TURBINE BLADE MACHINING

Transcription

1 TURBINE BLADE MACHINING ATI Stellram tooling systems for all your tooling requirements.

2 Turbine Blade Machining ATI Stellram s tooling systems are designed and manufactured for machining high performance materials used in the power industry. These difficult-to-machine materials are easily machined with our productive milling cutters. This brochure introduces the portfolio of ATI Stellram products specific to the machining of gas and steam turbines, compressor blades and jet engine blades. The most common materials for turbine blades are stainless steels and high temperature alloys. This Turbine Blade Machining Catalogue contains specific cutting information based on our experience and knowledge of this industry. All ATI Stellram s products are supported by a highly technical sales team backed by an extensive customer care policy. Please contact us for additional information on any of the products illustrated in this catalogue or any other part of ATI Stellram s comprehensive tooling programme. Contents Page 3 NEW X700 4 Grade & Geometry Information VR08 9 NEW 7710 VR VR VSE VOD VA VA12 33 Test Reports 2 FREEPHONE CUSTOMER SERVICE TEL: FAX: TECHNICAL HELPLINE TEL:

3 NEW X700 The X Grades range is further complimented by X700, a newly designed PVD coating suitable for difficult materials and most suited to machining titanium alloys. Coated with TiAIN by PVD Test Reports Part: Airfoil - Blade Size - Length 600mm x Width 300mm Performance 7710VR12-A052R RPHT1204MOE-421-X4 X700 Vc 80m/min Fz 0.22 mm/z Ap mm Ae 20-35mm Toolife: 110 minutes Material: Titanium Alloys Material applications for machining titanium (alpha and beta titanium alloys) and stainless steels at high cutting speed and low cutting feed. Cutting Conditions Family Material Rm and Hardness X700 vcm/min f z, min f z, max High Temperature Alloys Titanium Based ISO Application MATERIALS TO BE MACHINED Heavy machining material: Heat resistant special alloys based iron, nickel & cobalt, titanium & titanium alloys. CODE Milling PVD coat C ISO X700 S01 S05 S10 P20 S15 S20 S25 S30 X700 Insert Listing EDP# Part Number Grade ODMT040408EN-41 X RPHT1204MOE-421-X4 X RPHT1204MOT-X4 X SDHT09T3AEEN-421 X700 3

4 Grades X500 High performance grade with exceptional resistance to shock and the effects of large metal removal rates. First choice for stainless steel and high temperature alloys or where conditions are unstable. ISO applications: M20 - M40, S20 S30. SP6564 High performance grade with wear and heat resistance properties associated with higher cutting speeds and stable conditions when machining stainless steels. ISO applications: M30 - M40. Geometries 4-41 A positive cutting action and reinforced cutting edge for roughing applications A positive geometry with high accuracy periphery grinding. For use on roughing and finishing applications. Precise control of the cutting edge makes this geometry the first choice for high temperature alloys NEW A positive geometry with a 11º chip angle and an E edge preparation for roughing and semi finishing applications in stainless steels and high temperature alloys. -44 A positive geometry with high accuracy periphery grinding. For finishing applications on stainless steel and high temperature alloys. -46 A positive geometry with high accuracy periphery grinding. The positive cutting action and precise treatment of the cutting edge ensures effective machining in 90-degree approach (square shoulder) applications A high positive geometry with a full precision grind of periphery and chip groove. For finish machining of high temperature alloys and difficult to machine stainless steels, where work hardening or highly ductile materials are problematic.

5 Material applications Stainless Steels High Temperature Alloys 7700VR08 Contour Milling Cutter Positive cutting action for semi-finish profiling. Low cutting forces. Tough grade for less stable applications. Wear resistant grade for longer tool life. Round button inserts for maximum strength. 5

6 Contour 7700 VR 08 Milling Cutter d VR 08 Weldon Shank Dimensions (mm) Spares Screw No. of tightening EDP # Part Number D 1 D 2 L/H l 2 d 1 a p max. Inserts EDP# EDP# Nm VR 08 WA025R070-M F3006T T9 1, VR 08 WA025R124-M F3006T T9 1, VR 08 WA025R154-M F3006T T9 1, VR 08 Cylindrical Shank VR 08 CA20/025RZ F3006T T9 1,4 L I 2 D 2 D 1 Weldon Shank Application Semi-finishing and finishing of the blade form (aerofoil). Key: Tip end section Cylindrical Shank Aerofoil Blade holding section a p Depth of Cut (ap) 6

7 Inserts for 7700 VR 08 Application & Material Dimensions (mm) EDP# Part Number Grade Roughing Semi-Finishing Finishing d l s r h m min RPMT 08 03M3E-41 X500 8,0-3,18-0, RPMT 08 03M3E-41 SP6564 8,0-3,18-0,06 CHNS RPEX 08 03M3E-701 X500 8,0-3,18-0,04 d RPMT 08_ -41 RPEX 08_ -701 s Chip Thickness With round inserts, the thickness of the chip varies depending on the depth of cut. For best tool-life it is important to maintain the proper chip thickness as shown below. a p f z mm/tooth Average Chip Thickness Insert D.O.C mm min. h m (mm) RPMT RPMT RPMT RPMT RPMT RPEX RPEX RPEX The feed per tooth recommended is the minimum value to be used for an optimum result. Formulae: * f z h m = a p /d h m a p f z d = Average chip thickness = Depth of cut = feed per tooth = inserts diameter Star Guide Key to Recommended Tools Material Designations P Unalloyed Steels M Stainless Steels K Cast Irons S High Temp. Alloys P Alloyed Steels M PH Stainless N Aluminium & Alloys H Hard Materials 7

