in feed direction B = bore dia., helical interpolation IC = inscribed circle (2 x R) Q = metal removal rate Cutting Speed To find the SFM π x x RPM SFM = = x x RPM of a cutter: 12 Example: To find the SFM of a 3/4 Ø cutter.262 x x RPM = x 0.75 x 6000 = 1179 SFM rotating at 6000 RPM: Formula: n π w v c = = m / minute 1000 Spindle Speed To find the RPM of a cutter: Example To find the RPM of a 1/2 Ø cutter rotating at 800 SFM: Formula: 12 x SFM 3.82 x SFM RPM = = π x RPM = 3.82 x = 6112 RPM v c 1000 n = = min -1 π w Feed Per Tooth To find the feed per tooth of a cutter: Example To find the feed per tooth of a two flute cutter rotating at RPM with a table travel of 240 inches per minute: Formula: FZ = IPM z x RPM 240 FZ = 2 x = FZ f = v f n z = mm / tooth Feed Rate or Table Feed To find the feed (table feed) IPM = RPM x f z x z in inches per minute: Example To find the feed per tooth of a IPM = 5000 x x 2 = 60 IPM two flute cutter rotating at 5000 RPM with a feed per tooth of 0.006: Formula: v f = n f z z = mm / minute Effective Cutting iameter, Toroid Effective Cutting iameter, Ball Nose To find the effective cutter To find the effective w = 2 x R 2 - (R - a p ) 2 w = 2 x R 2 - (R - a p ) 2 + ( - 2R) Ø of a Toroid bull nose tool: cutter Ø of a ball nose tool: Example Example w = 2 x ( ) 2 + (.75 - (2 x.1875)) =.707 To find the effective cutter w = 2 x ( ) 2 = diameter engaged of a 1.0 Ø ball nose tool cutting at a p depth of cut: a p Formula: use same formula in mm. R w V 1 To find the effective cutter diameter engaged of a 3/4 Ø Toroid bull nose tool cutting at depth of cut: Formula: use same formula in mm. R w V f Surface Roughness, Step-Over To find the surface a R e th,ae = roughness in step-over direction: Example To find the theoretical roughness of a 3/4 Ø ball nose tool in R 2 th,ae = - = step-over direction of the cut 2 4 (peak-to-valley or cusp height), with a step-over value: Formula: use same formula in mm. Page 25 Surface Roughness, Feed irection To find the surface roughness in feed direction: Example To find the theoretical roughness of a 3/4 Ø ball nose tool in feed direction of the cut (peak-to-valley or cusp height), with a feed per tooth value: Formula: use same formula in mm f R z th,fz = R 2 th,fz = - = Inch 25

12 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. Carbide Modular Shrink System 69

13 Carbide Modular Shrink System Inserts & Holders 71 Profile Milling Program Tools BS Series in PC and CBN Tipped Copy Milling Program Tools 75 Cutting Parameters Carbide Modular Shrink System 70 Shrink System Identification Head, Steel Measurement System enotes Type iameter Size Connection Compatability Imperial CHY 500 T1 CHY 12 T1 Shank, Carbide Measurement System enotes Type iameter Size Overall Length Connection Compatability Imperial CSS T1 CSS T1 CHTA or CHTAV = Taper Neck Head CHY = Straight Head for Ball Insert CHF = Straight Head for Flat Type Insert Imperial = Hundredths of an Inch = Millimeters

14 Carbide Modular Shrink System, Insert Shrink Fit HEA Shrink Fit SHANK Type Code Tool Number imensions imensions Ø1 Tool Number 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, RBT CHTA-10-T1 11,7 43,2 21,5 RB, MB, MBT, BS, RBT CHY-12-T1 11,7 43,2 21,5 CSS T1 CSS T ,60 124,40 15,24 15,24 FB, B, BS, HF, TO, TOB-NF CHF-12-T1 11,7 43,2 21,5 BS, RB, MB, MBT, RBT FB, B, BS, HF, TO, TOB-NF CHY-16-T2 14,0 38,2 CHF-16-T2 14,0 38,2 CSS T2 CSS T ,80 180,80 16,51 16,51 RB, BS, MB, MBT, RBT FB, B, BS, HF, TO, TOB-NF CHTAV-06-T1 7,97 T1 1 CHY-20-T3 17,1 48,3 CHF-20-T3 17,1 48,3 CHTAV-08-T T1 1 6 T1 CHTA-10-T1 10,43 T1 1 6 CSS T3 CSS T3 CSS T3 CHY-12-T1 CHF-12-T1 11,05 T CHY-16-T2 CHF-16-T2 13,97 T2 T2 96,50 172, CHY-20-T3 CHF-20-T3 17,14 T3 T3 17,78 17,78 17,78 Carbide Modular Shrink System Inserts & Holders Page

