Milling

Selecting cutting data

Example of how to nd the values when calculating spindle speed (n) and table feed (vf):
Conditions: CutterInsertWorkpiece material: R245-125Q40-12M R245-12 T3 M-PM SS1672-08 n= vc 1000 Dc GC4030 HB =180 vf = zn n fz fz = hex sin r

A
Formulas to be used:

vc

In order to get vc, the max chip thickness (hex) for an operation and the Coromant Material Classication (CMC) code is needed. See feed recommendations. The cutter selected has a 45 entering angle (r) and PM insert geometry will be used.

Dc zn

The cutter selected has a diameter, Dc, of 125 mm. Number of teeth is found on the same page and zn is in this case 8. The selected cutter has a 45 entering angle. Feed per tooth for the cutter and selected insert geometry. Feed per tooth

r
fz

Max chip thickness (hex) for the operation is 0.17 mm The material is SS1672-08 and corresponding CMC code is 01.2.

n vf

Revolutions per minute Table feed per minute vf = 8 667 0.24 = 1281 mm/min

The cutting speed vc is approx. 283 m/min for CMC 01.2 (between 325 and 270 m/min for hex = 0.10 and 0.20 mm respectively). This cutting speed is valid for hardness HB150. If your hardness is HB180 a compensation factor of 0.92 for the deviation of +30 units. The compensated cutting speed becomes 0.925 x 283 m/min 262-m/min.

Hardness of workpiece
The cutting speeds given on the following pages are valid for a specic material hardness. If the material being machined differs in hardness from those values, the recommended cutting speed must be multiplied by a factor obtained from the table below.

Difference in hardness
Reduced hardness CMC No. Hardness Brinell (HB) 80 01 02 03 05 06 07 08 09 20 CMC No. 1.26 1.26 60 1.18 1.14 40 1.12 1.21 1.21 1.31 1.08 1.25 1.07 1.11 6 04 1.10 20 1.07 1.05 1.10 1.10 1.13 1.03 1.10 1.03 3 1.02 0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 0 1.0 +20 0.95 0.94 0.91 0.91 0.87 0.96 0.92 0.97 +3 0.96 +40 0.90 0.91 0.84 0.85 0.80 0.92 0.86 0.95 0.90 +6 0.93 +60 0.86 0.79 0.79 0.73 0.80 0.93 +9 0.90 +80 0.83 0.75 0.91 0.82 Increased hardness

Hardness Rockwell (HRC)

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Terminology and units for milling

Dc lm De ap ae vc Q Tc zn fz fn vf hex hm = Cutting diameter = Machined length = Effective cutting diameter = Cutting depth = Working engagement = Cutting speed = Metal removal rate = Period of engagement = Total number of edges in the tool = Feed per tooth = Feed per revolution = Table feed (feed speed) = Max chip thickness = Average chip thickness mm mm mm mm mm m/min cm3/min min piece mm mm mm/min mm mm zc = Effective number of teeth kc1 = Specic cutting force (for hex =1 mm) n = Spindle speed Pc = Cutting power net = Efciency piece N/mm2 rev/min kW

= Major cutting edge angle degrees vc0 = Constant for cutting speed cvc = Correction factor for cutting speed mc = Rise in specic cutting force (kc) as a function of chip thickness iC = inscribed circle

C
fn

General milling formulas

Cutting speed (m/min) Spindle speed (rev/min) Table feed (feed speed) (mm/min) Feed per tooth (mm) Feed per revolution (mm/rev) Removal rate (cm3) Specic cutting force (N/mm2) Average chip thickness (mm) (Side and facemilling) when ae/Dc 0.1 Average chip thickness (mm) when ae/Dc 0.1 Machining time (min) Net power (kW) vc = Dc n 1000 n = vc 1000 Dc vf = fz n zn fz = vf n zn

fz

D
zn=8

E
fz hex hm ae

fn = vf n Q= ap ae vf 1000
Dc

r = 90

kc = kc1 hm-mc

hm fz

a D

e c

sin 180 ae fz hm = r D arcsin ae c (D ) c Tc = lm vf ap ae vf kc 60 106

Pc =

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Milling

Formulas for specic milling cutters

Facemilling cutters, side and facemilling cutters and endmills
These tools are characterized by having straight cutting edges.

ap
Dc De

Max cutting diameter at a specic depth (mm)

De = Dc +

2 ap tan r

Feed per tooth (mm/tooth), cutter centered

fz =

hex sin r

Feed per tooth (mm/tooth), side milling

fz =

sin r De2 (De 2 ae)2

De hex

Cutters with round inserts

D
ap
Dc De

Max cutting diameter at a specic depth (mm)