8 RP_08 Recommended Cutting Conditions M Roughing/ Semi-Finishing RPMT08-41 RPEX V c (m/min) Feed (mm/tooth) D.O.C Feed (mm/tooth) D.O.C Number Material X500 SP6564 X500 SP6564 a p (mm) X500 a p (mm) Stainless X20Cr ,06-0,12 0,06-0,10 0,5-2,5 0,04-0,08 0,5-1,5 Stainless X22CrMoV ,06-0,12 0,06-0,10 0,5-2,5 0,04-0,08 0,5-1,5 Stainless - 1Cr12MoNb ,06-0,12 0,06-0,10 0,5-2,5 0,04-0,08 0,5-1,5 Stainless X4CrNiMo ,06-0,12 0,06-0,10 0,5-2,5 0,04-0,08 0,5-1,5 Stainless X12CrNiM0V ,06-0,12 0,06-0,10 0,5-2,5 0,04-0,08 0,5-1,5 Stainless - 1Cr12Ni3Mo2VN ,06-0,12 0,06-0,10 0,5-2,5 0,04-0,08 0,5-1,5 Stainless - 0Cr17Ni4Cu4Nb ,06-0,12 0,06-0,10 0,5-2,5 0,04-0,08 0,5-1,5 Stainless X19CrMoVbN ,06-0,12 0,06-0,10 0,5-2,5 0,04-0,08 0,5-1,5 Stainless X12CrNiMo ,06-0,10 0,06-0,10 0,5-2,0 0,04-0,08 0,5-1,5 Stainless X12CrNiWTi ,06-0,10-0,5-2,0 0,04-0,08 0,5-1,5 Stainless X2CrNiMoCuN ,06-0,10-0,5-2,0 0,04-0,08 0,5-1,5 Stainless X5NiCrTi ,06-0,10-0,5-2,0 0,04-0,08 0,5-1,0 Ni-Alloy - Rene ,06-0,08-0,5-1,5 0,04-0,06 0,5-1,0 Ni-Alloy - Udimet ,04-0,06 0,5-1,0 Ni-Alloy - Nickelvac 80A ,04-0,06 0,5-1,0 Hastelloy C - NiCr17Mo17FeW ,04-0,06 0,5-1,0 S Allvac NiCr19Fe19NbMo ,06-0,08-0,5-1,5 0,04-0,06 0,5-1,0 Waspaloy NiCr20Co14MoTi ,06-0,08-0,5-1,5 0,04-0,06 0,5-1,0 Fe-Alloy S590 - X40CoCrNi ,06-0,08-0,5-1,5 0,04-0,06 0,5-1,0 Alpha/Beta Ti - TiAl6V ,06-0,08-0,5-1,5 0,04-0,06 0,5-1,0 8

9 Material applications Stainless Steels High Temperature Alloys 7710VR10 New Insert Location Design for RP 10 Inserts Anti-rotation system for maximum stability at high feed rates. Positive cutting action for semi-finish profiling. Low cutting forces. Tough grade for less stable applications. Wear resistant grade for longer tool life. Round button inserts for maximum strength. 9

10 Contour 7710 VR 10 Milling Cutter Dimensions (mm) Spares Screw No. of tightening EDP # Part Number D 1 D 2 d 1 h 6 L a p max. Inserts EDP# EDP# Nm NEW VR10CA25/032Z4R D4008T T15 3,10 NEW NEW NEW 7710 VR 10 Cylindrical Shank 7710 VR 10 Shell Mill VR10-A040Z05R D4008T T15 3, VR10-A050Z07R D4008T T15 3, VR 10 Modular VR10SA32R M D4008T T15 3,10 Note for inserts: all RP..10 -X4 inserts can be used on 7700VR10.. cutters. For 7710VR10.. cutters RP..10 -X4 inserts only can be used. Cylindrical Shank Application Semi-finishing and finishing of the blade form (aerofoil). Shell Mill Fixation Key: Tip end section Aerofoil Modular Blade holding section a p Depth of Cut (ap) 10

11 Inserts for 7710 VR 10 NEW NEW Application & Material Dimensions (mm) EDP# Part Number Grade Roughing Semi-Finishing Finishing d l s r h m min RPHT 10 T3M0T-X4 X500 10,0-3,97-0, RPHT 10 T3M0T-X4 SP ,0-3,97-0,08 d RPHT 10_ s NEW NEW NEW NEW RPHT 10 T3M0E-421-X4 X500 10,0-3,97-0, RPHT 10 T3M0E-421-X4 SP ,0-3,97-0, RPMT 10 T3M0E-41-X4 X500 10,0-3,97-0, RPMT 10 T3M0E-41-X4 SP ,0-3,97-0,04 RPHT 10_ -421 RPMT 10_ -41 Chip Thickness With round inserts, the thickness of the chip varies depending on the depth of cut. For best tool-life it is important to maintain the proper chip thickness as shown below. a p f z mm/tooth Average Chip Thickness Insert D.O.C mm min. h m (mm) RPHT10-T RPHT10-T RPHT10-T RPHT10-T RPHT10-T RPHT RPHT RPHT RPMT RPMT RPMT RPMT RPMT The feed per tooth recommended is the minimum value to be used for an optimum result. Formulae: * f z h m = a p /d h m a p f z d = Average chip thickness = Depth of cut = feed per tooth = inserts diameter Star Guide Key to Recommended Tools Material Designations P Unalloyed Steels M Stainless Steels K Cast Irons S High Temp. Alloys P Alloyed Steels M PH Stainless N Aluminium & Alloys H Hard Materials 11

