Ttm 2019.1 Face Milling

TTM 2019.1 FACE MILLING

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Seco and face milling Seco has a long and proud history in face milling. Today, we offer a wide range of face milling products to meet the roughing, semi- finishing and finishing needs of our customers. With our modern production techniques and patented technology, combined with our world class insert grades, Seco offers a comprehensive array of cutters to overcome a variety of machining challenges.

. In face milling the surface is perpendicular to the cutter axis. . Face milling can be used for roughing, semi finishing and finishing. . Roughing operations are completed to create a plainer surface with the highest metal removal possible. . Semi-finishing usually requires a nice surface appearance and can be combined with a roughing operation. . Finishing operations typically have a small depth of cut combined with tight requirements on surface quality, and parameters are often measured with Ra, Rz and/or waviness specifications.

. Cutting forces need to be considered when selecting the best face mill for an operation. . The lead angle of the face mill changes the force direction applied in the machining process. . Cutting forces are directed bi-axially, meaning forces are directed both axially and radially almost equally.

. 43° to 48° lead angel . the most common variant used . Unstable machining operations and/or long overhangs . 71°-75° lead angle . higher depths of cut with the same size I.C.< on the insert . beneficial at clamping fixture or other obstacle that cannot be avoided in the machining process. . 88°-89° lead angle . high depth of cut capabilities with smaller I.C. inserts. . optimal when machining next to a side wall on a workpiece . to avoid fixture clamping and other obstacles in the machining process. . produces very high radial cutting forces (needs to be kept in mind in relation to fixture and machine stability)

. The cutting geometry has a big impact on tool performance . The combination of axial and radial rake angles and the lead angles influences how the cutter will perform. . The primary angles that should be noted are . Lead angle (KAPR) . Axial rake angle (GAMP) . Radial rake angle (GAMF)

. Altering these angles results in many potential combinations, each providing different behaviors and features.

Positive axial rake (GAMP) and positive radial rake (GAMF) face mill . Example: Octomill™ . Benefits • Smooth cutting action that produces low cutting forces • Very good chip evacuation, ideal in sticky materials • Good surface smoothness, less risk of vibrations • Reduced risk of chip jamming, reduced risk of marking of the workpiece . Disadvantages • Reduced cutting edge strength • Unfavorable entry contact • Tendency to pull the workpiece upwards away from the machine table or fixture clamping

Positive axial rake (GAMP) and positive radial rake (GAMF) face mills . Example: Octomill™ . When to apply on the machine . Lower powered spindles . At stable setup . In sticky materials like stainless steels and titanium . Weak spindles with a lot of “play” . Note: Weak spindles with a lot of “play” or very weak fixturing can be problematic with this type of system because of the tendency to pull the workpiece up and away from the machine table.

Negative axial (GAMP) and negative radial (GAMF) . Example: Double Octomill™, R220.88 with SNMU inserts and Double Quattromill™ . Benefits . A strong cutting edge geometry . High productivity with the ability to take heavy feed rates and endure interrupted cuts and other difficult machining operations . Tendency to push the workpiece toward the machine table or fixture, which can be an advantage in some cases and a negative in others

. Disadvantages (potential) . Higher cutting forces . Chip jamming . Obstructions

Negative axial (GAMP) and negative radial (GAMF) . Example: Double Octomill™, R220.88 with SNMU inserts and Double Quattromill™ . When to apply on the machine . Ideal for steels and cast irons . Can also be effective in stainless steels and super alloys if the insert is provided with the proper cutting edge and high positive rake angles. . Good choices for heavy duty, strong spindles and on rigid setups. . When using high positive geometries, such as ME12 and M12 for Double Octomill, this cutter can be applied on less rigid and strong spindles (will require some consideration to make the cutters work properly and effectively)

Positive axial (GAMP) and negative radial (GAMF). . Example: Quattromill™ . Benefits: . Good chip removal from the cutting zone . Suitable for machining sticky materials . Favorable cutting forces with very little axial push or pull, optimal for unstable machining operations

. Disadvantages (potential) . Typically single sided inserts with less number of edges per insert.

Positive axial (GAMP) and negative radial (GAMF) . Example: Quattromill™ . When to apply on the machine . The operation zone for this type of geometry is wide because it combines the advantages of both positive axial cutting rakes and negative radial rakes, which make for an easy cutting system with strong edge protection.

. Differential pitch - the variation of angles between pocket seats from one to the next. . Helps to reduce vibrations in the machining process . Increases tool life and surface finish possibilities. . Most standard pitch cutters are differentially pitched. Keep in mind that close pitch Normal versions typically do not have differential pitch pitch.

Differential pitch

Different types of cutters . Fixed pocketed cutters . Inserts are mounted and fixed in the cutter body with insert screws or wedges. . The most rigid types since they are contained in the solid cutter body. . Default selection when adjustability is not needed to compensate for runout.

. Cassette cutters . Offer the versatility of adjustment to eliminate or reduce axial runout. . Offer the ability to replace one pocket by replacing a cassette instead of entire cutter body. . Disadvantages: . More spare parts . In some cases a less rigid cutter . Offer limited number of teeth

Common types of insert clamping . Mounted inserts with a center locking screw . Provides a secure way of mounting inserts to the body. . Limitation of center-locking types is that spacing must allow a torque wrench within the socket

. Wedge-style type . Screw and wedge combine to lock the insert in the pocket. . The key advantage of wedge-style mounting is the ability to make super close pitch cutters.

Fixed pockets vs cassette versions Axial run-out with a non . Surface finish is greatly influenced by the adjusted cutter axial runout of the cutter. . Seco standards for most face milling systems are 20 microns of axial runout on fixed pocket cutters. Cassettes give a better . Combined with insert tolerances, this means surface finish when approximately 30–40 microns from insert to correctly adjusted insert. . Affects the ability to obtain high surface finishes . The cassette version gives the ability to set the cutter to eliminate or reduce axial runout from one insert to the next.

