Third ISCAR’s Quick Edition Reference Guide for ISCAR’s Quick and Mold Making Reference Guide for Metric Version Die and Mold Making Metric Version Die and Mold Making ISCAR’s Quick Reference Guide for ISCAR’s

www.iscar.com www.iscar.com ISCAR LTD. Croatia New Zealand Spain Dear Die and Mold Maker, Headquarters ISCAR ALATI d.o.o. ISCAR PACIFIC LTD. ISCAR IBERICA SA Tefen 24959, Israel J. Jelačiča 134 1/501 Mt. Wellington Hwy. Parc Tecnològic del Vallès Tel + 972 (0)4 997 0311 CRO-10430 Samobor Mt. Wellington Auckland Avda. Universitat Autònoma 19-21 our Distinguished Customer and Colleague, Fax + 972 (0)4 987 3741 Tel +385 (0) 1 33 23 301 Tel + 64 9 5731280 08290 Cerdanyola-Barcelona www.iscar.com Fax +385 (0) 1 33 76 145 Fax + 64 9 5730781 Tel +34 93 594 6484 [email protected] [email protected] [email protected] Fax +34 93 582 4458 Our primary concern, as a manufacturer, is to provide you with the most progressive and most www.iscar.hr [email protected] Argentina Poland www.iscarib.es high-efficiency that will meet your requirements and answer the purpose of ISCAR TOOLS ARGENTINA SA Czech Republic ISCAR POLAND Sp. z o.o. Monteagudo 222 ISCAR CR s.r.o. ul. 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Therefore, we hope that this guide will help you in right tool selection and will be a good Tel + 43 7252 71200-0 www.iscar.fr Tel + 40 (0)312 286 614 Taichung 408 Fax + 43 7252 71200-999 Fax + 40 (0)312 286 615 Tel +886 (0)4-24731573 supplement to our catalogs, reference forms and leaflets because it takes into account specific [email protected] [email protected] Fax +886 (0)4-24731530 www.iscar.at ISCAR GERMANY GmbH [email protected] features of die and mold making. First of all the guide emphasizes the latest solutions in order to Eisenstockstrasse 14 Russia www.iscar.org.tw give you the opportunity of becoming familiar with them. Belarus D 76275 Ettlingen Moscow JV ALC “TWING-M” Tel + 49 (0) 72 43 9908-0 ISCAR RUSSIA CIS Thailand Slutskaya str. 3, Fax + 49 (0) 72 43 9908-93 Godovikova str. 9, build. 10 ISCAR THAILAND LTD. 223056 v. 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We consider ourselves as your true colleague in the die and mold making process at your location B 1702 Dilbeek (Groot-Bijgaarden) www.iscar.ru Gebze Organize Sanayi Bölgesi (GOSB) and will be proud and sincerely pleased if you will feel the same. Tel + 32 (0) 2 464 2020 Italy Ihsan Dede Cad. No: 105 Fax + 32 (0) 2 522 5121 ISCAR ITALIA srl Serbia Gebze / Kocaeli [email protected] Via Mattei 49 / 51 ISCAR TOOLS d.o.o. Tel + 90 (262) 751 04 84 (Pbx) www.iscar.be 20020 Arese [MI] Autoput 22 Fax + 90 (262) 751 04 85 Tel + 39 02 93 528 1 SRB-11080 Zemun [email protected] Bosnia Fax + 39 02 93 528 213 Tel +381 11 314 90 38 www.iscar.com.tr (Representative Office) [email protected] Fax +381 11 314 91 47 Kralja Tvrtka I br. 17 www.iscaritalia.it [email protected] Ukraine BIH- 72000 Zenica ISCAR UKRAINE LLC Tel +387 32 201 100 Japan Slovakia Volgodonska str., 66 Fax +387 32 201 101 ISCAR JAPAN LTD. ISCAR SR, s.r.o. 02099 Kiev [email protected] Head Office K múzeu 3 Tel/fax +38 (044) 503-07-08 15th Floor, Senri Asahi 010 03 Zilina [email protected] Brazil Hankyu Building Tel +421 (0) 41 5074301 www.iscar.ru ISCAR DO BRASIL COML. LTDA. 1-5-3, Shinsenri-Higashimachi Fax +421 (0) 41 5074311 Rodovia Miguel Melhado Campos, Toyonaka-Shi, [email protected] United Kingdom Km 79, Bairro Moinho Osaka 560-0082 www.iscar.sk ISCAR TOOLS LTD. CEP: 13280-000 - Vinhedo - SP Tel + 81 6 6835 5471 Woodgate Business Park Tel + 55 19 3826-7100 Fax + 81 6 6835 5472 Slovenia Bartley Green Fax + 55 19 3826-7171 [email protected] ISCAR SLOVENIJA d.o.o. Birmingham B32 3DE DDG 0800 701 8877 www.iscar.co.jp IOC, Motnica 14 Tel + 44 (0) 121 422 8585 [email protected] SI-1236 Trzin Fax + 44 (0) 121 423 2789 www.iscar.com.br Macedonia Tel + 386 1 580 92 30 [email protected] (Representative Office) Fax + 386 1 562 21 84 www.iscaruk.co.uk Bulgaria Londonska 19/4 [email protected] ISCAR BULGARIA MK-1000 Skopje www.iscar.si United States Starozagorska 1, Str. Tel +389 2 309 02 52 ISCAR METALS INC. Floor 1, Office G, Fax +389 2 309 02 54 South Africa 300 Westway Place 6100 Kazanlak [email protected] ISCAR SOUTH AFRICA (PTY) LTD. Arlington, TX 76018-1021 Tel/Fax +359 431 62557 47 Lake Road Tel + 1 817 258 3200 [email protected] Mexico Longmeadow Business Estate - North Tech Tel 1-877-BY-ISCAR ISCAR DE MÉXICO, Extension 7, Modderfontein, Fax + 1 817 258 3221 Canada S.A de C.V. Edenvale, Gauteng [email protected] ISCAR TOOLS INC. Fray Pedro de Gante 15 P.O. Box 392 www.iscarmetals.com 2100 Bristol Circle Col. Cimatario Longmeadow Business Estate - North 1609 Oakville, Ontario L6H 5R3 Querétaro, Qro. ShareCall 08600-47227 Vietnam Tel + 1 905 829 9000 C.P. 76030 Tel +27 11 997 2700 ISCAR VIETNAM Fax + 1 905 829 9100 Tel + 52 (442) 214 5505 Fax +27 11 388 9750 (Representative Office) [email protected] Fax + 52 (442) 214 5510 [email protected] Room D 2.8, Etown Building, www.iscar.ca [email protected] www.iscar.co.za 364 Cong Hoa, Tan Binh Dist., www.iscar.com.mx Ho Chi Minh City China South Korea Tel +84 38 123 519/20 ISCAR CHINA The Netherlands ISCAR KOREA Fax +84 38 123 521 7B21, Hanwei Plaza, ISCAR NEDERLAND B.V. 304 Youggye-Ri, [email protected] 7 Guanghua Road Postbus 704, 2800 AS Gouda Gachang-myeon Chaoyang District Tel + 31 (0) 182 535523 Dalsung-gun, Daegu 711-860 Bejiing 100004 Fax + 31 (0) 182 572777 Tel + 82 53 760 7590 Tel + 86 10 6561 0261/2/3 [email protected] Fax + 82 53 767 7203 © ISCAR LTD. Fax + 86 10 6561 0264 www.iscar.nl [email protected] All rights reserved [email protected] www.iscarkorea.co.kr 02/2017 www.iscar.com.cn

7861458 Contents

Foreword ...... 3 Die and Mold Materials ...... 4 Typical Examples of Dies and Molds ...... 8 Cutting Tools in the Die and Mold Industry...... 9 Tools...... 10 1. 90˚ Shoulder Milling...... 13 2. Milling Surfaces...... 36 3. Milling Contoured Surfaces (Profiling)...... 44 Making Tools...... 119 In Summation...... 121 Technical Information...... 122

3

Die and Mold ISCAR Tool Families Referenced in this Guide

1. Milling Tools

2. Hole Making Tools

4

• • •

die andmoldmaking. or moldmaterial.Thepartshapeandthediematerialare asource datafor mold andaccuracyrequirements; andaformingtechnologythepartrunsize–die A partintendedtobeproduced inadieormolddictatesshapeandsizesofthe craft intoawholebranchoftrade. itfromtechnology andCAD/CAMsystemssubstantiallychangediemoldmaking, considered asoneofthemost professionally CNC skilledworkersinmanufacturing.Modern die andmoldmakersrichknowledge,skillsexperience.Amakerisrightfully Shaping thecomponentsisacentraloperationindieandmoldmanufacturingthatdemandsfrom is determinedbyseveralmaincomponents(cavities,rams,etc.). many ofthemare standard orunified.Aformofapartthatisproduced inthedieormold Broadly speakingadieor a mold,beinganassemblyunit,comprisesvariouselements,and processing ofplastics. properties, andare manufactured bydifferent technologicalmethodsofmetalformingor turbine ,atinsoldierorboat.Theseobjectsdiffer intheirform,material,sizes,mechanical cylinderblockoratoy,molds: aninternal aplasticcontainerorcrankshaft, abottleorjet A lotofthingsaround us,partsorevenfullycompletedproducts, are produced indiesand for thecorrect tool choice. We willdiscussthemhere briefly, explainthetools’features andthusbuildabase requirement ofthebranch.Therighttoolselectiondependsondifferent factors. to provide thedieandmoldmakerwithreliable andefficient toolingthatmeetsevery We, atISCAR,distinctlyunderstandtherole ofcuttingtoolsinthedieandmoldindustrytry of thedieandmoldprocess, isasubstantialfactorofproductivity andprofitability. perform materialremoval duringoperation.Atool,whichseemstobeasecondaryelement The rightmachiningstrategyisdirectly related tocorrectly chosencuttingtools that machinetools. modern simulation inorder tofindthemostefficient solutionthatallowsfulluseofadvantages die ormolddesign,definingmachiningstrategy, developingCNCprograms andmachining operations, assemblyandfinishingworks. Today’s CAD/CAMsoftware enablesanalyzingthe of technologythedieormoldmanufacturingthat,ingeneral,includesmachining The keytoproductive andeffective dieandmoldmakingistheprocess planning–thechoice Also, difficulty inmachiningisafunctionofmachinabilitythedieormoldmaterial. difference betweenheights,etc. High degree inthecontextofverycomplexshape,narrow anddeepcavities,considerable deeper; ramshavesteepwalls,etc. Medium, whentheshapebecomesmore complicated,thesizesbiggerandcavities Low degree incaseofplaneareas, simpleshapes,shallowcavitiesetc. of difficulty formachining: In manufacturingadieormold,theshapeandsizesare themainfactorsof degree types: forgingdies,(pressing) dies,diecastingdiesandmoldsforplastics. There are different kindsofdiesandmolds,whichcanbegrouped inthefollowingprincipal Foreword Automotive Industry is a major consumer of dies and molds. Approximately 60% Approximately molds. and dies of consumer major a is Industry Automotive of stamping dies and 40% of plastic molds produce automotive parts. automotive produce molds plastic of 40% and dies stamping of Die andMold 5 Foreword 6 Die and Mold Materials • Special-purpose • • • • Hot-work •

into thefollowingconditional groups dependingontheirhardness: to cuttingtooldevelopmentandtheirabilitycutmaterial. Therefore, steelscanbedivided withthathardness oftenrelate tohard .Thetermanditshardness limitare allied specification. Generally, it islessthanHRC45,however, intechnicalliterature and references the to relatively nothighhardness butdifferent steelproducers usedifferent limitsforits The term“pre-hardened steel”isnotwell-defined.Itmeansthatsteelhardened andtempered a softmaterialwhileclosedallowancesare usualforfinishcutswhenmaterialhardness ishigh. to HRC63(hard steel).Normally, highstockremoval ratecharacterizesrough machiningof (even thesamegrade)canvarywithinawiderangefrom HB200andless(softsteel) and hardened. Consequently, indieandmoldmakingprocess, hardness oftoolsteel The steelmanufacturers supplysteelsindifferent deliveryconditions:annealed, pre-hardened machinability, polishabilityanddimensionalstability. which hasalready beenspecifiedbydesigners, more importantproperties are: hardness, corrosion resistance, etc.However, while foradieandtoolmakerdealingwiththematerial, In dieandmolddesign,themainproperties oftoolsteelsare strength, wearresistance, Shock resistant Sseries Plastic moldPseries Water hardening Wseries D series(high-carbonhigh-chromium) andOseries(oilhardening) Cold-work toolsteelsincludingAseries(air-hardening medium-), of toolsteels,from whichthefollowingare themostpopularindieandmoldindustry: In linewiththemainfieldofapplicationthere are sixgeneralandtwospecial-purposeclasses in keepingwiththedifferent nationalstandards. end ofthisguidecontainsacross-reference tablewithcomparativedesignationoftoolsteels with otheractingstandards issometimesgiveninthetext;andinformationsectionat and theSocietyofAutomotiveEngineers(SAE).Theparalleldesignationinconformity trade names.Inthisguideweusethestandards oftheAmericanIron andSteelInstitute(AISI) own specification.Thesesteelsoftenhavenostandard designationandare identifiedbytheir requirements ofindustry, steelmanufacturers produce different steelsinaccordance withtheir standardsinternational forspecifiedtoolsteels.Moreover, inorder toanswertheparticular making toolsforcuttingandformingmetalsothermaterials.There are manynationaland Tool steelsrelate toatypeofsteelsthat,asindicatedinitsname,isintendedfirst ofallfor usually are from particularmaterials,whichshouldbeemphasized. However, keydieormoldpartsthatactonspecific requirements ofthedieandmoldindustry different engineeringmaterials,from plasticstocementedcarbides. (clamping elements,springs,pins,bolts,bushings,supportpillars,etc.)generallymadefrom We havealready noticedthatadieormoldhasdifferent movableandstationaryparts Tool Steels Die andMoldMaterials Die and mold makers deal with steel in wide ranges of hardness, from low (HB 200 and less) and 200 (HB low from hardness, of ranges wide in steel with deal makers mold and Die to high (HRC 63). (HRC high to H series L series(low-alloy) • • • Not relating directly totoolsteels,socalledmaragingsteels(thetermincludesthewords mold industryislimited. considerably expensivecomparingwithmoldsteels,and therefore theirapplicationinthedieand to HRC58.Nevertheless,despitetheirdimensionalstability andgoodpolishability, theyare still pre-hardened state(HRC30-36,Maraging250and300,forinstance)are hardened manufacturing plasticmolds.Theyhaverelatively highNiandCopercentage, canbesuppliedin martensitic die andmoldindustry. Table 1showssomefeatures ofthemosttypicaltoolsteelsthatare commoninthe - HRC56-63andmore - HRC50-55 - HRC45-49 Hardened totworanges: - HRC38-44 - HRC30-37 Pre-hardened totworanges: Soft annealedtohardness uptoHB250 Table 1 tool steels Cold-work Category tool steels Hot-work steels Plastic mold steels Shock-resistant purpose steels Special- Typical Tool SteelsforDieandMoldMaking and AISI/SAE aging H11 H13 P20 O1 D3 D2 A2 S7 L6

Designation ) becamebemore andmore usableindieandmoldmaking,particularly, in DIN W.-Nr. 1.2363 1.2080 1.2510 1.2379 1.2343 1.2344 1.2330 1.2713

Annealed to HB 220 HB 240 HB 200 HB 210 HB 180 HB 190 HB 280 HB 200 HB 230

Delivery Prehardened HRC 32-36 HRC 36-44 HRC 56-60 HRC 56-62 HRC 56-62 HRC 58-62 HRC 46-52 HRC 44-54 HRC 48-52 HRC 50-60 HRC 50-58 Hardening

Drop forgingdies,die- Hot forgingdies,punches,master Cold stampingandextrusiondies Cold stampingdiesandpunches Hot extrusiondies,plasticmolds Die-casting dies,punches, dies,masterhobs hobs, coldextrusiondies Cold blanking,, diesandparts, Application examples dies,molds cold stampingdies and punches, Plastic molds plastic molds plastic molds Die andMold 7 Die and Mold Materials 8 Die and Mold Materials (60-70% oftungsten)andgraphite. in dieandmoldmaking.Electrodes forEDM are produced from brass,, coppertungsten Electrical dischargemachining(EDM)isanotherimportantfieldofnonferrous metalsapplication material insomecases. reason theberyllium-copperalloyscanreplace traditionaltoolsteelsandstainlessasamold than toolsteels.Thealloys’hardness isHRC30-42,dependingonthehardness grade.Forthis and goodwearcorrosion resistance properties. Inmachining,theyare cut2-3timesfaster metalproducersand cavityinserts.Modern offer beryllium-copperalloysthathaveenoughstrength Beryllium-copper alloysandzincalloyare materialsforblowmolds,injectionmoldcomponents common inmoldmakingpractice. with theAluminumAssociationAlloyandTemper DesignationSystem)are more andmore compared tomoldsteels.Thefollowingaluminumalloys:2024,6061and7075(inaccordance mold manufacturingduetoitsmuchbetterthermalconductivity, machinabilityandpolishability molds becauseitiseasytomachineandlowcost.Today aluminumstartstopenetrateintoresin prototype diesandmolds,formultipliedidenticalshortlifemoldsvariousextrusion Aluminum isnotthemostpopularmaterialindieandmoldindustry, butitoftenusedfor Nonferrous Metals addition, nodularcastiron sometimesisusedfordies,punches,jigsandpadsevenmolds. sized parts,plates,spacers,bushingsandothercomponentswhere wearisnotexpected.In Cast (especiallygrey) isalsoconsidered asadieandmoldmaterialformanufacturinglarge- Cast Iron supplied inanannealedstateorpre-hardened toHRC32-35andcanbehardened toHRC44-52. 4130, 4140and4150steelsare mainmaterialsforformingparts.Thesethree steelsare usually rings, etc.Moreover, inmanycases(low-runproduction dies,somekindsofmolds)AISI/SAE Alloy andevenplaincarbonsteelsare usedforvariousgeneralpartssuchasholders,pillars,pins, Alloy SteelsandPlainCarbon simple. sections. Theyare suppliedasannealedtoHB200,andtheirheattreatment aftermachiningis for cavitiesofsmalltomediumsizeswithcomplicatedshapesandsubstantialdifferences incross- Martensitic stainlesssteels(AISI420,420F)are widelyusedforproducing plasticmolds,especially, Stainless Steels

The die and mold industry handles practically all types of engineering materials, but the most typical typical most the but materials, engineering of types all practically handles industry mold and die The for the branch are tool steels. tool are branch the for ¹ ASTM istheAmericanSocietyfor Testing andMaterials Copper andcopperalloys 6061-T Aluminum alloys 65-45-12 (DINGGG50) Nodular castiron (ASTMA536-80classes) 20 (DINGG10) Grey castiron (ASTMA48-76classes¹) 403 Martensitic stainlesssteels Maraging 300 A2 Tool steels 4130 Alloy steels 1060 1020 Carbon steels steel as100%. regular deliveryconditions. MachinabilityratingisbasedonAISI/SAE1212free cutting The followingdatacanbeusefulforestimatingmachinabilityofcommondieandmoldmaterialsin Machinability ofDieandMoldMaterials D7 5015 H13 L6 P2 P21 S7 200% 51% 1212 72% 1030 55% 420 42% D2 72% 4140 25% H11 78% 8620 46% H19 39% O1 42% P5 38% S1 45% W1 73% 61%80-55-06(DINGGG60) 33% 80%-120% 7075-T 40 (DINGG25) 100% 1215 72% 1045 45% 27% 66% 49 68% 43% 42% 42% 36% 48% 140% 48% 430 D3 4340 H12 8720 H21 O6 P20 S5 W2 39% 136% 57% 45% 28% 57% 46% 68% 36% 57% 38% 31% 45% Die andMold 9 Die and Mold Materials 10 Typical Examples of Dies and Molds Formed part………………...... Run size……………...... ………..... Difficulty formachining……...... Hardness……………………...... Material……………………...... Mold component……………...... Plastic mold Formed part………………...... Run size……………………...... Difficulty formachining……...... Hardness Material……………………...... Mold component…………...... Plastic mold Formed part………………...... Run size……………………...... Difficulty formachining……...... Hardness……………………...... Material……………………...... Die component……………...... Die-casting die Formed part………………...... Run size……………………...... Difficulty formachining……...... Hardness……………………...... Material……………………...... Die component……………...... Die-casting die Formed part………………...... Run size……………………...... Difficulty formachining……...... Hardness……………………...... Material……………………...... Die component……………...... Stamping die Formed part………………...... Run size………………...... ……..... Machining difficulty...... Hardness……………...... ………... Material…………….………...... Die component……………...... Forging die Typical ExamplesofDiesandMolds car bumper high-run production medium HRC 48 P20 cavity cellular phonehousing medium-run production low HRC 50 H13 cavity crankshaft high-run production high HRC 54 H13 cavity tap's housing medium-run production low tomedium HRC 51 H21 cavity hood high-run production medium HRC 60 D2 connecting rod high-run production medium tohigh HRC 52 S7 cavity Cutting Tools in Die and Mold Industry

In die and mold manufacturing, there are different machining operations: cutting (milling, , reaming, etc.), machining (grinding, , honing, etc.) and EDM. Even water jet cutting is used by die and mold makers. However, metal cutting remains to be the predominant method of die and mold production.

Dies and molds have different shapes and sizes, varying from small to large. In many cases machining dies and molds requires removing a large amount of material. A typical machining process contains rough and finish cutting operations. The main parameter for rough machining with a large stock allowance is metal removal rate, while for finishing, the most important factors are accuracy and surface finish.

For the development of machine tools, CNC control and CAD/CAM systems cardinally changed the die and mold industry by giving the die and mold maker new methods of multi-axis machining and introducing advanced computer techniques of machining simulation and verification. Modern cutting strategies, such as high speed machining (HSM), high feed milling (HFM) and trochoidal milling have penetrated into die and mold production. Machining hard materials, long tool life, stability, reliability and high performance intended for reducing or even full elimination EDM and manual polishing – only the tool that meets these requirements can be considered a passport to success in productive and effective die and mold making.