15 Profile Milling Program Tools Small Ball Nose & Back raft Inserts VRBS VB 1 L R L Tool Ordering Number imensions L R XRN TLN HSN escription VRBS-6 6 8,10 3 Used for semi and finish-milling small radius or detail VRBS-8 8 4,50 4 work, and surface milling in soft and hard steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling. Tool Ordering Number imensions L R XRN TLN HSN VB ,6 0,1/0,4 Used for semi and finish-milling small radius VB ,1/0,4 or detail work, and surface milling in soft and hard steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling VRBS, VB, HF Inserts HF Cutting Recommendations 72 High Feed Inserts HF L 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 Tool Ordering imensions Number L PR XRN TLN HSN escription HF ,00 Millstar HF insert is designed for High feed and High HF ,43 speed machining. It runs at high cutting speed and feed rates with shallow depth of cut. It allows the chip to flow HF ,94 up and out of the cut quickly. It allows heavy chip loads. HF ,26 HF ,82 Cutting epth at iameter ap max Cutting Width Coating Insert Type Recom. Cut speed at Max feed per tooth fz at cutting insert diameter Hrc Ae max sfm/min <41 0,38 0,46 0,61 0,76 0, % HF XRN/HSN ,28~0,48 0,36~0,56 0,051~0,71 0,66~0,86 0,85~1, ,32 0,38 0,51 0,64 0, % HF XRN/HSN ,22~0,42 0,28~0,48 0,41~0,61 0,54~0,74 0,70~0, ,26 0,31 0,42 0,52 0, % HF HSN ,16~0,36 0,21~0,41 0,32~0,52 0,42~0,62 0,55~0,75 <41 0,38 0,46 0,61 0,76 0, % HF XRN/HSN ,28~0,48 0,36~0,56 0,51~0,71 0,66~0,86 0,85~1, ,32 0,38 0,51 0,64 0, % HF XRN/HSN ,220~0,42 0,28~0,48 0,32~0,52 0,54~0,74 0,70~0, ,26 0,31 0,42 0,52 0, % HF HSN ,16~0,36 0,21~0,41 0,51~0,71 0,42~0,62 0,55~0,75 P20/1,2330 <41 0,38 0,46 0,61 0,76 0, % HF XRN/HSN ,28~0,48 0,36~0,56 0,41~0,61 0,66~0,86 0,85~1,05 P20/1, ,32 0,38 0,51 0,64 0, % HF XRN/HSN ,22~0,42 0,28~0,48 0,51~0,71 0,54~0,74 0,70~0,90 2/1,2379/ SK11 <41 0,38 0,46 0,61 0,76 0, % HF XRN/HSN ,28~0,48 0,36~0,56 0,41~0,71 0,66~0,86 0,85~1,05 2/1,2379/ SK ,32 0,38 0,51 0,64 0, % HF XRN/HSN ,22~0,42 0,28~0,48 0,41~0,61 0,54~0,744 0,70~0,90 2/1,2379/ SK ,26 0,31 0,42 0,52 0, % HF HSN ,16~0,36 0,21~0,41 0,32~052 0,42~0,62 0,55~0,75 Grey Cast Iron/ GG <41 0,38 0,46 0,61 0,76 0, % HF XRN/HSN ,282~0,48 0,36~0,56 0,51~0,71 0,66~0,86 0,85~1,05 Cast Iron/GGG 41+ 0,38 0,46 0,61 0,76 0, % HF XRN/HSN ,28~0,48 0,36~0,56 0,51~0,71 0,66~0,86 0,85~1,05