Insert geometries . Smaller corner radii can produce very pronounced machining marks on the workpiece.

. Larger corner radii produce a wider mark Small radius and can create a better appearance. corner insert . Note that the surface peaks and valleys can also be affected. For example comparing a 45° lead and small corner radii to the same Large radius insert with a larger radii, the bigger radii will corner insert produce a better finish

Insert geometries . Chamfers or faceted inserts will produce a wider machining mark. . Wiper inserts produce a very high surface finish. Faceted corner insert . Wipers have a geometry with a very large radii on the contact face of the insert to rub/wipe the material smooth.

. Wipers reduce machining marks and also Faceted insert plus wiper insert improve surface roughness measurements.

. Consider machine and fixture rigidity during the selection of a cutter and inserts. . Wipers create a lot of axial cutting forces and this can be problematic if the machine or fixture is weak.

. Insert geometry . The size of radii and integrated wiper will influence what level of surface finish can be achieved. . In sticky materials, the cutting edge geometry also plays a role in the surface finish.

cont…

. Speeds and feeds are critical to optimizing surface finish. . When using a wiper geometry think of calculating the feed per revolution in relation to the effective wiper flat per revolution. . Create a better surface finish by increasing surface speed keeping same feed rate = lower feed per revolution. This can also be a problem solver in some sticky materials, as it can help reduce bonding of the material to the insert which can drag back across the workpiece and create poor finish.

Three primary factors affect average chip thickness: . ae (radial tool engagement) . lead angle of the insert (KAPR) . feed per tooth (fz). Feed rate

Average chip thickness can affect both tool life and cutting. . Too low of a average chip thickness can Hm average cause vibration, poor surface finish and chip thickness decreased tool life of an insert. . Inserts are designed to work with a certain average chip thickness.

Here we see the effect of average chip thickness when less than 50% of the cutter is engaged with the work piece. In this scenario, higher feed rates are needed to increase chip thickness and produce an acceptable average chip thickness.

As radial engagement decreases, so does average chip thickness. Once the cutter's radial depth of cut (ae) is below 50% of diameter, feed rates need to be compensated to maintain acceptable average chip thickness. This diagram illustrates the chip, in red, and how the average thickness of the chip is changed with reduced radial engagement.

The lead angle of the face mill also contributes to the average chip thickness. This diagram highlights how average chip thickness is affected by the lead angle. This is why a 45° lead angle face mill should have a higher linear feed than a 90° square shoulder mill. So, the use of 45° lead angle face mills not only impacts cutting forces, but also the thinning of the chip in the machining process.

This diagram further illustrates the chip thinning effect of different lead angles. H is the chip thickness as impacted by the lead angle and the feed (fz). The far right illustration demonstrates how high feed geometries thin the chip and allow for high feed rates.

This formula provides a means to calculate average chip thickness. The example provides the calculation for a face mill Calculating average chip thickenss with a 43° lead angle. Formula to calculate fz for facemilling Most machinist calculators and programming software can perform this calculation, so manual use of this 0,102 mm x 56,794 x 35,81=0,330 mm formula is usually unnecessary. .004” x 2.236 x 1.41=.013”

Legend Example fz= feed rate per tooth hm=average chip thickness Find the Fz of an Octomill face mill D=cutter diameter hm=0,102 mm (.004”) Ae= radial with of cut D=101,6 mm(4”) ae= 2,032 mm (.088”) Ƙ=lead angle Ƙ=43°

Making the correct choice between climb milling and conventional milling to ensure optimal results.

. Climb milling is almost always the preferred machining method and should always be the first option. . Provides a thick chip on entry and thin chip on exit, which results in Climb milling longer tool life and higher performance of the insert.

Conventional milling . Conventional milling may be necessary when the machine is very old and unstable to achieve acceptable performance from the cutter.

Making the correct choice between climb milling and conventional milling to ensure optimal results.

. When stability is poor or the spindle is very weak or worn out, climb milling will “grab” the workpiece and the cutting forces will pull both axially and radially, creating vibrations and Climb milling damaging the inserts. If this can not be corrected with the

geometry of the cutter, conventional milling will be necessary Conventional milling to eliminate the condition. When this approach is required, decreased tool life should be expected.

. Cutter positioning is very important to how an Conventional milling application is approached. When face milling a workpiece, the term “central milling” means that the center of the workpiece aligns to the center of the cutter body. In this situation, climb and conventional milling occur simultaneously, which can result in unfavorable cutting forces and Central milling Climb milling decreased tool life. This approach should always be avoided if possible. It is far preferable to offset the position of the cutter to create a climb milling Entry shock situation. (pressure stress) . Also the cutter can be offset to create a climb milling situation. Sometimes this may not be possible due to part clamping/ fixturing or Exit shock machine travel limitations. (tensile stress)

. In conventional milling operations, the chip begins thin at the cutter entry and then thickens. This situation results in increased heat being transferred to the carbide instead of being removed in the chip. The rubbing effect has a negative impact on tool life and can also cause issues with hardening the workpiece, depending on the material being machined. This situation should be avoided if at all possible.

. Full engagement/slotting operations create a situation very similar to center-to-center operations, with climb milling and conventional milling occurring in one operation. If possible, a larger diameter face mill should be selected to avoid full engagement and create the situation on Under-formed chip Thick chip the right of the illustration. Undesirable, sometimes unavoidable Desirable, better tool life

. There are times when it may be impossible to create an optimal cutter position. Interrupted cuts are one example where it can be difficult to create good cutting conditions, as shown below. Vibrations and short tool life can result from this type of situation. An effort should be made to combine the geometry of the cutter with the positioning to create the best solution possible in these difficult operations.