De = Dc +iC2 (iC 2ap)2

Feed per tooth (mm/ tooth), cutter centered

fz =

iC hex De Dc

Feed per tooth (mm/tooth), side milling

fz =

De iC hex (De Dc) De2 (De 2 ae)2

Ballnose endmills
G
ap

Max cutting diameter at a specic depth (mm)

De

De = D32 (D3 2 ap)2

Feed per tooth (mm/tooth), side milling

fz =

D3 hex D (De 2 ae)2

2 e

H
Feed per tooth (mm/tooth), cutter centered fz = D3 hex De

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Milling

Calculation of power consumption

The example is valid for 0 top rake angle. The power consumption changes 1% per degree of change in top rake. A positive top rake angle decreases the power consumption and a negative top rake increases the power consumption. A positive cutter with +15 top rake angle requires 15% less power than a cutter with 0 top rake angle.

Plunge milling
A x vf x K 60 x 106 x A ae x D3 (slot) A ae x S (stepover S) Pc =

Example
45 facemilling of steel, CMC 01.3 Cutter diameter, Dc=125 mm Depth of cut, ap=5 mm Width of cut, ae=100 mm Feed per insert, fz=0.2 mm Table feed, vf=1000 mm Milling in general Pc = ap ae vf K 100 000 Pc() = Pc M For a top rake angle of +21 the M value is 0.79. Pc() = 27.0 0.79 = 21.3 kW For different insert geometries the power consumption must be adjusted. For each degree more positive top rake angle the power consumption will decrease with 1%. For a CoroMill 245 facemill with M-geometry. The M-geometry has +21 top rake angle.

For an engagement of 80% the K value is 5.4. 5 100 1000 5.4 Pc = 100 000 = 27.0 kW

Optimized power consumption calculation

Use multiplying factor from top rake angle to adjust Pc values.
True rake angle, 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 Multiplying factor, M 1.07 1.06 1.05 1.04 1.03 1.02 1.01 1 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91 0.90 0.89 True rake angle, 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Multiplying factor, M 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.80 0.79 0.78 0.77 0.76 0.75 0.74 0.73 0.72 0.71 0.70

When machine power is a problem

Go from close to coarse pitch, i.e. less number of teeth. A positive cutter is more power efcient than a negative. Reduce the cutting speed before the table feed. Warning: Be aware of the power curve for machining centres. The machine may lose efciency if the rpm is too low. Use a smaller cutter and take several passes. Reduce the depth of cut.

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Milling

Constant K for use in power requirement calculation1)

ISO CMC Description No.
Steel Unalloyed C = 0.100.25% C = 0.250.55% C = 0.550.80%

ae/Dc=0.8 fz=0.1 fz=0.2 fz=0.4

ae/Dc=0.4 fz=0.1 fz=0.2 fz=0.4

6.2 6.6 7.1 7.5 8.3 7.1 8.3 8.1 8.9 12.0 12.9 5.8 6.6 8.1 6.7 10.4 8.6 7.4 10.4 7.4 8.9 7.1 10.4 8.7 7.5 10.4 7.5 9.1 10.0 10.4 11.0 12.0 12.5 11.2 12.5 12.9 5.1 5.5 5.5 17.4 9.9 2.2 2.5 2.5 3.1 2.5 3.6 4.1 4.1 5.0 4.1 6.1 1.7 2.7 2.5 2.9 1.5 2.9 2.9 2.3 2.3 5.6 5.2 5.6 5.9 6.3 7.0 5.9 7.0 6.8 7.5 10.1 10.8 4.9 5.6 6.8 5.8 9.0 7.4 6.4 9.0 6.4 7.7 5.9 8.7 7.3 6.3 8.7 6.3 7.7 8.4 8.7 9.3 10.1 10.5 9.4 10.5 10.8 4.4 4.7 4.7 14.7 8.2 3.0 3.3 3.3 4.1 3.3 5.0 1.4 2.3 2.1 2.4 1.2 2.4 2.4 1.9 1.9 4.7 2.4 2.8 2.8 3.4 2.8 4.4 4.7 5.0 5.3 5.9 5.0 5.9 5.7 6.3 8.5 9.1 4.1 4.7 5.7 5.0 7.8 6.4 5.6 7.8 5.6 6.7 5.0 7.3 6.2 5.3 7.3 5.3