16 Copy Milling Program Tools NA Non-coated grade. XRN Multi-layer hybrid coating of AlCrN. 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. HSN Millstar s new coating is a multi-layer hybrid Nano coating. This new coating has very good heat resistance and high hardness. The HSN coating is designed for use in HSM of Heat Treated materials up to 72 HRc. ALTiN-EXALON (TLN) Titanium Aluminum Nitride advanced PV coating. A special, improved ALTiN coating approaching surface hardness of CBN on a tough substrate. Recommended for tough and hard metal machining applications. M iamond coating. Custom coating for cutting nonferrous, 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. Flat Bottom, Back raft, Toroid B-N R L Tool Ordering Number imensions L R XRN TLN HSN escription B-10-N 10 8,5 0,5/0,8/1,0 Precision ground with 7º back taper. B-12-N 12 9,95 0,5/1,0/2,0 Used for milling of B-16-N 16 11,55 0,5/1,0/1,3/2,0/3,0 cores, cavities, fillets with straight or very B-20-N 20 13,35 0,5/1,0/1,6/2,0/3,0 steep walls of harder B-25-N 25 19,95 1,0/2,0 materials. B-32-N 32 8,5 1,0/2,6 B-R Number L R XRN TLN HSN escription B-10-R 10 8,5 0,5/0,8/1,0 Precision ground with R positive ground B-12-R 12 9,95 0,5/1,0 chip-breaker and 7º back L B-16-R 16 11,55 0,5/1,0/1,3 taper. Used for milling of cores, cavities, fillets B-20-R 20 13,35 0,5/1,0/1,6 with straight or very B-25-R 25 19,95 1,0/2,0 steep walls of softer materials. B-32-R 32 23,35 2,6 BS Number L R XRN TLN HSN escription BS-10-N 10 8,5 0,1/0,8/1,0 3 Precision ground with unique crossover design between BS-12-N 12 9,95 0,1/1,0 3 flat bottom FB and back draft BS-16-N 16 11,55 0,1/1,0/1,3 3 B inserts. Allows straight walls with a larger step down BS-20-N 20 13,35 0,1/1,0/1,6 3 than B. Allows higher cutting BS-25-N 25 19,95 1,0/2,0 3 speeds and feeds. BS-32-N 32 23,35 1,0/2,0 3 FB-R Number L R XRN TLN HSN escription R FB-10-R 10 8,5 0,8 Precision ground with positive ground FB-12-R 12 9,15 1,0 chip-breaker. Flat bottom L FB-16-R 16 10,65 0,5/1,3 inserts for shoulder milling, fillet finishing and long FB-20-R 20 12,25 1,6 reach angular wall finishing FB-25-R 25 16,35 2,0 of softer materials. FB-32-R 32 21,3 2,6 TO Number L R XRN TLN HSN escription TO ,65 3,0 Precision ground large R corner radius & back taper TO ,20 3,0 for spiral and pocket milling. L TO ,25 4,0 Milling of pre-hard and hardened flat surfaces at TO ,15 5,0 higher speeds than tools TO ,25 6,0 with smaller corner radii. Good choice for HS milling TO ,15 7,5 of Aluminum. TO ,95 8,0 TOB-NF Number L R XRN TLN HSN escription TOB-12-NF 12 9,2 3,0 Millstar inserts designed R for high seed high feed TOB-16-NF 16 11,25 3,0 roughing of Aluminum, but L TOB-20-NF 20 13,15 3,0 also has the versatility to be used for fine finishing TOB-25-NF 25 18,25 3,0 as well. Flat Bottom, Back raft & Toroid Inserts Page 73 73

17 BS Series in PC and CBN Tipped Back raft BS Tool imensions Ordering Number L R XRN TLN HSN escription BS-10-N 10 8,5 0,1/0,8/1,0 3 Precision ground with unique crossover design BS-12-N 12 9,95 0,1/1 3 between flat bottom FB BS-16-N 16 11,55 0,1/1/1,3 3 and back draft B inserts. Allows straight walls with BS-20-N 20 13,35 0,1/1/1,6 3 a larger step down than B. Allows higher cutting BS-25-N 25 19,95 1/2 3 speeds and feeds. PC Tipped For carbon milling with longer tool life CBN Tipped For high speed machining or milling of high hardness materials with longer tool life and superior finishes. NEW! Higher cutting speeds and feeds with new Back raft Tools Back raft 74 Radius Ordering Numbers: For.015 use ordering #.015 For 1/32 use ordering # 02 1/16 use ordering # 04 For 1/8 use ordering # 08 Example: 1/2 BS-0500N-04-PC or CBN