11

Die and Mold 12 Milling Tools inserts orwholecuttingheads,andsolid. making. Millingtoolsare availableindifferent configurations:indexable,thathas replaceable cutting by professionals). Thelatter, includingmachiningshaped3Dsurfaces,isthepivotofdieandmold operations: shouldering,,slotting,countering,chamferingandprofiling, alsoare oftenused face milling,millingslots,contoursandchamfers;profile milling(theparallel definition ofthe All typicalmillingoperationsare involvedindieandmoldmanufacturing:90˚shouldermilling, cutting toolswillbediscussedonthefollowingpagesofguide. millingtechniques,theiradvantagesandproblematicThe modern pointsandrequirements of roughing surfaceswithacomplexshape(socalledsculpturingoperations). ofcavitiesandexternal (or plunging)withatoolfeeddirection towards thetoolaxis.Itgivesopportunityforefficient Yet onemethodofrough millinggrowing inpopularitythedieandmoldindustryisplungemilling material directly. FurtherHSMdevelopmenthasresulted introchoidal milling. medium partsorincaseswithslightdifferences indepthorheightbecauseitenablescuttinghard Nevertheless, itcanbeeffective alsoforrough andsemi-finishmachining,particularlyfor smallto wayofmetalcutting,isintendedfirstallforfinishmillinghardHSM, anothermodern steels. productivity. hardened steelswithsmall depthofcutandextremely highfeedpertoothandleadstoincreased developed, HFMbecamearelevant techniqueinroughing. Itallowsmachiningsofttopre- CNC programs ortraditional thinkinginprocess planning.Overtime,andasindustrialinnovations some producers are stillsupportersofthismethodduetolimitationsavailablemachinetools, large-sized dieandmoldpartsthathaveconsiderabledifferences indepthorheight.However, further heattreatment isnecessary. Thementionedapproach usuallycharacterizesproduction of requirements andinaddition,heavy-dutyrough millingleadstosignificant residual stresses, maximum productivity whencuttingasoftmaterial.Duetodieormoldhasappropriate hardness machine toolswithlowspindlespeedsforlargemillingtools.Thiswayofmachiningprovides is basedoncuttingwithlargedepthandwidthofcut.Correspondingly, itdemandshigh-power comprises rough, semi-finishandfinishmillingoperations.Thetraditionalapproach to roughmilling share ofmaterial,shaping a workpiecetodieormoldpart.Aconventionalprocess planning Milling playsakeyrole inmachiningdiesandmolds.Indeed,millingtoolsremove themost Milling Tools for gradeDT7150,thepreferred grades,which are produced bySUMOTECmethod,have more recent ofthemintendedprimarilyformachiningthepopulardieandmoldmaterials.Except ISCAR offers arichprogram ofthecarbidegradesformillinginserts.We observebrieflythe steps intechnologydevelopmentincludecombinations ofbothcoatingmethods:CVDandPVD. process bymoderate-temperature CVD(MTCVD)withitslowerdepositiontemperatures. Further applied athightemperature (approximately 1000˚C).Current technologyenables improving CVD CVD coatingsare muchthickerandthatcontributestowearresistance. TheCVDcoatingsare (about 500˚C). leave thecuttingedgessharp.PVDcoatingsare appliedatrelatively lowtemperature PVD coatingshaveawidedistributioninmillinginserts andsolidcarbideendmillsbecausethey CVD respectively). carbide grades,mostlycoatedbymethodsofphysicalorchemicalvapordeposition(PVDand The indexableinsertsformillingthedieandmoldmaterialsare produced from different Carbide GradesforIndexableMillingInserts Grade Geometry Application which allowsforthetoolchoice: applied. Inbrief,AGGmeansthefollowingcommonlyknowncheckpoints-questions,answeron selection more specifically, theanalysisbychain:Application-Geometry-Grade(AGG)shallbe Taking thesesoobvious,butoftenleftoutpointsintoconsiderationandspeakingaboutthetool anddoesnotrequire timeforsetupprocedures. heads, whichrender apossibleheadchangewhenthetooloritsholderisclampedintomachine An additionalwayofincreasing versatilityisusingthetoolswithinterchangeable precise cutting needed fortoolchangeduringmachining. allow forusingonetooldifferent applicationsand,whenmachiningapart,shortening time operations effectively. Forexample:shouldermilling,rampingandplungemilling.Suchcombinations Another importantaspectisversatilityofthecuttingtool,itsabilitytoperformvariousmilling should beused. Hence, forbetterproductivity andasaresult forlowerCPUthemosthigh-efficiency tool obstacle foramachinetooltorunfasterandthuscutmachiningtime. considerable. Namelythetool,thissmallpartofamanufacturingprocess, sometimesisasingle the toolingcostshare inCPUisminor, thetool’s indirect influenceonCPU reduction canbe emphasized: costperunit(CPU)forapartthatismachinedbythetool.Inspiteoffact Putting thequestionoftoolselectionintobroad perspective,themainsideofissueshallbe Selection Guideline:HowtoChoosetheRightMillingTool workpiece fortheaboverequirements? Which gradeofacuttingtoolmaterialismore suitableformachiningthe indexable andsolid. for theaboverequirements? Bothtypesoftoolsshouldbechecked: Which cuttinggeometryisrecommended for machiningtheworkpiece Coolant (coolanttype:dry, wet;possibilityofcoolantthrow spindle) (sufficient/limited power, condition,spindlespeed) Operation stability(good,bad) What typeoftool,inaccordance toadaptation (amillwithshank,shellmill)? Type ofmachining(light,medium,heavy) Machining strategy Machining allowance Required accuracyandsurfacefinish Workpiece: itsmaterial,hardness before theoperation What isthetypeofmachiningoperation? Die andMold 13 Milling Tools 14 Milling Tools

for MillingDieandMoldMaterials

cutting speed. coating. Usedformillingawiderangeofdieandmoldmaterials,atlowtomedium carbonitride(TiCN) IC330 –amulti-purposetoughgradewithtitaniumnitride(TiN)/titanium results forinterruptedcutand heavydutyoperations. coatedtoughgradeformillingalloysteelandstainlesssteel.Showsgood IC830 –aPVDTiAlN machining ofcastiron andcaststeel,especiallywithsiliceousskin. Features highwearandchipping resistance. Recommendedformediumtohighcuttingspeeds for PVDcoating. DT7150 –acarbidegradewithtoughsubstratethathasdualMTCVDandTiAlN at lowtomediumcuttingspeedunderunstableconditions. resistance, enablingmachining athighspeed.Agoodchoiceformilingnodularandgrey castiron thatproduces highoxidation IC810 –aPVDgradecoatedwithaluminumtitaniumnitride(AlTiN) recommended formillinggrey castiron athighcuttingspeeds,providing excellenttoollife. Table 2 IC5100 –atoughsubstratewithMTCVDandalphaaluminumoxide(Al resistance. medium-to-high cuttingspeed.Theyare notedforexcellentnotchwearandbuilt-upedge coating, designedformillingdieandmoldmaterialssuchashard alloyandcarbonsteelsat PVD IC808 isagradewithtoughsubmicron substrateandtitaniumaluminumnitride(TiAlN) general characteristicsofthegrades. a specialpost-coatingtreatment withextraadvantages.Table 2containsthecomparativedatafor

DIN/ISO 513 ISO Class H K M P Coating The SUMO TEC grades feature a special post-coating treatment which provides substantially provides which treatment post-coating special a feature grades TEC SUMO The improved life and better reliability. The new process enhances toughness and chipping resistance, chipping and toughness enhances process new The reliability. better and life improved For more detailed information about the carbide grades and coating technology refer to ISCAR ISCAR to refer technology coating and grades carbide the about information detailed more For grades carbide TEC SUMO reduces friction and built-up edge, thus increasing tool life. The golden-colored flank facilitates facilitates flank golden-colored The life. tool increasing thus edge, built-up and friction reduces catalogs, guides and technical leaflets. technical and guides catalogs, wear detection. The post-coating treatment has the effect of making the rake face even and uniform, uniform, and even face rake the making of effect the has treatment post-coating The detection. wear minimizing inner stresses and droplets in coating, which lead to smooth chip flow and extended extended and flow chip smooth to lead which coating, in droplets and stresses inner minimizing tool life. Yet at the same time the untreated flank continues to be rough enough for good contact contact good for enough rough be to continues flank untreated the time same the at Yet life. tool with base surfaces of tool pockets. tool of surfaces base with - Firstchoice Ferritic andmartensitics.s.(ISCARmaterialgroups 12;13) Selected CarbideGradesforIndexableInsertsIntended IC808 H20-H30 K20-K40 M20-M30 P15-P30 PVD IC5100 K05-K20 P10-P25 MT CVD Harder IC810 K05-K25 P15-P30 PVD Carbide Grades DT7150 K05-K25 Combination IC830 K15-K40 M20-M40 P20-P50 PVD 2 O 3 ) coatingthatis Tougher IC330 M30-M40 P25-P50 PVD 1

• • • •

ability ofthetools. tool diameteranditsmaximaldepthofcut;Table 4isintendedforestimatingtherampdown summarized inTables 3and4.Table 3showsthenumberofteethtoolsasafunction The mainfunctionalfeatures ofthemostpopularISCARendmillswithindexableinsertsare endmills are usedinallkindsofoperations:roughing, semi-finishingandfinishing. The extendedfluteendmillcuttersare for roughing, whiletheotherkindsof Extended fluteendmillcuttersofdiameterrange12-100mm of 6-25mmdiameters Replaceable millingheadswithMULTI-MASTER adaptation(orsimplyMULTI-MASTER heads) Solid carbideendmillswithdiametersto25mm Endmills withindexableinsertsofdiameterrange8-50mm milling slotsandgrooves, are beingdevelopedinthefollowingdirections: ISCAR endmillsthatare intendedmostlyfor90˚() shouldermillingbutusedalsofor Endmills withIndexableInserts 90˚ ShoulderMilling cavities by a different technique. different a by cavities Chip evacuation and chip re-cutting are factors that affect a milling tool machined tool milling a affect that factors are re-cutting chip and evacuation Chip The depth of a machined hole depends on the maximal allowed depth of cut of the tool. tool. the of cut of depth allowed maximal the on depends hole machined a of depth The the planetary movement is made. is movement planetary the The particular case of helical interpolation is two milling by circular interpolation when only only when interpolation circular by milling axes two is interpolation helical of case particular The The helical tool path maintains smooth entry in the material and uniform loading of the tool. tool. the of loading uniform and material the in entry smooth maintains path tool helical The The helix angle is dependent of the maximal rampdown angle of the tool performed interpolation. interpolation. performed tool the of angle rampdown maximal the of dependent is angle helix The cutting helical movement. movement. helical cutting a machine tool, moves planetary about an internal hole diameter and creates the summarized summarized the creates and diameter hole internal an about planetary moves tool, machine a with a large diameter. A cutter, which travels simultaneously along three coordinate axes of of axes coordinate three along simultaneously travels which cutter, A diameter. large a with about revolutionary changes in the cutting tools industry. industry. tools cutting the in changes revolutionary about Three axes milling by helical interpolation is a widely used method for machining holes especially holes machining for method used widely a is interpolation helical by milling axes Three pressing technology only was a serious problem at that time, and its solution by ISCAR brought brought ISCAR by solution its and time, that at problem serious a was only technology pressing diminished. additionally be should angle rampdown the length) overall tool the of by grinding. Nonetheless, producing a replaceable carbide insert with a helical edge by means of of means by edge helical a with insert carbide replaceable a producing Nonetheless, grinding. by diameter of a tool. For tools with high overhang from a toolholder (long and extra long series series long extra and (long toolholder a from overhang high with tools For tool. a of diameter which were known long before, already had helical edges; however, the edge was made was edge the however, edges; helical had already before, long known were which is a valued feature for tool selection. The angle depends on cutting geometry and the nominal nominal the and geometry cutting on depends angle The selection. tool for feature valued a is smooth cutting and considerably improved insert life. Ground HSS and solid carbide tools, tools, carbide solid and HSS Ground life. insert improved considerably and cutting smooth down – ramp down milling. Maximal rampdown angle characterizing tool possibilities in ramping ramping in possibilities tool characterizing angle rampdown Maximal milling. down ramp – down But in the 1990’s it was a real innovative solution. A helical edge ensured constant cutting geometry, cutting constant ensured edge helical A solution. innovative real a was it 1990’s the in But If the tool moves axially upward, it is ramp up milling (ramping up); and if it moves axially axially moves it if and up); (ramping milling up ramp is it upward, axially moves tool the If manufacturers use this approach for producing their milling inserts. inserts. milling their producing for approach this use manufacturers capability to ramp milling when the tool is simultaneously fed in radial and axial directions. directions. axial and radial in fed simultaneously is tool the when milling ramp to capability edge as a part of a helix that is built on a cutting cylinder seems apparent, and many tool many and apparent, seems cylinder cutting a on built is that helix a of part a as edge subsequent milling is an important attribute of a milling tool. Another significant factor is a tool tool a is factor significant Another tool. milling a of attribute important an is milling subsequent inserts APKT 1003 PDR-HM. It was the first insert with a helical cutting edge. Now an insert cutting insert an Now edge. cutting helical a with insert first the was It PDR-HM. 1003 APKT inserts Machining cavities is a typical feature of die and mold making. Hence, the ability to with with drill to ability the Hence, making. mold and die of feature typical a is cavities Machining edge cutting helical with Insert In the 1990’s ISCAR introduced new milling cutters which carried indexable sintered carbide sintered indexable carried which cutters milling new introduced ISCAR 1990’s the In HELIMILL – a line of new milling tools was born. was tools milling new of line a – Die andMold 15 Milling Tools 16 Milling Tools Table 3 Table 3 Inserts 50 40 32 30 28 25 22 21 20 18 17 16 14 12 10 8 25 22 21 20 18 17 16 14 12 10 8 32 30 28 40 50 Inserts Tool D Tool D ap ap Quick Selectorfor90˚IndexableEndmills(cont.) Quick Selectorfor90˚IndexableEndmills T290 LNMT05 4; 5 3 2; 3 2 1 5 H490 E90AX-12 T290 ELN-05 12 2 3 4 5 H490 AN..X12 HP ANKT 8; 10 6; 8 5; 7 4; 5 3; 4 2 1 7.7 HP E90AN T490 ELN-13 12.5 3 3; 4 4; 5 T490 LN..T13 T490 LN..T08 4; 6 3; 5 3; 4 2; 3 2 8 T490 E90LN-08 T490 ELN-08 Number ofTeeth (Effective) Number ofTeeth (Effective) HM90 E90AD 1 14.3 2 2; 3 2; 3;4 5 AD..15 HM90 AD..15 H490 ANKX09 5 4 3 2 8 H490 E90AX-09 T490 ELN-16 16 2 3 4 T490 LN..T16 AP…10 HM90 AP…10 3; 5;6 7 3; 4;5 2; 3;4 4 4 2; 3 3 3 2 2 2 1 1 1 10 HM90 E90A H490 E90AX-17 16 2 3 4 H490 AN..X17 T290 LNMT10 6 4; 5 3; 4 2; 3 10 T290 ELN-10 ** * Lowervaluesfortoolswithlongoveralllength Valid onlywhenH490ANKX1706R15T-FF isused. Table 4 Table 4

Inserts 50 40 32 30 28 25 22 21 20 18 17 16 14 12 10 8 8 10 12 14 16 17 18 20 21 22 25 28 30 Inserts 50 40 32 Tool D Tool D ap ap Rampdown Anglefor90˚IndexableEndmills(cont.) Rampdown Anglefor90˚IndexableEndmills H490 E90AX-12 5 T290 ELN-05 T290 LNMT05 1 1.5 2 2.3 2.5 12

Ramp

down

prohibited

H490 AN..X12 7.7 HP E90AN HP ANKT 1 1.4 2 2.4 3.2 2.7 2.5 T490 ELN-13 12.5

Ramp

down

prohibited

T490 LN..T13 8 T490 E90LN-08 T490 ELN-08 T490 LN..T08 prohibited down Ramp Rampdownangle,˚ HM90 E90AD 14.3

3

11.5

5 4 5. 3 AD..15 HM90 AD..15 Rampdown angle,˚ 8 H490 E90AX-09 H490 ANKX09 prohibited down Ramp T490 ELN-16 16

Ramp

down

prohibited

T490 LN..T16 10 HM90 E90A AP…10 HM90 AP…10 2.7 2.7 3 2 2 5 7.5 7.5/2.8* 7.5 7.5 15/4.5* 15 7 32 5 H490 E90AX-17 16

3.8** 4.4** 6.5** H490 AN..X17 10 T290 ELN-10 T290 LNMT10 1.2 1.6 2.2 4 Die andMold 17 Milling Tools 18 Milling Tools applications. and positiverakeangles;theMILL2000–strong construction,mostsuitedforheavymilling This familycombinesthemostadvantageousfeatures ofboththeHELIMILL–helicalcuttingedge stepover andcanperformmillingslotsfaces. produced withcoolantholes,canmachine90˚shouldersnomismatch,plungelarge the familystandsouthighdurability, lowcuttingforces andlongtoollife.Thetools,whichare strong construction,uniquechipdeflectorwithpositiverakeanglesandgoodgradecombinations, provides averyrigidclamping,andhaswiperthatleavesanexcellentsurfacefinish.Duetoits Insert constructionisverythickandstrong. Itisclampedintoadovetailinclinedpocket, which of theinsertwithcuttingedgelengths8,12and16mm. The H490AN..Xlaydown(radial)inserthas4right-handcuttingedges.There are 3standard sizes HELIDO H490,afamilyoftoolsfor90˚milling,isanevolutiontheoriginalISCARHELIMILLline. the T490LN..0804PN-Rwithfourcuttingedges. It isinteresting tonotethatnoneofISCARcompetitors canoffer suchasmalltangentialinsertas the mostadvancedinsertproduction technologyandexcellentgradecombination. The familyfeatures highdurabilityandoutstanding toollife,duetothetangentiallyorientedpocket, at highrates,withnomismatchandtheyare capableofplungingaswell. provided coolant supply. withholesforinternal Thetoolsare intendedformillingsquare shoulders FLEXFIT systems;andthetoolsare availablewithcoarseorfinepitch.Mostofthetoolsare configuration: endandfacemills, replaceable millingheadsforISCARMULTI-MASTER and edges. Thesmallesttooldiameteris16mm,with2teeth.lineoffers thetoolsindifferent hand helicalcuttingedges.TheT490insertsare availablein8,12.5 and16mmlongcutting HELITANG T490isafamilyofmillingtoolsthatusestangentiallyclampedinsertswithfourright- Indexable Tools for90˚Milling General CharacteristicsoftheLatestISCARLines

3P ISCAR Premium Productivity Products Productivity Premium ISCAR 3P mismatch No Since 2007 this symbol started coming into view on packages of various ISCAR products and on on and products ISCAR various of packages on view into coming started symbol this 2007 Since than more be can height shoulder the tools, milling indexable by shoulders square machining In pages of leaflets. The symbol stands for new tools, inserts and toolholders, which are are which toolholders, and inserts tools, new for stands symbol The leaflets. of pages in clamped insert an of edge cutting of length the by determined is that (D.O.C.) cut of depth tool a manufactured in accordance with the advanced designed principles and the latest technology, technology, latest the and principles designed advanced the with accordance in manufactured true Ensuring passes. continuous more or two needs machining shoulder the case this In tool. the and allow to the customer substantial productivity increase. productivity substantial customer the to allow and – passes the between burrs or marks steps, border, detectible a without profile shoulder 90˚ In addition to the progressive cutting geometry, the features of the 3P cutting inserts are the new new the are inserts cutting 3P the of features key the geometry, cutting progressive the to addition In milling for intended tools milling indexable precise modern of feature essential an is – mismatch no SUMO TEC carbide grades with their special post-coating treatment. post-coating special their with grades carbide TEC SUMO shoulders. square Use of such tools substantially improves productivity by eliminating additional finish cuts and ensures and cuts finish additional eliminating by productivity improves substantially tools such of Use the high-accuracy profile with good surface finish. Perpendicularity of the shoulder wall to its base of base its to wall shoulder the of Perpendicularity finish. surface good with profile high-accuracy the no more than 0.02 mm is today a normal requirement to the “no mismatch” milling tools. milling mismatch” “no the to requirement normal a today is mm 0.02 than more no

even 8mmdiameter. The T290uniqueconvexshapedinsertenabledthedevelopmentofsmalldiametercuttingtools the cuttingedge. axial rakeanglesleadtoamajorreduction incuttingforces, improve toolstabilityandprolong lifeof mismatch; andare suitableforplungingandrampdownapplications.Theirincreased radialand The toolsrunsathigherfeedspeeds(tablefeeds),producing excellentsurfacefinishandno the tangentialorientationofinsertsinpocketsandhighertoothdensity. similar sizes,thetoolsoflinefeature highlong-termstrength andremarkable toollife,dueto risk offracture toaminimum.Whencompared tothecurrent HELIMILLandHELIPLUStoolsof providing amuchstronger toolconstruction,whichsustainsahigherimpactloadandreduces the their tangentialorientationinthepocket,insertsallowtooldesignwithlargercore diameter, edges. Theinsertsare thenextevolutionofmostpopularHELIMILLinserts.Asaresult of inserts withtwocuttingedges.TheT290are availablein5and10mmlongcutting SUMOMILL T290isafamilyofmillingtoolswithcoolantholesthatusestangentiallyclamped

Tangential or radial? or Tangential The question: what is more effective – tangential or radial clamping, often can lead the lead can often clamping, radial or tangential – effective more is what question: The user to hesitate when selecting the right cutting tool when there are both milling cutters with with cutters milling both are there when tool cutting right the selecting when hesitate to user laydown (radial) inserts and with inserts clamped tangentially. As in many practical cases, cases, practical many in As tangentially. clamped inserts with and inserts (radial) laydown the question has no strictly unambiguous answer. The academic studies of the question are are question the of studies academic The answer. unambiguous strictly no has question the beyond the scope of the guide. Therefore, a brief review of advantages and disadvantages of each of disadvantages and advantages of review brief a Therefore, guide. the of scope the beyond clamping principle can be useful for the right choice. In general, the tangential configuration allows configuration tangential the general, In choice. right the for useful be can principle clamping increasing feed per tooth because the tangential component of a cutting force acts against an an against acts force cutting a of component tangential the because tooth per feed increasing insert with more rational orientation of its cross-section. cross-section. its of orientation rational more with insert The well-designed tangential insert contributes to optimal loading of a clamping while while screw clamping a of loading optimal to contributes insert tangential well-designed The the resultant cutting force is transmitted directly to the cutter body. The tangential clamping clamping tangential The body. cutter the to directly transmitted is force cutting resultant the enables cutter design with larger core diameter than tools with radial inserts. It is much easier easier much is It inserts. radial with tools than diameter core larger with design cutter enables to provide an indexable double-sided insert with helical cutting edges if a tangential configuration tangential a if edges cutting helical with insert double-sided indexable an provide to is applied. And finally, the tangential clamping configuration also offers a higher insert density. density. insert higher a offers also configuration clamping tangential the finally, And applied. is Typically, the milling cutters with tangentially clamped inserts run at high feed rates especially rates feed high at run inserts clamped tangentially with cutters milling the Typically, when machining cast iron. cast machining when However, relative to milling tools with the laydown (radial) inserts, the cutters with the tangential tangential the with cutters the inserts, (radial) laydown the with tools milling to relative However, clamping normally have lesser ramping abilities, and their resources for shaping rake face and high and face rake shaping for resources their and abilities, ramping lesser have normally clamping positive axial rake, which can significantly reduce cutting forces, are limited. Greater chip gullets in in gullets chip Greater limited. are forces, cutting reduce significantly can which rake, axial positive case of the radial inserts go a long way towards better chip evacuation when milling materials such materials milling when evacuation chip better towards way long a go inserts radial the of case as steel with high metal removal rate, particularly in machining deep cavities. deep machining in particularly rate, removal metal high with steel as The latest ISCAR design provides the customers with the milling tools with tangential and radial radial and tangential with tools milling the with customers the provides design ISCAR latest The inserts for which in many cases the disadvantages related to tangential and radial clamping radial and tangential to related disadvantages the cases many in which for inserts correspondingly were overcome. For example, the H490 line with double-sided radial H490 AN…X H490 radial double-sided with line H490 the example, For overcome. were correspondingly inserts, real workhorses, are intended for heavy milling operations with high feed per tooth; tooth; per feed high with operations milling heavy for intended are workhorses, real inserts, and T290 line that is based on tangential T290 LN…T inserts is notable by excellent rampdown excellent by notable is inserts LN…T T290 tangential on based is that line T290 and performance. In either event the question of using the cutters with tangentially or radially clamping radially or tangentially with cutters the using of question the event either In performance. inserts should be solved specifically. The ISCAR application specialists will be glad to advise to glad be will specialists application ISCAR The specifically. solved be should inserts you the best choice. best the you Die andMold 19 Milling Tools 20 Milling Tools