ae/Dc=0.2 fz=0.1 fz=0.2 fz=0.4

6.8 7.2 7.7 8.2 9.1 7.7 9.1 8.8 9.7 13.1 14.0 6.3 7.2 8.8 7.2 11.2 9.2 8.0 11.2 8.0 9.6 7.7 11.3 9.5 8.2 11.3 8.2 10.0 10.9 11.3 12.0 13.1 13.6 12.2 13.6 14.0 5.5 6.0 6.0 19.0 10.9 4.0 4.5 4.5 5.5 4.5 6.7 1.8 2.9 2.7 3.2 1.6 3.2 3.2 2.5 2.5 6.1 5.7 6.1 6.5 6.9 7.6 6.5 7.6 7.4 8.2 11.0 11.8 5.3 6.1 7.4 6.2 9.7 8.0 6.9 9.7 6.9 8.3 6.5 9.5 8.0 6.9 9.5 6.9 8.4 9.1 9.5 10.1 11.0 11.4 10.3 11.4 11.8 4.7 5.1 5.1 16.0 9.0 3.3 3.7 3.7 4.5 3.7 5.5 1.5 2.5 2.3 2.7 1.3 2.7 2.7 2.1 2.1 5.1 2.7 3.0 3.0 3.7 3.0 4.8 5.1 5.4 5.8 6.4 5.4 6.4 6.2 6.9 9.3 9.9 4.5 5.1 6.2 5.4 8.4 6.9 6.0 8.4 6.0 7.2 5.4 8.0 6.7 5.8 8.0 5.8

P
A

01.1 01.2 01.3 01.4 01.5 02.1 02.2 03.11 03.13 03.21 03.22

5.7 6.1 6.5 6.9 7.6 6.5 7.6 7.4 8.2 11.0 11.8 5.3 6.1 7.4 6.2 9.7 8.0 6.9 9.7 6.9 8.3 6.5 9.5 8.0 6.9 9.5 6.9 8.4 9.1 9.5 10.1 11.0 11.4 10.3 11.4 11.8 4.7 5.1 5.1 16.0 9.0 3.3 3.7 3.7 4.5 3.7 5.5 1.5 2.5 2.3 2.7 1.3

4.8 5.1 5.4 5.8 6.4 5.4 6.4 6.2 6.9 9.3 9.9 4.5 5.1 6.2 5.4 8.4 6.9 6.0 8.4 6.0 7.2 5.4 8.0 6.7 5.8 8.0 5.8 7.0 7.7 8.0 8.5 9.3 9.6 8.6 9.6 9.9 4.0 4.3 4.3 13.5 7.4 2.7 3.0 3.0 3.7 3.0 4.6 1.3 2.1 1.9 2.2 1.1 2.2 2.2 1.8 1.8 4.3

4.0 4.3 4.6 4.8 5.4 4.6 5.4 5.3 5.8 7.8 8.4 3.8 4.3 5.3 4.7 7.2 5.9 5.2 7.2 5.2 6.2 4.6 6.7 5.7 4.8 6.7 4.8

Low-alloyed (alloying elements 5%) High-alloyed (alloying elements 5%)

Non-hardened Hardened and tempered Annealed Hardened tool steel

06.1 06.2 06.3

Castings

Unalloyed Low-alloy, alloying elements 5% High-alloy, alloying elements >5%

M
C

05.11 05.12 05.13 05.21 05.22 05.51 05.52 15.11 15.12 15.13

Stainless steel Ferritic/Martensitic Non-hardened PH-hardened Hardened Non-hardened PH-hardened Non-weldable 0.05%C Weldable <0.05%C Non-hardened PH-hardened Hardened Non-hardened PH-hardened Non-weldable 0.05%C Weldable <0.05%C

Austenitic Austenitic-Ferritic (Duplex) Stainless steel cast Ferritic/Martensitic

15.21 15.22 15.51 15.52

Austenitic Austenitic-Ferritic (Duplex) Heat resistant super alloys

S
E

20.11 20.12 20.21 20.22 20.24 20.31 20.32 20.33 23.1 23.21 23.22

Iron base NIckel base

Annealed or solution treated Aged or solution treated and aged Annealed or solution treated Aged or solution treated and aged Cast or cast and aged Annealed or solution treated Solution treated and aged Cast or cast and aged

Cobalt base

Titanium alloys Commercial pure (99.5% Ti) , near and + alloys, annealed + alloys in aged cond. alloys, annealed or aged Extra hard steel Hard steel Chilled cast iron Malleable cast iron Grey cast iron Nodular SG iron Aluminium alloys Hardened and tempered Cast or cast and aged Ferritic (short chipping) Pearlitic (long chipping) Low tensile strength High tensile strength Ferritic Pearlitic Wrought or wrought and coldworked, non-aging Wrought or wrought and aged Aluminium alloys Cast, non-aging Cast or cast and aged