12 RP_10 Recommended Cutting Conditions M Roughing/ Semi-Finishing RPHT10-T V c (m/min) Feed (mm/tooth) D.O.C Number Material X500 SP6564 X500 SP6564 a p (mm) Stainless X20Cr ,08-0,35 0,08-0,28 0,5-2,5 Stainless X22CrMoV ,08-0,35 0,08-0,28 0,5-2,5 Stainless - 1Cr12MoNb ,08-0,30 0,08-0,26 0,5-2,5 Stainless X4CrNiMo ,08-0,30 0,08-0,26 0,5-2,5 Stainless X12CrNiM0V ,08-0,30 0,08-0,26 0,5-2,5 Stainless - 1Cr12Ni3Mo2VN ,08-0,26 0,08-0,22 0,5-2,5 Stainless - 0Cr17Ni4Cu4Nb ,08-0,26 0,08-0,22 0,5-2,5 Stainless X19CrMoVbN ,08-0,26 0,08-0,22 0,5-2,5 Stainless X12CrNiMo ,08-0,26 0,08-0,22 0,5-2,5 Stainless X12CrNiWTi ,08-0,26-0,5-2,5 Stainless X2CrNiMoCuN Stainless X5NiCrTi Ni-Alloy - Rene Ni-Alloy - Udimet Ni-Alloy - Nickelvac 80A Hastelloy C - NiCr17Mo17FeW S Allvac NiCr19Fe19NbMo Waspaloy NiCr20Co14MoTi Fe-Alloy S590 - X40CoCrNi Alpha/Beta Ti - TiAl6V M Roughing/ RPHT10-41 Semi-Finishing RPMT Feed (mm/tooth) D.O.C Feed (mm/tooth) D.O.C Number Material X500 SP6564 a p (mm) X500 a p (mm) Stainless X20Cr13 0,06-0,22 0,06-0,18 0,5-2,5 0,04-0,20 0,5-2,0 Stainless X22CrMoV12.1 0,06-0,22 0,06-0,18 0,5-2,5 0,04-0,20 0,5-2,0 Stainless 1Cr12MoNb 0,06-0,20 0,06-0,16 0,5-2,5 0,04-0,18 0,5-2,0 Stainless X4CrNiMo ,06-0,20 0,06-0,16 0,5-2,5 0,04-0,18 0,5-2,0 Stainless X12CrNiM0V ,06-0,20 0,06-0,16 0,5-2,5 0,04-0,18 0,5-2,0 Stainless 1Cr12Ni3Mo2VN-5 0,06-0,18 0,06-0,14 0,5-2,0 0,04-0,16 0,5-1,5 Stainless 0Cr17Ni4Cu4Nb 0,06-0,18 0,06-0,14 0,5-2,0 0,04-0,16 0,5-1,5 Stainless X19CrMoVbN11-1 0,06-0,18 0,06-0,14 0,5-2,0 0,04-0,16 0,5-1,5 Stainless X12CrNiMo12 0,06-0,18 0,06-0,14 0,5-2,0 0,04-0,16 0,5-1,5 Stainless X12CrNiWTi ,06-0,18-0,5-2,0 0,04-0,16 0,5-1,5 Stainless X2CrNiMoCuN ,06-0,18-0,5-2,0 0,04-0,16 0,5-1,5 Stainless X5NiCrTi2615 0,06-0,18-0,5-2,0 0,04-0,16 0,5-1,5 Ni-Alloy Rene ,5-1,5 0,04-0,12 0,5-1,5 Ni-Alloy Udimet Ni-Alloy Nickelvac 80A Hastelloy C NiCr17Mo17FeW ,04-0,12 0,5-1,5 S Allvac NiCr19Fe19NbMo - - 0,5-1,5 0,04-0,12 0,5-1,5 Waspaloy NiCr20Co14MoTi - - 0,5-1,5 0,04-0,12 0,5-1,5 Fe-Alloy S590 X40CoCrNi2020 0,06-0,12-0,5-1,5 0,04-0,12 0,5-1,5 Alpha/Beta Ti TiAl6V4 0,06-0,12-0,5-1,5 0,04-0,12 0,5-1,5 12

13 Material applications Stainless Steels High Temperature Alloys 7710VR12 New Insert Location Design for RP 12 Inserts Anti-rotation system for maximum stability at high feed rates. Maximum number of teeth for heavy feed operations. Flute design maximises swarf evacuation. New insert indexation (insert locking) for exact positioning. Medium and close pitch cutters available. 13

14 7710 VR 12 Milling Cutter 7710VR12 Shell Mill Fixation Dimensions (mm) Spares Screw EDP # Part Number D 1 D 2 L/H d 1 No. of tightening a p max. Inserts EDP# EDP# Nm VR12-A040R D4010T T15 3, VR12-A040Z05R D4010T T15 3, VR12-A052R D4010T T15 3, VR12-A052Z06R D4010T T15 3, VR12-A066R D4010T T15 3,10 NEW VR12-A66Z07R D4010T T15 3,10 Shell Mill Fixation Application Roughing of the rhomboid (blank) and aerofoil in stable and marginal conditions with high chip volume high feed rate. Close pitch cutters should be used when conditions are stable for high volume of metal removal and as the 1 st choice for high temperature alloys applications. Key: Tip end section Aerofoil a p Blade holding section Depth of Cut (a p) 14

15 Inserts for 7710 VR 12 Application & Material Dimensions (mm) Roughing Semi-Finishing Finishing EDP# Part Number Grade d l s r h m min RPEX1204M0E-701-X4 X500 12,0-4,76-0, RPHT1204M0T-X4 X500 12,0-4,76-0, RPHT1204M0T-X4 SP ,0-4,76-0,15 d RPEX 12_ -701 RPHT 12_ s RPHT1204M0E-421-X4 X500 12,0-4,76-0,06 RPHT 12_ -421 NEW RPHT1204MOE-422-X4 X500 12,0-4,76-0,09 RPHT 12_ -422 With round inserts, the thickness of the chip varies depending on the depth of cut. For best tool-life it is important to maintain the proper chip thickness as shown below. a p f z mm/tooth Average Chip Thickness Insert D.O.C mm min. h m (mm) RPEX RPEX RPEX RPHT12-T RPHT12-T RPHT12-T RPHT12-T RPHT12-T RPHT12-T RPHT12-T RPHT12-T RPHT RPHT RPHT RPHT RPHT RPHT RPHT RPHT RPHT RPHT RPHT RPHT Star Guide Key to Recommended Tools Material Designations P Unalloyed Steels M Stainless Steels K Cast Irons S High Temp. Alloys Formulae: h m = a p /d h m a p f z d Chip Thickness * f z = Average chip thickness = Depth of cut = feed per tooth = inserts diameter The feed per tooth recommended is the minimum value to be used for an optimum result. P Alloyed Steels M PH Stainless N Aluminium & Alloys H Hard Materials 15