guides, tooladvicesoftware andspecificguidelines useitinfull. cutting data.Itisacorrect approach; andthecuttingdatarecommendations infullapplication recommended cuttingspeedandfeedforeverymillinglinethusprovide theuserwith operation estimation:light,mediumandheavy. Thenwecanprepare thetableswith We cantakeintoaccounttheapplicationfactorandmachinetoolconditionsbyintroducing starting cuttingdata? different attributes.Howtogofrom thegeneralitiestoparticularsandspecify is familiarwiththem.Theyare agoodillustration ofcomplexdependenceorthecuttingdataon The mentionedargumentsare verygeneral;andnodoubteveryonewhoisinvolvedinmetalcutting an additionalbarrierforincreased cuttingdata. Lastly, themachinetoolandtoolholding.Poorconditionsnotrigidtoolholderscreate a thinwallandothersleadtodecreasing thespeed,feedorevenboth. such aslargeoverhang(inmillingdeepcavities,forexample),improper clamping, workpiecewith small tomediumfeedsforhighmachiningaccuracyandgoodsurfacefinish.Different limitations time, finishmillingoperationsperformingwithsmallallowancesdemandsmaximalspeedsand volume ofmaterialisremoved, thefeedishigh andthecuttingspeedismoderate.Atsame Further, theapplication.Whatisaimoftooluse?Inrough milling,whenarelatively large securing theinsertensure machiningunderhighcuttingdata. Another factor-themillingtoolbody. Adurabledesignofthebodyandareliable methodof considerably increased cuttingforce. the cuttingedge,conversely, bindsthefeedbelowbecausetoosmallacausesinthiscase, against aseriousload,setstheupperlimittofeed.TheT-land, anegativelandprotecting Insert geometryisalsoimportant.Asharpcuttingedge,whichbrittleandcannotstandup taken intoconsideration. section, andloadactingonaninsertdiffer too.Itisevident;themachinabilityfactorshouldbe pre-hardened andhardened). Therefore, aspecificforce neededfor removal ofaunitchip different byitsmachinability(forexample,millingatoolsteelindifferent conditions:annealed, Machinability ofengineeringmaterialsisdifferent, andeventhesamematerialcanbesubstantially lesser speed,butallowsgreater feedpertooth. higher cuttingspeed.Thetoughergradewithitsbetterimpactstrength isintendedforthe Before everythingelse,acarbide grade.Theharder gradehashigherwearresistance andenables different factors. Cutting speedVcandfeedpertoothfz,thefirstkeyparametersinmilling,dependon General Principles How toStart:CuttingData – “feed speed” (“feed per minute”, “fpm”, or “table feed”). “table or “fpm”, minute”, per (“feed speed” “feed – revolution” means “feed per revolution” (“fpr” or “feed”) and “advance per minute” or “feed rate” rate” “feed or minute” per “advance and “feed”) or (“fpr” revolution” per “feed means revolution” In the U.S.A., instead of the term “feed per tooth” (“fpt”), “chip load” is often used; “advance per per “advance used; often is load” “chip (“fpt”), tooth” per “feed term the of instead U.S.A., the In • • Where:

and thefeedsclosedtoupperborder –tofzmax. closed tothelowerborder ofthefield relate tofzmin,theaveragevalues–moderate, Do nottakeliterally“minimum”,“maximum”and“moderate”feeds:thefeeds The feedintervalfrom fzmintomaxrelate toafieldoftheestimatedstartingfeedsasabove. The toothloadincombinationwiththefeedperdefinestypeofmachining(Table 7). Type ofMachining estimate, Table 6maybeenough. The diagramshowninFig.1allowsdefiningthetoothload,butforaquick rough affect thetoollife. While remaining inthematerialtoolong,toothexperiencesmore intensiveheatloadsthat of thetoothinworkpiecematerialfrom thetoothenteringtoexit. The toothloadingreflects afractionofthecutting edgeinvolvedincuttingandacyclingpath ofcutbtothenominaldiameteramillingtoolD Width Cutting depthhtoalengthofcuttingedge In shouldermilling,toothloadingisafunctionoftheratios: Tooth Loading more rigorous, weintroduce thefollowingtwo-stepprocedure. In order todefinewhatis known aslightduty, moderatedutyandheavymachining material andtypeofmachining.Thebasiccuttingspeedrelates toa20minutetool-lifeperiod. Table 9determinesthebasiccuttingspeeddependingoncarbidegrade,workpiece a) BasiccuttingspeedVo Starting Speed the feedshouldbereduced by20-30%. and unstabletechnologicalsystem(poorclamping,cuttingthinwallworkpiecessoon), finish operationsandgreater feedsusuallycharacterize rough milling.Incaseofhightooloverhang Table 5containsdataforestimatingstartingfeedpertooth.Smallervaluesmore suitablefor Starting Feed Kt –toollifefactor Ks –stabilityfactor Vo –basiccuttingspeed Vc –startingcuttingspeed Vc =Vo xKsKt p (1) Die andMold 21 Milling Tools 22 Milling Tools *

For millinghardened steel,seetheappropriate chapterforfurtherdiscussion. For thefacemillswithinsertsHPANKX…07andT490LN..T…08tablevaluesshouldbereduced by20%. For T290millingtoolsthetablevaluesshouldbereduced by30%. -Firstchoiceforgrades ISCAR materialgroup inaccordance withVDI3323standard Table 5 DIN/ISO 513 Fig. 1. Fig. ISO Class M H K P a 4 3 2 1 1 4 1 h EstimatedStartingFeedfz Tooth load areas load Tooth p Grey castiron Nodular cast Plain carbon Martensitic Alloy steel Hardened tool steel steel steel Type Light and iron s.s. Workpiece material 4 1 Group* 12, 13 17-18 15-16 Moderate 38.2 38.1 Mat. 8, 9 6, 7 1-4 39 11 10 5 <2500 >2000 <2000 >1700 <1000 <1700 >1480 <1000 <1200 >1000 <1450 >1100 <1000 <1000 N/ <850 <850 >850 <850 σ 2 1 mm T 2 56-63 50-55 45-49 Hard- ness, <300 <250 <300 >325 <250 <350 >300 <300 <300 >250 <250 HRC HRC HRC Heavy HB 4 3 Harder 0.05-0.08 0.06-0.09 0.07-0.12 0.08-0.12 0.08-0.15 0.08-0.18 0.1-0.25 0.1-0.25 0.1-0.25 0.1-0.2 IC808 0.08-0.12 0.08-0.15 1 0.2-0.35 0.2-0.35 0.1-0.18 0.1-0.25 0.1-0.25 IC5100 0.1-0.2 Starting feedfz,mm/tooth,forgrades D b 0.08-0.15 0.08-0.18 0.1-0.25 0.1-0.25 0.1-0.25 0.2-0.4 0.2-0.4 0.1-0.2 IC810 DT7150 0.2-0.4 0.2-0.4 D b 0.08-0.15 0.07-0.1 0.08-0.2 0.1-0.25 0.1-0.25 0.1-0.35 0.2-0.3 0.2-0.3 0.1-0.3 0.1-0.3 IC830 h a 4 3 1 h 4 1 2 1 p 0.08-0.25 0.08-0.2 0.1-0.25 0.1-0.4 0.1-0.4 0.1-0.3 0.1-0.4 Light a IC330 Tougher p 4 1 Moderate 2 1 Heavy 4 3 1 D b • • The factorthatrelies ontherelationship cuttingspeed-toollifeisshowninTable 8 Ks =0.7 for unstableoperations(highoverhang,poorclamping,millingthinwalls,etc.) for normalstabilityKs=1, The factorisdefinedbythebelowestimateofmillingoperationstability: c) Tool LifeFactorKt b) StabilityFactorKs will be108m/min. For 60minutetoollife,lifefactorKt=0.8(Table 8);andthestartingcuttingspeedinthiscase Therefore, asperTable 9startingcuttingspeedfor20min.toollifeVc=135 m/min. duty" definition.Ksisacceptedas1(paragraphb). From Table 6thetooth load ismoderate;andfrom Table 7thetypeofmachiningtakes"medium- Hence, h/ap=4/8=0.5andb/D=16/25≈0.6. The lengthofthecuttingedgeforinsertaboveis8 mm(from thecatalogorTable 3). the upperborder). In accordance withTable 5startingfeedfz=0.2mm/tooth(thevaluethatiscloseto The machinedmaterialrelates totheninthmaterial group (No.9). (machine tool+) isestimatedassufficient. width. Theworkpieceisproperly clamped;and thestiffness ofthewholetechnologicalsystem The application–rough tosemi-finishmilling ofasquare shoulderwith4mmdepthand16 cutter H490E90AXD25-4-C25-09.ThecarriesinsertsANKX090408PNTRIC830. The workpiecefrom AISIP20steelwithhardness HRC32ismachinedbyISCARindexableendmill Example Table 8 Table 7 Table 6 Tool life,min. Heavy toothloading Moderate toothloading Light toothloading Tooth loading b/D Kt 1/4 1/2 3/4 1 Tool lifefactorKt Type ofMachining Tooth Load fz min 10 Medium-duty (M) Light-duty (L) Light-duty (L) 1/4 1.15 light moderate moderate moderate 20 1/2 1 moderate moderate heavy heavy Type ofMachiningforFeedperTooth fz Heavy-duty (H) Medium-duty (M) Light-duty (L) fz moderate h/ap 40 3/4 0.85 moderate moderate heavy heavy Heavy-duty (H) Heavy-duty (H) Medium-duty (M) fz max 60 1 0.8 moderate heavy heavy heavy Die andMold 23 Milling Tools 24 Milling Tools

Table 9 Basic Speed Vo for Selected Grades in Relation to Type of Machining* Workpiece Material Basic speed Vo, m/min, for grades and type of machining ISO Class IC808 IC5100 IC810 DT7150 IC830 IC330 DIN/ISO 513 Material Hardness Type 2 group** σT , N/mm HB L M H L M H L M H L M H L M H L M H

1 <850 <250 300 240 220 260 230 200 200 170 150 185 160 135 Plain carbon 2-4 <850 <250 280 220 200 240 200 180 180 150 135 170 140 125 steel 5 >850 <1000 >250 <300 240 200 180 215 190 170 150 135 120 135 120 115

P 6, 7 <1000 <300 230 200 170 200 180 160 170 140 125 150 135 120

Alloy steel 8, 9 >1000 <1200 >300 <350 215 185 165 180 150 125 150 135 120 140 125 115 and tool steel 10 <850 <250 210 190 170 165 135 110 140 125 115 130 120 110

11 >1100 <1450 >325 165 135 115 150 125 105 135 120 115 125 110 100

M Martensitic s.s. 12, 13 <850 <250 200 170 140 170 140 125 150 130 120

Grey cast iron 15-16 <1000 <300 260 220 200 300 250 220 300 250 220 300 250 220 260 220 190 K Nodular cast iron 17-18 <1000 <300 240 200 180 250 220 200 250 220 200 250 220 200 200 185 160

38.1 >1480 <1700 HRC 45-49 120 100 80 100 80 70

H Hardened steel*** 38.2 >1700 <2000 HRC 50-55 75 55

39 >2000 <2500 HRC 56-63 65 45

* 2 For 20 min. tool life. **2 ISCAR material group in accordance with VDI 3323 standard ***2 Milling hardened steel see under the appropriate chapter for further discussion. - First choice for grades

Uncoated fine-graingradeIC08isaimedmainlyatmilling nonferrous materials. cutting speeds. and stainlesssteelworkpieces,specificallyunderunfavorable conditions,atlowtomedium PVDcoatedgradethatissuitableformachiningsteel IC300 isatoughsubmicron TiCN The gradeshouldnotbeusedforheavy-dutymachining. recommended formillinghardened steel,especiallyifitshardness isHRC56-63andevenmore. TiAlN coatingcanbe IC903 withanultra-finegrainsubstrate12%cobaltcontentandPVD hardened steelwithhardness toHRC55. speeds inmillingcarbon,alloy, toolandstainlesssteel.Also,thegradeissuitable formilling coating,whichhaswide-spectrumrough tofinishapplicationsatmediumhighcutting TiAlN The majorityofthesolidmillsisproduced from IC900–atoughsubmicron substratewithPVD There are severalcarbidegradesforISCARsolidendmills. features ofcuttinggeometry. tool lifeofthemills.Thereason liesincarbide grades,grindingtechnologyandofcourse,unique a formalresemblance, occasionallysimplyamazing,there isagreat difference inperformanceand carbide endmillsofthesamesizesthatoftenseemlikecopieseachother. However, inspiteof Endless cuttingtoolmanufacturers from smallshopstoworld-knowncompaniesproduce solid feed islimitedbythenominaldiameterandnumberofflutesasolidcarbideendmill. defined byachipgullet(aformoffluteanditsdepth).Hence,duetothementionedfactors factors are notonlytoothstrength andtoolrigidity, butalsotheabilityofchiphandlingthatis material. However, whenspeakingaboutfeedlimitations,itshouldbeemphasizedthatthemain Commonly, atoolchoiceandcuttingdatadependonapplication requirements andworkpiece of accuracyandsurfacequality. slots andplunging;themulti-flutemillsare usuallyusedinfinishapplicationswithhigh requirements have largestchipgulletcharacteristics,are intendedmostlyforrough shouldermachining,milling shoulder milling.Ingeneral,recommended practicesaysthatiftheendmillswithtwoflutes,which ISCAR catalogsandleafletscontaindetailedguidelinesforusingthesolidcarbideendmillsin of milling:rough, semi-finish andfinishoperations. geometry, helixangle,numberofflutesandlengthseries(short toextralong)andperformallkinds such astoolandalloysteels,martensiticstainlesssteel,castiron, etc.Thetoolsdiffer incutting varied informare intendedformachiningalltypesofmaterialsusedinthedieandmoldindustry machining square shoulders.Thesetoolswithnominaldiametersfrom 0.4mmto25and ISCAR offers thedieandmoldmakersarichlineofsolidcarbideendmillswith90˚leadanglefor Solid CarbideEndmills

Dry machining (or using air as a coolant) is preferable for solid carbide endmills. In machining steels machining In endmills. carbide solid for preferable is coolant) a as air using (or machining Dry and hard steels (ISO classes P and H correspondingly) by mills of IC900 and IC903 carbide grades, grades, carbide IC903 and IC900 of mills by correspondingly) H and P classes (ISO steels hard and Dry or wet or Dry a wet coolant is not recommended. If, however, an application requires wet cooling cooling wet requires application an however, If, recommended. not is coolant wet a (machining austenitic , for instance), grade IC300 should be a first choice. first a be should IC300 grade instance), for steel, stainless austenitic (machining

Die andMold 25 Milling Tools 26 Milling Tools

FINISHRED. performance. Theusergetsa“Three inOne”ratherthanjusta“Two inOne”versionofthe Combining thelinestogetherdeliversapowerfulhybridsolidcarbidemillwithextraordinary The FINISHREDVARIABLE PITCHcombinesalltheremarkable features ofthetwolinesabove. works involvedindieandmoldmaking.Themillsare ablemachinefullslotswith2xDdepth. solution forlowpowermachinetoolswithISO40orBT40adaptations,whichare popularinsmall arrangement oftheteeththesetoolsfeature excellentdampeningability. Theyprovide aneffective The CHATTERFREE endmillshave4or5flutesandunequaltoothspacing.Duetotheuneven easily, whichisagoodsolutionformachiningcavitiesofdies and molds. heavy-duty applications;andthechipmixture from longandsplitshortchipsisevacuatedmore power consumption,andincreasing productivity. Theuniquetooldesignreduces vibrationsat (“One”) canreplace therough andfinishendmills(“Two”), dramatically reducing cycletimeand machining parameters,resulting insemi-finishorevenfinishsurfacequality. Suchasingletool (continuous teeth)andtherefore sometimesare called“Two inOne”.Theyenablerunningatrough teeth, combinetwogeometries:rough (serratedteethwithchipsplittingeffect) andfinish The FINISHREDendmillsfeature 4fluteswitha45˚helix,twoserratedteethandcontinuous the followingthree lineshaveexceptionalgeometry. therichanddiversifiedfamilyofISCARsolidcarbidesquare endmills(with90˚leadangle), Within Table 10

H K M P ISO class 2 2 The progress in technology of tools led to impressive achievements in regrinding regrinding in achievements impressive to led tools machine grinding of technology in progress The (resharpening) solid carbide endmills, allowing accurate restoration of cutting geometries of worn-out of geometries cutting of restoration accurate allowing endmills, carbide solid (resharpening) Regrinding solid carbide endmills carbide solid Regrinding tools. Reground mills still have shorter tool life due uncoated areas or problematic recoating. problematic or areas uncoated due life tool shorter have still mills Reground tools. However, the main reason of the efficiency losses is a reduction of a tool diameter as a result of result a as diameter tool a of reduction a is losses efficiency the of reason main the However, regrinding the tool relief surfaces. Regrinding the relief surfaces causes decreasing rake angles rake decreasing causes surfaces relief the Regrinding surfaces. relief tool the regrinding and flute depth. Therefore, the tool cuts harder; its chip handling properties become worse. worse. become properties handling chip its harder; cuts tool the Therefore, depth. flute and On average, every 1% decrease of the tool diameter results in a decline of the tool performance tool the of decline a in results diameter tool the of decrease 1% every average, On by 2%-3%, and from the definite reduction value the tool performance drops dramatically. drops performance tool the value reduction definite the from and 2%-3%, by In order to avoid negative sides of regrinding it is very important to follow ISCAR’s instructions ISCAR’s follow to important very is it regrinding of sides negative avoid to order In regarding this operation. this regarding - Firstchoice - Optional Above HRC55 Up toHRC55 Grade SelectorforSolidCarbideMills IC900 IC903 IC300 :

* * *

FINISHRED Variable PitchMills Table 13 Table 12 Table 11 slot millinginsteel;andtheyshouldbedoubledforworkpiecesfrom castiron. The maximaldepthshouldnotexceedthevaluesshowninTables 11to13.Thevaluesrelate to VARIABLE PITCHcansubstantiallyimprove thementioneddifficulty. feed pertoothinorder toensure proper chipevacuation.UsingFINISHREDand chip handlingproperties. Inmanycasesmillingdeepslotsdemandsconsiderablereduction of In fullslotmilling,themaximaldepthdependsnotonlyonstrength andstiffness ofamillbuton Maximal DepthforMillingFullSlot Cutting Data for D≥16mmfzshouldbereduced by20% with fzreduced by30% with fzreduced by50% Ap max D, mm Ap max D, mm Ap max D, mm Maximal DepthofSlotApmax,mm,forCHATTERFREE and Maximal DepthofSlotApmax,mm,forFINISHREDMills Maximal DepthofSlotApmax,mm,forS.C.MillsStandard Line 0.9 D 0.4 D 0.3 D to 4 to 4 to 4 0.6 D 0.4 D 4-5 4-5 4-5 D 0.7 D/1.2D* 0.4 D/D* 1.2 D 6-8 6-8 6-8 0.9 D/1.5D* 0.5 D/D* 10-25 10-25 10-25 2 D* Die andMold 27 Milling Tools 28 Milling Tools ** * *

HRC 45-49 ISCAR materialgroup inaccordance withVDI3323standard Ap maxasitspecifiedin Tables 11-13

Table 15 should bereduced by20-30%. In caseofunfavorableconditions(poorclamping,millingthinwalls,highoverhang),thetablevalues are discussedonthenextpagesseparately. The tablesrelate torough andsemi-finishmilling.The recommendations regarding finishoperations FINISHRED, CHATTERFREE andFINISHREDVariable Pitchendmills. The followingtablesspecifyestimatedvaluesforfeedpertoothandcuttingspeedsreferring to Starting FeedsandSpeeds Table 14 in accordance withTable 14. In rough tofinishshoulder milling,depthofcutapandwidthaecanbeestimated Milling Square Shoulder:DimensionalLimitations

DIN/ISO 513 ≥ 0.75D 0.5 D

FINISHRED: StartingFeedfz,mm/tooth,forMillDiametersD Shoulder Milling:Size Mat. Group* 12, 13 38.1** 17-18 15-16 38.2 8, 9 6, 7 1-4 11 10 39 5 0.008 0.008 0.008 0.008 0.009 0.008 0.009 0.008 0.008

1

0.012 0.017 0.019 0.020 0.022 0.020 0.022 0.015 0.020

2

0.022 0.025 0.028 0.028 0.032 0.028 0.032 0.028 0.030

3

Ap max* 1.25 D 2 D 2 D D ≤16mm 0.032 0.036 0.038 0.038 0.043 0.038 0.043 0.038 0.040 0.022

4 D,mm 0.045 0.048 0.050 0.055 0.060 0.055 0.060 0.048 0.055 0.028

5 0.055 0.058 0.060 0.065 0.070 0.065 0.070 0.058 0.065 0.032

6 ap max 0.065 0.070 0.072 0.077 0.083 0.077 0.083 0.070 0.080 0.038

8 0.065 0.072 0.077 0.082 0.088 0.082 0.088 0.077 0.085 0.040 10

0.077 0.082 0.085 0.090 0.095 0.090 0.095 0.082 0.092 0.045 0.8 D 1.8 D 1.8 D D >16mm 12

0.110 0.125 0.130 0.130 0.142 0.130 0.142 0.125 0.138 0.055 16

0.120 0.130 0.137 0.137 0.150 0.137 0.150 0.130 0.145 0.060 20

0.132 0.137 0.142 0.142 0.163 0.148 0.163 0.137 0.155 0.065 25

** * ** *

HRC 45-49 ISCAR materialgroup inaccordance withVDI3323standard HRC 45-49 ISCAR materialgroup inaccordance withVDI3323standard

Starting Feedfz,mm/tooth,forMillDiametersD Table 17 Table 16

DIN/ISO 513 DIN/ISO 513 ISO Class ISO Class We have already underlined that in die and mold making, where machining cavities and pockets are pockets and cavities machining where making, mold and die in that underlined already have We so widely used, the ramp down ability is a very important feature of a milling tool. It stands to reason to stands It tool. milling a of feature important very a is ability down ramp the used, widely so Ramp down milling and solid carbide endmills carbide solid and milling down Ramp that the slot drills have no limitations regarding a ramping angle, but the ramp down characteristics characteristics down ramp the but angle, ramping a regarding limitations no have drills slot the that of other endmills shall be thoroughly examined before planning and CNC programming the programming CNC and planning before examined thoroughly be shall endmills other of corresponding milling operations (helical interpolation, for example) – refer to ISCAR catalogs catalogs ISCAR to refer – example) for interpolation, (helical operations milling corresponding or product guidelines for appropriate data. appropriate for guidelines product or P P M H M K H K

Starting SpeedVc,m/min(rough tosemi-finish milling) CHATTERFREE andFINISHREDVariable Pitch Mat. Group* 12, 13 38.1** 15-16 17-18 38.2 6, 7 8, 9 1-4 39 10 11 5 Mat. Group* ISCAR 12, 13 38.1** 17-18 15-16 7-9 2-4 11 10 6 5 1 0.016 0.022 0.019 0.022 0.022 0.020 0.019 0.016 0.012

3

0.022 0.032 0.027 0.032 0.032 0.027 0.027 0.022 0.016

4 0.016 0.027 0.045 0.042 0.045 0.040 0.032 0.032 0.027 0.022

5

0.020 0.030 0.055 0.052 0.055 0.050 0.042 0.036 0.030 0.027

6 D,mm Milling Slot 125 130 105 100 115 145 50 85 80 70 85 0.022 0.032 0.055 0.052 0.058 0.055 0.045 0.038 0.032 0.030

8 0.025 0.038 0.062 0.060 0.060 0.058 0.050 0.042 0.038 0.035 10

0.027 0.045 0.072 0.068 0.065 0.060 0.055 0.050 0.045 0.038 12

0.032 0.050 0.082 0.078 0.078 0.065 0.060 0.055 0.050 0.045 16

Shoulder Milling 120 150 160 130 125 150 180 110 100 115 70 0.035 0.060 0.100 0.090 0.088 0.077 0.072 0.065 0.060 0.055 20

0.045 0.067 0.130 0.110 0.110 0.100 0.088 0.075 0.067 0.060 25

Die andMold 29 Milling Tools 30 Milling Tools ** *

HRC 45-49 ISCAR materialgroup inaccordance withVDI3323standard Table 18 DIN/ISO 513 ISO Class P H K M Starting SpeedVc,m/min(finishmilling) Mat. Group* ISCAR 12, 13 17-18 15-16 38.2 38.1 7-9 2-4 39 11 10 6 5 1 m/min 190 170 150 170 200 100 200 220 120 165 280 Vc, 60 90

speed Vc=120m/min. From Table 16startingfeedfz=0.038mm/toothandfrom Table 17startingcutting hence theshouldercanbemachinedbyonepass(Table 14). The specified requirements tothemilledsurfaceare nothigh;ae/D=3/8,ap