H K
G

04.1 10.1 07.1 07.2 08.1 08.2 09.1 09.2

N
H

30.11 30.12 30.21 30.22 30.3 30.41 30.42 33.1 33.2 33.3

Aluminium alloys Copper and copper alloys

Cast, 1315% Si Cast, 1622% Si Free cutting alloys, 1% Pb Brass, leaded bronzes, 1% Pb Bronze and non-leaded copper incl. electrolytic copper

2.7 2.7 2.1 2.1 5.1

1)

Calculated with an efciency mt = 0.8

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Milling

Cutting data calculations for milling operations

Facemilling
Example Cutter: Insert: Workpiece material: ae: ap: R245-125Q40-12M R245-12 T3 M-PM SS 1672-08 HB =150 85 mm 4 mm 45 zn = 8 GC4030 CMC 01.2

85

Calculate spindle speed (n)

n= vc 1000 Dc n= 283 1000 125 721 rpm
To get vc, rst nd hex value for -PM geometry. The cutting speed vc for hex= 0.17 mm is 283-m/min (between 325 and 270-m/min).

Calculate table feed (vf)

vf = zn n fz vf = 8 721 0.24 1384 mm/min

fz =

hex
sin r

fz =

0.17 0.24 sin 45

mm/tooth

Facemilling with round inserts

Example Cutter: Insert: Workpiece material: ae: ap: 85 R200-109Q32-16M RCKT 16 06 M0-PM SS 1672-08 HB =150 85 mm 4 mm zn = 6 GC4030 CMC 01.2

F
Calculate spindle speed (n)
vc 1000 n= De
=

283 1000 732 rpm 123

To get vc, rst nd hex value for -PM geometry. The cutting speed vc for hex= 0.17 mm is 283-m/min (between 325 and 270-m/min).

De = Dc + iC2 (iC - 2ap)2

De = 109 + 162 (16 - 2 4)2 123 mm

Calculate table feed (vf)

vf = n fz zn hex sin r = 732 0.34 6 1493 mm/min

45 30
Max ap
100% of max ap r = 45 75% of max ap r = 38 50% of max ap r = 30 25% of max ap r = 21

fz =

fz =

0.17 = 0.34 mm/tooth sin 30

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Milling

Slotting/facemilling with 90 entering angle

Example Cutter: Insert: Workpiece material: ae: ap: R390-063Q22-17M zn = 5 R390-063Q22-17M zn = 5 R390-17 04 08M-PM GC1025 04=150 08M-PM CMC GC1025 SS R390-17 1672-08 HB 01.2 50 mm 5 mm

A
50

Calculate spindle speed (n)

vc 1000 n= Dc

250 1000 63

1263

rpm

To get vc, rst nd hex value for -PM geometry. The cutting speed vc for hex 0.15 is 250-m/ min (between 280 and 230-m/min).

Calculate table feed (vf)

vf = n fz zn

= 1263 0.15 5 = 947

mm/min

Shoulder milling with 90 entering angle

Example Cutter: Insert: Workpiece material: ae: ap: R390-063Q22-17M R390-17 04 08M-PM SS 1672-08 HB =150 5 mm 5 mm zn = 5 GC1025 CMC 01.2

Calculate spindle speed (n)

F
n= vc 1000 Dc = 318 1000 63 1607 rpm

To get vc, rst nd hex value for -PM geometry. The cutting speed vc for hex 0.15 is 318-m/ min (between 325 and 310-m/min).

Calculate table feed (vf)

For sidemilling the feed can be increased with a compensation factor.

vf = k1 zn n fz

vf = 1.82 5 1607 0.15 2193

mm/min

Find the compensation factor, k1, in the table below by calculating Dc/ae

Dc k1 = 1.82 ae = 12.6
2 3 4 5 6 8 10 12 1.8 15 2.0 20 2.2 25 2.5 30 2.8 40 3.2 50 3.6 100 5.0

Dc ae Factor k1

1.0 1.1 1.2 1.3 1.4 1.5 1.6

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Milling

Side and facemilling

Example Cutter: Insert: Workpiece material: ae: ap: R245-125Q40-12M R245-12 T3 M-PM SS 1672-08 HB =150 2 mm 4 mm zn = 8 GC4030 CMC 01.2

23 (ae)

A
14 (ap) Calculate spindle speed (n)
vc 1000 n= Dc
This gives: n= 283 1000 125 720 rpm To get vc, rst nd hex value for -PM geometry. The cutting speed vc for hex 0.17 is 283-m/min (between 325 and 270-m/min).