. Arc of engagement, also called arc of contact, is another factor that should be kept in mind when face milling. . A larger arc of engagement can create situations as unfavorable cutting conditions and increased heat engagement tool of Arc in the cutting zone. . If possible and within reason, a larger diameter cutter should be used to reduce arc of engagement and create good cutting conditions. . Decreased arc of engagement can also help reduce heat in the cutting zone and result in longer tool life. When selecting a diameter to apply on a customer application, an effort should be made to select the best diameter and create the best situation for arc of engagement and good cutting conditions, e.g. climb milling.

Seco offer a wide variety of solutions to meet customer demands and applications. The overall portfolio positioning splits the systems into easy cutting and economical. Single- sided solutions fall in the easy cutting category, Easy cutting Economical with the Double Quattromill™ in the transition Material suitability area between easy cutting and economical.

Easy cutting soultions Quattromill™ . Very easy cutting . Available in three inserts sizes with cassette versions Easy cutting Economical Comprehensive product family with many . Material suitability different grade and geometry combinations of inserts.

Octomill™ . Positive axial and radial geometry . Available in two insert sizes with wedge and cassette versions.

Economical solutions Double Octomill™ . Offering in two insert sizes . Wedge clamped and cassette styles . Offers various geometry and grade Easy cutting Economical combinations for versatility across various operations and materials Material suitability

Double Quattromill™ 22 & Double Quattromill™ 14 . Features a center locking solution . Two different lead angles . Cutter bodies in fixed pocket and cassette styles . Inserts offer a large depth of cut capability

Economical solutions R220.88 with SNMU inserts. . Focuses on steels and cast irons . available in two insert sizes. . R220.88 is off with fixed pocket cutter Easy cutting Economical bodies and normal and close pitch variants. Material suitability . In the supporting area, we have various systems available. Most noteworthy is the R220.30 for finishing. This system is designed for small depths of cut and high surface finish quality capabilities.

In this TTM for face milling, four products will be highlighted: . Double Quattromill™ 22, Double Quattromill™ 14, Double Octomill™ and the R220.88 with SNMU inserts. . This table (also included in the technical sales guide) shows the recommended materials and diameters with number of teeth available for the products featured in this TTM. Use these charts for quick reference of what is available.

Double Quattromill 22 and 14

. Features a center locking solution . Two different lead angles . Cutter bodies in fixed pocket and cassette styles Easy cutting Economical . Inserts offer a large depth of cut capability Material suitability

. Both Double Quattromill 22 and Double Quattromill 14 systems features two insert designs, 45° and 68° and gives large depth of cut capabilities to fill the gap in the Seco face milling portfolio. . The 45° design gives a 48° lead angle and the 68° design gives a lead angle of 71°. These two lead angle options enhances flexibility to meet customers’ needs by combining easy cutting and economy. . Cutter body options and comprehensive range of inserts for steels, cast irons, stainless steels and super alloys. . High positive geometry makes this system easy cutting, even though it is a double-sided solution. . Cutter bodies will feature standard and close pitch variants along with cassette versions. . The bodies feature Idun material . New unique chip spacing design that enhances the cutter’s performance.

Cutter body features R220.54/56 . Application area for roughing and semi roughing . 220.54 (48° lead angle) . 80-160 mm (3.00”-6.00”) dia. fixed pocket . 200-315 mm (8.00”-12.50”) dia. in cassette. Standard pitch only . 220.56 (71° lead angle) . 80-160 mm (3.00”-6.00”) dia. fixed pocket . 200-315 mm (8.00” -12.50”) dia. in cassette. Standard pitch only . Depth of cut . R220.54 – 9mm (.35”) . R220.56 – 11mm (.43”)

Cutter body features R220.54/56 . Application area for roughing and semi roughing . 220.54 (48° lead angle) . 50 - 200 mm (2.00 – 8.00”) dia. fixed pocket . 160 -315 mm (6.00”-12.50”) dia. in cassette. Standard pitch only . 220.56 (71° lead angle) . 50 -200 mm (2.00 – 8.00”) dia. fixed pocket . 160 -315 mm (6.00-12.50”) dia. in cassette. Standard pitch only . Depth of cut . R220.54 – 6 mm (.24”) . R220.56 – 8 mm (.31”)

. Cutter body features R220.54/56 . Center lock inserts . Cassette versions . Same basic body for insert design 45° (48°lead) and insert design 68° (71° lead) and different insert sizes. One body fits all. . Two pitch variants . Normal pitch – standard operations . Close pitch – stable operations . Cutter bodies in Idun . No nickel coating . Optimized for longevity . Environmentally friendly (thanks to the uncoated cutter body)

R220.54 Cutter body features

Positive axial rake angle with all Idun body geometries

48° lead angel DOC (ap) DQ22: 9 mm (.35”) DQ14: 6 mm (.24”)

Center lock mounted inserts Through coolant channels

R220.56 Cutter body features Positive axial rake angle with all geometries

71° lead angle Idun body

DOC (ap) DQ22: 11 mm (.43”) DQ14: 8 mm (.31”)

Center lock mounted inserts Through coolant channels

R220.54/56 Cassette cutter body features

Idun body and cassettes Same basic body for all Double Quattromill cassettes. Cassettes designed for 45° inserts as well as casettes designed for 68° inserts Cover Plate for will fit central coolant

Cassettes for pocket replacement and adjustability Through coolant channels

Features SN… 14 inserts . SNHX1407ANR – ME10, 45° insert design (48° lead) . SNMX1407ANTR – M10 & M16, 45° insert design (48° lead) . SNHX1407ZNR – ME10, 68° insert design (71° lead) . SNMX1407ZNTR –M10 & M16, 68° insert design (71° lead) . Strong inserts with high productivity capabilities . 8 cutting edges per insert . Cost effective . Depth of cut capability . SNMX1407ANTR – 6 mm (.24”) . SNMX1407ZNTR – 8 mm (.31”)