18 Copy Milling Program Tools Ball Nose Inserts BS-N Tool Ordering Number imensions L S XRN TLN HSN escription BS-10-N 10 9,50 3,65 Sidecutting, non-chipbreaker. Side cutting insert used in BS-12-N 12 8,80 2,90 cavity and core profiling, for L BS-16-N 16 10,70 2,85 S BS-20-N 20 12,75 2,85 blending of fillets on medium and hard materials. 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 Number L XRN TLN HSN escription MB ,65 Unique cutting edge allows performance in all operations in MB ,20 material below 42 HRc; in semi, L MB ,25 & finishing operations above. MB ,15 Significant benefits in chip evacuation. Insert geometry MB ,25 allows smoother cutting MB ,15 motion-diminishing heat build up & tool deflection, MB ,95 reduces vibration caused by cutting action. MBT Number L XRN TLN HSN escription MBT ,65 Precision ground, harder grade, for semi-finish and finish MBT ,20 milling. Excellent choice for L MBT ,25 unattended finish milling at small depth and high speeds MBT ,15 and feed rates. MBT ,25 MBT ,15 MBT ,95 RB-N Number L XRN TLN HSN escription RB-10-N 10 9,50 Precision ground, non-chipbreaker. Best choice RB-12-N 12 9,20 for cavity, core and profile L RB-14-N 14 9,45 milling of pre-hard and fully hard die/mold steels, cast RB-16-N 16 11,25 steels and cast iron. Strongest RB-20-N 20 13,15 cutting edge design. RB-22-N 22 17,45 RB-25-N 25 18,25 RB-30-N 30 22,15 RB-32-N 32 21,95 RBT RBT Number L XRN TLN HSN escription RB-10-T 10 8,65 Precision ground for semi-finish and finish milling. Excellent choice RB-12-T 12 9,20 for unattended finish milling at RB-16-T 16 11,25 small depth and high speed and feed rates. L RB-20-T 20 13,15 RB-25-T 25 18,25 RB-30-T 30 22,15 RB-32-T 32 21,95 NA Non-coated grade. XRN Multi-layer hybrid coating of AlCrN. 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. HSN Millstar s new coating is a multi-layer hybrid Nano coating. This new coating has very good heat resistance and high hardness. The HSN coating is designed for use in HSM of Heat Treated materials up to 72 HRc. ALTiN-EXALON (TLN) Titanium Aluminum Nitride advanced PV coating. A special, improved ALTiN coating approaching surface hardness of CBN on a tough substrate. Recommended for tough and hard metal machining applications. M iamond coating. Custom coating for cutting nonferrous, 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. Ball Nose Inserts Page 75 75