Calculate table feed (vf)

vf = n zc fz This gives: vf = 720 5 0.22 792 zc = 5 mm/min

zc = Number of effective edges = zn/2 For N331.32-125S40FM zn = 10 fz = factor k1 hex The factor k1 can be found in table below.

10

12 1.8

15 2.0

20 2.2

25 2.5

30 2.8

40 3.2

50 3.6

100 5.0

Dc ae Factor k1

1.0 1.0

1.1 1.2 1.3 1.4 1.5 1.6

Dc 125 = 5.43 = ae 23 fz = 1.3 0.17 0.22

k1 = 1.3 mm/tooth

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Milling

Prole milling
Example 4 Cutter: Insert: Workpiece material: ae: ap: 2 R216-20A25-055 R2160-20 T3 M-M SS 1672-08 HB =150 2 mm 4 mm zn = 2 GC4040 CMC 01.2

A
vc 1000 De

Calculate spindle speed (n)

n=
n= 308 1000 16 6130 rpm

B
Find effective diameter, De Select axial depth of cut in this diagram. Go horizontally across the diagram to the curve representing the tool diameter. Move down vertically to the axis and read the effective diameter.

To get vc, rst nd hex value for -M geometry. The cutting speed vc for hex 0.15 is 308-m/min (between 310 and 295-m/min).

Axial depth of cut (mm) ap

17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
D3 32 mm

D3 = 10 32 mm D3 = 40 50 mm

25

D3 25 mm D3 20 mm D3 16 mm D3 12 mm
D3 10 mm

D3 50 mm D3 40 mm

Calculate table feed (vf)

vf = zn n fz vf = 2 6130 0.1 1226 mm/min

fz according to table below. In stable conditions the feed can be increased. When working with long tools and difcult conditions the feed can be lowered.
Recommended feed, fz mm Diameter, D3 Start value Range

24 22 20 18 16 14 12 10 8 6 4 2 0

De
2 4 6 8 10 12 14 16 18 20-22-24-26-28-30-32 4 8 12 16 20 24 28-32-36-40-44-48 50 Effective tool dia.(mm)

12 0.05 0.05 0.10

16 0.08 0.08 0.15

20 0.10 0.10 0.20

25 0.12 0.12 0.25

30 0.15 0.15 0.35

32 0.15 0.15 0.35

40 0.20 0.20 0.40

50 0.25 0.25 0.40

F Recommended radial steps and depth of cut for ball nose endmills G
Large cuts It is not recommended to exceed the values below for radial step and axial depth of cut. Small cuts With the same axial depth of cut as for large cuts, surface can be improved by decreasing the radial step.

Cutter Max. recommended dia.

Cutter dia. D3 12 16 20 25 30 32 40 50 Radial step 1.0 1.0 2.0 3.0 3.0 3.0 4.0 4.0 0.02 0.02 0.05 0.09 0.08 0.07 0.10 0.08 Radial step 1.5 2.0 3.0 4.0 4.0 4.0 6.0 6.0 0.05 0.06 0.11 0.16 0.13 0.13 0.23 0.18 Radial step 2.0 3.0 4.0 5.0 5.0 5.0 8.0 8.0 0.08 0.14 0.20 0.25 0.21 0.20 0.40 0.32

D3 12 16 20 25 30 32 40 50

Radial step

Depth of cut 5 6 6 8 10 10 12 12 15 12 16 12 20 15 20

D 30

Milling

Method for internal circular interpolation

Calculated version
De
vf = n zc fz De hex sin r De2 (De 2 ae)2 Tool centre feed, mm/min

fz

Feed per insert, mm

B
Radial depth of cut, mm

ae

Dm2 Dw2 4 (Dm De)