Features SN… 14 inserts . Geometries . ME10 – no protection chamfer for sticky materials . M10 small T-land ideal for sticky materials and steel . M16 heavy duty geometry ideal for cast iron and steels . Incorporated wiper flat . 1,5mm (.06”) wiper flat length . Designed for semi finishing operations

Features SNHX1407ANR & SNMX1407ANTR, 48° KAPRS

8 cutting edges Corner Radii 45° insert design 1 mm (.039”)

Edge with same positive rake for entire cutting depth DOC 6 mm (.24”) Wiper flat 1,5 mm (.059”) Good surface quality

Numbered cutting edges

Features SNHX1407ZNR & SNMX1407ZNTR, 71° KAPRS

8 cutting edges Corner Radii 68° insert design 1 mm (.039”)

Edge with same positive rake for entire cutting depth DOC 8 mm (.31”) Wiper flat 1,5 mm (.059”) Good surface quality

Numbered cutting edges

Features SNMX 22 inserts . SNMX2209ANR – ME12, 45° insert design (48° lead) . SNMX2209ANTR – M12 & M18, 45° insert design (48° lead) . SNMX2209ZNR – ME12, 68° insert design (71° lead) . SNMX2209ZNTR –M12 & M18, 68° insert design (71° lead) . Strong inserts with high productivity capabilities . 8 cutting edges per insert . Cost effective . Depth of cut capability . SNMX2209ANTR – 9mm (.354”) . SNMX2209ZNTR – 11mm (.433”)

cont…

Features SNMX 22 inserts . Geometries . ME12 – no protection chamfer for sticky materials . M12 small T-land ideal for sticky materials and steel . M18 heavy duty geometry ideal for cast iron and steels . Incorporated wiper flat . 1,5mm (0.06”) wiper flat length . Designed for semi finishing operations

Features SNMX2209ANR & SNMX2209ANTR , 48° KAPRS

8 cutting edges Corner Radii 45° insert design 2 mm (.079”)

Edge with same rake for entire cutting depth DOC 9 mm (.354”)

Numbered cutting edges

Wiper flat 1,5 mm (.059”) Good surface quality

Features SNMX2209ZNR & SNMX2209ZNTR , 71° KAPRS

8 cutting edges Corner Radii 68° insert design 2 mm (.079”)

Edge with same rake for entire cutting depth DOC 11 mm (.433”)

Numbered cutting edges

Wiper flat 1,5 mm (.059”) Good surface quality

48° vs 71° lead angle . Higher feed rates typically are achieved with a lead angle of 48° . 71° lead angle can help to avoid sidewalls or fixture clamping and provide a higher depth of cut with the same I.C. on the insert. . Advantages of 48° lead angle . Better chip thinning and higher feed rates . Positive impact on cutting forces with a more bi-directional effect . Better choice in unstable or weak fixturing . Advantages of 71° lead angle . Higher depth of cut capabilities with same I.C. of insert vs. 48° . Better chip thinning than 90° . Better clearance than 48° to avoid sidewalls or fixturing

R220.54/56 SNHX/SNMX – Features . Shell Mill style mounting . Dedicated and marked cutters designed to fit either 45° inserts or 68° inserts . Idun body for better wear resistance. No nickel coating. . Standard and close pitches in relation to the customer applications . Fixed pocket and cassette versions . Through coolant available on all diameters . Optimized chip spacing for excellent chip evacuation . Big cross section on insert

R220.54/56 SNHX / SNMX– Features . Positive cutting rake with ME10, M10 and M16 geometry . Corner radii of 1 mm (.039”) . Integrated wiper flat of 1,5 mm (.059”) . T20P screw

R220.54/56 SNMX – Features . Positive cutting rake with ME12, M12 and M18 geometry . Corner radii of 2 mm (.079”) . Integrated wiper flat of 1,5mm (.059”) . T20P screw

Example Double Quattromill 22 - R220.54 Body Code Key 45°, to fit 45° insert design

Effective No. of 220=Shell mount teeth (Zc)

SA=Center locking (S), Right hand Cutter system Cutter Insert size with through coolant rotation (45°marking) diameter (A)

Example Double Quattromill 22 - R220.56 Body Code Key 68°, to fit 68° insert design

Effective No. of 220=Shell mount teeth (Zc)

SA=Center locking (S), Right hand Cutter system Cutter Insert size with through coolant rotation (68° marking) diameter (A)

Example Double Quattromill 22 - SNMX Inserts Code Key 45° insert design

Side clearance Insert type Insert Edge Edge angle thickness protection geometry

Insert shape Tolerances Cutting edge Lead angle and Right hand length side clearance rotation

Example Double Quattromill 22 - SNMX Inserts Code Key 68° insert design

Side clearance Insert type Insert Edge Edge angle thickness protection geometry

Insert shape Tolerances Cutting edge Lead angle and Right hand length side clearance rotation

= full offering = limited offering = not offered

Copyright © Seco Tools AB 70 FABI - R220.54/56 Double Quattromill™ 22 & 14 Features Advantages Benefits Involvement Optimized • Reliable machining process • Improved machining process (less • How important is tool life for you? Body Design • Optimal chip evacuation from risk of machine down time) the cutting zone • Better tool life • What effect would better process security have for you? • Decrease risk of insert breakage • Process Security • How would you like to improve your machining and re -cutting of chips operation and reduce cost? • Flute spacing design to enhance • Less chance of chip jamming • How can better chip evacuation help you on this good chip flow. especially in stick materials operation?