16 RP_12 Recommended Cutting Conditions M Roughing/ Semi-Finishing RPHT RPHT12-T V c (m/min) Feed (mm/tooth) D.O.C Feed (mm/tooth) Feed (mm/tooth) D.O.C Number Material X500 SP6564 X500 a p (mm) X500 SP6564 a p (mm) Stainless X20Cr ,10-0,55 1,0-4,0 0,15-0,58 0, ,0-4,5 Stainless X22CrMoV ,10-0,55 1,0-4,0 0,15-0,58 0, ,0-4,5 Stainless - 1Cr12MoNb ,10-0,55 1,0-3,0 0,15-0,58 0, ,0-3,5 Stainless X4CrNiMo ,10-0,55 1,0-3,0 0,15-0,58 0, ,0-3,5 Stainless X12CrNiM0V ,10-0,35 1,0-3,0 0,15-0,35 0, ,0-3,5 Stainless - 1Cr12Ni3Mo2VN ,10-0,35 1,0-3,0 0,15-0,35 0, ,0-3,5 Stainless - 0Cr17Ni4Cu4Nb ,10-0,35 1,0-3,0 0,15-0,35 0, ,0-3,5 Stainless X19CrMoVbN ,10-0,35 1,0-3,0 0,15-0,35 0, ,0-3,5 Stainless X12CrNiMo ,08-0,25 1,0-3,0 0,15-0,25-1,0-3,5 Stainless X12CrNiWTi ,08-0,25 1,0-3,0 0,15-0,25-1,0-3,5 Stainless X2CrNiMoCuN ,08-0,25 1,0-3,0 0,15-0,25-1,0-3,5 Stainless X5NiCrTi ,08-0,25 1,0-3, Ni-Alloy - Rene Ni-Alloy - Udimet Ni-Alloy - Nickelvac 80A Hastelloy C - NiCr17Mo17FeW ,08-0,25 1,0-3, S Allvac NiCr19Fe19NbMo ,08-0,25 1,0-3, Waspaloy NiCr20Co14MoTi ,08-0,25 1,0-3, Fe-Alloy S590 - X40CoCrNi ,08-0,25 1,0-3, Alpha/Beta Ti - TiAl6V ,08-0,25 1,0-3, M RPHT Roughing/ Semi-Finishing RPEX Feed (mm/tooth) D.O.C Feed (mm/tooth) D.O.C Number Material X500 a p (mm) X500 a p (mm) Stainless X20Cr13 0,10-0,25 1,0-3,0 0,04-0,18 0,5-2,0 Stainless X22CrMoV12.1 0,10-0,25 1,0-3,0 0,04-0,18 0,5-2,0 Stainless - 1Cr12MoNb 0,10-0,25 1,0-3,0 0,04-0,18 0,5-2,0 Stainless X4CrNiMo ,10-0,25 1,0-3,0 0,04-0,18 0,5-2,0 Stainless X12CrNiM0V ,10-0,25 1,0-3,0 0,04-0,18 0,5-2,0 Stainless - 1Cr12Ni3Mo2VN-5 0,10-0,25 1,0-3,0 0,04-0,18 0,5-2,0 Stainless - 0Cr17Ni4Cu4Nb 0,10-0,25 1,0-3,0 0,04-0,18 0,5-2,0 Stainless X19CrMoVbN11-1 0,10-0,25 1,0-3,0 0,04-0,18 0,5-2,0 Stainless X12CrNiMo12 0,10-0,18 1,0-3,0 0,04-0,18 0,5-2,0 Stainless X12CrNiWTi ,10-0,18 1,0-3,0 0,04-0,14 0,5-2,0 Stainless X2CrNiMoCuN ,10-0,18 1,0-3,0 0,04-0,14 0,5-2,0 Stainless X5NiCrTi2615 0,10-0,18 1,0-3,0 0,04-0,14 0,5-2,0 Ni-Alloy - Rene 80 0,10-0,18 1,0-3,0 0,04-0,14 0,5-2,0 Ni-Alloy - Udimet ,04-0,14 0,5-2,0 Ni-Alloy - Nickelvac 80A - - 0,04-0,14 0,5-2,0 Hastelloy C - NiCr17Mo17FeW 0,06-0,25 0,5-3,0 0,04-0,14 0,5-2,0 S Allvac NiCr19Fe19NbMo 0,06-0,25 0,5-3,0 0,04-0,14 0,5-2,0 Waspaloy NiCr20Co14MoTi 0,06-0,25 0,5-3,0 0,04-0,14 0,5-2,0 Fe-Alloy S590 - X40CoCrNi2020 0,06-0,25 0,5-3,0 0,04-0,14 0,5-2,0 Alpha/Beta Ti - TiAl6V4 0,06-0,25 0,5-3,0 0,04-0,14 0,5-2,0 16

17 Material applications Stainless Steels High Temperature Alloys 7745VSE09 Milling Cutter High positive cutting action for smooth cut. Close pitch cutters for high volume metal removal. 45º approach cutter reduces the effect of impact at cutting depth. High positive insert geometry for stainless steel and high temperature alloys. 17

18 7745 VSE 09 Milling Cutter d VSE 09 Weldon Shank Dimensions (mm) Spares Screw EDP # Part Number D L/H l 1 Plunge No. of tightening d 1 a p max. max. Inserts EDP# EDP# Nm VSE 09 WA016Z02R F3508T T15 2, VSE 09 WA020Z02R F3508T T15 2, VSE 09 WA025Z03R F3508T T15 2, VSE 09 WA032Z03R F3508T T15 2, VSE 09 WA040Z04R F3510T T15 2,10 L I VSE 09 Shell Mill Fixation VSE 09 -A032Z04R F3510T T15 2, VSE 09 -A040Z05R F3510T T15 2, VSE 09 -A050Z05R F3510T T15 2, VSE 09 -A050Z06R F3510T T15 2, VSE 09 -A063Z05R F3510T T15 2, VSE 09 -A063Z07R F3510T T15 2,10 D Weldon Shank d 1 Application Roughing of the blade rhomboid and finishing of the blade holding section and tip end section in poor or marginal conditions. Very positive cutting action. H 45 Close pitch cutters should be used for high volume of metal removal and as the 1 st choice for high temperature alloys applications. D Shell Mill Fixation Key: Tip end section Aerofoil a p Blade holding section Depth of Cut (a p) 18