19 Choosing Cutting Parameters/Calculating Cutting Speed and Feed METRIC For Ball Nose Inserts Cutting Parameters / Cutting Speed & Feed Table 1 - Cutting Conditions for Using Steel Shank Holders Working Material Hardness Vc m/min Feed fn (mm/rev) Insert iameter (mm) Low Alloy Steel(1.7225) HB TLN, HSN ,2 0,3 0,4 0,4 0,5 0,5 0,6 0,6 0,6.15 x.15 x Alloy & ie Steel (1.2311, P20, ME2/3/5) Ap Max Ae Max 32-42HRC TLN, HSN ,15 0,25 0,3 0,4 0,4 0,4 0,5 0,5 0,5.20 x.20 x Tool Steel (1.2344, ) 42-52HRC TLN, HSN ,15 0,25 0,3 0,4 0,5 0,5 0,6 0,6 0,6.20 x.20 x Stainless Steel (1.4301, ) HB XRN, TLN, HSN ,15 0,25 0,3 0,4 0,4 0,4 0,5 0,5 0,5.20 x.20 x Gray Cast Iron (GG25-GG30) HB TLN, HSN ,2 0,3 0,4 0,5 0,6 0,6 0,7 0,7 0,7.10 x.10 x Nodular Cast Iron (GGG60-GGG70) HB TLN, HSN, HSN ,2 0,3 0,4 0,5 0,6 0,6 0,7 0,7 0,7.15 x.15 x Copper Alloy HB XRN ,25 0,4 0,5 0,6 0,7 0,7 0,8 0,8 0,8.10 x.10 x Aluminum Alloys HB XRN ,25 0,4 0,5 0,6 0,7 0,7 0,8 0,8 0,8.6 x.6 x Graphite TLN ,3 0,5 0,6 0,7 0,8 0,8 0,9 0,9 0,9.5 x.5 x Ni & Co Based Alloy HB XRN, HSN ,15 0,2 0,3 0,4 0,4 0,5 0,5 0,6 0,6.30 x.30 x Titanium Alloy (Annealed) <350HB XRN, HSN ,15 0,2 0,25 0,35 0,35 0,4 0,45 0,5 0,5.33 x.33 x Titanium Alloy (Sol. Treated/Aged) <380HB XRN, HSN ,1 0,15 0,2 0,3 0,3 0,35 0,4 0,45 0,45.35 x.35 x Harden Steel (1.2344, ) 45-55HRC TLN, HSN ,15 0,25 0,3 0,4 0,5 0,5 0,6 0,6 0,6.30 x.30 x Table 2 - Cutting Conditions for Using Carbide Shank Holders Working Material Hardness Vc m/min Feed fn (mm/rev) Insert iameter (mm) Ap Max Ae Max Low Alloy Steel (1.7225) HB TLN, HSN ,3 0,4 0,4 0,5 0,6 0,6 0,7 0,7 0,7.15 x.50 x Alloy & ie Steel (1.2311, P20, ME2/3/5) 32-42HRC TLN, HSN ,25 0,3 0,3 0,4 0,5 0,5 0,6 0,6 0,6.20 x.50 x Tool Steel (1.2344, ) 42-52HRC TLN, HSN ,25 0,3 0,3 0,4 0,5 0,5 0,6 0,6 0,6.20 x.50 x Stainless Steel (1.4301, ) HB XRN, TLN, HSN ,25 0,3 0,4 0,5 0,6 0,65 0,7 0,8 0,8.20 x.50 x Gray Cast Iron (GG25-GG30) HB TLN, HSN ,35 0,45 0,5 0,5 0,6 0,7 0,8 1,0 1,0.10 x.40 x Nodular Cast Iron (GGG60-GGG70) HB TLN, HSN ,3 0,4 0,4 0,5 0,6 0,6 0,7 0,8 0,8.15 x.15 x Copper Alloy HB XRN ,3 0,4 0,4 0,5 0,6 0,6 0,7 0,7 0,7.10 x.40 x Aluminum Alloys HB XRN ,3 0,4 0,5 0,6 0,7 0,7 0,8 0,8 0,8.6 x.40 x Graphite TLN, HSN ,3 0,5 0,6 0,7 0,8 0,8 0,9 0,9 0,9.5 x.40 x Ni & Co Based Alloy HB XRN, HSN ,25 0,3 0,4 0,4 0,5 0,6 0,6 0,7 0,7.30 x.50 x Titanium Alloy (Annealed) <350HB XRN, HSN ,15 0,2 0,25 0,35 0,35 0,4 0,45 0,5 0,5.33 x.50 x Titanium Alloy (Sol. Treated/Aged) <380HB XRN, HSN ,1 0,15 0,2 0,3 0,3 0,35 0,4 0,45 0,45.35 x.50 x Harden Steel (1.2344, ) 45-55HRC TLN, HSN ,2 0,25 0,3 0,4 0,5 0,5 0,6 0,6 0,6.30 x.30 x 76