Table 19

5 andmore No. offlutes Solid endmills as integral, monolith tools ensure high dimensional and form accuracy (tolerance (tolerance accuracy form and dimensional high ensure tools monolith integral, as endmills Solid In milling, metal removal rate, the litmus test of productivity, depends both on feed per tooth and tooth per feed on both depends productivity, of test litmus the rate, removal metal milling, In limits for a tool diameter, runout of teeth relative to the tool shank, etc.). Therefore, they fully meet meet fully they Therefore, etc.). shank, tool the to relative teeth of runout diameter, tool a for limits on depth of cut. The question: “What is more effective for effective productivity control – varying varying – control productivity effective for effective more is “What question: The cut. of depth on the feed or the depth within the acceptable limits?” has no unambiguous answer. answer. unambiguous no has limits?” acceptable the within depth the or feed the cut? of depth or tooth per Feed the requirements for finish milling (or finishing) of die and mold parts. The typical features of finishing of features typical The parts. mold and die of finishing) (or milling finish for requirements the But in general, under the same metal removal rate, increasing the feed coupled with reduced depth reduced with coupled feed the increasing rate, removal metal same the under general, in But operations are high accuracy and surface quality of machined surface, and small allowances allowances small and surface, machined of quality surface and accuracy high are operations because cut) deeper the with feed lesser (the combination opposite the than favorable more is cut of (to 5% of a mill diameter and 0.1-0.2 mm for hardened steels). In finishing, the cutting speed is high is speed cutting the finishing, In steels). hardened for mm 0.1-0.2 and diameter mill a of 5% (to it normally results in greater tool life. tool greater in results normally it and the feed per tooth is low relative to rough and semi-finish operations. The tool strength allows strength tool The operations. semi-finish and rough to relative low is tooth per feed the and By the way, high feed milling (HFM), one of the progressive rough milling techniques that are are that techniques milling rough progressive the of one (HFM), milling feed high way, the By cutting with feeds greater than in Table 15 and 16, but due to insufficient surface finish it is it finish surface insufficient to due but 16, and 15 Table in than greater feeds with cutting Short or Extra-Long Reach? Extra-Long or Short also taken into consideration in this guide, rests in particular on this principle. this on particular in rests guide, this in consideration into taken also recommended to start cutting under the table values and then try to increase until the surface the until increase to try then and values table the under cutting start to recommended Solid carbide endmills of the same type and nominal diameter vary in flute lengths and overall and lengths flute in vary diameter nominal and type same the of endmills carbide Solid roughness is enough. is roughness lengths. The mills of short length ensure highest strength and rigidity whereas the extra long reach reach long extra the whereas rigidity and strength highest ensure length short of mills The lengths. mills are designed for deep cavities and high shoulders. As a rule, a series of standard endmills standard of series a rule, a As shoulders. high and cavities deep for designed are mills comprise short, medium, long reach and extra long reach tools. reach long extra and reach long medium, short, comprise For more detailed information regarding 90˚ solid carbide endmills, refer to ISCAR catalogs, catalogs, ISCAR to refer endmills, carbide solid 90˚ regarding information detailed more For guides and technical leaflets. technical and guides 2 3 4 General CharacteristicsofSolidCarbideEndmills Strength **** *** ** * Rigidity **** *** ** * handling Chip **** *** ** * Roughing **** *** **

Finishing **** *** ** * Slot milling **** ***

* Plunge milling **** **

Die andMold 31 Milling Tools 32 Milling Tools

and reduces procurement cost. heads andtheshankstherefore, excellentlyanswersthedemandsofdieandmoldmaking replaced. Thefamilyrenders apossibilityofnumerous toolsbyanunlimitedcombinationofthe necessary. cuttingheadissimply Resharpeningoftoolsisnolongerneeded,becauseaworn-out increase oftoolversatilityand willdiminishneedsforspecialtools.Ahugestockoftoolsisnot concept is,whenashankcancarryheadsofdifferent shapesandaccuracy, thisallowsdramatic The MULTI-MASTER familyfeatures alargevarietyofheads,shanksandextensions.Thebasic additional adjustment. requirements ofrepeatability, andthus,replacement oftheheadsdoesnotrequire heads are quicklyreplaced byeasyrotation ofanappliedkey. Moreover, theyanswertostrict concentricity withinverycloselimits.Inaddition,thetoolsare simple-to-operate,becausethe because theheadgeometryisfinishedbyprecise grindingandtheconnectionguaranteeshigh interchangeable heads.The MULTI-MASTERtools meettherequirements ofhighaccuracy This principleofcouplingensures strength andrigidclampingofawiderangethe cutting partwillcontactthefaceofshank. corresponding thread internal andthetaperuntilfinalsecuringwhenbackfaceofhead threadand abackconnectionwiththeexternal andthetaper, whichscrews intoashankwiththe centering byashortprecise taperandafacecontact.AMULTI-MASTER headhasacuttingpart The MULTI-MASTER designapproach basesuponathread systemoftheuniqueprofile, machining applications:milling,countersinking,spotandcenterdrilling,slitting. MULTI-MASTER isafamilyoftoolswithshanksandinterchangeable cuttingheadsforavarietyof General Notes MULTI-MASTER EndmillHeads

Repeatability of an assembled mechanical system with interchangeable elements means that a key key a that means elements interchangeable with system mechanical assembled an of Repeatability parameter of the system remains in agreed limits in case of replacing an interchangeable element of of element interchangeable an replacing of case in limits agreed in remains system the of parameter No setup time advantages time setup No tools, repeatability in tool length is about 0.04 mm 0.04 about is length tool in repeatability tools, MULTI-MASTER standard the For type. same the for the milling heads of normal accuracy and about 0.02 mm for the precise milling heads. heads. milling precise the for mm 0.02 about and accuracy normal of heads milling the for That is why there is no need for additional adjustment in tool length after replacing a head; and the and head; a replacing after length tool in adjustment additional for need no is there why is That head can be replaced when a shank remains clamped in a machine tool spindle without new without spindle tool machine a in clamped remains shank a when replaced be can head presetting. No setup time for replacement considerably cuts cycle time and is a good source source good a is and time cycle cuts considerably replacement for time setup No presetting. for increasing productivity. increasing for ** *

a

HRC 45-49 ISCAR materialgroup inaccordance withVDI3323standard Tables 20and21showdataforestimatedstartingfeedsspeedsMMHC…heads. or millingslots. for depthofcutwhilemillingshoulderswithwidthsmore thanahalfoftheheaddiameter limitation iscuttinglengthApofahead.Atanyrateitnotrecommended toexceed 0.8Ap In millingslotorsquare shoulderwiththeuse ofMMHC…heads,thenaturalgeometrical rough millingandslotdrilling. This property makesMMHC … headstobeanattractiveeconomicalsolutionespeciallyin of cuttingspeedrelative tothesolidcarbidetools/headsforsametoollifeperiod. multi-flute millsorheads.Thementionedstrength property allowsevenaslightincrease endmills orMMEC…heads,sodespiteonlytwoteeth,thefeedspeedissameasfor the headsrunatfeedspertooththatare significantlygreater thanincaseofsolidcarbide of thistypeismerely finishedbygrinding.Duetothehigh-impactstructure ofapressed tooth helix angle.Beingpressed andsintered toshapeandsize,thecuttinggeometryofheads The second,“economy”type,designatedMMHC…features onlytwoflutesandalesser considered intheprevious pages. Naturally, thecuttingdataforMMEC…headsissameas90˚solidcarbideendmills It goeswithoutsayingthateverytypeofsolidcarbideendmillhasalsobeenproduced as The onlydifference isasmallercuttinglength:normally, itdoesnotexceedaheaddiameter. helix angle,etc.)asthesolidcarbideendmills. The first,whichisdesignatedMMEC…,hasexactlythesamecuttinggeometry(numberofflutes, shoulder milling. There are twokindsoftherelatively small-diameter(8-25mm)MULTI-MASTER headsforsquare 90˚ EndmillCuttingHeads Table 20 DIN/ISO 513 ISO Class MULTI-MASTER head. solid tools, unlikely as it may seem with the combination of the words “indexable” and “solid”. and “indexable” words the of combination the with seem may it as unlikely tools, solid Having a replaceable solid carbide cutting part they relate to a new type of cutting tools: indexable indexable tools: cutting of type new a to relate they part cutting carbide solid replaceable a Having MULTI-MASTER productivity. improving and money saving carbide nor indexable tools in a popular sense, lay in the intermediate field between them. them. between field intermediate the in lay sense, popular a in tools indexable nor carbide MULTI-MASTER the from assembled are that endmills The Indexable solid carbide tools carbide solid Indexable P M H K MM HC…Heads:StartingFeedfz,mm/tooth Mat.Group* 12, 13 38.1** 17-18 15-16 8, 9 6, 7 1-4 11 10 5 0.06 0.07 0.08 0.09 0.09 0.07 0.11 0.04 0.1 0.1 8 fz,mm/tooth, forD,mm 0.07 0.08 0.09 0.12 0.12 0.08 0.13 0.13 0.05 0.1 10 modular tools, which are neither solid solid neither are which tools, modular doors to to doors new open shanks and heads 0.08 0.09 0.13 0.13 0.09 0.13 0.14 0.06 0.1 0.1 12 0.09 0.12 0.12 0.13 0.15 0.15 0.16 0.06 0.1 0.1 16 Die andMold 33 Milling Tools 34 Milling Tools ** *

HRC 45-49 ISCAR materialgroup inaccordance withVDI3323standard speed Vc=140m/min. From Table 20,startingfeedfz=0.12mm/toothand from Table 21,startingcutting shoulder (ae/D=6/16=3/8, ap

Table 21

DIN/ISO 513 ISO Class steel (for general applications), tungsten carbide (has high stiffness) and heavy metal (an alloy with alloy (an metal heavy and stiffness) high (has carbide tungsten applications), general (for steel MULTI-MASTER shanks MULTI-MASTER great tungsten percentage with small alloying additions of other metals; the alloy features excellent features alloy the metals; other of additions alloying small with percentage tungsten great vibration damping properties but not recommended for heavy-duty applications due to its limited its to due applications heavy-duty for recommended not but properties damping vibration impact fatigue strength). fatigue impact The shanks differ in configuration: without neck and with straight or tapered neck. neck. tapered or straight with and neck without configuration: in differ shanks The The taper angle for standard shanks varies from 5˚ on side to 1˚. Of course, overall lengths and lengths overall course, Of 1˚. to side on 5˚ from varies shanks standard for angle taper The neck lengths vary also. vary lengths neck Combining the above shank characteristics provides the die maker with the tool that is exactly is that tool the with maker die the provides characteristics shank above the Combining needed in his specific operation, whether it be roughing or finishing, machining deep cavities or cavities deep machining finishing, or roughing be it whether operation, specific his in needed shoulders, milling under poor clamping or with high overhang. high with or clamping poor under milling shoulders, tools into a powerful means for choosing the right tool. right the choosing for means powerful a into tools MULTI-MASTER the converts Modularity M H K P MULTI-MASTER MM HC…Heads:StartingSpeedVc,m/min(rough tosemi-finishmilling) Mat. Group* shanks are produced from various materials: various from produced are shanks ISCAR 12, 13 38.1** 17-18 15-16 7-9 2-4 11 10 1 6 5 Milling Slot 160 135 145 115 110 125 90 95 80 95 55 Shoulder Milling 190 120 130 165 175 140 135 160 110 125 75

ap/D>1.25, thevaluesshouldbereduced by20%. The speedsformillingfullslottakevaluesofshoulderwithap/D>0.5;andifinthiscase diameter. ap inthetablesisdepthofcut,aemeanswidthcutcorrespondingly, andD–nominalcutter carbide grades. the dataofTables 22-24thatrelate totheextendedflutecutterscarryinginsertsofSUMOTEC adversely affect performanceandtoollife.Therefore, forinitialestimationitisquitesufficient touse demands takingintoaccountdifferent combinationsofthemainmachiningparameters,whichcan flute cutterswiththelatestinserts.Thedetailedmethodofdefiningspeedsandfeedsinthiscase scope ofthereference guideweconsiderbrieflytheassignmentofcutting datafortheextended type ofthemillingtoolsisnotmostcommonindieandmoldmakingprocess, withinthe ISCAR offers thebroad-range lineofthefullyeffective extendedflutemillcutters.Althoughthis slots, grooves andshoulders.Theyare usedalsoasedgingmill. The extendedflutecuttersperformheavy roughing operationssuchasheavy-duty millingdeep mills. sections. Inaccordance tosizesandadaptationthecuttersare produced withshanksorlikeshell The extendedflutecutterscanbewithintegralbodyormodulartoolsassembledfrom different the halfeffective onesunderthesamecuttingspeedandfeedpertooth. twice assmalltheflutenumber. Understandably, thefullyeffective cuttersruntwiceasfast and forhalfeffective cutterswithstaggered order oftheinserts,numberfaceteethis For fullyeffective extendedflutecuttersthenumberoffaceteethisequaltoflutes; in afullfluteforproper chiphandling. due tothewholesetofinsert.Correspondingly, achipgulletoftheordinary milltransforms the mill,cuttinglengthofextendedflutecutterissignificantlylarger–it“extended” ordinary indexablemillwith lengthofcutthatislimitedbythecuttingedgeinsertmountedon andengagethematerialduringmachiningresults inasmoothcut.Asagainstan are placedgraduallyandwith mutualoffset ofoneanother, produce continuoushelical cutting Cutting bladesofextendedflutemillcuttersconsistsetsindexableinserts.Theinserts,which 90˚ ExtendedFluteMillCutters In the technical literature the extended flute mill cutters are called also long-edge, porcupine-type porcupine-type long-edge, also called are cutters mill flute extended the literature technical the In or porcupine cutters and even, as it is sometimes called in shoptalk, “porkies”. “porkies”. shoptalk, in called sometimes is it as even, and cutters porcupine or Cutting porcupine Cutting endmill cutting heads, shanks and and shanks heads, cutting endmill MULTI-MASTER regarding extensions information detail more For ISCAR catalogs, guides and technical leaflets. technical and guides catalogs, ISCAR to refer , Die andMold 35 Milling Tools 36 Milling Tools * ** * ** *

For T290LNK…cuttersae/Dshallnotexceed1/4 HRC 45-49 ISCAR materialgroup inaccordance withVDI3323standard HRC 45-49 ISCAR materialgroup inaccordance withVDI3323standard Table 24 Table 23 Table 22 1/20 1/4 1/2 3/4 1 >1.25 ISO Class DIN/ISO DIN/ISO ap/D – Class ISO 513 513 M M H K H K First choiceforgrades P P

Loading FactorK Basic Feedfo,mm/tooth,forExtendedFluteCutters Starting SpeedVc,m/min(averagedataforextendedflutecutters) 11 10 9 8 7 6 5 17-18 2-4 38.1** 15-16 12, 13 1 Material Group* Group* ISCAR ISCAR 12, 13 38.1** 15-16 17-18 Mat. 2-4 10 11 1

5 6 7 8 9 1/10 1.2 1.2 1.2 0.9 0.7 1 <0.3 225 125 175 200 165 170 180 170 170 140 140 120 70 12-16 0.06 0.08 0.08 0.09 0.09 0.09 0.09 0.12 0.11 0.05 0.14 0.12 0.13 T290 LNK… 0.3…0.5 IC808 200 110 160 175 140 155 165 150 140 125 120 105

L forExtendedFluteCutters 0.07 0.09 0.09 0.12 0.06 0.12 0.14 0.1 0.1 0.1 0.1 0.1 0.1 20 1/4* 0.8 0.7 0.6 >0.5 170 100 135 160 125 140 130 130 125 120 115 1 1 1 95

<0.3 T490 LNK 200 200 180 170 155 165 155 155 130 130 110

20-32 0.08 0.12 0.12 0.12 0.12 0.12 0.14 0.07 0.14 0.12 0.16 0.1 0.1 0.3…0.5 IC810 180 170 160 150 140 150 135 130 115 110 100

(LNM)… ae/D 40-50 0.12 0.12 0.15 0.15 0.15 0.15 0.15 0.17 ae/D forgrades 0.08 0.17 0.15 1/2 0.9 0.9 0.8 0.7 0.6 0.5 0.1 0.2 fo, mm/tooth >0.5 160 150 150 135 130 120 120 115 110 105 90

<0.3 110 160 170 140 160 120 130 125 120 105 105 85

40-50 0.12 0.12 0.15 0.15 0.15 0.15 0.15 0.17 0.08 0.17 0.15 0.1 0.2 T490 SM… 0.3…0.5 IC830 100 140 150 125 135 110 115 110 105 90 90 80

0.55 0.45 3/4 0.8 0.8 0.7 0.6 0.13 0.13 0.16 0.16 0.16 0.16 0.16 0.18 0.09 0.19 0.16 0.22 0.1 63 >0.5 125 130 115 120 100 90 95 95 90 85 85 75

<0.3 110 150 125 110 120 115 115 100 100 80

0.13 0.13 0.16 0.16 0.16 0.16 0.16 0.18 0.09 0.19 0.16 0.22 0.1 63 H490 SM… 0.3…0.5 IC330 100 130 115 100 110 105 100 85 85 75 0.75 0.65 0.55

0.7 0.5 0.4 1 80-100 0.12 0.14 0.14 0.17 0.17 0.17 0.17 0.17 0.19 0.16 0.25 0.1 0.2 >0.5 115 110 100 90 95 85 85 80 80 70

specification ofyourmachinetool! demands highmachinepower. Checkpowerconsumptionandcompare itwiththemaindrive Heavy-duty rough millingwiththeextendedflute cutters,especiallyofshellmilltype,often Important Note Thus thestartingfeedfz=0.17x0.75≈0.13mm/tooth.

23, basicfeedfo=0.17mm/tooth.Table 24specifiesloadingfactork Hence, from Table 22,startingcuttingspeedVccanbeestimatedas110m/min; andfrom Table ae/D =40/100=0.4;ap/D60/100=0.6. catalog data.Theinserts’carbidegrade–IC830. The nominaldiameterofthecutteris100mm(D),itsmaximalcuttinglength61.5(Ap)- The machinedmaterialrelates totheseventhmaterialgroup (No.7). The machinetoolpowerissufficient, theclampingconditionsare good. dimensions are asfollows:60mmdepthand40width. component madefrom AISI/SAE4130alloysteel,whichhashardness HB270.Theshoulder 170608PNTR IC830performsrough millingofadeepshoulderlarge-sizediestructural Extended fluteshellmillcutterH490SMD100-64-5-40-17CcarryinginsertsANKX Example Where:

following equation: Starting feedpertoothfzfortheextendedflutecutterscanbeestimatedinaccordance withthe

Further to our discussion regarding tangential and radial (laydown) insert clamping in the context of context the in clamping insert (laydown) radial and tangential regarding discussion our to Further the extended flute cutters, it can be noted that under otherwise equal conditions the extended flute extended the conditions equal otherwise under that noted be can it cutters, flute extended the Tangential or radial? (2) radial? or Tangential cutters with radial clamping have certain advantages in chip handling and can show better results better show can and handling chip in advantages certain have clamping radial with cutters while milling full deep slots. The cutters with tangential clamping, however, provide an advantage an provide however, clamping, tangential with cutters The slots. deep full milling while when machining deep shoulders due to their more rigid body structure. body rigid more their to due shoulders deep machining when Of course, these remarks should not be considered as absolute guidelines for choosing a cutter cutter a choosing for guidelines absolute as considered be not should remarks these course, Of or as a final solution of the question of the header, but is a good illustration of a reason for different for reason a of illustration good a is but header, the of question the of solution final a as or principles of tool configurations. tool of principles k fo L –loadingfactor(Table 24)thattakesintoconsiderationtoolloading. –basicfeed(Table 23) fz =foxk L

(2) L as0.75(approximation). Die andMold 37 Milling Tools 38 Milling Tools 2 • • • • *

(maximal chipthickness)–agoodsource forincreasing productivity*. Seetables25,26. Therefore, thesmalleranglesallowhigherfeedpertoothundersamemillloading edge anglesdiffering 90˚,totheproduct ofthefeedtosinecuttingedgeangle. which characterizesthemillloading,isequaltofullfeedpertoothfor90˚millsand,cutting smallest cuttingedgeangleisrecommended. Thepointisthatthemaximalchipthickness, Classically, ifthere isnolimitationregarding theshapeofmachined surface, thefacemillwith 45˚ (45˚lead) 60˚ (30˚lead) 75˚ (15˚lead) 90˚ (0˚leadanglecorrespondingly) following cuttingedgeangles: the facemillswithdifferent cuttingedgeangles.Themostcommontypesofthefacemillshave So astomeetvariousshaperequirements ofmachinedparts,cuttingtoolmanufacturers produce with respect tomachinesurfaces. Thepositiondefinesthecuttingedgeangle(enteringangle). One ofthemaindesigncharacteristicsamillingtoolispositioncuttingedge and activationisperformedbyshank. torque transfer. Theendmills,onthecontrary, belongtoshank-typetoolsforwhichmounting an adapter, anarbororamachinetoolspindle;andhavekeyslotonitsnon-cuttingfacefor Generally, thefacemillsare designedasshellmillswithasteppedbore formountingdirectly upon the ratiobetweenmentionedkeydimensionsfarexceedscorresponding ratioinendmills. endmills. Thecuttingdiameterofafacemillisconsiderablylargerthanitsmaximaldepthcut;and Due tomainapplicationthefacemillshaveadditionaldesignfeatures incomparisonwiththe them inspecification. square shoulders.Butthe definition ofmilltypes relates tomaindistinctivefeatures andunderlines also belongstosuchgeneraldefinition.Moreover, thefacemillandlikewiseendmillsmachine surfaces thatare paralleltothemillface.Obviously, theendmillexaminedinprevious section, The firstchoiceformillingplanesurfacesisfacemills.millsare intendedformachining Milling PlaneSurfaces This approach resides inhigh-feedmachining(HFM). Table 26 Table 25 Cutting edgeangle Cutting edgeangle Feed pertooth Chip thickness Feed Increasing fortheSameChipThickness Chip ThicknessfortheSameFeedperTooth 90˚ 90˚ 100% 100% 75˚ 75˚ 103% 97% 60˚ 60˚ 115% 87% 45˚ 45˚ 141% 71% *

90˚ and45˚facemills. Summary tables27and28showmaingeneraldataof someadvancedISCAR edge inserts. strength insertshave16cuttingedges,eitherright-handorleft-handandare veryeconomical per durable structure, positivegeometryoftherakefaceand8cuttingedges;octagonalhigh- an effective solutionofinsertswith8or16cuttingedges.Ifthesquare right-hand insertsfeature using eithersquare oroctagonaldouble-sidedinsertsonthesametool.Themillsoffamilyoffer The 45˚facemillsgrew inthenewestHELIDOS845familywithaninnovativesolutionthatenables family withtheclassicallydesigned2cuttingedgedinsertisingreat request. been discussedinbriefthesectionofendmillsthisguide.Asbefore, HELI2000HM90 SUMOMILL T290andHELIDOH490families.Themainfeatures ofthesetoolshave already applications. Amongthelatest90˚facemillsare thetoolsofHELITANG T490, ISCAR hasarichlineoffacemillswithvariouscuttingedgeanglesforbroad spectrum will bringtheproper choiceofmill. understanding operationrequirements coupledwiththemainproperties ofthedifferent milltypes It standstoreason thatmillingoperationsneed adifferent typeofmill;andonlycorrectly important feature ofthemill. other insertdimensionsbeingmore orlessequal,90˚millshavegreater maximaldepthofcut–an which cancausedeflectedmachinedsurfaces,especiallyifaworkpiecehasthinwalls.Moreover, reduces theradialcomponentofcuttingforce butleadstoincreasing itsaxialcomponent*, However, manyapplicationsdemand90˚shouldershapes.Decreasing thecuttingedgeangle of break-out edges(castiron, forinstance).Heatdissipationisbetter;insert lifeislonger. the radialpressure, correspondingly, too.Thatisveryimportantformaterials thathaveatendency material andexitduringmillingoperations.Theradialcomponentofacuttingforce isreduced, and In addition,thesmallercuttingedgeanglesleadpossiblyrender asmootherengagmentintothe

specialists.