19 Inserts for 7745 VSE 09 d r Application & Material Dimensions (mm) EDP# Part Number Grade Roughing Semi-Finishing Finishing d l s r h m min SDHT 09 T3AEEN-421 X500 9,52 9,52 3,97-0, SDHT 09 T3AEEN-421 SP6564 9,52 9,52 3,97-0,03 l SDHT 09_ -421 s Star Guide Key to Recommended Tools Material Designations P Unalloyed Steels M Stainless Steels K Cast Irons S High Temp. Alloys P Alloyed Steels M PH Stainless N Aluminium & Alloys H Hard Materials 19

20 SD_09 Recommended Cutting Conditions M Roughing SDHT V c (m/min) Feed (mm/tooth) D.O.C Number Material X500 SP6564 X500 SP6564 a p (mm) Stainless X20Cr ,10-0,30 0,08-0,26 1,0-3,0 Stainless X22CrMoV ,10-0,30 0,08-0,26 1,0-3,0 Stainless 1Cr12MoNb ,10-0,30 0,08-0,26 1,0-3,0 Stainless X4CrNiMo ,10-0,30 0,08-0,26 1,0-3,0 Stainless X12CrNiM0V ,10-0,30 0,08-0,26 1,0-3,0 Stainless 1Cr12Ni3Mo2VN ,10-0,30 0,08-0,26 1,0-3,0 Stainless 0Cr17Ni4Cu4Nb ,10-0,30 0,08-0,26 1,0-3,0 Stainless X19CrMoVbN ,10-0,30 0,08-0,26 1,0-3,0 Stainless X12CrNiMo ,10-0,25 0,08-0,26 1,0-3,0 Stainless X12CrNiWTi ,10-0,25-1,0-2,5 Stainless X2CrNiMoCuN ,10-0,25-1,0-2,5 Stainless X5NiCrTi ,10-0,25-1,0-2,5 Ni-Alloy Rene ,08-0,12-1,0-2,0 Ni-Alloy Udimet ,0-2,0 Ni-Alloy Nickelvac 80A ,0-2,0 Hastelloy C NiCr17Mo17FeW ,08-0,12-1,0-2,0 S Allvac NiCr19Fe19NbMo ,08-0,12-1,0-2,0 Waspaloy NiCr20Co14MoTi ,08-0,12-1,0-2,0 Fe-Alloy S590 X40CoCrNi ,08-0,15-1,0-2,0 Alpha/Beta Ti TiAl6V ,08-0,15-1,0-2,0 M Feed (mm/tooth) Finishing SDHT Number Material X500 SP6564 D.O.C a p (mm) Stainless X20Cr13 0,08-0,25 0,08-0,25 0,1-0,25 Stainless X22CrMoV12.1 0,08-0,25 0,08-0,25 0,1-0,25 Stainless 1Cr12MoNb 0,08-0,25 0,08-0,25 0,1-0,25 Stainless X4CrNiMo ,08-0,25 0,08-0,25 0,1-0,25 Stainless X12CrNiM0V ,08-0,25 0,08-0,25 0,1-0,25 Stainless 1Cr12Ni3Mo2VN-5 0,08-0,25 0,08-0,25 0,1-0,25 Stainless 0Cr17Ni4Cu4Nb 0,08-0,25 0,08-0,25 0,1-0,25 Stainless X19CrMoVbN11-1 0,08-0,25 0,08-0,25 0,1-0,25 Stainless X12CrNiMo12 0,08-0,25 0,08-0,25 0,1-0,25 Stainless X12CrNiWTi ,08-0,25-0,1-0,25 Stainless X2CrNiMoCuN ,08-0,25-0,1-0,25 Stainless X5NiCrTi2615 0,08-0,25-0,1-0,25 Ni-Alloy Rene 80 0,05-0,08-0,1-0,25 Ni-Alloy Udimet 710 0,05-0,12-0,1-0,25 Ni-Alloy Nickelvac 80A 0,05-0,12-0,1-0,25 Hastelloy C NiCr17Mo17FeW 0,05-0,12-0,1-0,25 S Allvac NiCr19Fe19NbMo 0,05-0,12-0,1-0,25 Waspaloy NiCr20Co14MoTi 0,05-0,12-0,1-0,25 Fe-Alloy S590 X40CoCrNi2020 0,05-0,15-0,1-0,25 Alpha/Beta Ti TiAl6V4 0,05-0,15-0,1-0,25 20

21 Material applications Stainless Steels High Temperature Alloys 7745VOD04 Milling Cutter 1 tool, multiple operations: face milling, ramp milling, pocket milling and chamfering. 8 economical cutting edges per insert. Thick and strong inserts for greater machining security. Standard and close pitch cutter range from 50mm up to 125mm diameter. Close pitch cutters allow high feed rates with improved finish in stable conditions. 21

22 7745 VOD 04 Milling Cutter L l 2 d VOD 04 Weldon Shank Dimensions (mm) Spares Screw No. of tightening EDP # Part Number D L/H l 1 d 1 a 1 max. a p max. Inserts EDP# EDP# Nm VOD 04 WA025R , F4011T T20 3, VOD 04 WA032R , F4011T T20 3, VOD 04 WA040R , F4011T T20 3, VOD 04 Shell Mill Fixation VOD 04 -A040R , F4011T T20 3, VOD 04 -A050R , F4011T T20 3, VOD 04 -A050Z06R , F4011T T20 3, VOD 04 -A063R , F4011T T20 3, VOD 04 -A063Z07R , F4011T T20 3, VOD 04 -A080R , F4011T T20 3, VOD 04 -A080Z09R , F4011T T20 3, VOD 04 -A100R , F4011T T20 3, VOD 04 -A100Z11R , F4011T T20 3, VOD 04 -A125R , F4011T T20 3, VOD 04 -A125Z12R , F4011T T20 3,10 45 D Weldon Shank d 1 Application Roughing and finishing of the blade rhomboid in stable conditions and finishing of the blade holding section and tip end section. Close pitch cutters should be used for high volume of metal removal and as the 1 st choice for high temperature alloys applications. H D Shell Mill Fixation Key: Tip end section Aerofoil a 1 max. a p Blade holding section Depth of Cut (a p) 22