Simplied version
vf = n zc fz vf1 = vf K 1 Straight line feed, mm/min

Tool centre feed, mm/min

K=

DD + D
m m

The values can be taken from the table below

Cutter diameter Dc mm 10 16 20 25 32 40 50 63 80 100 125 160 200

Hole diameter = Dm 15 20 25 30 40 50 60 75 100 125 150 200 250 300

Factor K 0.58 0.71 0.45 0.77 0.60 0.45 0.82 0.68 0.58 0.41 0.87 0.77 0.71 0.61 0.45 0.89 0.82 0.77 0.71 0.60 0.45 0.91 0.86 0.82 0.76 0.68 0.58 0.41 0.93 0.89 0.86 0.82 0.76 0.68 0.58 0.40 0.95 0.92 0.89 0.87 0.82 0.77 0.71 0.61 0.45 0.96 0.93 0.92 0.89 0.86 0.82 0.77 0.70 0.60 0.45 0.97 0.95 0.93 0.91 0.89 0.86 0.82 0.76 0.68 0.58 0.41 0.97 0.96 0.95 0.94 0.92 0.89 0.87 0.83 0.77 0.71 0.61 0.45 0.98 0.97 0.96 0.95 0.93 0.92 0.89 0.86 0.82 0.77 0.71 0.60 0.45 0.98 0.97 0.97 0.96 0.95 0.93 0.91 0.89 0.86 0.82 0.76 0.68 0.58

D 31

Milling

Method for external circular interpolation

Calculated version
De vf = n zc fz De hex sin r De2 (De 2 ae)2 Tool centre feed, mm/min

fz

Feed per insert, mm

ae

Dw2 Dm2 4 (Dm De)

Radial depth of cut, mm

Simplied version D
vf1 vf = n zc fz vf1 = vf K Straight line feed, mm/min

Tool centre feed, mm/min

K=

DD + D
m m

The values can be taken from the table below

Cutter diameter Dc mm 10 16

Hole diameter = Dm 15 20 25 30 40 50 60 75 100 125 150 200 250 300 Factor K 1.29 1.44 1.53 1.63 1.77 1.91 2.08 2.28 2.52 2.77 3.06 3.42 3.79 1.22 1.34 1.41 1.50 1.61 1.73 1.87 2.04 2.24 2.45 2.69 3.00 3.32 1.18 1.28 1.34 1.41 1.51 1.61 1.73 1.88 2.05 2.24 2.45 2.72 3.00 1.15 1.24 1.29 1.35 1.44 1.53 1.63 1.76 1.91 2.08 2.27 2.52 2.77 1.12 1.18 1.22 1.27 1.34 1.41 1.50 1.60 1.73 1.87 2.03 2.24 2.45 1.10 1.15 1.18 1.22 1.28 1.34 1.41 1.50 1.61 1.73 1.87 2.05 2.24 1.08 1.13 1.15 1.19 1.24 1.29 1.35 1.43 1.53 1.63 1.76 1.91 2.08 1.06 1.10 1.13 1.15 1.19 1.24 1.29 1.36 1.44 1.53 1.63 1.77 1.91 1.05 1.08 1.10 1.12 1.15 1.18 1.22 1.28 1.34 1.41 1.50 1.61 1.73 1.04 1.06 1.08 1.10 1.12 1.15 1.18 1.23 1.28 1.34 1.41 1.51 1.61 1.03 1.05 1.06 1.08 1.10 1.13 1.15 1.19 1.24 1.29 1.35 1.44 1.53 1.02 1.04 1.05 1.06 1.08 1.10 1.12 1.15 1.18 1.22 1.27 1.34 1.41 1.02 1.03 1.04 1.05 1.06 1.08 1.10 1.12 1.15 1.18 1.22 1.28 1.34 1.02 1.03 1.03 1.04 1.05 1.06 1.08 1.10 1.13 1.15 1.19 1.24 1.29

20 25 32 40 50

63 80 100 125 160 200

D 32

Milling

Mounting dimensions for milling cutters

Style A
Mounting diameter (dmm)

Dia. 50 63

Dia. 80

Dia. 100

A
Centre bolts
1)For all Modulmill cutters and for R/L262.2AL the dimensions are 22.0 and 10.4 mm respectively.

Style B
Mounting diameter (dmm)

B Dia. 125

Centre bolts + washer

Style C
Mounting diameter (dmm)

D Dia. 160 Dia. 200 250 E

Design with single pcd ( 4 bolts)

Mounting diameter (dmm)

G Dia. 315 500

Design with double pcd ( 8 bolts)

D 33

Milling

Insert mounting with Torx Plus

Sandvik Coromant has introduced the Torx Plus system on all insert screws to ensure an improved and secure clamping. The new Torx Plus screws will keep their previous codes, while the keys will change the code. All keys for insert clamping are concerned: screwdrivers, T-style keys, L-style keys, ag-style keys and combination keys (Torx Plus/hex).
Cross section Torx Plus Torx

Torque wrench for Torx Plus screws

The torque wrench for Torx Plus screws offers a possibility to always ensure correct torque value, in the machine shop as well as in the tool-room environments. Correct torque values are imperative especially when clamping ceramic and CBN inserts. Always use protective goggles when using ceramic inserts.

Note! Torx Plus is a registered trademark of Camcar-Textron (USA).