This approach resides inhigh-feedmachining(HFM). There a well-defined strict specification for the angles’ defined cutting geometry of the milling tools. milling the of geometry cutting defined angles’ the for specification strict well-defined a There However, national standard sometimes defines the same parameters in a different manner that manner different a in parameters same the defines sometimes standard national However, Cutting edge angle or approach angle? approach or angle edge Cutting causes misunderstandings even in technical literature and between experienced metal cutting metal experienced between and literature technical in even misunderstandings causes The angle between the plane of the main cutting plane (the plane that the edge machines) and the the and machines) edge the that plane (the plane cutting main the of plane the between angle The machined plane surface (which the mill machined) is called the tool cutting edge angle or the the or angle edge cutting tool the called is machined) mill the (which surface plane machined cutting edge angle. angle. edge cutting As it is not always clear what angle is specified, please pay attention to prevent confusion. prevent to attention pay please specified, is angle what clear always not is it As Some technical sources call it also the entering angle, the cut-entering angle, the entry entry the angle, cut-entering the angle, entering the also it call sources technical Some In the U.S.A. and U.K., it is common practice to specify the angle that is complimentary to the cutting the to complimentary is that angle the specify to practice common is it U.K., and U.S.A. the In Being the complimentary angles, the cutting edge angle and the lead angle produce together 90˚; 90˚; together produce angle lead the and angle edge cutting the angles, complimentary the Being angle or the entrance angle. Its value is often indicated before a general type or header of milling milling of header or type general a before indicated often is value Its angle. entrance the or angle edge angle: so-called the lead angle (USA) and the approach angle (UK) – the angle formed by the the by formed angle the – (UK) angle approach the and (USA) angle lead the so-called angle: edge and they are equal only in case of 45˚ mills. For our example above the lead angle is 0˚ (“zero lead”). (“zero 0˚ is angle lead the above example our For mills. 45˚ of case in only equal are they and tool families. For example: “90˚ milling tool” means that the mill has a 90˚ cutting edge angle. angle. edge cutting 90˚ a has mill the that means tool” milling “90˚ example: For families. tool main cutting edge and a line parallel to the axis of the cutter rotation. cutter the of axis the to parallel line a and edge cutting main Die andMold 39 Milling Tools 40 Milling Tools

Table 27 definition definition

Table 28 40 32 Tool D 125 100 80 63 50 160 200 250 Inserts 315 40 Tool D 50 63 80 100 125 Inserts 315 250 200 160 The situation becomes much better if in addition to the ordinary inserts, a face mill carries mill face a inserts, ordinary the to addition in if better much becomes situation The machined surface. For this, although the wiper flat improves the surface roughness, it is not is it roughness, surface the improves flat wiper the although this, For surface. machined a specially designed insert (or more rarely two for large-sized tools), for which the wiper flat is flat wiper the which for tools), large-sized for two rarely more (or insert designed specially a Normally, the ordinary inserts for face milling are provided today with a wiper flat for improving for flat wiper a with today provided are milling face for inserts ordinary the Normally, always enough, particularly for the face mills with a relatively large nominal diameter. diameter. nominal large relatively a with mills face the for particularly enough, always significantly larger than for the ordinary one. This wiper insert is mounted in the same pocket but it it but pocket same the in mounted is insert wiper This one. ordinary the for than larger significantly quality of a machined plane surface. This is a small secondary cutting edge, which in spite of the the of spite in which edge, cutting secondary small a is This surface. plane machined a of quality protrudes 0.05…0.07 mm relative to the ordinary inserts towards to the machined plane. plane. machined the to towards inserts ordinary the to relative mm 0.05…0.07 protrudes Wiper insert Wiper Due to the wide wiper flat the wiper insert applies additional force to the workpiece that needs needs that workpiece the to force additional applies insert wiper the flat wiper wide the to Due special emphasis for milling brittle materials. brittle milling for emphasis special ap ap 8; 10 6; 8 7.7 F90AN HP 12; 16 9; 12 ANKT 07 HP Quick SelectorforCertain90˚IndexableFaceMills Quick SelectorforHELIDO45˚IndexableFaceMills " SOF45 8/16 3.5 4 4; 6 6; 8 7; 10 8; 12 10; 16 ON…U 0505 flat ", sometimes has a complex geometry but can be considered to be parallel to the to parallel be to considered be can but geometry complex a has sometimes 4; 6 3; 5 8 FLN -08 T490 6; 9 5; 7 LN..T 08 T490 6 5 8 E90AX -09 H490 9 7 ANKX 09 H490 5;6 3; 5 10 F90AP HM90 10; 16 9; 13 8; 11 7; 9 6; 7 AP…10 HM90 4 12 E90AX -12 H490 6; 9 5; 7 4; 6 3; 5 AN..X 12 H490 SOF45 8/16 6 4 4; 6 6; 8 7; 10 8; 12 10; 16 S845 SN…U1305 Number ofTeeth (Effective) Number ofTeeth (Effective) 4; 5 12.5 FLN -13 T490 9;17 8; 13 7; 10 6; 8 5; 6 LN..T 13 T490 3; 4 14.3 F90A HM90 7; 9 6; 8 5; 7 4; 6 3; 5 8; 10 9; 12 10 AD..15 HM90 12 4 15 FLN -15 T290 7 6 5 LN..T 15 T290 S845 F45SX 7.1 4 4; 5 5; 7 6; 9 7; 11 19 15 12 10; 18 8; 14 S845 SXMU 3 16 FLN -16 T490 7; 10 5; 8 5; 7 4; 6 3; 4 LN..T 16 T490 3 16 E90AX -17 H490 7; 10 5; 8 5; 7 4; 6 3; 4 8; 12 10 12 AN..X 17 H490 16 F90AT -19 HP 5; 7 4; 6 4; 5 3; 4 AD.. 1906 HP90

Table 28 40 32 Tool D 125 100 80 63 50 160 200 250 Inserts 315 Pitch of milling tool milling of Pitch The pitch is the distance between two nearest-neighbor teeth of a milling tool measured between between measured tool milling a of teeth nearest-neighbor two between distance the is pitch The the same points of the cutting edges of the teeth. The pitch shows density of tooth of a milling tool tool milling a of tooth of density shows pitch The teeth. the of edges cutting the of points same the in accordance to which the tools differ from the tools with coarse, fine and extra fine pitch. fine extra and fine coarse, with tools the from differ tools the which to accordance in Choosing the proper right tooth density depends on two main things. On the one hand, at least least at hand, one the On things. main two on depends density tooth right proper the Choosing one tooth should always cut material. On the other hand, the space of a chip gullet should be be should gullet chip a of space the hand, other the On material. cut always should tooth one enough for chip handling. Hence, the machined material and type of machining are the principal the are machining of type and material machined the Hence, handling. chip for enough factors for choosing. General-duty coarse pitch with maximum chip gullet space and a few teeth are are teeth few a and space gullet chip maximum with pitch coarse General-duty choosing. for factors the first choice for rough and finish milling of steel. Also, in many cases the coarse pitch is a way way a is pitch coarse the cases many in Also, steel. of milling finish and rough for choice first the to reduce vibration. reduce to Fine pitch, which provides less space for the chip gullet but more teeth, allows increased feed speed. speed. feed increased allows teeth, more but gullet chip the for space less provides which pitch, Fine In technical literature parallel with the coarse-fine-extra fine pitch, grading also exists: exists: also grading pitch, fine coarse-fine-extra the with parallel literature technical In It is recommended for milling cast iron and for applications requiring limited feed per tooth. per feed limited requiring applications for and iron cast milling for recommended is It Sometimes, in order to overcome vibrations during operations, the teeth are produced with unequal with produced are teeth the operations, during vibrations overcome to order in Sometimes, coarse-medium (or regular)-fine, normal-close-extra close and other definitions. In addition, tools tools addition, In definitions. other and close normal-close-extra regular)-fine, (or coarse-medium Extra fine pitch generally is suitable for milling steel with shallow depth of cut, milling cast iron and and iron cast milling cut, of depth shallow with steel milling for suitable is generally pitch fine Extra spacing, which is to say, the tool has differential pitch. differential has tool the say, to is which spacing, with extra-fine pitch can be called high-density cutters. high-density called be can pitch extra-fine with high-efficiency machining with considerable feed speed. feed considerable with machining high-efficiency ap 8; 10 6; 8 7.7 F90AN HP 12; 16 9; 12 ANKT 07 HP Quick SelectorforHELIDO45˚IndexableFaceMills(cont.) 4; 6 3; 5 8 FLN -08 T490 6; 9 5; 7 LN..T 08 T490 6 5 8 E90AX -09 H490 9 7 ANKX 09 H490 5;6 3;5 10 F90AP HM90 10; 16 9;13 8;11 7;9 6;7 AP…10 HM90 4 12 E90AX -12 H490 6; 9 5; 7 4; 6 3; 5 AN..X 12 H490 Number ofTeeth (Effective) 4; 5 12.5 FLN -13 T490 9;17 8; 13 7; 10 6; 8 5; 6 LN..T 13 T490 3; 4 14.3 F90A HM90 7; 9 6; 8 5; 7 4; 6 3; 5 8; 10 9; 12 10 AD..15 HM90 12 4 15 FLN -15 T290 7 6 5 LN..T 15 T290 3 16 FLN -16 T490 7; 10 5; 8 5; 7 4; 6 3; 4 LN..T 16 T490 3 16 E90AX -17 H490 7; 10 5; 8 5; 7 4; 6 3; 4 8; 12 10 12 AN..X 17 H490 16 F90AT -19 HP 5; 7 4; 6 4; 5 3; 4 AD.. 1906 HP90 Die andMold 41 Milling Tools 42 Milling Tools *

The guidealsousesthisspecification. spindle speed,etc.withrespect tocuttingdiameterDasdefinedinISO6462.* allows neglectingtheabovecorrection; anditisconventionaltospecifythecuttingspeed, But thefactthatinfacemillsmaximaldepthofcutatoolfarlesscuttingdiameterD, D+2×ap×tan At thesametime,ifcuttingedgeangle( different depthsofcut(ap). For 90˚facemillsthecuttingdiameterisconsistentalongedgeanddoesnotchangefor the mill,anditofteniscallednominaldiameter. edge andtheplanemachinedbymill.Thecuttingdiameterisoneofmaindimensions Fig. 2(diameterD).PointPisthetheoretical pointproduced byintersectionofthemaincutting clarification. Inaccordance withISOstandard 6462itshallbetakenfrom pointPasdefinedin The meaningofthecuttingdiameterforfacemillingtoolwithindexableinsertsneeds a fullslot,buttheaboveratioisalwayspreferable. cutting diameter. Ofcourse,thereal situationoftendictatesotherproportions evenwhenmilling Normally, peakefficiency infacemillingcanbeachievedifawidthofcutwill60-80%mill Cutting diameterandwidthofcut Cutting diameter D and cutting edge angle (in accordance with ISO 6462) ISO with accordance (in angle edge cutting and D diameter Cutting 2. Fig. χ r. Onewouldthinkthattherightcalculationshouldtakethispoint intoconsideration. ØD P χ r) differs from 90˚,thereal cuttingdiameterwillbe ØD P Xr

*

For millinghardened steel,seetheappropriate chapterforfurtherdiscussion For thefacemillswithinsertsHPANKX…07andT490LN..T…08tablevaluesshouldbereduced by20%. For T290facemillsthetablevaluesshouldbereduced by30%. –Firstchoiceforgrades ISCAR materialgroup inaccordance withVDI3323standard Table 30 Table 29

Where: a) Startingfeedpertoothfz inserts, already examined. Basically, thewayofdefininginitialcuttingdataissame asfortheendmillswithindexable Initial CuttingData (compare withTable 26). chip thicknessduetopositionofthemaincuttingedgerelative tothemachinedplane surface The factorofthecuttingedgeanglekχ(Table 30)reflects possibleincreasing offeedforthesame values forthefacemills. estimation ofthebasicfeedisachievedwithuseTable 29,whichcontainstheaverage for themore popularISCARcarbidegrades.Optionally, asthecasemaybe,satisfactory The basicstartingfeedcanbechoseninaccordance withTable 5,thatspecifiesthefeedlimits Cutting edgeangle kχ ISO Class DIN/ISO 513 P M H K

kχ fz 0 Factor oftheCuttingEdgeAnglekχ Basic StartingFeedfzoforFaceMills –thefactorofcuttingedgeangle –thebasicstartingfeed Nodular castiron Hardened steel Martensitic s.s. Grey castiron Plain carbon Alloy steel tool steel Workpiece material Type steel and Mat. Group* 90˚ 1 12, 13 17-18 15-16 38.2 38.1 8, 9 6, 7 1-4 11 10 39 5 fz = IC808 0.12 0.12 0.15 0.18 0.05 0.07 0.08 0.1 0.2 0.1

0 x kχ 75˚ 1 IC5100 0.12 0.12 0.15 0.18 0.22 0.2 0.1 0.2

Basic feedfz (3) IC810 0.22 0.12 0.12 0.15 0.18 0.18 0.25 0.2

0 , mm/tooth,forgrades 1.1 60˚ DT7150 0.22 0.25

IC830 0.12 0.15 0.18 0.22 0.22 0.08 0.12 0.2 0.2 0.2

1.4 45˚ IC330 0.15 0.15 0.22 0.22 0.25 0.15 0.2

Die andMold 43 Milling Tools 44 Milling Tools

** * Where:

Be aware: millingwithawidthofcutthatis60%-80%milldiameterensures peakefficiency infacemilling Milling fullslot For startingfeedfzinaccordance withequation(3) rests onequation(1): Exactly asfortheindexableendmills,calculationofstartingcuttingspeedVcfacemills

b) StartingcuttingspeedVc

taken from Table 31. is 60-80%ofthemilldiameter)orformillingafullslot(100%diameterengagement),canbe the typeofmachiningforafacemillmore suitablefortheoperation(whenwidthofcut If desired, uponconditionthatthestartingfeedwascalculatedfrom equation(3)andTable 29, grade andthetypeofmachining,whilstdefininglattercanbedonethrough Tables 6and7. Table 9specifiesbasiccuttingspeed Vo asdictatedbytheworkpiecematerial,carbide Table 31

3/4 1/2 1/4 1/8 h/ap and and slotting, – milling slot facing, simply called often is milling face cutting, metal of art the In shoulder milling, correspondingly - shouldering. - correspondingly milling, shoulder Shoptalk: facing and shouldering and facing Shoptalk: Kt Ks Vo Vc Type ofMachining:FaceMilling* –toollifefactor(Table 8) –stabilityfactor(1ifisenoughand0.7forunstableoperations) –basiccuttingspeed –startingcuttingspeed Heavy-duty (H) Medium-duty (M) Light-duty (L) Light-duty (L) 60% Vc =Vo xKsKt Heavy-duty (H) Medium-duty (M) Medium-duty (M) Light-duty (L) 70% b/D Heavy-duty (H) Heavy-duty (H) Medium-duty (M) Light-duty (L) 80% Heavy-duty (H) Heavy-duty (H) Medium-duty (M) Medium-duty (M) 100%**

thus Vc=130m/min. accept amore orlessaveragevaluebetweentheselimitsasthestartingcuttingspeed, Table 9recommends thestartingspeeds140and125m/mincorrespondingly. Asitstandswecan The typeofmachiningaccording toTable 31laysbetweenmedium-toheavy-duty, forwhich (Table 30)andstartingfeedfz=0.2mm/tooth. Then basicstartingfeedfzo=0.2mm/tooth(Table 29),factorofthecuttingedgeanglekχ=1 h/ap =6/16=0.38;b/D50/63=0.8. The cuttingedgeangleofthefacemillcutteris90˚. catalog data.Theinserts’carbidegrade–IC330. The nominaldiameterofthecutteris63mm(D),itsmaximalcuttinglength16(ap)- The machinedmaterialrelates tothesecond materialgroup (No.2). stability canbeestimatedassufficient. of cutis50mm.TheblockmaterialcarbonsteelAISI/SAE1030,HB200…220.operation milling ofalarge-scaleblockbyseveralpasses,forwhichthedepthcutis6mmandwidth Cutter H490F90AXD063-6-27-17withinsertsANKX170608PNTRIC330performsface Example (Table 9). The typeofmachiningisheavy-duty(Table 31),andstartingcuttingspeedVc=200m/min (Table 30)andstartingfeedfz=0.22x1.4≈0.3mm/tooth. So, basicstartingfeedfzo=0.22mm/tooth(Table 29),factorofthecuttingedgeanglekχ =1.4 h/ap =3/3.5=0.86;b/D90/125=0.72. The cuttingedgeangleofthefacemillcutteris44˚(itcanberounded off to45˚). catalog data.Theinserts’carbidegrade–IC810. The nominaldiameterofthecutteris125mm(D),itsmaximalcuttinglength3.5(ap)- The machinedmaterialrelates totheseventeenthmaterialgroup (No.17). device ofthemachinetool. Power ofthemachinetoolmaindriveissufficient; theplateissecure mountedintheclamping that carriesinsertsONMU050505-TNIC810.Thedepthofcutis3mm. (ASTM 65-45-12)withhardness HB180ismachinedbyfacemillcutterSOF8/16-D125-16-40R A faceofaplate90mm×406from nodularcastiron DINGGG50 Example

Most conventionally designed shell-type face mills are equipped with coolant holes for the for holes coolant with equipped are mills face shell-type designed conventionally Most the inserts. the spindle-through coolant supply. The holes are usually located in the chip gullets and are directed are and gullets chip the in located usually are holes The supply. coolant spindle-through Several cutting tool manufacturers produce clamping with internal ports. ports. internal with screws clamping produce manufacturers tool cutting Several Clamping screws with adjustable protrusion nozzle for shell-type face m ills m face shell-type for nozzle protrusion adjustable with screws Clamping towards the cutting edges. This design ensures coolant supply at the cutting zone, but in many many in but zone, cutting the at supply coolant ensures design This edges. cutting the towards The screws secure the face mills on the adapter and ensure flow through the axis of a tool to its to tool a of axis the through flow ensure and adapter the on mills face the secure screws The evacuation, chip facilitate not does cases periphery and thus facilitate improved chip evacuation. However, as shell mills have central central have mills shell as However, evacuation. chip improved facilitate thus and periphery with different depths, effective application of such screws is limited. is screws such of application effective depths, different with countersink The ISCAR clamping screws with movable nozzle eliminate the above disadvantage. disadvantage. above the eliminate nozzle movable with screws clamping ISCAR The The protrusion of the nozzle of the screw can be easily adjusted according to countersink depth, depth, countersink to according adjusted easily be can screw the of nozzle the of protrusion The insert size or any other application requirements. The nozzle screw position can be secured by by secured be can position screw nozzle The requirements. application other any or size insert a locking-nut. a The adjustable protrusion nozzle effectively directs the coolant supply to the cutting zone, zone, cutting the to supply coolant the directs effectively nozzle protrusion adjustable The thus improving chip evacuation substantially. evacuation chip improving thus as the coolant flow tends to push the chips back towards back chips the push to tends flow coolant the as Die andMold 45 Milling Tools 46 Milling Tools 3

• • • surfaces Contoured Due tosomelimitationstheyoftenlooklikeabull-noseorback-draftmills(Fig.4) The solidcarbidetoolsandheadsare more suitableforsmallnominaldiameters. Interchangeable solidcarbidetoroidal millingheads Solid carbidetoroidal millingtools Milling toolswithindexableround inserts Structurally, thisprofile is realized inthefollowing designs: touch a torus–geometricalform,whichisgeneratedbyrevolving acircle aboutanaxisthatdoesnot A millingtoolwithtoroidal cuttingprofile being rotated around thetoolaxisproduces tools represent themajorityofmetalcuttingtoolsrequired bydieandmoldmakers. and firstofallmillingcutters,formachiningtheverysamecontoured surfaces.Thesekindsof Therefore, whilespeakingaboutthespecifictoolsfordieandmold,oneoftenmeanstools, contoured surfaces,especially intheproduction ofplasticmoldsanddie-castingdies. The outstandingcharacteristicsofthedieandmoldindustryshowthrough alargeproportion of 3.1. Millingtoolswithtoroidal cuttingprofile Milling Contoured Surfaces(profiling) Fig. 4. Fig. Fig. 3. Fig. surfaces, 3-D shaped surfaces, and etc. etc. and surfaces, shaped 3-D surfaces, In the technical literature the contoured surfaces are also called formed surfaces, profiled profiled surfaces, formed called also are surfaces contoured the literature technical the In the circle andiscoplanarwith it–aring-shapedbagel(Fig.3). α° r

that isequaltotheinsertradius,maximalcuttingedgeanglewillbe90˚. the maximalcuttingedgeangle(χmax,Fig.5).Whentoolrunsatitsmaximumdepthofcut measured atthehighestpointofcuttingedgethatisinvolvedincutting.Thelatterdefines polygonal insert,variesalongthecuttingedgeofround insertfrom zero tothevalue Secondly, avaryingcuttingedgeangle.Theangle,whichisconsistantincaseofthe more feedandspeedthat causetheimproved metalremoval rate. The higherstrength allowsmore heavytoolloadorinotherwords, stronger cuttingdata: polygonal shape,theround ismuchstronger. insertwithoutacuttingcorner Firstly, strength istheAchillesheelforaninsertofany ofthecuttingedge.Ifcorner to theround shapeofthe inserts. contribute greatly totheirsuccessfuluse.Whetherornot,bothoftheadvantagesrelate is thehighestmetalremoval rate,theround insertshavetwosignificantadvantagesthat male-female mainpartssuchascavitiesandprojections. Inroughing, whentheprimarytarget popular roughing andsemi-finishingmillsinmachiningdiesmolds,especiallycomplex By allaccounts,themillingtoolswithround (orasitalsocalledbutton)insertsare themost 3.1.1. Millingtoolswithindexableround inserts Fig. 5. Fig.

about – a round! a – about toroidal or ball nose, are very popular in the die and mold industry. One way or another, but look look but another, or way One industry. mold and die the in popular very are nose, ball or toroidal on lays which edge, cutting the only operations, requirements. Therefore the milling tools with complex cutting form: form: cutting complex with tools milling the Therefore requirements. Generally speaking, for rough milling any cutting geometry can be suitable; but in finish finish in but suitable; be can geometry cutting any milling rough for speaking, Generally the surface but also ensures correct generation of a needed shape in every direction. direction. every in shape needed a of generation correct ensures also but surface the A tool intended for milling countered surfaces should have a cutting geometry that not only contacts only not that geometry cutting a have should surfaces countered milling for intended tool A All around … a round! a … around All

5

6 7 3 4

2 1 8

6

5

4 8 3 1 2

a spherical portion, meets the above the meets portion, spherical a

5

6 7 3 4

2 1 8 D D D

1 eff

=D+d 6

5 4 8 X

max 3 1 2 d=2r X X eff max a p Die andMold 47 Milling Tools 48 Milling Tools * apisanaxialdepthofcut,r-theradiusaround insert

characteristics, clampingfixture, etc. optimal loadingconditionsformachiningaspecificpartdependingontheshape,machinetool Therefore, thecorrect choiceofthedepthcutallowsdieandmoldmakertodefine axial componentadverselyaffects machining accuracyandcancauseproblems withworkholding. The considerableradialcomponentleadstothetooldeflectionandvibrations,whileexcessive and thecuttingforce actingonthemaincutting planeisdirected towards thetoolaxis. components, andvice-versa.Evidently, inveryshallowcutstheradialcomponentwillbenegligible force monitoring.Thegrowth ofthedepthcausesincreasing theradialandreducing theaxial between thecuttingforce components,this phenomenon allowsforaneffective wayofcutting of thedepthcutcausesachangeeffective cuttingedgeangleandhence, ofrelationship of cutand45˚whenthedepthisequaltoradiusaround insert.Becauseachange on adepthofcutandtherefore, itchanges,betweenaclosetozero valueforveryshallowdepths the radialandaxialcomponentsofacuttingforce. Theeffective cuttingedgeangledepends round inserts.Similartothe toolswithpolygonalinsertsitdeterminestherelationship between The effective cuttingedge angle isoneoftheimportantfactorscuttinggeometrytoolswith cutting edgeangle(Fig.6)isdefinedas: In caseofsidemillingwhenthefaceatoolwithround insertsdoesnotcut,theeffective χ the averageoreffective cuttingedgeangleχeff oftenusedincalculations. Due tovariationofthecuttingedgeanglealongarea involvedinmilling, Where cos The maximalcuttingedgeanglecanbefoundfrom thefollowingequation:

Table 32 thinning demandsevenhigher feedsandthusmakesimproving productivity possible. be increased correspondingly inorder toproduce thechipsofrequired thickness.Thatiswhychip under themaximaldepth,chipisthinner(Fig.7);and theprogrammed feedpertoothshould round insertsismore orlesssimilartoamillingtoolwith45˚cuttingedgeangle.Butifthecuts maximal possibledepthofcutthatisequaltotheradius ofaround insert.Inthiscaseatoolwith higher productivity. Indeed,thefeedpertoothused forprogramming atoolroute relates tothe Decreasing thecuttingedgeangleproduces more thinchips andthusallowsaneffective wayfor ap/r Xmax Xeff The absolute majority of new 3P products relates to state-of-the-art development and meets meets and development state-of-the-art to relates products 3P new of majority absolute The the requirements of up-to-the minute technology. Therefore, these 3P tools and inserts are the are inserts and tools 3P these Therefore, technology. minute up-to-the of requirements the 3P(2): Patent-Protected Products Patent-Protected 3P(2): products protected by patent or at least are patent-pending products. patent-pending are least at or patent by protected products r –theradiusofaround insert ap –adepthofcut χ eff Cutting EdgeAnglesasFunctionofRatioap/r* =[arccos(1-ap 1/16 20˚ 10˚ 1/8 29˚ 14.5˚ eff 2 3/8 52˚ 26˚

χ /r)+arccos (1-ap = max χ max =1-ap/r 1/2 60˚ 30˚ /2

(5) 5/8 68˚ 34˚ (4) 1 /r)]/2 3/4 76˚ 38˚ 7/8 83˚ 41.5˚ (5a) 1 90˚ 45˚

Fig. 7. Fig. Fig. 6. Fig.