8 Cutting Edges • Lower cost per edge • Economical benefit to customer. • How important is cost per edge to you? • Less inventory • Fewer insert changes

Idun Cutter Body • Positive environmental impact • Attractive appearance with post • How important is your impact on the with elimination of the nickel treatment to prevent marking of environment? coating the cutter from handling and • Material optimized for cutter machining longevity • Idun material is very durable for • How important is the longevity of the cutter body Face Milling operations to you and your company? cont… Copyright © Seco Tools AB FABI - R220.54/56 Double Quattromill™ 22 & 14 Features Advantages Benefits Involvement Positive Rake • Lower power consumption • Easier on machine and can • Tell me about the constraints on your machine Geometries reduce cycle time and if taking this material in one pass can be beneficial to you? • Effective in sticky materials • Longer tool life and wider range • Explain how your workshop can benefit with even at high depths of cut of applications. large depth of cut facing operations in this material.

Seco Coromant Diameter 63 mm (2.48”) 63 mm (2.48”) Cutter R220.54-0063-14-5A 345.063Q22-13HX-939631 Insert SNMX1407ANTR-M16-P03, MP2500 345R-1305M-PM, 4230 Vc 218 m/min (7086”) 218 m/min (7086“) n 1100 rpm 1100 rpm Fz 0,191 mm(.0075”)/tooth 0,136 mm (.0054”)/tooth Vf 1050 mm (41.34”)/min 1050 mm (41.34”)/min D.O.C 5+3,5+3,5 mm (.2”+.14”+.14”) 5+3,5+3,5 mm (.2”+.14”+.14”) Ae 30 max mm (1.18”) 30 max mm (1.18”) Tool life 80 min, 80 pcs 50 min, 50 pcs

Additional information: No need to improve performance due to cycle (bottleneck are other operations on lathes). Compared power consumption: Coromant 110-125% and Seco 100-112%. Very good chip control. Consistent tool life (+/- 5% difference between edges). Reliable tool life, no breakages. Despite of less no of teeth (higher feed per tooth) surface finishing is good.

Seco Seco Diameter 80 mm (3.15”) 80 mm (3.15”) Cutter R220.54-0080-14-8A R220.54-0080-14-8A Insert SNMX1407ANTR-MD16, MK1500 SNMX1407ANTR-MD16, MP1500 Vc 350 m (13779”)/min 350 m (13779”)/min n 1400 rpm 1400 rpm fz 0,31 mm (.012”)/tooth 0,31 mm (.012”)/tooth Vf 3500 mm (138”)/min (138”) 3500 mm (138”)/min ap 2 mm (.078) 2 mm (.078”) Ae 60 mm (2.36”) 60 max mm (2.36”) Tool life 43 min, 168 pcs 43 min, 168 pcs

MK1500 MP1500 Additional information: DQ allows higher parameters with same tool life, very good reliability, soft cut and good surface finishing. Customer tested DO & DODEKA with same parameters that DQ14, but power consumption is too high for the machine. Feedback is really good because customer has decided to implement in his facility DQ14 as soon as it will be available.

Seco Walter Diameter 160 mm 160 mm Cutter R220.56-8160-22-8A M3016-160-B40-07-16 Insert SNMX2209ZNTR-M18 MP3000 LNMX201012R-F57T WKP35S Vc 176 m (6929”)/min 176 m (6929”)/min n 350 rpm 350 rpm fz 0,49 mm (.19”)/tooth 0,49 mm (.19”)/tooth Vf 1200 mm (47.24”)/min 1200 mm (47.24”)/min ap 8 mm (.31”) 6 mm (.24”) Ae 120 mm (4.72”) 120 mm (4.72”) Tool life 26 pcs 20 pcs

Additional information: Improved metal removal with DQ 22. Ap of 10mm was possible with spindle load of 85%. Customer was more comfortable with 8mm Ap and load of 70%. Walter was only able to run at 6mm Ap max.

Seco Cutter R220.54-0080-22-6A-PROTO Insert SNMX2209ANTR-M12-P01 T350M Vc 200 m (7874”)/min RPM 790 fz 0,35 mm (.014”)/tooth Feed 1671,6 mm (65.81”)/min ap 9 mm (.35”) Ae 80 mm (3.15”) (100%) MMR 1203,6 cm3/min

Economical solutions Double Octomill . Offering in two insert sizes . Wedge clamped and cassette styles . Offers various geometry and grade Easy cutting combinations for versatility across various Economical operations and materials Material suitability

. The Double Octomill has been a very successful product since its introduction in 2010. . With 16 cutting edges, this cutter offers superior economy and has proven to be extremely versatile. . Originally designed for use in steel and cast iron, the Double Octomill has broadened its use with proven performance in ISO M & ISO S materials. . The versatility is enhanced even more with the cutter being highly effective in both roughing and finishing applications.

Advantages . Higher feed rates . Less radial cutting forces . Ideal for roughing, semi finishing and finishing operations . Robust inserts to stand up to difficult operations

Cutter body design . The cutter body uses a patented technology, unique on the market. Radial and axial support pins provide ease of mounting for the insert and ensure high accuracy of the system with reduced run-out. . Inserts are easy to handle and index in a secure way . Hard body coating ensures better tool life for the cutter body . Cutters are available in the quick change cap system. . Cassette version available for both versions and feature the same pocket . The cutter body feature center locked inserts along with wedge clamped designs.

Range . Cutter bodies 25-500 mm (1.00”-20.00”) . Fixed and cassette version . Insert sizes 05 and 09 . 16 cutting edges . Grades and geometries for almost all materials

This family also features patented technology with pins for insert seating and ground grooves on the insert to provide reduced runout, secure indexing and high longevity of the insert pockets. Double Octomill has become one of the most recognizable face mills on the market and combines economy with high performance.