20 Choosing Cutting Parameters/Calculating Cutting Speed and Feed METRIC 1. Find the Cutting Speed Vc (m/min) & Feed fn (mm/n -1 ) Find Vc and fn range in Table 1 or Table 2 above. 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)/ * w Table 3 - Working iameter For Ball Nose Tools (tip cutting) Ø 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 Toroid Tools (tip cutting) Insert iameter epth of Cut w Working iameter (metric) Actual cutting diameter of toroid inserts 0,5 7,3 9,3 11,9 14,3 17,8 20,4 21,6 1,0 8,5 10,5 13,3 16,0 19,6 22,5 23,8 2,0 9,7 11,7 14,9 18,0 22,0 25,2 26,6 3,0 10,0 12,0 15,8 19,2 23,4 27,0 28,5 4,0 16,0 19,8 24,3 28,3 29,9 5,0 20,0 24,9 29,2 30,8 6,0 25,0 29,7 31,5 8,.0 30,0 32,0 4. 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 into consideration that chip load is less than theoretical value. Take the value of K f from Table 5 or Table 6. Table 5 - Feed Rate Multiplier For Ball Nose Inserts Insert iameter epth of Cut Feedrate Multiplier Factors (for working diameters w) 0,5 1,8 2,0 2,2 2,5 2,8 3,2 3,5 3,8 4,0 1,0 1,2 1,5 1,6 1,8 2,0 2,2 2,5 2,6 2,8 2,0 1,0 1,1 1,2 1,3 1,5 1,6 1,8 1,9 2,0 3,0 0,0 1,0 1,1 1,1 1,2 1,4 1,5 1,6 1,7 4,0 1,0 1,0 1,1 1,2 1,2 1,3 1,4 1,5 5,0 1,0 1,0 1,1 1,1 1,2 1,3 1,4 6,0 1,0 1,0 1,1 1,2 1,2 1,3 8,0 1,0 1,0 1,1 1,1 1,2 10,0 1.,0 1,0 1,1 1,1 12,5 1,0 1,0 1,0 Page 7716,0 1,0 1,0 Ap Table 6 - Feed Rate Multiplier For Toroid Tools Insert iameter epth of Cut Feedrate Multiplier Factors (for Toroid working diameters w) 0,5 1,8 1,8 2,0 2,2 2,5 2,6 2,8 1,0 1,2 1,2 1,5 1,6 1,8 1,9 2,0 2,0 1,0 1,0 1,1 1,2 1,3 1,4 1,5 3,0 1,0 1,0 1,0 1,1 1,1 1,2 1,2 4,0 1,0 1,0 1,1 1,2 1,2 5,0 1,0 1,0 1,1 1,1 6,0 1,0 1,0 1,0 8,0 1,0 1,0 Cutting Parameters / Cutting Speed & Feed 77

21 Verify 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. Surface Roughness Step-Over Surface Roughness Feed ir 78

22 Normal Cutting Parameter Recommendations for BS, B and FB inserts For typical mold steels (1.2311, , , , etc.) The following parameters are ONLY if cutting a flat surface with the bottom of the tool. For finish machining using only the side of the tool, use the cutting parameters for Ball Inserts. 1. Spindle speed: n(s) (min -1 ) FB or B Ø==> Material hardness Spindle speed n(s) < 40 HRc HRc HRc Feed per tooth: fz (mm/tooth) FB or B Ø ==> Material hardness Feed per tooth f z < 40 HRc HRc HRc Cutting depth: ap (mm) FB or B Ø ==> Material hardness Maximum Cutting depth a p < 40 HRc HRc HRc Maximum Cutting width / step-over: ae (mm) FB or B Ø ==> Material hardness Cutting width a e < 40 HRc HRc HRc Additional recommendations and conditions which make it necessary to modify normal cutting parameters 1. Always use climb cutting in roughing operation. 2. Enter the material with the cutter by straight ramping or helical interpolation ramping. A 2 ramp angle will achieve best results. 3. When roughing a cavity level by level (Z-level) it is best to start in the center and work outward in a square, rectangular or round spiral depending on the shape of the work piece. Use climb cutting. 4. Long tool body extension from the spindle or tool adapter will make it necessary to decrease the recommended parameters above: If the tool body extension is 3 times the ball insert diameter or less, use the recommendations on page 1. If the tool body extension is 4 times the ball insert diameter, multiply the cutting parameters by 0.9 (90 %). If the tool body extension is 5 times the ball insert diameter, multiply the cutting parameters by 0.75 (75 %). Use a tapered tool body for additional strength. If the tool body extension is 6 times the ball insert diameter, multiply the cutting parameters by 0.6 (60 %). Use a tapered tool body for additional strength. If the tool extension is greater than 6 times the ball insert diameter, it is recommended to use a carbide tool body instead of a steel body for additional rigidity. 5. If the spindle speed recommended is higher than the spindle speed available on the machine, use the highest spindle speed available. You may use the same recommended feed per tooth, cutting depth and cutting width as shown above. We do not Page recommend 79 reducing the feed per tooth. 79

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