23 Inserts for 7745 VOD 04 d 135 Application & Material Dimensions (mm) EDP# Part Number Grade Roughing Semi-Finishing Finishing d l s r h m min ODET 04 04APEN-44 X500 12,7 4,0 4,76 Facet 0, ODET 04 04APEN-44 SP ,7 4,0 4,76 Facet 0,04 r l ODET 04_ -44 s ODMT EN-41 X500 12,7 4,0 4,76 0,8 0, ODMT EN-41 SP ,7 4,0 4,76 0,8 0,04 ODMT 04_ ODMW SN X500 12,7 4,0 4,76 0,8 0, ODMW SN SP ,7 4,0 4,76 0,8 0,27 ODMW 04_ -SN Star Guide Key to Recommended Tools Material Designations P Unalloyed Steels M Stainless Steels K Cast Irons S High Temp. Alloys P Alloyed Steels M PH Stainless N Aluminium & Alloys H Hard Materials 23

24 OD_04 Recommended Cutting Conditions Roughing ODMW04 V c (m/min) Feed (mm/tooth) D.O.C Number Material X500 SP6564 X500 SP6564 a p (mm) Stainless X20Cr , ,30-0,40 1,0-3,5 Stainless X22CrMoV , ,30-0,40 1,0-3,5 Stainless - 1Cr12MoNb , ,30-0,40 1,0-3,5 Stainless X4CrNiMo Stainless X12CrNiM0V Stainless - 1Cr12Ni3Mo2VN M Stainless - 0Cr17Ni4Cu4Nb Stainless X19CrMoVbN Stainless X12CrNiMo Stainless X12CrNiWTi Stainless X2CrNiMoCuN Stainless X5NiCrTi Ni-Alloy - Rene Ni-Alloy - Udimet Ni-Alloy - Nickelvac 80A Hastelloy C - NiCr17Mo17FeW S Allvac NiCr19Fe19NbMo Waspaloy NiCr20Co14MoTi Fe-Alloy S590 - X40CoCrNi Alpha/Beta Ti - TiAl6V M ODMT04-41 Roughing/ Finishing ODET04-44 Feed (mm/tooth) D.O.C Feed (mm/tooth) D.O.C Number Material X500 SP6564 a p (mm) X500 SP6564 a p (mm) Stainless X20Cr13 0,16-0,32 0,12-0,30 1,0-3,5 0,1-0,22 0,08-0,20 0,1-0,25 Stainless X22CrMoV12.1 0,16-0,32 0,12-0,30 1,0-3,5 0,1-0,22 0,08-0,20 0,1-0,25 Stainless - 1Cr12MoNb 0,16-0,32 0,12-0,30 1,0-3,5 0,1-0,22 0,08-0,20 0,1-0,25 Stainless X4CrNiMo ,16-0,32 0,12-0,30 1,0-3,5 0,1-0,22 0,08-0,20 0,1-0,25 Stainless X12CrNiM0V ,16-0,32 0,12-0,30 1,0-3,5 0,1-0,22 0,08-0,20 0,1-0,25 Stainless - 1Cr12Ni3Mo2VN-5 0,16-0,32 0,12-0,30 1,0-3,5 0,1-0,22 0,08-0,20 0,1-0,25 Stainless - 0Cr17Ni4Cu4Nb 0,16-0,32 0,12-0,30 1,0-3,5 0,1-0,22 0,08-0,20 0,1-0,25 Stainless X19CrMoVbN11-1 0,16-0,32 0,12-0,30 1,0-3,5 0,1-0,22 0,08-0,20 0,1-0,25 Stainless X12CrNiMo12 0,16-0,32 0,12-0,30 1,0-3,5 0,1-0,22 0,08-0,20 0,1-0,25 Stainless X12CrNiWTi ,16-0,32-1,0-3,5 0,1-0,22-0,1-0,25 Stainless X2CrNiMoCuN ,12-0,28-1,0-2,5 0,08-0,20-0,1-0,25 Stainless X5NiCrTi2615 0,12-0, Ni-Alloy - Rene 80 0,12-0, Ni-Alloy - Udimet Ni-Alloy - Nickelvac 80A Hastelloy C - NiCr17Mo17FeW S Allvac NiCr19Fe19NbMo Waspaloy NiCr20Co14MoTi ,06-0,12-0,1-1,5 Fe-Alloy S590 - X40CoCrNi ,06-0,12-0,1-1,5 Alpha/Beta Ti - TiAl6V ,06-0,12-0,1-1,5 24

25 Material applications Stainless Steels High Temperature Alloys 7690VA12-90 Milling 90 approach angle for accurate shoulder, slot and pocket milling. 11mm cutting depth: high feed rate with a compact design. Choice of two body styles: coarse and medium pitch. High metal removal capability and excellent surface finish. 4mm thick inserts for greater security in difficult applications. Through coolant for optimum chip evacuation. 25

26 L 7690 VA 12 d 1 Milling Cutter 7690 VA 12 Weldon Shank Coarse Pitch Dimensions (mm) Spares Screw EDP # Part Number D L/H l 1 d 1 No. of tightening a p max. Inserts EDP# EDP# Nm VA12WA020Z02R F3007T T8 1, VA12WA025Z02R F3007T T8 1, VA12WA032Z03R F3007T T8 1, VA12WA040Z04R F3007T T8 1,4 I 2 90 D Weldon Shank 7690 VA 12 Weldon Shank Fine Pitch VA12WA025Z03R F3007T T8 1, VA12WA032Z04R F3007T T8 1, VA12WA040Z05R F3007T T8 1, VA 12 Long Version Cylindrical Shank * VA12CA020Z02R F3007T T8 1, VA12CA020Z02R F3007T T8 1,4 * VA12CA025Z03R F3007T T8 1, VA12CA025Z03R F3007T T8 1, VA12CA032Z04R F3007T T8 1,4 *Both cutters allow inserts radius up to 3.2mm. All cutters will allow inserts radius up to 1.6mm, with the exception of and Cutters will have to be modified to accommodate higher radii. The chart below shows the multiplication factor for the feed rate based on the percentage of radial engagement of the cutter diameter. Feed correcting for profiling Cylindrical Shank Coefficient Application Engagement a e /diam (%) Example: 7690VA12WA025Z02R040 using a 2,5mm radial engagement (a e ) = 10% ofthe cutter diameter At 10%, your coefficient is 1.6 (see chart); therefore you must multiply your feed rate by 1.6 for correcting the feed for profiling. Semi-finishing of the blade form (aerofoil). Slotting and shoulder milling operations on the blade holding section. a p Key: Tip end section Depth of Cut (ap) 26 Aerofoil Blade holding section