Cutter body features R217/220.48 . Application area for roughing , semi finishing and finishing . R217/220.48 (09 Size) . 63-500mm (2.50 – 20.00”) dia. . 125 – 315 mm (5.00-12.50”) dia. in cassette. Standard pitch only . R217/220.48 (05 Size) . 25-200 mm (1.00 – 8.00”) dia. . 80-200 mm (3.00 – 8.00”) dia. in cassette. Standard pitch only . Depth of cut . R220.48-09 – 6mm (.24”) . R220.48-05 – 3mm (.12”)

Cutter body features R217/220.48 . Centre lock and wedge style insert clamping . Cassette versions . Right and left hand versions for R220.48 size 09 . Multiple pitch variants . Coarse pitch for sticky materials or unstable operations . Normal pitch for standard operations . Close pitch for stable operations . Pins in cutter body for secure indexing . Reduced insert runout . Seco patented solution

Features ONMU/ONEU inserts . ONMU/ONEU0905 size 09 inserts . ME12, ME13, M12, M13, M14, M14, M15, MD16 and MD17 . Wiper inserts ONEU090520ZZTN4 in M12 and M14 . ONMU/ONEU0904 size 05 inserts . ME10, ME11, M10, M11 . Wiper inserts ONEU050410ZZTN4-M10 . 16 cutting edges per insert . Cost effective

Features ONMU/ONEU inserts . Max depth of cut ONMU0905 inserts . ME13, M13, M15 & MD17 is 4,5 mm (.178”) . ME12, M12, M14 & MD16 is 6 mm (.236”) . Max depth of cut ONMU0504 . ME11 & M11 is 2,5 mm (.098”) . ME10 & M10 is 3 mm (.118”) . Strong inserts with high productivity capability and low axial runout . Incorporated wiper flat on most geometries . ME12, M14, MD16 wiper flat of 0,45 (.018”) . ME13, M13, M15 & MD17 wiper flat of 2,11 mm (.083”) . Semi finishing operations

Wiper inserts ONEU090520ZZTN . Designed to be paired with cutting inserts to increase surface finish quality on the work piece. . Inserts have four right-hand wiper edges and four left-hand wiper edges. Two different edges exists for the wipers with the M12 and M14 available in various grades.

M12 Wiper setting height comparison between different geometries

YES NO NO NO NO NO

M12 Wiper M12/ME12 M13/ME13 MD16 M14 MD17 M15 0,04 mm 0,19 mm 0,21 mm 0,215 mm 0,33mm 0,37 mm .0015” .0074” .0082” .0084” .015” .0015”

Lower than Lower than Lower than Lower than Lower than Lower than M12 wiper M12 wiper M12 wiper M12 wiper M12 wiper M12 wiper

M14 Wiper setting height comparison between different geometries

NO YES YES YES NO NO

M14 Wiper M12/ME12 M13/ME13 MD16 M14 MD17 M15 0,10 mm 0,055 mm 0,06 mm 0,064 mm 0,178mm 0,21 mm .00425” .0014” .0024” .0025” .007” .0082”

Higher than Lower than Lower than Lower than Lower than Lower than M14 wiper M14 wiper M14 wiper M14 wiper M14 wiper M14 wiper

Summary Double Octomill . Shell mill style mounting; CAP style available on larger diameters . Nickel coated bodies to prevent marking of the body and increase longevity . Standard, close and super close pitch versions . Optimized chip spacing for excellent chip evacuation . Thick and strong cross section on insert . Comprehensive edge and grade offering to optimize in most materials . Fixed pocket and cassette versions available . T20P screw

Cutter body key

Effective No. of 220=Shell mount teeth (Zc)

48 09 07

SA=Center locking (S), Right hand Cutter system Cutter Insert size with through coolant rotation (68 degree) diameter (A)

ONMU Inserts Code Key

Insert Angle and Edge Edge Side clearance Insert type angle thickness clearance protection geometry

Insert shape Tolerances Cutting edge Corner radius Neutral hand rotation length

= full offering = limited offering = not offered

Features Advantages Benefits Involvement Optimized • Reliable machining process • Improved machining process (less • How important is tool life for you? Body Design risk of machine down time) • Optimal chip evacuation from • What effect would better process security have for the cutting zone • Better tool life you? • Process Security • How would you like to improve your machining • Decrease risk of insert breakage operation and reduce cost? and re -cutting of chips • One solution for roughing and finishing operations • How important is the longevity of the cutter body • Fixed pocket and cassette • Large cutter offering utilizing the to you and your company? versions same insert.

16 Cutting Edges • Lower cost per edge • Economical benefit to customer. • How important is cost per edge to you? • Less inventory • Fewer insert changes

Insert offering • Wide offering of edges • 16 cutting edges for maximum • How important is your impact on the • Comprehensive offering of economy environment? grades • Grade & edge combinations to be • How important is the longevity of the cutter body • Integrated wiper flat with 2 effective in most materials to you and your company? wiper lengths and no wiper variant • Ground seat location to reduce run- • How can better chip evacuation help you on this • Numbered cutting edges out which improves tool life and operation? surface finish.