Wrench benets:
ergonomic handle consisting of two materials, one of which has a rubber base for best grip a "click" function when tightening the screws - is impossible to over tighten. a fixed stop in counter clockwise direction, making it easier to loosening screws design of blade tip has been optimised for best screw fitting blade material consists of a higher class of material grade

Note! The new Torx Plus keys and screw-drivers do NOT t into the standard Torx screws. However, the standard Torx keys and screw-drivers will t the new Torx Plus screws.

Milling cutter mountings Coromant Capto: provides the best stability and thus basis for high productivity, reliablity and quality. Cutters are available as over-size in relation the the coupling for extended tooling. Best choice, especially for long edge milling. Cylindrical shanks: Recommended for use with precision chucks like CoroGrip for best stability and precision. Extra long tools available. Weldon: established tool mounting but not recommended as rst choice if productivity and precision are issues. Arbor: established tool mounting and the only solution for large-diameter cutters. Gives good stability for high productivity. Threaded: modular system with exchangeable cutting heads. Silent tool solution and carbide shank adapters for extended tooling.

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Tool wear
Flank and notch wear a. Rapid ank wear causing poor surface nish or out of tolerance.

Cause:
a. Cutting speed too high or insufcient wear resistance.

Remedy:
Reduce cutting speed. Select a more wear resistant grade.

a. Too low feed.

Increase feed.

b/c. Notch wear causing poor surface nish and risk of edge breakage.

b/c. Work hardening materials.

Reduce cutting speed. Select tougher grade.

b/c. Skin and scale.

Increase cutting speed.

Frittering

Small cutting edge fractures (frittering) causing poor surface nish and excessive ank wear.

Grade too brittle. Insert geometry too weak. Built-up edge.

Select tougher grade. Select an insert with a stronger geometry . Increase cutting speed or select a positive geometry. Reduce feed at beginning of cut.

Thermal cracks

Small cracks perpendicular to the cutting edge causing frittering and poor surface nish.

Thermal cracks due to temperature variations caused by: - Intermittent machining. Select a tougher grade with better resistance to thermal shocks. Coolant should be applied copiously or not at all.

- Varying coolant supply.

Built-up edge (B.U.E.)

Built-up edge causing poor surface nish and cutting edge frittering when the B.U.E. is torn away.

Workpiece material is welded to the insert due to: Low cutting speed. Low feed. Negative cutting geometry. Increase cutting speed. Increase feed. Select a positive geometry.

G
Poor surface nish Too high feed. Wrong insert position. Deection. Bad stability. Vibrations Wrong cutting data. Reduce feed. Change position. Check overhang. Better stability. Reduce cutting speed. Increase feed. Change cutting depth. Reduce overhang. Better stability.

Bad stability.

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If problems should occur

Some typical problems in milling and possible solutions
Excessive vibration
A
1. Weak xture Possible solutions: Assess the direction of cutting forces and provide adequate support or improve the xture. Reduce cutting forces by decreasing cutting depths. Select a coarse and differentially pitched cutter with a more positive cutting action. Select an L-geometry with small corner radius and small parallel land. Seplect a ne-grain, uncoated insert or thinner coating 2. Weak workpiece Consider a square shoulder cutter (90-degree entering angle) with positive geometry. Select an insert with L-geoemetry Decrease axial cutting force lower depth of cut, smaller corner radius and parallel land. Select a coarse-pitch cutter with differential pitch. 3. Long tool overhang Minimize the overhang. Use coarse-pitch cutters with differential pitch. Balance radial and axial cutting forces 45 degree entering angle, large corner radius or round insert cutter. Increase the feed per tooth Use a light-cutting insert geoemtry L/M 4. Milling square shoulder with weak spindle Select smallest possible cutter diameter. Select positive cutter and insert. Try up-milling. Check spindle deection to see if acceptable for machine. 5. Irregular table feed Try up-milling Tighten machine feed mechanism.

Unsatisfactory surface nish

1. Excessive feed per revolution Set cutter axially or classify inserts. Check height with indicator. Check the spindle run-out and the cutter mounting surfaces. Decrease the feed per rev to max. 70% of the width of the parallel land. Use wiper inserts if possible. (Finishing operations) 2. Vibration See section on vibration. 3. Built-up edge formation on insert Increase cutting speed to elevate machining temperature. Turn off coolant. Use sharp cutting edge inserts, with smooth rake side. Use positve insert geometry. Try a cermet grade with higher cutting data.