27 Inserts for 7690 VA 12 d 85 Application & Material Dimensions (mm) EDP# Part Number Grade Roughing Semi-Finishing Finishing d l s r h m min ADHT12T3PDER-46 SP6564 8,0 12,9 4,4 Facet 0, ADHT12T3PDER-46 X500 8,0 12,9 4,4 Facet 0, ADHT12T308ER-46 SP6564 8,0 12,9 4,4 0,8 0, ADHT12T308ER-46 X500 8,0 12,9 4,4 0,8 0, ADHT12T316ER-46 SP6564 8,0 12,9 4,4 1,6 0, ADHT12T316ER-46 X500 8,0 12,9 4,4 1,6 0, ADHT12T320ER-46 SP6564 8,0 12,9 4,4 2,0 0, ADHT12T320ER-46 X500 8,0 12,9 4,4 2,0 0, ADHT12T324ER-46 SP6564 8,0 12,9 4,4 2,4 0, ADHT12T324ER-46 X500 8,0 12,9 4,4 2,4 0, ADHT12T330ER-46 SP6564 8,0 12,9 4,4 3,0 0, ADHT12T330ER-46 X500 8,0 12,9 4,4 3,0 0, ADHT12T332ER-46 SP6564 8,0 12,9 4,4 3,2 0, ADHT12T332ER-46 X500 8,0 12,9 4,4 3,2 0, ADHT12T340ER-46 SP6564 8,0 12,9 4,4 4,0 0, ADHT12T340ER-46 X500 8,0 12,9 4,4 4,0 0,05 r ADHT 12_ -46 l s Star Guide Key to Recommended Tools Material Designations P Unalloyed Steels M Stainless Steels K Cast Irons S High Temp. Alloys P Alloyed Steels M PH Stainless N Aluminium & Alloys H Hard Materials 27

28 AD_12 Recommended Cutting Conditions M Roughing/ Semi-Finishing ADHT12-46 V c (m/min) Feed (mm/tooth) D.O.C Number Material X500 SP6564 X500 SP6564 a p (mm) Stainless X20Cr ,10-0,18 0,08-0,16 1,0-7,0 Stainless X22CrMoV ,10-0,18 0,08-0,16 1,0-7,0 Stainless - 1Cr12MoNb ,10-0,18 0,08-0,16 1,0-7,0 Stainless X4CrNiMo ,10-0,18 0,08-0,16 1,0-7,0 Stainless X12CrNiM0V ,10-0,18 0,08-0,16 1,0-7,0 Stainless - 1Cr12Ni3Mo2VN ,10-0,18 0,08-0,16 1,0-7,0 Stainless - 0Cr17Ni4Cu4Nb ,10-0,18 0,08-0,16 1,0-7,0 Stainless X19CrMoVbN ,10-0,18 0,08-0,16 1,0-7,0 Stainless X12CrNiMo ,08-0,16 0,08-0,16 1,0-7,0 Stainless X12CrNiWTi ,08-0,16-1,0-5,0 Stainless X2CrNiMoCuN ,08-0, Stainless X5NiCrTi ,08-0,16-1,0-5,0 Ni-Alloy - Rene ,06-0,10-1,0-5,0 Ni-Alloy - Udimet Ni-Alloy - Nickelvac 80A ,06-0,10-1,0-5,0 Hastelloy C - NiCr17Mo17FeW ,06-0,12-1,0-5,0 S Allvac NiCr19Fe19NbMo ,06-0,12-1,0-5,0 Waspaloy NiCr20Co14MoTi ,06-0,12-1,0-5,0 Fe-Alloy S590 - X40CoCrNi ,06-0,12-1,0-6,0 Alpha/Beta Ti - TiAl6V ,06-0,12-1,0-6,0 28

29 Material applications Stainless Steels High Temperature Alloys 5315VA12 Long edge milling cutter for profiling, slotting and face milling. Full effective flutes allowing higher feed rates. Through tool coolant for optimum swarf evacuation. 29

30 5315VA12 Milling Cutter 5315VA12 Shell Mill Fixation Dimensions (mm) Spares Screw l 1 l 1 No. of tightening EDP # Part Number D L/H Profiling Slotting l 2 d 1 inserts EDP # EDP # Nm VA12-A040R F3007T T8 1,4 5315VA12 Weldon Shank VA12WA025R F3007T T8 1, VA12WA025R F3007T T8 1, VA12WA032R F3007T T8 1, VA12WA040R F3007T T8 1,4 The chart below shows the multiplication factor for the feed rate based on the percentage of radial engagement of the cutter diameter. Feed correcting for profiling Weldon Shank Coefficient d 1 Engagement a e /diam (%) a p H Example: 5315VA12WA025R23 using a 2,5mm radial engagement (a e ) = 10% ofthe cutter diameter At 10%, your coefficient is 1.6 (see chart); therefore you must multiply your feed rate by 1.6 for correcting the feed for profiling. D Application Roughing and semi-finishing of the aerofoil. Shell Mill Fixation Key: Tip end section Aerofoil Blade holding section 30

31 Inserts for 5315 VA 12 d 85 Application & Material Dimensions (mm) EDP# Part Number Grade Roughing Semi-Finishing Finishing d l s r h m min ADHT12T3PDER-46 SP6564 8,0 12,9 4,4 Facet 0, ADHT12T3PDER-46 X500 8,0 12,9 4,4 Facet 0, ADHT12T308R-46 SP6564 8,00 12,90 4,40 0,8 0, ADHT12T308R-46 X500 8,00 12,90 4,40 0,8 0,05 Please note that for the 5315 range, only a maximum 0,8mm radius is allowed. r ADHT 12_ -46 l s Star Guide Key to Recommended Tools Material Designations P Unalloyed Steels M Stainless Steels K Cast Irons S High Temp. Alloys P Alloyed Steels M PH Stainless N Aluminium & Alloys H Hard Materials 31