5

6 7 3 4

2 1 8

5

6 7

3 4

2 1 8

6

6

5 5

4 8

3 1 2

4 8 3 1 2 h 1 a

p1

5

6 7 3 4

2 1 8

6

5

4 8

3

1 5

2 6 7

4

5 3

8

6

7 2 1 3 4

2 1 8

6

5 6

5

4 8

h 4 8 3

1 1 3 2

1 d=2r 2 f z X 1 h max X a eff p1 X 2 a a a p max p1 p2 Die andMold 49 Milling Tools 50 Milling Tools

inserts (RCC…MO). carry eithertheround insertswithserratedcutting edge(designatedasRCMT…)orregular round so theyoverlap,providing afullyeffective toolconfiguration.TheMILLSHREDmillingtoolscan indexed workingpositionsfor90˚indexing;andtheserrationsoncuttingedgewere designed the chipsplittingeffect. Itisachievedbythe serrated cuttingedgeoftheinsert.Theinserthas4 The mainprincipleoftheMILLSHREDinsertisacombinationround cuttingprofile with provides theuserswithanother operatingbenefitofefficient millingatthefullpossibledepth. cutting data.ISCARMILLSHREDlineoffers agoodsolution fortheproblem. Inaddition,it while millingnearthinwallsandinpoorworkholding:bothofthesecasesalsoresult inreduced diameter requires decreasing cuttingdataforstablemachining.Thesamesituationisobserved inserts are noexception.Asarule,millingwiththeoverhangalready twiceaslargethemill High overhangdramaticallyreduces vibrationstabilityofmillingcuttersandthemillswithround surfaces orthebottomprotrusions oftheinsertskeepaninsertfrom driftingduringcutting. corresponding numbers:1, 2,3,…forbetterusability. Thespeciallyshapedsidefacesontherelief indexed workingpositionsfor45˚or90˚indexing.Therakefaceofsomethemisindicatedinthe words, 0.05…0.15oftheinsert diameter).Forthatreason theISCARregular round insertshave8 maximal cuttingedgeangle25˚…45˚,thatisapproximately 0.1…0.3oftheinsertradius(orinother area. Ontheotherhand,maximum effect isatthehighestifdepthofcutensures thatthe machined contoured surfacesometimesdemandscomingintocuttingcontactexactlyatthis of thecuttingforce, extraneousvibrations,andasaresult, excessivewear, -theshapeofa engagement betweenatoolandworkpiece,considerableincrease oftheradialcomponent Although millingatthefullpossibledepth(theradiusofaround insert)leadstomaximum

molds. molds.

round insert round The serrated cutting edge that splits chips into small pieces significantly upgrades the round insert. round the upgrades significantly pieces small into chips splits that edge cutting serrated The diameter mm 12 “a means 12” size “insert example, For diameter. its is insert round a of size The First of all, reducing the cutting force (and especially its radial component) accrued from the chip the from accrued component) radial its especially (and force cutting the reducing all, of First Serrate around Serrate size Insert splitting, substantially improves the dynamic behavior and less of a tool, that ensures stable ensures that tool, a of bending less and behavior dynamic the improves substantially splitting, cutting with normal feeds if the tool overhang is high. Therefore the overhang range can be can range overhang the Therefore high. is overhang tool the if feeds normal with cutting considerably extended. Normally the upper border of the range comes close to the ten tool tool ten the to close comes range the of border upper the Normally extended. considerably diameters. In many cases such a simple and cheap solution renders unnecessary use of complex complex of use unnecessary renders solution cheap and simple a such cases many In diameters. and expensive toolholding devices with vibration-dampening properties. vibration-dampening with devices toolholding expensive and It is very important to note that the serrated cutting edge provides a means of depth equal to the to equal depth of means a provides edge cutting serrated the that note to important very is It insert radius. insert Also, the lower the cutting force the lower the machining power. machining the lower the force cutting the lower the Also, Secondly, the small chip pieces simplify chip evacuation, specifically in deep cavities of dies and dies of cavities deep in specifically evacuation, chip simplify pieces chip small the Secondly, And thirdly, the small pieces have fewer tendencies to be re-cut and that greatly improves rough improves greatly that and re-cut be to tendencies fewer have pieces small the thirdly, And milling of the deep cavities and increases tool life. tool increases and cavities deep the of milling ”. ** * disthediameterofaround insert Disthenominaldiameterofatool

the the Table 33 workpiece material(listedinTables 33and34). for MILLSHREDplainandserratedinsertsdependsonmachiningparametersthetypeof The selectionguidelineandgeneralrecommendations regarding amore suitablecuttinggeometry

-Recommendedchoice Poor workholding Milling nearthinwalls Tool overhangabove2.5×D Tool overhangto2.5×D** Depth ofcutabove0.15×d Depth ofcutto0.15×d* Cutting EdgeType Insert 8. Fig. Due to the ability to carry both types of round insert, with plain and serrated cutting edge, edge, cutting serrated and plain with insert, round of types both carry to ability the to Due Round wiper: a plain round insert improves surface finish surface improves insert round plain a wiper: Round alternate mounting plain and serrated inserts together in one tool (a sort of “FINISHRED”) “FINISHRED”) of sort (a tool one in together inserts serrated and plain mounting alternate does generally we change a serrated insert on the plain round one, the surface finish of a machined workpiece will will workpiece machined a of finish surface the one, round plain the on insert serrated a change we be improved. Here the regular plain insert looks like a wiper insert. Although the MILLSHRED tools tools MILLSHRED the Although insert. wiper a like looks insert plain regular the Here improved. be are intended mostly for rough milling, they are also used for semi-finish operations and the above above the and operations semi-finish for used also are they milling, rough for mostly intended are way of improvement is a simple but effective means. The plain round insert should be mounted in in mounted be should insert round plain The means. effective but simple a is improvement of way the pocket that is marked by a small round recess (so-called “watermark”, Fig. 8). Fig. “watermark”, (so-called recess round small a by marked is that pocket the MILLSHRED A plain round insert mounted for better surface finish surface better for mounted insert round plain A Selection GuidelinesforMILLSHREDRoundInserts Watermark not lead to essential advantages. Nevertheless, if in a tool with the serrated inserts inserts serrated the with tool a in if Nevertheless, advantages. essential to lead not cutter allows for combining into one tool assembly. However, so promising an an promising so However, assembly. tool one into combining for allows cutter RCC…MO plain RCMT… serrated Die andMold 51 Milling Tools 52 Milling Tools √√√ √√ √ (2) (1)

Last recommended Recommended forausteniticstainlesssteel Recommended formartensiticstainlesssteel Most recommended Second option Where: carried outduringmachining. to theradiusofaround insert.Itcorresponds toamaximalchip thickness,whichisplannedtobe The basicstartingfeed(Table 35)isarecommended feedformillingwithdepthofcutthat isequal found from thefollowingequation: Generally, thestartingcuttingfeedpertooththatshouldbeuseforCNCprogramming canbe i. MILLSHREDplainround inserts a) Startingfeedpertoothfz Starting CuttingData are coatedcarbide gradeIC910. madefrom PVDAlTiN recommended forheavy-dutyoperations.Additionally, theinsertsintendedformachiningcastiron coatedtoughgradethatisespecially mentioned intheprevious sections,andIC928 –aPVDTiAlN Mainly, theMILLSHREDinsertsare produced from gradesIC908,whichhasalready been Table 34 group 12-14 10-11 15-20 Mat. 38.1 6-9 1-5 Type ofMilling M H K P

Designation Application Insert Selection ofMILLSHREDInsertsforMachiningDieandMoldMaterials High-alloy steel Workpiece Hardened steel Low-alloy steel Geometry Stainless steel (HRC 45max) and toolsteel Plain carbon Cast iron steel fz Ks –thestabilityfactor KTH –thechipthinningfactor 0 –thebasicstartingfeed RCMT...FW interpolation Positive rakeface Helical 12º √√√ √√√ √√√ √√ √ fz = Shouldering RCMT...FW-T20 20º Positive rakeface Roughing with T-land √√√ 0 0.15 x KTHKs √ √ √ (1) 20º Contour Milling RCMT...FW-F20 Positive rakeface sharp edge 20º √√√ Ramping Down √ √ √ (2)

RCCT...MO Plunging Positive rakeface Roughing andSemi-Finishing 12º √√√ √√√ (6) √ √ Profiling RCCW..MO Flat topface with at-land √√√ √√√ √√√ √√ √ Pocket Milling 15º * ISCARmaterialgroup inaccordance withVDI3323standard less thantheradiusofinsert. the plannedmaximalchipthicknessatatimewhenmachiningisperformedwithdepthofcut reflects thenecessityforincreasing thebasicstartingfeed;whileCNCprogramming forobtaining The chipthinningfactor, asthefunctionofadepthcutandhencecuttingedgeangle, and formillingmaterialgroups 12-13(ferriticandmartensiticstainlesssteels) –by0.85. RC..T…MO. Incaseofmilling materialgroups 10-11,thetablefeedsshouldbemultiplied by 0.7; The feedsinTable 37correspond tomillingplaincarbonandlowalloysteels(groups 1-9)byinserts steels, HRC45max)–by0.55. machining groups 17-18(nodularcastiron) -by0.85andformachininggroup 38.1 (hardened groups 10-11(highalloyandtoolsteels),thetablevaluesshouldbemultipliedby 0.7,for plain carbonsteel)and15-16(grey castiron) withtheuseofinsertsRC..W…MO.Formachining Table 36,forinstance,reflects millingworkpiece materialgroups 5-9(lowalloysteelandquenched other materialgroups thetablevaluesshouldbemultipliedbycorresponding coefficients. The datainthetablesrelates tomachiningagroup ofmaterialsthatischosenasbasic;andforthe The tablescontainfeedspertoothasafunctionofthe diameterofaninsertandadepthcut. Alternatively, thefeedcanbedeterminedbyapplying Tables 36and37following. Hence, fz=0.15×1.95×1=0.29(mm/tooth);andtheprogrammed feedshouldbe0.29mm/tooth. is 0.15mm.Usingequation(4),χmax=41˚;and(7),KTH=1.95. From Table 35thebasingstartingfeedformaterialgroup No.10,related tothespecifiedsteel, What isthefeedpertoothnecessaryforCNCprogramming oftheoperation? cut. Theplateisproperly clampedintoaworkholding deviceandthecutterhaslightoverhang. D068A080-07-27-12carryinginsertsRCCW1206MOIC908with1.5mmdepthof cutter FRW The faceofaplatefrom AISIH13toolsteelannealed toHB170…190ismachinedbyshellmill Example overhang, poortoolholding,non-rigidworkholding,etc.). normal conditionsandto0.7iftheestimatedcuttingstabilityisinsufficient (millingthinwalls,high The stabilityfactorthattakesintoaccounttheeffect ofcuttingstabilityistakento be1for Table 35 -recommended choice ISO Class (DIN/ISO 513) M H K P

MILLSHRED PlainRoundInserts.BasicStartingFeedfzo,mm/tooth Material Group* 12 ,13 15-16 17-18 10-11 38.1 1-4 5-9 KTH =1/sin(1.5 or, thatisthesame, KTH =1/sin(0.75 0.12 0.18 0.21 0.21 0.18 0.21 0.15 Ø12 RC..W…MO 0.15 0.24 0.28 0.28 0.24 0.28 Ø16 0.2 Basic startingfeedfzo,mm/tooth,forinserts ef x χeff) 0.19 0.29 0.34 0.34 0.29 0.34 0.24 Ø20 x χmax) 0.12 0.14 0.14 Ø12 0.1 (7a) (7) RC..T…MO 0.16 0.19 0.19 0.13 Ø16

0.23 0.23 0.16 Ø20 0.2 Die andMold 53 Milling Tools 54 Milling Tools -Recommendeddepthsofcut for machininggroup 38.1(hardened steel,HRC45max)-by0.55. for machininggroups 17-18(nodularcastiron) -by0.85and For machininggroups 10-11(highalloyandtoolsteels),thetablevaluesshouldbemultipliedby0.7, The feedsrelate toworkpiecematerialgroups 5-9(lowalloyandquenchedcarbonsteels)15-16(grey castiron). Table 36 will be:0.54×0.7×0.7=0.26(mm/tooth). After correcting bythematerialcoefficient (0.7)andthestabilityfactor(0.7),programmed feed From Table 36fzo=0.54mm/tooth(forgroups 5-9). d (theinsertdiameter)=12mm;andtheratio“depthofcuttoradius”:ap/r=2×ap/d=0.1. The machinedmaterialrelates togroup No.10. depth ofcut. programmed feedpertooth needstobefoundifthecavityplannedmachinediswith0.6mm spring colletwithoverhang150mm.Theworkpiecematerialisunhardened AISIA2toolsteel.The D028A040-A-4-C32-12withinsertsRCCW1206MOIC908.Thecutterisclampedintoa ERW A workshopplanstoperformasemi-finishmachiningofdeepmoldcavitybyusingendmillcutter Example be asfollows:0.4(thetablevalue)×0.7(coefficient formaterialgroup No.10)=0.28(mm/tooth). the feedby30%.UsingTable 36,theprogrammed startingfeedfortheprevious exampleshould In eithercase,machiningunderunstableoperationalconditionswillalsodemandreducing – ap/r 1/16 1/10 1/8 1/4 3/10 1/2 5/8 3/4 7/8 1 MILLSHRED PlainRoundInsertsRC..W…MO.BasicFeeds,mm/tooth 0.15 0.37 0.75 3.75 5.25 0.6 1.5 1.8 4.5 ap 3 6 Ø12 0.54 0.36 0.27 0.21 0.21 0.21 0.21 fz 0.8 0.7 0.5 0.4 o Basic startingfeedfzo,mm/tooth,forinserts 0.15 0.5 0.8 2.4 ap 1 2 4 5 6 7 8 Ø16 0.54 0.45 0.36 0.28 0.28 0.28 0.28 fz 0.9 0.7 0.6 1 o 0.15 0.62 1.25 6.25 8.75 2.5 7.5 ap 10 1 3 5 Ø20 0.67 0.54 0.45 0.34 0.34 0.34 0.34 fzo 1.3 1.2 0.9 0.8 The The

Where: • • • • -Recommendeddepthsofcut multiplied by0.7,formachininggroups 12-13(ferriticandmartensiticstainlesssteels)–by0.85. For machininggroups 10-11(highalloyandtoolsteels)thetablevaluesshouldbe The feedsrelate toworkpiecematerialgroups 1-9(plaincarbonandlowalloysteels). Table 37

A programmed startingfeedpertoothfzisdefinedbyequation(8): (to 15%oftheinsertdiameter)whenmaindrivepower ofamachinetoolislimited. Additionally, theserrated inserts are sometimesappliedinmillingwith usual depthofcut Poor workholding Milling nearthinwalls Considerable toolprojection (theoverhangmore than2.5ofthetooldiameter) High depthofcut(above15%theinsertdiameter) following cases: As previously noted(Table 33),theserratedround insertsare intendedfirst of allforthe machining stability. The tool overhang being 5% less reduces the tool deflection by 15%, 10% 10% 15%, by deflection tool the reduces less 5% being overhang tool The stability. machining ii. MILLSHREDserratedround inserts Tool overhang Tool less –by 27% and 20% less – already by 50%. Minimizing the overhang substantially improves substantially overhang the Minimizing 50%. by already – less 20% and 27% –by less operational efficiency, allowing for increased cutting conditions and good surface finish. surface good and conditions cutting increased for allowing efficiency, operational But, what can we do - manufacturing real parts often demands long tools. How to determine the the determine to How tools. long demands often parts real manufacturing - do we can what But, cutting data for such tools? And what is a high overhang, for which various techniques of cutting of techniques various which for overhang, high a is what And tools? such for data cutting data determination recommend correction factors? correction recommend determination data This not simple question is directly connected with the dynamic behavior of a tool. It relates to the to relates It tool. a of behavior dynamic the with connected directly is question simple not This sphere of serious research and needs a separate discussion. We are sure that the reader on reader the that sure are We discussion. separate a needs and research serious of sphere the basis of his own knowledge and experience knows exactly if the overhang of a tool that he uses he that tool a of overhang the if exactly knows experience and knowledge own his of basis the is high. For a rough estimate, the following rule of thumb often can be helpful: the overhang is high is overhang the helpful: be can often thumb of rule following the estimate, rough a For high. is being 4-5 and more times as much as the nominal diameter of the tool. However, one thing needs thing one However, tool. the of diameter nominal the as much as times more and 4-5 being clarification: from which point should the overhang be measured? be overhang the should point which from clarification: Generally, in case of the shell mills mounted on arbors, the correct way is to measure the overhang the measure to is way correct the arbors, on mounted mills shell the of case in Generally, for the whole assembly, which is to say from the line (datum) of the arbor shank (Fig. 9). 9). (Fig. shank arbor the of (datum) line gauge the from say to is which assembly, whole the for For the endmills that are clamped into holders with spring or adapter-style holders holders adapter-style or collets spring with holders into clamped are that endmills the For with side screws, the overhang is measured from the holder (Fig. 10). (Fig. holder the from measured is overhang the screws, side with – ap/r 1/16 1/10 1/8 1/4 3/10 1/2 5/8 3/4 7/8 1 overhang MILLSHRED PlainRoundInsertsRC..T…MO.BasicFeeds,mm/tooth (or the projection) of a milling tool is an important factor of the tool stiffness and stiffness tool the of factor important an is tool milling a of projection) the (or KH fzo 0.15 0.37 0.75 3.75 5.25 0.6 1.5 1.8 4.5 ap –thebasicstartingfeed(Tables 39-41) 3 6 –theoverhangcoefficient (Table 38) Ø12 0.56 0.41 0.36 0.26 0.24 0.18 0.14 0.14 0.14 0.14 fz 0.5 fz =fzoxKH o Basic startingfeedfzo,mm/tooth,forinserts 0.15 0.5 0.8 2.4 ap 1 2 4 5 6 7 8 Ø16 (8) 0.75 0.68 0.55 0.47 0.34 0.32 0.25 0.19 0.19 0.19 0.19 fz o 0.15 0.62 1.25 6.25 8.75 2.5 7.5 ap 10 1 3 5 Ø20 0.83 0.67 0.57 0.42 0.39 0.23 0.23 0.23 0.23 fz 0.9 0.3 o Die andMold 55 Milling Tools 56 Milling Tools Therefore wehavefz=0.2×0.9×1=0.18 (mm/tooth). coefficient isequalto1(Table 38). for materialgroup No.10.Thecutterdiameteris50mm;andforoverhang 120mmtheoverhang feed fora16mmdiameterinsertwith6depthofcut as0.2,whichshouldbemultipliedby0.9 The workpiecematerialrelates tothetenthmaterialgroup (No.10).Table 39specifiesthebasic mm. Whatisaprogrammed feedtostartmilling? inserts RCMT1607-FWIC908mountedonit.Thecutter overhangis120mm,thedepthofcut–6 A diepartmadefrom D034A050-04-22-16with AISID2toolsteel,HB210,ismilledbycutterFRW Example as theFunctionofRatioanOverhangHtoaTool DiameterD1 Table 38OverhangCoefficient KHfortheMILLSHRED SerratedRoundInserts H/D1 KH Fig. 9 Fig.

Datum

to 4 1

5

6 7 3 4

2 1 8

6

5

4 8 3 1 2 h over 4to6 0.85 Fig. 10 Fig. over 6to8 0.7 over 8to10 0.65 h Basic Feeds, Table 39 machining carbon First choice Consequently, thestarting programmed feedis:0.13×0.7=0.09(mm/tooth). loading) directly, itiseasilyseenthat0.13mm. does notcontainthebasicfeedfor12mmdiameterinserts with4mmdepthofcut(worstcase The materialrepresents group No.14;ratio “overhang/diameter”is220/32=6.9.AlthoughTable 40 the toolpath. performs cuttingwith220mmoverhangfrom acollet.Findfeedpertoothneeded forprogramming FW-T20 IC928.Duetotheunsteadyallowancedepth ofcutvariesfrom 3to4mm.Thetool D020A032-B-3-C32-12carryinginserts RCMT1206- machining allowanceismilledbytoolERW A moldpartfrom AISI420stainlesssteelwith athin-walledcomplicatedshapeandnon-uniform Example -Recommendeddepthsofcut For machininggroups 1-9(carbonandlowalloysteels)thetablevaluesshouldbemultipliedby1.1. The feedsrelate toworkpiecematerialgroups 12-13(ferriticandmartensiticstainlesssteels). Table 40 -Recommendeddepthsofcut group 38.1(hardened steel,HRC45max)–by0.6. multiplied by0.9,formachininggroups 15-18(castiron) –by1.3andformachining For machininggroups 10-11(highalloyandtoolsteels)thetablevaluesshouldbe The feedsrelate toworkpiecematerialgroups 1-9(plaincarbonandlowalloysteels). ap min ap/r ap min ap/r 1/4 1/4 3/10 3/10 1/2 1/2 5/8 5/8 3/4 3/4 7/8 7/8 1 1 MILLSHRED General-purposeSerratedRoundInsertsRCMT…FW. MILLSHRED SerratedRoundInsertsRCMT…FW-T20.

for machiningmartensiticstainlesssteelcanalsobeused

mm/tooth

0.9 ap 0.9 ap 1.5 1.5 1.8 1.8 3 3 3.75 3.75 4.5 4.5 5.25 5.25 6 6 and lowalloysteels Ø12 Ø12 0.26 fz 0.3 fz 0.23 0.28 0.21 0.25 0.18 0.22 0.13 0.15 0.13 0.15 0.13 0.15 0.13 0.15 o o Basic startingfeedfzo,mm/tooth,forinserts Basic startingfeedfzo,mm/tooth,forinserts ap ap 1.2 1.2 2 2 2.4 2.4 4 4 5 5 6 6 7 7 8 8 Ø16 Ø16 fz fz 0.35 0.4 0.3 0.35 0.28 0.32 0.25 0.28 0.18 0.2 0.18 0.2 0.18 0.2 0.18 0.2 o o ap ap 1.2 1.2 2.5 2.5 3 3 5 5 6.25 6.25 7.5 7.5 8.75 8.75 10 10 Ø20 Ø20 fz fz 0.4 0.52 0.35 0.46 0.3 0.42 0.28 0.35 0.21 0.25 0.21 0.25 0.21 0.25 0.21 0.25 o o Die andMold 57 Milling Tools 58 Milling Tools Where: • • •

can beusedalsoformachininglowcarbonsteel. Recommended cuttingspeed a waythatthecuttingspeedrelative totheeffective diameterwillbeequaltothefoundvalue Calculate theprogrammed spindlespeedrelative tothenominaldiameterofatoolinsuch Calculate theeffective diameter Find therecommended cuttingspeedwiththe useoftheaverageddataintables The startingcuttingspeedshouldbedeterminedbythefollowingsteps: b) First choice Table 41 -Recommendeddepthsofcut For machininggroups 21-25(aluminumalloys)thetablevaluesshouldbemultipliedby3. For machininggroup 1(lowcarbonsteel)thetablevaluesshouldbemultipliedby1.5. The feedsrelate toworkpiecematerialgroup 14(austeniticstainlesssteel). ap min ap/r 1/4 3/10 1/2 5/8 3/4 7/8 1 Starting cuttingspeedVc MILLSHRED SerratedRoundInsertsRCMT…FW-F20.

for machiningausteniticstainlesssteelandaluminumalloys; Kt KH KF Vo – – – – 0.9 ap 1.5 1.8 3 3.75 4.5 5.25 6 The basiccuttingspeed(Table 43) KF=0.75 fortheserratedround inserts KF=1 fortheplainround insertsand The factorofacuttingedgeform: The toollifefactor(Table 8) For theplainround insertsKHisspecifiedin Table 42 For theserratedround insertsKHcanbefound from Table 38 The overhangcoefficient: Vc =Vo xKHKt xKF Ø12 0.13 fz 0.12 0.1 0.09 0.07 0.07 0.07 0.07 o Basic startingfeedfzo,mm/tooth,forinserts ap 1.2 2 2.4 4 5 6 7 8 Ø16 fz 0.17 0.16 0.14 0.12 0.09 0.09 0.09 0.09 o (9) ap 1.2 2.5 3 5 6.25 7.5 8.75 10 Ø20 fz 0.2 0.18 0.16 0.14 0.1 0.1 0.1 0.1 o Cutting speedVnrelative tonominaldiameter D1,canbefoundfrom thefollowingequation:

thin-walled parts,thestartingspeedshouldbereduced by20%. In addition,forhard loadingwithbroad-area engagement,improper workholdingormilling Round InsertsastheFunctionofRatioanOverhangHtoaTool DiameterD1 Calculating theprogrammed spindlespeedN Calculating theeffective diameter De Calculating theeffective diameter De Table 42 Where: Tool Application KH H/D1 Overhang Coefficient KHfortheMILLSHREDPlainRoundandHELIDOH400 (For nominaldiameterD1ofatoolD=D1-d) ap d D – – –

N =1000xVc/(πDe) insert centercircle axial depthofcut insert diameter Vn =πxD1N/1000 De =D+2x√d×ap-ap to 2.5 1 Recommended

over 2.5to3 0.9

(12) 2

over 3to5 0.65 (10) Less recommended (11)

over 5 0.5 Die andMold 59 Milling Tools 60 Milling Tools

Fig. 12 Fig. Fig. 11 Fig.