Seco Walter Diameter 63 mm (2.48”) 63 mm (2.48”) Cutter R220.48-0063-09-5SA M3024-063-B22-05-04 Insert ONMU090510ANTN-M12 T350M XNGU705ANN-F67 WSM35S Vc 110 m (4331”)/min 110 m (4331”)/min n 556 rpm 556 rpm fz 0,22 mm (.008”)/tooth 0,22 mm (.008”)/tooth Vf 611 mm (24.05”)/min 611 mm (24.05”)/min ap 4 mm (.157”) 4 mm (.057”) Ae 40 mm (1.57”) 40 max mm (1.57”) Tool life 26 pcs 20 pcs

Copyright © Seco Tools AB 101 R220.48 Double Octomill™ China SMG 1,4837 Cast Stainless Steel Operation Rough milling Machine Mazak Clamping: Weak Fixture Coolant: Dry Workpiece Turbo Charger Seco Pramet Diameter 63 mm (2.48”) 63 mm (2.48”) Cutter R220.48-0063-09-5SA 63 mm with 5 teeth Insert ONMU090510ANTN-M12, MS2500 High positive 8 edge insert Vc 109 m (4291”)/min 109 m (4291”)/min RPM 551 551 Feed 661 mm (26”)/min 661 mm (26”)/min Fz 0,24mm (.009”) 0,24 mm (.009”) D.O.C 2 mm (.078”) (3 passes) 2 mm (.078”) (3 passes) Ae 80% 80% Tool life 25 pcs 15 pcs

Copyright © Seco Tools AB 102 R220.48 Double Octomill™ China SMG 1,4848 Cast Stainless Steel Operation Finish face milling Machine OKUMA Clamping: Weak Fixture Coolant: Emulsion Workpiece Turbo Charger Seco Double Octomill Tungaloy Cutter R220.48-0100-05-7SA TEN09R100M31.7-05 Insert ONMU050410ANTN-M11, T350M PNCU0905GNEN.MJ/AH3135 Vc 120 m (4724”)/min 120 m (4274”)/min RPM 382 382 Feed 508 mm (20”)/min 508 mm (20”)/min Fz 0,19mm (.007”) 0,19 mm (.007”) D.O.C 0,3 mm (.012”) 0,3 mm (.012”) Ae 90 mm (3.54”) 90 mm (3.54”) Tool life 48 pcs 30 pcs

Copyright © Seco Tools AB 103 R220.48 Double Octomill™ USA SMG Spray weld / cast iron Operation Rough milling and finishing Machine Fives U-5 Clamping: Fixture Coolant: Dry Workpiece Engine block Seco Coromant Cutter R220.48-820.00-09-21S Special 508 mm Face mill Insert ONEU090520ANE30-E12-K, MS2050 Special Vc 148 m (5826”)/min 100 m (3937”)/min RPM 93 63 Feed 635 mm (25”)/min 376 mm(14.8”)/min Fz 0,33mm (.013”) 0,2 mm (.008”) D.O.C 0,2 mm (.008”) 0,05 mm (.0019”) Ae 457 mm (18”) 457 mm (18”) Tool life 30 pcs Unpredictable

Economical solutions . R220.88 with SNMU inserts. . Focuses on steels and cast irons . Available in two insert sizes. . R220.88 is off with fixed pocket cutter bodies and normal and close pitch variants. Easy cutting Economical . In the supporting area, we have various Material suitability systems available. Most noteworthy is the R220.30 for finishing. This system is designed for small depths of cut and high surface finish quality capabilities.

R220.88 with SNMNMU inserts features

. Large depth of cut capability . Two insert sizes, 12 and 16 . Designed for steel and cast iron applications . Center locking inserts to improve upon the old wedge system

R220.88 offers better process security and with productivity in mind, R220.88 meets the customers demands for a near 90° face mill in both roughing and semi finishing operations

Cutter body features 220.88 – 12&16

. Size 12 diameter range Ø50 – 160 mm (2.00‘’-6.00'') . Size 16 diameter range Ø63 – 160mm (3.00”- 6.00”) . Depth of cut capability . Size 12 is 9mm (0.354”) . Size 16 is 13mm (0.511”) . 88° lead angle, near 90° . Face Milling operations near sidewalls or obstacles in the machining process . Center lock inserts . Secure and easy mounting of the insert, no wedges.

Cutter body features 220.88 – 12&16

. Two pitch variants . Normal pitch for standard operations . Close pitch for stable operations . Bodies made from Idun material . No nickel coating . Optimized material for longevity . Application area for roughing and semi-finishing

Features – SNMU 12 &16 insert range

. 8 cutting edges per insert . Cost effective . Strong insert with high productivity capability . Depth of cut capability . Size 12 is 9mm (0.354”) . Two geometries M10 / MD13), both with and without wiper flat . Size 16 is 13mm (0.511”) . Two geometries M10/ MD16, both with and without wiper flat

Features – SNMU 12 &16 insert range

. Good surface quality result . Positive rake angle with M10 geometry . Smooth cutting . Negative geometry with MD13/16 . Heavy edge protection for difficult operations . Focus on Cast Iron and Steels. K and P materials . Both PVD and CVD-coated variants

. R220.88 Cutter body features

Idun body

88° DOC Positive axial rake angle

Size 12-ap=9 mm (.354”) with M10 insert Size 16-ap=13 mm (.512”) geometry

Through coolant Center lock mounted inserts channels

. SNMU size 12, 8 cutting edges

M10 Geometry MD13 Geometry

Curved edge for Corner Radii Flat geometry for positive cutting rake 1 mm (.034”) difficult operations

DOC 9 mm (.354”)

Numbered cutting edges Wiper flat 1 mm (.034”) “Dot” to mark side of Good surface quality insert

. SNMU size 16, 8 cutting edges

M10 Geometry MD16 Geometry

Curved edge for Corner Radii Flat geometry for positive cutting rake 1,2mm (.047”) difficult operations

DOC 13 mm (.512”)

Numbered cutting edges Wiper flat 1,2mm (.047”) “Dot” to mark side of Good surface quality insert

. SNMU 120408TN-M10 & MD13, 8 cutting edges

M10 Geometry MD13 Geometry

Curved edge for Corner Radii Flat geometry for positive cutting rake 0,8 mm (.031”) difficult operations

DOC 9 mm (.354”)

Numbered cutting edges No wiper flat “Dot” to mark side of insert

. SNMU 160610TN-M10 & MD16, 8 cutting edges

M10 Geometry MD16 Geometry

Curved edge for Corner Radii Flat geometry for positive cutting rake 1 mm (.039”) difficult operations

DOC 12 mm (.512”)

Numbered cutting edges No wiper flat “Dot” to mark side of insert

. Features Cutter body . Shell Mill style mounting . Idun body for better wear resistance. No nickel coating. . Standard and close pitches in relation to the customer applications . Optimized chip spacing for excellent chip evacuation . Big cross section on insert . Positive cutting rake with M10 geometry . Corner radii of 1 mm (.039”) for size 12 and 1,2 mm (.047”) for size 16 . T15P screw

Step down mismatch The R220.88 is a near 90 solution, 88 degree lead angle. Therefore when machining multiple passes the R220.88 SNMU cutter will leave a mismatch on a sidewall. See the picture below that shows the mismatch relative to the depth of cut.