32 VA_12 Recommended Cutting Conditions Roughing/ Semi-Finishing ADHT12-46 V c (m/min) Feed (mm/tooth) D.O.C Number Material X500 SP6564 X500 SP6564 a p (mm) Stainless X20Cr ,12 0,04-0,10 see l 1 & l 2 Stainless X22CrMoV ,12 0,04-0,10 see l 1 & l 2 Stainless 1Cr12MoNb ,12 0,04-0,10 see l 1 & l 2 Stainless X4CrNiMo ,12 0,04-0,10 see l 1 & l 2 Stainless X12CrNiM0V ,12 0,04-0,10 see l 1 & l 2 M Stainless 1Cr12Ni3Mo2VN ,12 0,04-0,10 see l 1 & l 2 Stainless 0Cr17Ni4Cu4Nb ,12 0,04-0,10 see l 1 & l 2 Stainless X19CrMoVbN ,12 0,04-0,10 see l 1 & l 2 Stainless X12CrNiMo ,12 0,04-0,10 see l 1 profiling only Stainless X12CrNiWTi ,04-0,10 - see l 1 profiling only Stainless X2CrNiMoCuN ,04-0,10 - see l 1 profiling only Stainless X5NiCrTi ,04-0,10 - see l 1 profiling only Ni-Alloy Rene ,04-0,10 - see l 1 profiling only Ni-Alloy Udimet see l 1 profiling only Ni-Alloy Nickelvac 80A see l 1 profiling only S Hastelloy C NiCr17Mo17FeW see l 1 profiling only Allvac NiCr19Fe19NbMo ,04-0,10 - see l 1 profiling only Waspaloy NiCr20Co14MoTi ,04-0,10 - see l 1 profiling only Fe-Alloy S590 X40CoCrNi ,04-0,10 - see l 1 profiling only Alpha/Beta Ti TiAl6V ,04-0,10 - see l 1 profiling only 32

33 7710 Test Reports Test reports Tool: Insert: Grade: V c : F z : A p : a e : Material: Toolife: 7710VR10SA32R43 RPHT10T3MOT-X4 X m/min 0,35 mm/z 2,5mm 10-32mm X22CrMo minutes Test reports Tool: Insert: Grade: V c : F z : A p : a e : Material: Toolife: 7710VR12VR12-A66Z07R RPHT1204MOE-422-X4 X m/min 0,54 mm/z 3,0mm 25-66mm X20Cr13 Stainless 300 series 60 minutes 33

34 Notes 34

35 35

36 G L O B A L D I V I S I O N S China France Germany Great Britain Italy METALWORKING PRODUCTS Tel: (86-21) Fax: (86-21) ATI STELLRAM SAS 6, Rue du Parc, Blue Business Building Annemasse Tel: Fax: ATI STELLRAM GmbH Seligenstädter Grund 11, D Heusenstamm Tel: (06104) Fax: (06104) ATI STELLRAM LTD Hercules Way, Bowerhill Industrial Estate, GB-Melksham, Wilts. SN12 6TS Tel: (01225) Fax: (01225) ATI STELLRAM Srl Strada Nazionale 71, Cambiano (TO) Tel: Fax: Spain Switzerland Taiwan USA ATI STELLRAM IBERICA S.A. C/ Maracaibo, 7 Apdo. Correos 98 ES Fuenlabrada Madrid, Spain Tel: Fax: ATI STELLRAM SA Avenue du Mont-Blanc 24, Case Postale 339 CH-1196 Gland Tel: Fax: ALLEGHENY TECHNOLOGIES TAIWAN, INC. Room 901, 9th Floor, No. 54, Sec. 4, Mingshen East Road Taipei, Taiwan 105 Tel: (2) Fax: (2) ATI STELLRAM U.S.A. One Teledyne Place, LaVergne, Tennessee U.S.A. Tel: (615) Fax: (800) A S S O C I A T E D C O M P A N I E S Australia Austria Belgium Canada Denmark Finland Holland Japan Mexico New Zealand Norway Portugal South Africa South Korea Sweden Thailand Allegheny Technologies Incorporated is one of the largest and most diversified specialty metals producers in the world. ATI has approximately 9,300 full-time employees world-wide who use innovative technologies to offer growing global markets a wide range of specialty metals solutions. ATI major markets are aerospace and defense, chemical process industry/oil and gas, electrical energy, medical, automotive, food equipment and appliance, machine and cutting tools, and construction and mining. ATI products include titanium and titanium alloys, nickel-based alloys and superalloys, stainless and specialty steels, zirconium, hafnium, and niobium, tungsten materials, grain-oriented silicon electrical steel and tool steels, and forgings and castings. Allegheny Ludlum, Shanghai STAL. Allvac - Allvac Ltd. Wah Chang. Metalworking Products - Alldyne Powder Technologies, ATI Firth Sterling, Landis Threading Systems, ATI Stellram, ATI Garryson. Rome Metals. Portland Forge. Casting Service. For further information please visit the ATI website: LITERATURE RE-ORDER NUMBER 230CATUK.V1 381CATUK.V2 SUPERIOR 03/07 - PRINTED IN THE U.K. ATI STELLRAM LTD. HERCULES WAY, BOWERHILL INDUSTRIAL ESTATE, MELKSHAM, WILTSHIRE. SN12 6TS TEL: FAX: CUSTOMER ORDER TEL: CUSTOMER ORDER FAX: TECHNICAL HELPLINE: , ATI Stellram, an Allegheny Technologies company. The Starburst Logo, Allvac, and Nickelvac are registered trademarks of ATI Properties Inc. Stellram is a registered trademark of ATI Stellram, an Allegheny Technologies company. Star Guide and Metalcutting Answers are trademarks of ATI Stellram. All other trademarks are the property of their respective companies.