The correct approach to finding the cutting speed of a profiling milling tool is to calculate the speed the calculate to is tool milling profiling a of speed cutting the finding to approach correct The with respect to the effective diameter of the tool. In profiling, due to the shaped, non-straight form form non-straight shaped, the to due profiling, In tool. the of diameter effective the to respect with Effective diameter Effective of the tool, a cutting diameter is a function of a depth of cut; and it is not the same for different areas different for same the not is it and cut; of depth a of function a is diameter cutting a tool, the of of the tool cutting edge that is involved in milling. The effective diameter is the largest true cutting true largest the is diameter effective The milling. in involved is that edge cutting tool the of Ignoring the cutting diameter in calculating spindle speeds can cause essential errors in cutting in errors essential cause can speeds spindle calculating in diameter cutting the Ignoring diameter: maximum of the cutting diameters of the mentioned areas (Fig. 11). Generally, it Generally, 11). (Fig. areas mentioned the of diameters cutting the of maximum diameter: data and incorrect tool operation. In the milling cutters with round inserts, specifically, specifically, inserts, round with cutters milling the In operation. tool incorrect and data corresponds to the diameter measured at the axial depth of cut. of depth axial the at measured diameter the to corresponds this is particularly significant for relatively small tool diameters. For example, for a 25 mm diameter mm 25 a for example, For diameters. tool small relatively for significant particularly is this tool with 12 mm diameter round inserts, the cutting diameter varies from the value closed to 13 mm 13 to closed value the from varies diameter cutting the inserts, round diameter mm 12 with tool (the axial depth of cut is nothing more than tenths of mm) to 25 mm (at maximum depth of cut that cut of depth maximum (at mm 25 to mm) of tenths than more nothing is cut of depth axial (the equal to the insert radius – 6 mm). If the effective diameter is, for instance, 19 mm, and the spindle the and mm, 19 instance, for is, diameter effective the If mm). 6 – radius insert the to equal speed was calculated with reference to 25 mm, the real cutting speed relative to 19 mm diameter diameter mm 19 to relative speed cutting real the mm, 25 to reference with calculated was speed will be 24% less! The error grows for shallow depths of cut: for effective diameter 14 mm it is is it mm 14 diameter effective for cut: of depths shallow for grows error The less! 24% be will already 44%. already Of course, for large-sized tools such error grows substantially smaller and can even be ignored. ignored. be even can and smaller substantially grows error such tools large-sized for course, Of Moreover, machining slots, milling near straight walls, etc. with even shallow depth of cut but with but cut of depth shallow even with etc. walls, straight near milling slots, machining Moreover, several passes, when after each pass the tool embeds deeper and deeper into the workpiece, workpiece, the into deeper and deeper embeds tool the pass each after when passes, several and its nominal diameter in some or other way cuts the material (Fig. 12), the calculations shall shall calculations the 12), (Fig. material the cuts way other or some in diameter nominal its and relate only to the nominal diameter! nominal the to only relate In any other case we always recommend to take the effective diameter into consideration and consideration into diameter effective the take to recommend always we case other any In make corresponding necessary corrections during programming the spindle speed. spindle the programming during corrections necessary corresponding make Remember, the cutting speed relates to the effective diameter, while the spindle speed refers refers speed spindle the while diameter, effective the to relates speed cutting the Remember, to the nominal diameter! nominal the to

5

6 7 3 4

2 1 8

6

5

4 8 3 1 2 D eff1 1 st st pass

n

5

6

7 3 4

2 1 8

5

6 7 3 4

2 1 8

D

6 eff

5

4 8 3 1 2

V 6

F 5

4 8

3 1 2

5

6

7 f

z 4 3

2 8 1 Area involvedincutting D eff a p = D D N nom eff=

pass

D

i 6 max n

D 5

5

6

7 3 4

2 1 8 i

4 8 6

5

4 8

3 1 3 2 1 2 V F a p *** ** *

-Firstchoiceforgrades

The effective diameter:De=80+2×√(20×1.8-1.8 If theratio“overhangtotooldiameter”,86/100,issmall,thenKH=1(Table 42). if thedepthofcutis1.8mmandtooloverhang86mm. D080A100-06-32-20withinsertsRCMW2009MOIC928, with theuseofshellmillFRW Find thecuttingdataformillingaplatefrom pre-hardened moldsteelAISIP20,HRC32, Example speed andthespindleshouldbe114m/min728rpmrespectively. Tool lifefactorKt=0.8for60min.toolexpectancy(Table 8),andinforthiscasethecutting The programmed spindlespeed:N=1000×143/(π×50)=910(rpm) spindle speedthelattercanbeusedbecauseerrors willbenegligible. The received valueisveryclosetothetoolnominaldiameter(50mm).Therefore incalculatingthe Vn= π×100×507/1000=160(m/min) The cuttingspeedwithrespect tothetoolnominaldiameter: The programmed spindlespeed:N=1000×145/(π×91)=507(rpm). The recommended cuttingspeed:Vc=145×1×1×1=145(m/min). table values0.8and0.67). The startingprogrammed feedisfoundfrom Table 36:fz≈0.73mm/tooth(thevalue between The workpiecematerialinitsconditioncorresponds tomaterialgroup No.9. KF=0.75 (forplainround inserts). The effective diameterfor6mmdepthofcut:De=34+2×√(16×6-0. Hence for20min.toollifeVc=190×0.75×1=143(m/min) KF=0.75 (forserratedinserts),KH=1(overhangcoefficient, Table 38). For materialgroup No.10,thatrelates toAISID2steelVo=190 m/min(Table 43). feed hasbeendefinedas0.18mm/tooth. IC908; whilethecutteroverhangis120mmanddepthofcut6mm.Thestartingprogrammed D034A050-04-22-16carryinginsertsRCMT1607-FW tool steel,HB210,ismilledbycutterFRW Find thecuttingspeedforoneofprevious examples,inwhichthediepartmadefrom AISID2 Example HRC 45max. ISCAR materialgroup inaccordance withVDI3323standard For 20min.toollife Table 43 ISO Class DIN/ISO 513 M H K P Basic SpeedVo, m/min,forMILLSHRED RoundInserts* Material Group** 38.1*** 12, 13 17-18 15-16 8-9 2-4 6,7 11 10 5 1 IC908 190 240 150 190 210 220 260 180 220 240 110 2 )=91 (mm). ISCAR CarbideGrades IC910 135 145 160 180 200 210 240 230 270

2 )=49.5 (mm). IC928 130 135 145 155 155 170 190 155 200 230 70 Die andMold 61 Milling Tools 62 Milling Tools • • The • The • • For

Example Machining depth ofcut,becausethewrong definitioncan leadtosubstantiallyreduced toollife. Cutting datamustbecorrectly definedwithrespect toproperly choseneffective diameterand machine tools. round inserts. system (poorworkholding,thin-walledpart,etc.)willbemore effective withtheserrated is asource ofseriousvibrations,intensivewearandmisoperation. (or 5-15%oftheinsertdiameter).Rememberthatmachiningwithdeepercutsinthiscase Their highestefficiency willbewhenthedepthofcutis10-30%insertradius MILLSHRED round inserts: and moldmaking.Markingtheendofsection,underlinedagainare the round shape,madetheround insertthereal workhorseofrough andsemi -finish millingindie In summation,theabove-mentionedadvantages:highstrength ofcuttingedge andbenefitsof relative toit. of cutissmall,thetoolnominaldiametercutsalsoandtherefore thecalculationshouldbe required. Inallappearances,itisthereason forthecustomer’s nominal diameter(thatbegancuttingafter8passes)is1.25(32/25.6=1.25)greater than value thecustomerdefinedspindlespeed.Asa result, thecuttingspeed referred tothe The calculatedeffective diameteris20+2×√(12×0.7-0.7 depth ofcutis6mm–theinsertradius. portions willbeinvolvedinmillingnearthecavitywall:8×0.7mm=5.6mm,andmaximal brings anewportionoftheedgeinengagement.Afteralready the8thpass,almostallcutting In thefirstpassonlyasmallpartofinsertcuttingedgecutsmaterial.Buteverynextpass and theeffective diameter. Whatisareason for theproblem? accordance withtheISCARrecommendations andtookintoaccountthehighoverhang passes andthusremoves materiallayer bylayer. Thecustomerdefinedthecuttingdatain machines thecavitybyrequired contourwithshallowcuts(0.7mmdepthofcut)bystepped D020A032-A-3-C25-12,withtheinsertsclampedintoitspockets steel. Duringoperation,toolERW milling adeepandnarrow cavitywithalmost verticalwallsfrom asolidblockofSAE/AISI4340 A customercomplainsofpoortoollifewithinsertsRCCW1206MOIC908,thatare usedin shallow depthsofcutandsmalltooloverhang,theplainround inserts are thebestsolution. serrated insertsneedlesscuttingpowerandtherefore are suitableforlow-power serrated insertsduetochipsplittingeffect cansolvetheproblem ofchipevacuation. with greater depthsofcut,highoverhang,insufficient stiffness ofthetechnological 2 )=25.6 (mm);andwithrespect tothis problem. Eventhoughthe depth somepointsofusing some kindsofmartensiticstainlesssteel. temperature alloys,canalsobeusedindieand moldpractice,sofarasmillingsoftcarbonsteelor inserts ofHP-typehavingso-called“highpositive”cuttinggeometryandbasicallyintendedfor ML- andAX-typesare more suitableformillingthedieandmoldmaterials. Atthesametime regarding theinsertsandtheirapplicationindiemoldindustry. Asseen, theinsertsof grades, featuringadvancedcoatingandposttreatment technology. Table 44showsgeneraldata the insertsofAX-type–helical(Fig.15).Theare madefrom thelatestSUMOTECcarbide various materialsandapplications.TheinsertsofML-HP-typeshavestraightmajoredges, There are three different typesoftheinsert:ML,HPandAX,whichare designedformachining diameters forthecuttersofstandard lineis32…80mm. and alsoasinterchangeable millingheadswithFLEXFITthreaded connection.The rangeof The HELIDOH400cuttersare availableinarbor-type facemill,shank-typeendmillconfiguration; a more closedangularpitch ofteeth. The H400…insertissmallerinsize,thatenablesacutterdesignwithmore insertattheperiphery– (Fig. 14)thatmakesitpromising fordieandmoldapplications. expand thefamilypossibilitiesinmillingcomplicated3-Dshapes,especially5-axismachining The fourfull120°majorcuttingedgesincombinationwiththe“ramping”significantly addition, theinserthasfourminorcuttingedges,actingmostlyduringrampdown. arc of6mmradius.Bycomparison, around insertoftraditionaldesignensures four90°arcs. In The H400RNHU1205…insert(Fig.13)hasfourmajorcuttingedgesandeachofthemisthe120° round inthesenseofword. double-sided insertH400RNHU1205…thatlookslikearound insert,butproperly speakingisnot the industryrequirement foraneffective millingtoolfor multiaxisprofiling. Thefamilyisbasedona The HELIDOH400family A ConceptuallyNewSolutionforEfficient Profiling 3.1.1.1. HELIDOH400RoundLine Fig. 14 Fig. Fig. 13 Fig. a , oneofthelatestISCARdevelopments,wasdesignedinorder tofulfill 6 mmradius of circle with Center b 2 R6 ˜ 11 120º 1 c Die andMold 63 Milling Tools 64 Milling Tools

estimation ofthebasicfeeddirectly (Table 47). values ofthebasicstartingfeedfzoandspeedVo (Tables 45and46correspondingly) andallow the radiusofaH400insert:namely, 6mmforinserts H400 RNHU1205).Thetablesbelowshow angles canbecalculatedbyequations(4)-(5a)orestimated usingTable 32(inthiscaserwillbe starting feed,equation(7)–achipthinningfactorand(9) –astartingcuttingspeed.Cuttingedge described methodrelative tothecutterswithindexableround inserts.Equation(6)specifiesa The wayofdefiningstartingcuttingdatafortheH400millingtoolsissimilartoalready Table 44

H400 RNHU...-HP H400 RNHU...-AX H400 RNHU...-ML Insert Fig. 15 Fig. rake and axial rake for indexable milling tools, which led to led which tools, milling indexable for rake axial and rake normal positive increasing of way effective and making cutting smoother cutting making and formation chip improving forces, cutting decreased substantially “ called is inserts milling of sort that why reason the is This stable. more and unlike turning, there is no standard classification for combinations of geometrical of combinations for classification standard no is there turning, unlike milling, In possibility became more and more impressive. The shaping resulted in resulted shaping The impressive. more and more became possibility the and face, rake the additional increas additional an to rise gave technology of development Further “ words but inserts, indexable of parameters and high positive high and positive Neutral, the insert cutting edge. Thus the axial rake can be more positive. positive. more be can rake axial the Thus edge. cutting insert the along corners cutting clarification. need they terms the with familiar be “ is what But “ differences height considerable the with inserts the call to accepted is It “ called is base insert the to parallel surface rake flat a with insert An possibility the about brought technology pressing and powder in progress The the pressing technology does not exhaust its potential, and maybe, today maybe, and potential, its exhaust not does technology pressing the course, Of geometry are inserts for milling hardened steel and cast iron. iron. cast and steel hardened milling for inserts are geometry a such of examples Typical be classified only as positive tomorrow. positive as only classified be will inserts milling positive HELIDO H400Inserts positive straight helical straight edge Cutting ? ” Straight Edge Straight positive neutral negative T-land a ML, HP ML, high temp.alloys stainless steel steel First priority neutral ” Intended for “ , positive stainless andsoftsteels steel stainless steel Second priority Helical Edge Edge Helical ” etc. are commonly used. In order to order In used. commonly are etc. , b neutral of difference in height for two for height in difference of e high positive high AX ” . . positive

IC808 ” . high ’s

IC830 ” Grades . of shaping an

IC330 *** ** * * *³ HP-type: *² AX-type: *¹ ML-type:

-Firstchoiceforgrades

For machininggroups 12-13(ferriticandmartensiticstainless steels)thetablevaluesshouldbemultipliedby0.85. The feedsrelate toworkpiecematerialgroups 1-4(plaincarbonsteel). for machininggroups 12-13(ferriticandmartensiticstainless steels)-by0.85. For machininggroups 10-11(highalloyandtoolsteels)thetable valuesshouldbemultipliedby0.7, The feedsrelate toworkpiecematerialgroups 1-9(plaincarbonandlowalloysteels). (hardened steel,HRC45max)-by0.55. groups 12-13(martensiticstainlesssteel)and17-18(nodularcastiron) -by0.85andformachininggroup 38.1 For machininggroups 10-11(highalloyandtoolsteels)thetablevaluesshouldbemultipliedby 0.7,formachining The feedsrelate toworkpiecematerialgroups 1-9(plaincarbonandlowalloysteels)15-16(grey castiron). fzo, mm/tooth,asaFunctionofDepthCutap Table 47 Table 46 Table 45 HRC 45max ISCAR materialgroup inaccordance withVDI3323standard For 20min.toollife -Recommendedapplication ISCAR materialgroup inaccordance withVDI3323standard ISO Class ISO Class (DIN/ISO DIN/ISO 513) 513 M M

H K H K P P 5.25 3.75 0.75 0.37 0.15 mm ap, 4.5 1.8 1.5 0.6 6 3 HELIDO H400RNHU1205RoundInserts.BasicFeeds Milling Tools withHELIDOH400RNHU1205Inserts.BasicSpeedVo, m/min HELIDO H400RNHU1205RoundInserts.BasicStartingFeedfzo,mm/tooth Material Material Group** Group* 38.1*** 12, 13 17-18 15-16 10-11 12-13 17-18 15-16 38.1 8-9 2-4 5-9 1-4 6,7 11 10 5 1 ML*¹ 0.21 0.21 0.21 0.21 0.27 0.36 0.54 0.4 0.5 0.7 0.8 IC808 0.15 0.21 0.21 0.18 0.12 0.18 0.21 190 240 220 240 150 190 210 220 260 180 110 ML Vo forcarbidegrades fzo fortypes fzo forinserttype AX*² 0.14 0.14 0.14 0.14 0.18 0.24 0.26 0.36 0.41 0.56 0.5 IC830 0.14 0.14 0.12 220 240 125 135 140 145 145 160 180 150 90 0.1 AX HP*³ 0.14 0.14 0.14 0.14 0.18 0.24 0.26 0.36 0.41 0.56 IC330 0.5 0.14 0.12 120 125 125 130 130 145 160 140 HP

Die andMold 65 Milling Tools 66 Milling Tools The startingfeedspeed:V The programmed startingspindlespeed:N=1000×150/(π×32)=1492(rpm). The basiccuttingspeed(Table 46):Vo=150 m/min 47 withreducing thetable valueby15%-seeremark tothetable). The basicfeedpertooth(Table 45):fzo=0.18mm/tooth(alternatively, fzocanbedefinedfrom Table cutting edgeperformscutting). MULTI-MASTER toroidal heads. Table radiiRofthestandard 48showsnominaldiametersDandcorner lineofthe multiflute MMETR…headsfullyground from solid. also represented bytwodesignversions:two-flutepressed toshapeandsizeMMHT…heads As forotherformsoftheMULTI-MASTER heads,thetoroidal cuttingprofile ifthistoolfamilyis Solid CarbideToroidal MillingTools 3.1.2. MULTI-MASTER Toroidal MillingHeadsand The effective diameter:De=(32-12)+2×√(12×4.5-4.5 calculation shouldrefer tothedepthmaximum(4.5mm). The componentmaterialrelates toISCARmaterial group No.13.Duetovariabledepthofcutthe approached alocalISCAR representative onrecommendations regarding startingcuttingdata. machining variesfrom 1to4.5mm.Machiningstabilityisestimatedasgood.Themanufacturer made from AISI420stainless steelwithhardness HB300…310.Thedepthofcutduring inserts H400RNHU1205-HPIC830for5-axismachiningacomplex-shapedmoldcomponent A dieandmoldmanufacturer decidedtouseendmillcutterH400ERD32-4-060-C32-12with Example correctionConcerning causedbyatooloverhang,Table 42givesnecessarydata. Table 48 6 flute 2 flute MM HT…MM 2 flute Tool diam. Corner radiusR,mm MM ETR… D, mm D, MULTI-MASTER Toroidal MillingHeads