Mismatch for Mismatch for size 12 at size 16 at 12mm

9mm (.354”) ap (.472”)ap

Cutter body code key

220=Shell mount Effective no of teeth (Zc)

SA=Center locking (S), Right hand Cutter Cutter Insert size with through coolant rotation system diameter (A)

Insert code key

Side clearance Insert type Insert Edge Edge angle thickness protection geometry

Insert shape Tolerances Cutting edge Corner radius Neutral rotation length

= full offering = limited offering

Features Advantages Benefits Involvement Optimized Body Design • Reliable machining process • Improved machining process (less risk • How important is tool life for you? • Optimal chip evacuation from the of machine down time) • What effect would better process cutting zone • Better tool life security have for you? • Decrease risk of insert breakage and • Process Security • How would you like to improve your re cutting of chips machining operation and reduce cost?

8 Cutting Edges • Lower cost per edge • Economical benefit to customer. • How important is cost per edge to • Less inventory • Fewer insert changes you?

Idun Cutter Body Material • Positive environmental impact with • Attractive appearance with post • How important is your impact on the elimination of the nickel coating treatment to prevent marking of the environment? • Material optimized for cutter cutter from handling and machining • How important is the longevity of the longevity • Idun material is very durable for Face cutter body to you and your Milling operations company?

SMG K4 (SS0727-02) Operation Face milling Machine Okuma MA-800HB PCS +30% Productivity 10 Seco Tungaloy Diameter 80 mm (3.15”) 100 mm (3.94”) Cutter R220.88-0080-12-7SA TPQ18R100M32.0E08 5 Insert SNMU120410TN-M10, MK1500 LQMU180804PNER-MJ, AH120 Vc 200 m (7874”)/min 200 m (7874”)/min 0 RPM 796 636 R220.88 Tungaloy Feed 1281 mm (50.43”)/rev 1171 mm (46.1”)/rev Fz 0,23 mm (.009”) 0,23mm /(.009”) Result Seco vs Tungaloy D.O.C 3-4 mm (.12-.16”) 3-4mm (.12-.16”) • Increased productivity with 30% Ae 50-100% 25-80%

Additional information: Unstable operation in material SS07 27-02 (SMG K4). Lower cutting forces than Tungaloy along with better sound in the machining operation. Customer wanted to purchase right away. 8 work pieces with Seco vs. 6 with Tungaloy. Smaller diameter than Tungaloy was ran by recommendation.

Seco Iscar Diameter 63 mm (2.48”) 63 mm (2.48”) Cutter R220.88-0063-12-7SA S890 FSN D063-05-22-R13 Insert SNMU160612TN-M10, MP1500 SNMU1305PNTR, IC5400 Vc 110 m (4331”)/min 110 m (4331”)/rev RPM 560 560 Feed 560 mm (22.04”)/rev 560 mm (22.04”)/rev Fz 0,143 mm (.006”) 0,2 mm /(.008”) D.O.C 4 mm (.16”) 4mm (.16”) Ae 50 mm (1.97”) 50 mm (1.97”)

Seco Iscar Diameter 100 mm (3.94”) 100 mm (3.94”) Cutter R220.88-0100-16-8SA H490 F90AX D100-7-25,4-17 Insert SNMU160612TN-M10, MP1500 H490ANKX1706PNTR-RM, IC810 Vc 386 m (15197”)/min 386 m (15197”)/rev RPM 1230 1230 Feed 2900 mm (114.17”)/rev 2900 mm (114.17”)/rev Fz 0,295 mm (.012”) 0,295 mm /(.012”) D.O.C 4-10 mm (.16 - .39”) 4-10 mm (.16- .39”) Ae 75% 75%

Additional information: Operation on rear axle housing, Material SS0717/GGG40, SMG: K4. Test against Iscar in which the customer remarked about the good sound and smooth cut on the Seco cutter. Tool life was equal to Iscar but only 4 edges vs Seco with 8 edges.

SMG: K4 (GGG50) Hardness: HB180-220Operation Machine: VMC850L ( local vertical machine center. Spindle : 7.5Kw/BT40 (low power of spindle) Clamping: Without support in the center Coolant: External Workpiece: Gearbox cover plate Application Rough milling upper surface

Seco Kolroy Diameter 80 mm (3.15”) 80 mm (3.15”) Cutter R220.88-0080-12-9SA RMH8EC4080HR-M (D80;Z7) Insert SNMU120410TN-M10, MK2050 SNEX1206ENN-MF, PC6510 Vc 280 m (11024”)/min 280 m (11024”)rev RPM 1100 1100 Feed 1900 mm (74.8”)/rev 1900 mm (74.8”)/rev Fz 0,19 mm (.0075”) 0,24 mm /(.0094”) D.O.C 2 mm (.08”) 2 mm (.08”) Ae 60 - 90% 60 - 90% Pcs 128 80

Additional information: Seco solution produced less cutting forces and vibrations in cut. Opportunity to reduce cycle time by increasing feed. No adjustments made, plug and play testing, still opportunity to increase tool life more by changing parameters. Overall potential for top and bottom face of workpiece at 60,000 per year.