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4. Back-cutting Check spindle tilt (Tilt spindle approx 0.10mm/1000 mm) Axial run-out of spindle should not exceed 7 microns during nishing. Reduce the radial cutting forces (decrease the depth of cut) Select a smaller cutter diameter. Check the parallelism on the parallel lands and on wiper insert used. (Should not be standing on heel or toe) Make sure the cutter is not wobbling adjust the mounting surfaces. 5. Workpiece frittering Decrease feed per tooth. Select a close or extra-close pitch cutter. Re-position the cutter to give a thinner chip at cutter exit. Select a more suitable entering angle (45-degrees) and lighter cutting geometry. Choose a sharp insert. Monitor ank wear to avoid excessive wear.

Insert fracture in general milling

1. Excessive chip thickness at cutter exit Minimize the chip thickness at exit by changing the cutter position in relation to workpiece. Use down-milling Decrease the feed per tooth. Select a smaller cutter diameter. Use a stronger insert geometry (H).

Insert fracture in square shoulder milling

1. Swarf follows cutter in up-milling, getting stuck between shoulder and edge. Change to down-milling. Use compressed air. Use a sharper insert to facilitate re-cutting of chips. Monitor ank wear to avoid excessive wear. 2. Down-milling with several passes. Consider performing the operation in one pass. 3. Chip jamming between shoulder and edge. Try up-milling Select a tougher insert grade. Select a horisontal milling machine.

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Selection and application process

A
Identify the type of operation: Facemilling Shoulder milling Prole milling Slot milling Then select the most suitable tool considering productivity, reliability and quality.

Dene the operation

B
P M K N S H

Dene the material

Dene workpiece material according to ISO: Steel (P) Stainless steel (M) Cast iron (K) Aluminium (N) Heat resistant and titanium alloy (S) Hardened material (H)

Select cutter concept

Assess which concept is the most productive for the application: CoroMill 245, CoroMill 210, CoroMill 390, CoroMill 290.

Select the milling cutter

Choose cutter pitch and mounting. Use a close pitch cutter as rst choice. Use a coarse pitch cutter for long overhang and unstable conditions. Use an extra close pitch cutter for short chipping materials and super alloys. Choose a mounting type.

Select the insert

Choose the insert geometry for your operation: Geometry L = Light For light cuts when low forces / power are required Geometry M = Medium First choice for mixed production Geometry H = Heavy For rough operations, forging, cast skin and vibrations Select insert grade for optimum productivity.

Dene the start values

Cutting speeds and feeds for different materials are given on the insert dispensers and in the tables. The values should be optimized according to machine and conditions!

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Operations tool recommendations

General facemilling
Material/ Application Steel Stainless steel Cast-iron Aluminium Super alloys Hardened steel

P
CoroMill 245 CoroMill 245 CoroMill 245 T-MAX 45

M
CoroMill 245 CoroMill 245 CoroMill 245 -

K
AUTO-AF* CoroMill 245 AUTO R CoroMill 245 (18)

N
CoroMill Century CoroMill Century CoroMill 245 -

S
CoroMill 245 CoroMill 300 CoroMill 300 T-Max 45

H
CoroMill 245 CoroMill 245 CoroMill 300 CoroMill 200

Finishing Semi-nishing Roughing Heavy roughing * CoroMill Century

B
Thin walls

P M K
CoroMill 390 CoroMill 390

N
CoroMill Century CoroMill Century CoroMill 390

Close to xture

C
Long overhang

P M K P M K
Back facing CoroMill 331

S S S

N N H H

CoroMill 210 (R)/CoroMill 245 (F)

P M K
High feed milling

CoroMill 210/CoroMill 300

E General shoulder milling

Material/ Application Steel Stainless steel Cast-iron Aluminium Super alloys Hardened steel

P
CoroMill 390 CoroMill 390 CoroMill 390

M
CoroMill 390 CoroMill 390 CoroMill 390

K
AUTO-AF CoroMill 290 CoroMill 290

N
CoroMill Century CoroMill 790 CoroMill 790

S
CoroMill Plura CoroMill 390 CoroMill 390

H
CoroMill Plura CoroMill 290 CoroMill 290

Finishing Semi-nishing Roughing

G
Repeated shoulder milling Deep shoulder milling Edging/ Contouring

P M K
CoroMill 390

N
CoroMill 790

H
CoroMill Plura
For diameters smaller than 20 mm, CoroMill Plura solid carbide endmills are rst choice generally for all materials.

(Small ae (ae/Dc<)

Large ae (ae/Dc>..) CoroMill 390 LE- 18

CoroMill 390 LE-11

CoroMill 390/CoroMill Plura

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