2 8

0.5 F =0.18×4×1492=1074 (mm/min).

1 10

2

3

1.6

2

2.5 12 2 )=31.6 (mm)≈32mm(themostpartofthe

3

4

2

3 16

4

5

3

4

20 5

6

8

diameter of a toroidal milling tool with round inserts decreases it causes reduc causes it decreases inserts round with tool milling toroidal a of diameter the If the toroidal solid tools and heads present the milling cutters with precise with cutters milling the present heads and tools solid toroidal the speaking, Properly called also radiused, the So, effectively mill light-size parts and small radii. In addition, increased requirements increased addition, In radii. small and parts light-size mill effectively to able where the insert is an integral part of the cutter body (Fig. 16). (Fig. body cutter the of part integral an is insert the where inserts, round edge cutting peripheral the of back A cutters. toroidal the as perform can edge, machined wall if this contact is undesirable (the tool deflection due the radial cutting radial the due deflection tool (the undesirable is contact this if wall machined a and of toroidal cutting bull cutting toroidal of draft Back that secures the insert. The tool becomes weaker, less productive; and at one point one at and productive; less weaker, becomes tool The insert. the secures that screw a provided with bottom or peripheral wiper flats and even chip splitting grooves. splitting chip even and flats wiper peripheral or bottom with provided are heads do we discussion. but current under chamfered; or consideration rounded into gently but features sharp design so not are conventional view these closer take not upon corners sharp chamfered corners. The cutting end of a tool (on the tool face) is made with made is face) tool the (on tool a of end cutting The corners. chamfered with mill accuracy set accuracy machining of taper back the by produced overhang, vibrations overhang, high force, tools is practically impossible. The same situation occurs when the when occurs situation same The impossible. practically is tools such producing have have not may or may end cutting peripheral the and s); endmill bottom flat (in it without or concavity small concavity, the straight peripheral cutting edge often have slight, and the and slight, have often edge cutting peripheral straight the concavity, small with produced some technical terms, which specify the solid tools and the heads. Because the Because heads. the and tools solid the specify which terms, technical some are There the number of teeth is generally 2 or 3. Being ground peripherally and mostly with mostly and peripherally ground Being 3. or 2 generally is teeth of number the and draft; endmill solid 90˚ the about Speaking d the However, decreases. radius insert for allows taper back The taper. back a with a with heads interchangeable and tools carbide Solid s and interchangeable toroidal milling heads feature the feature heads milling toroidal interchangeable and s endmill toroidal carbide solid Today and industrial workers often use different terms for the same things, things, same the for terms different use often workers industrial and manufacturers tool face rake ground endmill radius) (or radiused the corners, sharp application boundaries of toroidal milling tools. milling toroidal of boundaries application the extend thus and problems of the back draft radiused (bull nose) cutters. The most popular diameters popular most The cutters. nose) (bull radiused draft back the of configuration design short consideration. short requires matter the s and are suitable for rich applications from productive milling of small of milling productive from applications rich for suitable are and s endmill radiused precise tools and heads lay within 10…25 mm 10…25 within lay heads and tools the of mold components to finish fillets with high accuracy. In some cases these tools and and tools these cases some In accuracy. high with fillets finish to components mold and die the tool and heads combine the advantages of the round inserts with the the with inserts round the of advantages the combine heads and tool the , a limit to using the tool with round inserts in some operations. some in inserts round with tool the using to limit a improves efficiency of the cutter. the of efficiency improves , the bull nose, mills, especially with the concave end cutting end concave the with especially mills, nose, bull the s are are s endmill bottom flat the even told, be truth If etc.). , between divided traditionally are they , minimiz m and ie N . with rounded corners and the chamfered end chamfered the and corners rounded with ation of ation ormally they have 5˚...7˚ concavity and back back and concavity 5˚...7˚ have they ormally old industry demands toroidal cutters to be to cutters toroidal demands industry old toroidal cutting profile overcome th overcome profile cutting toroidal the area of contact between the tool tool the between contact of area the s with s endmill square the tion of tion , ese Die andMold 67 Milling Tools 68 Milling Tools that shouldbetakenintoaccountinsuchcases,forwhich 3 mm(2for8dia.heads)andmore. Table 50containsvalues ofchipthinningfactorKTH radius”hasnopreciselarge corner definition,butaruleofthumbsaysthat itistheradiusfrom with relatively radius,thechipthinningeffect largecorner mayplayanimportantrole. The“relatively are used,forexample,facemilling,anaxialdepthofcutdefinestheallowance; andforheads In millingwiththetoroidal heads,themachiningallowanceisnormally0.01D…0.2D.If heads greater overhangsKH=0.7. If theoverhangofatooldoesnotexceed3D(three diametersofthetool),KH=1;incase Table 49showsbasicstartingfeedfzofordifferent groups ofengineeringmaterials. above equation(8): Programmed feedpertoothfz,whichrelates tothenominaldiameter ofaheadisdefinedbythe a) Startingfeedpertoothfz STARTING CUTTINGDATA grade IC903. heads thatare intendedmostlyformillingsteels ofhighhardness (HRC56-63)are produced from IC908 isamaincarbidegradefortheMULTI-MASTER toroidal millingheads.Inaddition,some In addition,bothtypesoftheheadsare sometimesused formillingundercuts. high-performance rampingdownbystraightlineandhelix(interpolation). cutting teethandtherefore are notsuitablefordrillingoperations.However production finishmillingofhardened steelandprecise filletfinishing.Theheadsdonothavecenter Multiflute MMETR…headswith30˚helixandzero radialrakeare and ramping,sideplunging,alsodrillssmalldepth. successfully appliedtohighfeedmilling,machiningcavitiesandpocketsbyhelicalinterpolation make theheadsveryeffective inmillingsteel, hardened steelandcastiron. Theheadsare heavy toothloadingandneutralground rakeface(zero radialrake).Thesecharacteristicproperties The maindesignfeatures particulartoMMHT…headsare: high-strength structure thatallowed Fig. 16 Fig. Concavity fz =fzoxKHKTH fz =fzoxKH D Back draft intendedfirstofallforhigh- (13) R , theirgeometryenables * * * * * 5 4 3 2 1

–Mostrecommended applications HRC 56-63 HRC 50-55 HRC 45-49 ISCAR materialgroup inaccordance withVDI3323standard Machining allowance(0.01…0.2)DforMMHT…headsand(0.01…0.06)ETR…

reduced by20-30%. unfavorable (poorworkholding,hightooloverhang,millingthinwalls)thetablevaluesshouldbe Table 51givesaveragedstartingcuttingspeeds.Iftheconditionscanbeestimatedas b) StartingcuttingspeedVc

Table 49 DIN/ISO 513 ISO Class Fig. 17 Fig. surface finish surface better For flats (Fig. 17 and 18). and 17 (Fig. flats wiper side improved surface quality in milling die and mold cavities mold and die milling in quality surface improved for Toroid grooves allow producing smaller chips and thus reduce scratching the walls of walls the scratching reduce thus and chips smaller producing allow grooves splitting The this case a stepdown should not exceed the length of the wiper flat wiper the of length the exceed not should stepdown a case this in results wall cavity. In addition, the smaller chip, swarf, makes chip evacuation easier. evacuation chip makes swarf, chip, smaller the addition, In cavity. wall machined a wiper flat intended for better surface finish of the cavity walls. In order to achieve the best the achieve to order In walls. cavity the of finish surface better for intended flat wiper side The M K H P MULTI-MASTER Toroidal Heads:BasicFeedfzo,mm/tooth,forHeadDiameterD,mm Material Group* 12, 13 38.1* 38.2* 15-16 17-18 39* 6, 7 8, 9 1-4 10 11 5 5 3 4 ISCAR offers the customer toroidal heads with chip splitting grooves and grooves splitting chip with heads toroidal customer the offers ISCAR , 2 0.13 0.08 0.13 0.06 0.05 0.03 0.12 0.12 0.09 0.08 0.07 0.1 8 0.14 0.09 0.14 0.06 0.05 0.03 0.13 0.13 0.11 0.09 0.08 0.1 10 Fig. 18 Fig. Wiper flat Wiper fzoforD 0.16 0.16 0.07 0.06 0.04 0.15 0.15 0.12 0.12 0.09 0.1 0.1 12 0.18 0.11 0.18 0.07 0.06 0.04 0.16 0.17 0.13 0.13 0.11 0.1 16 0.13 0.08 0.07 0.05 0.18 0.18 0.15 0.15 0.13 0.11 0.2 0.2 20 Die andMold *1 69 Milling Tools 70 Milling Tools *

Machining allowance(0.01…0.2)DforMMHT…headsand(0.01…0.06)ETR…

and Corner RadiusR*,mm Diameter D,mm,andCorner and almost30%inthethird. nominal diameterwithoutcorrelation causeonlya3%error inthefirstcase,23%second, 9.3 mm,andfor0.3mmdepth–only8.6mm.Itisclear, thatcalculationscorresponding tothe radius, whichperformsmillingwith2mmdepthofcut,is11.6.For0.5itwillbe For example,theeffective diameterofthehead12mmnominalwith3corner radius. close tothecorner the effective diameterhasslightdeflection.Thesamesituationoccurswhenthecuttingdepthis as 0.5or1mmallowforneglectingitbecausethedifference betweenthenominaldiameterand This isthecorrect wayistoalwaysdefinetheeffective diameter. However, radii,such smallcorner effective diameterDeofa head inanapplication. in thecaseoftoolswithindexableround inserts,thespindlespeedistightlycorrelated with It willbenotedthataprogrammed spindlespeedrelates tothenominaldiameterofahead.So,as Table 50

Where: 0.2 0.15 0.1 0.05 0.02 0.01 ap/D difference between the nominal and the effective diameters is less than 20%, the cutting cutting the 20%, than less is diameters effective the and nominal the between difference the If be calculated with respect to the nominal diameter, and no correlation needs. correlation no and diameter, nominal the to respect with calculated be can speed of thumb of rule A 1.6 1.2 0.8 0.4 0.16 0.08 ap Chip ThinningFactorKTHforMULTI-MASTER Toroidal HeadswithNominal D=8 1 1.1 1.2 1.7 2.5 3.6 R2 ap R D the head corner radius –theheadcorner –thenominaldiameterofahead –axialdepthofcut ap 2 1.5 1 0.5 0.2 0.1 De =D-2R+2x√(2R×ap-ap²) D=10 R3 1 1 1.2 1.6 2.5 3.5 ap 2.4 1.8 1.2 0.6 0.24 0.12 R3 D=12 1 1 1.1 1.4 2.2 3.2 R4 1.1 1.1 1.3 1.7 2.2 3.6 ap 3.2 2.4 1.6 0.8 0.32 0.16 R3 — 1 1 1.3 2 2.8 D=16 R4 1 1 1.1 1.4 2.2 3.2 R5 1 1 1.2 1.6 2.5 3.5 ap 4 3 2 1 0.4 0.2 R3 — 1 1 1.2 1.8 2.4 (14) R4 1 1 1 1.3 2.1 2.9 D=20 R5 1 1 1.1 1.4 2.2 3.2 R6 1 1 1.2 1.6 2.5 3.5 1 1.1 1.3 1.8 2.9 4 R8 ** * –Mostrecommended applications In thiscaseHSMrecommended ISCAR materialgroup inaccordance withVDI3323standard as oftheoperationisHRC50…52. – 0.3mm.Findthestartingcuttingdataifinsertmaterial is AISIP20steel,anditshardness head MMETR080A04R2.0-6T05908clampedintoit.Thedepthofcutis1…1.3mm,thestepover An insertofaplasticmoldcavityisfinishedbyendmillcutterMMS-A-L090-C12-T08with Example than thetabledata. Tables 49-51.Infinishmillingwithsmallallowancethecuttingspeedisactually10-15%more cutting speedare thesameasforMMHT…headsandtherefore canbechosen from 0.03 D).Undersuchconditionsthestartingfeedpertooth, thethinningfactorandstarting hardness toHRC55.Machiningallowanceinthiscasedoesnotexceed0.06D(normallyeven cutting geometry)are mostadvantageousfor finishmillinghardened steel,more exactlywith As previously stated,multifluteheadsMMETR…(andalsothesolidcarbideendmillsofsimilar Feed speedV and thereal cuttingspeedtransformsto160m/min – 20%less. Compare: ifwerelate directly tothenominaldiameter12mm,result mightbe5305rpm, speed shouldbe1000×200/(π×9.6)=6630(rpm). Effective diameterDe=12-2×3+2×√(2×3×0.6-0.6²)=9.6(mm);hencetheprogrammed spindle (equation (13)). factor KTH=1.4(Table 50)andtheprogrammed feedpertoothshouldbe0.22mm/tooth Cutting speedVc=200m/min(Table 51),basicfeedfzo=0.16mm/tooth(Table 49).Chipthinning proper workholdingandstiffened toolclamping? defined as0.6mmandthestepover10mm.Whatisprogrammed cuttingdatafor MM HT120N06R3.0-2T08908formillingapartmadefrom gr A plannerdecidedtouseendmillcutterMMS-A-L065-W16-T08withtoroidal head Example Table 51 DIN/ISO 513 ISO Class H P M K MM HT…HeadsandHTR…Inserts:StartingSpeedVc,m/min F =0.22×2×6630=2917 (mm/min). Material Group* 12, 13 17-18 15-16 38.2 38.1 39** 7-9 5-6 2-4 11 10 1 ey castiron. Thedepthofcutwas m/min 120 130 140 150 160 180 120 100 120 180 200 Vc, 80 Die andMold 71 Milling Tools 72 Milling Tools

• V-shaped • Square • Toroidal • Spherical The 0.055×6×4377=1444 (mm/min). needed. Thespindlespeed1000×110/(π×8)=4377(rpm),thefeed the nominaldiameterofhead(96%);andcorrections foraprogrammed spindlespeed are not Effective diameterDe=8-2×2+2×√(2×2×1.3-1.3²)=7.7(mm).Theeffective diameterisveryclose to 10-15%, asabove,andisset110m/min. The startingcuttingspeed100m/min,whichistakenfrom Table 51,canbeevenincreased by 0.05×1.1=0.055 (mm/tooth). sufficient (theshortshankoftypeA,smallallowance)andtheprogrammed startingfeedwillbe anyinformationregardingWithout stabilityofmachiningwecan,however, assumethatitis The basicfeed(Table 49)is0.05mm/tooth,thechipthinningfactor(Table 50)–1.1. even underconsiderablecuttingforces. Replacingtheinserts isverysimple. contact surfaces-thatguaranteeshighaccuracyandfirmsecure insertmounting, V-formed slotoftheshank;andaclampingscrew beingtightenedpullstheinserttowards the (non cutting)V-shaped partispositionedagainsttwocontact surfaceswithinthecorresponding cutting teethandashank.Theshankhastheabilitytocarryeverytypeofinsert.insertrear options andinsertsofvarioustypes.Aone-inserttoolisacombinationaninsert,whichhas BALLPLUS (Fig.19)isamultifunctionsystemcomprisingstraightandtapered cylindricalshank 3.1.3. BALLPLUSone-inserttoroidal millingtools Fig. 19 Fig. BALLPLUS systemoffers thefollowinginsertshapes: and ballnose(hemispherical) (for chamferingandcountersinking)

Table 52

toroidal millinginserts. Table radiiwithreference 52showstherangeofcorner tothenominaldiameterofBALLPLUS design principles. the BALLPLUStoolsbasicallysimilartoMULTI-MASTER family Multifunctionality basedoncombiningtheshankwithinsertsofdifferent shapesmakes

the same shank with miscellaneous cutting heads produces effective tools from tools effective produces heads cutting miscellaneous with shank same the combining family, to ball nose cutters or from center drills and combined to disk slotting disk to countersinks combined and drills center from or cutters nose ball to endmills square variety of cutting of variety a on largely depends tool cutting indexable an of multifunctionality or Versatility the tool systems with replaceable heads have great possibilities for versatility when one when versatility for possibilities great have heads replaceable with systems tool the milling, In one-insert tool systems enable fewer options for such combinations but also can be can also but combinations such for options fewer enable systems tool one-insert The cutters. the tool provides. Using replaceable cutting heads or inserts of the same form but form same the of inserts or heads cutting replaceable Using provides. tool the that geometries allows mounting allows body tool cutting tool (1) tool cutting of Versatility to their main applications many toroidal tools are suitable for plunge with work feed along feed work with plunge for suitable are tools toroidal many applications main their to addition In bas good a this of example good a is inserts octagonal machining different workpiece material workpiece different machining for adopted forms. various of axis, peck drilling and also direct drilling on a small depth. depth. small a on drilling direct also and drilling peck axis, tool a endmill toroidal or nose ball a as performs practice. The tool become tool The practice. common a Plunged bull bull Plunged the combining possibilities are very limited, nevertheless hold out reserve for increasing for reserve out hold nevertheless limited, very are possibilities combining the which for tools considerably increase the range of tool us tool of range the increase considerably tools versatile The HELIDO discussed already The versatility. versatility is an important design principle that forms the bas the forms that principle design important an is versatility maximal Therefore, milling tool families tool milling for applications radius R,mm Corner Corner 1.5 6 5 4 3 2 1 BALLPLUS Toroidal MillingInserts is BALLPLUS the of shank A tooling. versatile for 12

MULTI-MASTER the in example, For shape. different substantially of heads those with those especially , more and more versatile if it can carry inserts or heads or inserts carry can it if versatile more and more s or a countersink. Even milling tools with indexable inserts, indexable with tools milling Even countersink. a or S845 family with its ability to carry either square or square either carry to ability its with family S845 . 16

Insert diam.D,mm by means of changed rake face and flank is flank and face rake changed of means by s replaceable cutting heads. cutting replaceable and allow and e system with system 20

, bythevirtueofmain for insert clamped in clamped insert an reduc is tion of tion of high efficiency high of a tool stock. tool a 25

to it to Die andMold

73 Milling Tools 74 Milling Tools *

ISCAR materialgroup inaccordance withVDI3323standard conditions are estimatedasunstable. cutting speedVc.Inthesamemanner, thevaluesshouldbereduced by20-30%iftheoperation As isthecasewithMULTI-MASTER toroidal heads,Table 51isintendedforratingstarting Table 53 38.2) and0.05×DforHRC56…63(group 39). 0.08×D forsteelwithhardness HRC45…49(materialgroup 38.1),0.06×DforHRC50…55 (group In finishmilling,themachiningallowanceisusuallynomore than0.12×Dforpre-hardened steel, ensures goodinsertlife. radius oftheappliedinsert).Undersuchconditionstoolperformswithhighproductivity and (0.08…0.15)×D (needlesstosaythatinanycasethedepthofcutshallnotexceedcorner of cutisnormally(0.6…0.7)×D,where D-thediameterofatool,anddepthcut– In rough andsemi-finishmilling,ifthe BALLPLUS toroidal toolsmachineplain surfaces,thewidth factor. starting feedfzoneededforcalculations.Table 54showsappropriate valuesofthechipthinning Equations (8)and(13)specifyprogrammed feedpertoothfz.Table 53containsvaluesofbasic diameter shouldbetakenintoaccount. when correlation duetochipthinningorsubstantialdifference betweenanominalandaneffective for theMULTI-MASTER toroidal mills.Again,thesimilarconsiderationstakeplaceforcases In general,startingcuttingdatafortheBALLPLUStoroidal toolsisdefinedin thesamewayas STARTING CUTTING DATA DIN/ISO 513 ISO Class M K H P BALLPLUS Toroidal Tools: BasicFeedfzo,mm/tooth Material Group* 12, 13 17-18 15-16 38.2 38.1 8, 9 6, 7 1-4 11 10 39 5 0.11 0.13 0.04 0.14 0.16 0.06 0.16 0.07 0.18 0.11 0.18 0.1 12 0.11 0.12 0.14 0.04 0.15 0.17 0.06 0.17 0.07 0.19 0.12 0.19 16 fzoforD,mm 0.12 0.13 0.15 0.05 0.16 0.19 0.07 0.19 0.08 0.21 0.13 0.21 20 0.13 0.14 0.16 0.06 0.18 0.21 0.08 0.21 0.23 0.14 0.23 0.1 25 Nominal Table 54 0.14×2×1528=427.8 (mm/min). diameter anditwillbe1000×120/(π×25)=1528(rpm).Correspondingly, thefeedspeedbecomes (25 mm).Therefore, thespindlespeedcanbecalculatedwithreference tothenominal De=25-2×5+2×√(2×2.5×5-2.5²)=23.7 (mm)thatcontains~95%oftheinsertnominaldiameter In accordance withTable 51therecommended startingspeedis120m/min.Effective diameter programmed feedwillbe0.14mmpertooth. radiusand2.5mmdepthofcut(TableKTH for25mmdia.insert,5corner 54)–1.Hence,the Basic feedfortoothfzogroups 12-13isequalto0.14mm/tooth(Table 53),chipthinningfactor fixture ofthemachinetool.Findprogrammed spindlespeedandfeed. 17 mm.Arigidmachinetoolperformsmilling;andthecavityisproperly secured intheworkholding The proposed cuttingparameters are asbelow:thedepthofcut–2.5mm,width – be appliedforrough millingofamoldinsertcavity. ThecavitymaterialisstainlesssteelAISI420F. In adie-makingshopmillHCED25-A-L170-C25withinsertHTRD250-R5.0-QFIC908plannedto Example Fig. 20 Fig. ap/D 0.01 0.02 0.15 0.05 0.2 0.1

and Corner RadiusR Diameter DandCorner Chip ThinningFactorKTHforBALLPLUSToroidal Insertswith 0.12 0.24 1.8 2.4 0.6 1.2 ap D=12 3.2 2.2 1.4 R3 .1 1 1 A 3.6 1.1 1.3 2.2 1.1 1.7 p R4 ≤ R 0.16 0.32 2.4 1.6 3.2 0.8 ap D=16 2.8 1.3 R3 — 1 1 2 0.2 0.4 ap 3 2 4 1 D=20 F 2.4 1.8 1.2 R3 v — 1 1 α° 2.9 2.1 1.3 R4 1 1 1 0.25 3.75 1.25 2.5 0.5 ap 5 R 2.2 1.6 1.1 R3 — 1 1 D=25 2.6 1.9 1.2 R4 1 1 1 2.9 2.1 1.3 R5 1 1 1 3.1 1.1 2.2 1.5 R6 Die andMold 1 1 75 Milling Tools 76 Milling Tools • Such • The • Toroidal • Toroidal • Toroidal finish milling,especiallyinmachiningcavitiesandfaces. exceptionally widespread indieandmoldmaking for variousapplicationsfrom rough to and ensures smoothfacemillingwithlargewidthofcut . machining thatgivesconvincingadvantages-incomparisonwithballnosecutters,forinstance, considerably reduces cycletime. interpolation andplunging.W the followingpoints: Marking theendofchapterdevotedtotoroidal tools,wecanemphasize

Unexpectedly

Pre-shaped the most popular applications of toroidal tools is machining cavities by helical interpolation. helical by cavities machining is tools toroidal of applications popular most the of One spite of impressive self-tuning possibilities of modern CNC machine tools with adaptive with tools machine CNC modern of possibilities self-tuning impressive of spite in Therefore, already may cavity A the thoroughly check and consideration into above the take always control its walls by a ; and a machining allowance (material stock to be removed) for for removed) be to stock (material allowance machining a and fillet; a by walls its with connected is surfaces data. cutting corresponding area increases area filleted the Fig. 22 Fig. Fig. 21 Fig. Machining profile allowance cutting profile ofthetoroidal toolshasnopointwhere thecuttingspeedwillbezero during versatility andthesources ofimproving productivity determinethetoroidal toolsas ∆ Fillet tools allowforsubstantialimprovement infeedspeedduetochipthinningeffect andthus tools feature successfulperformanceinfacemilling,helicalandcircular tools are suitableformilling planeandcontoured surfaces. punch, for instance) (Fig. 23). 23). (Fig. instance) for punch, (a large machining allowance allowance machining large too Allowance increase be pre-shaped by casting or pre-machined. In this case the bottom of a cavity a of bottom the case this In pre-machined. or casting by pre-shaped be F v T . occur when occur may picture same the addition, In hat may be problematic or even fatal for the tool (Fig. 22). (Fig. tool the for fatal even or problematic be may hat ithin certainlimitstheyoperateinlinearrampingandpeckdrilling. A p ≤ R R operation Profile after

interpolation).

tools can be used in used be can tools milling Toroidal whether linear whether applications milling rampdown profile and ramp and profile cutting Toroidal helix (helical helix by ramping or ramping ramping techniques a depth a techniques ramping these of each For no no be should cut of head, an insert or a solid tool solid a or insert an head, a of radius 21). 20, (Fig. is true also for milling for also true is such Obviously, by circular interpolation. interpolation. circular by Fig. 23 Fig. Fillet more that the corner the that more machining outer outer machining machined shape and shape machined down down milling Further, aninsertoratoothproduces arelatively narrow cutinsuchcases(W or thetoroidal radii(Fig.24). millingheads,solidcarbidetoolsorone-insertwithsmallcorner may noticeablychangethecuttingedgeangle,especiallyforround insertsofsmalldiameters application forthismethod.Firstofall,evenifadepthcutremains beshallow, itsslightincreas e One wouldthink,thetoroidal toolscanbeagoodsolutionforHFM.However, theyhavelimited stability ofmilling. of amachinetool.Asconsequence,itcausessubstantialvibrationreduction andcorrespondingly its axialcomponent.Therefore, theresultant force of thecomponentsactstowards thespindleaxis In addition,suchacombinationminimizestheradialcomponentofcuttingforce andmaximizes combined withanappropriate cuttinggeometryallowsforconsiderableincrease infeedpertooth. introduction tothemainprinciple ofhighfeedmilling.Aswasshown,ashallowdepthcut and especiallythechipthinningphenomenonconsidered intheprevious chapterare agood The notesregarding cuttingedgeanglesinthesectiondevotedtomillingplanesurfaces 3.2. Tools forHighFeedMilling(HFM) will beovercome. However, ifthecuttingedgewillbeanarc ofagreat cycle(Fig.25),thelimitations above Fig. 25 Fig. Fig. 24 Fig. a p2 a p1 W W 2 1 W W 2 1 a p2 W W 1 2 a p1 a χ p1 1 χ χ 1 2 χ 1 2 andW a χ p2 1 2 χ inFig.24). 2 Die andMold , 77 Milling Tools 78 Milling Tools

machine toolsintendedespeciallyforHFMdieandmoldparts. machining centerstakesthesefactorsintoconsideration;andmachinetoolbuildersproduce the moving partssuchasguideways,feedscrew s, bearings,etc.Therefore,’s theconceptoftoday combined withquicklychangedworkingtrajectoriescausemore intensivewearof themachine’s rates andbeequippedbyappropriate CNCdevices.Further, rapidaccelerationandslowingdown However, thefeeddriveofamachinetoolusedforHFMshouldcorrespond totherequired feed increased area aftersomepasses(Fig.26),thatcausedvibrationsandinstablecutting. the toroidal tool,workingevenatshallowdepthofcutcomesincontactwiththecavitymaterial contact withacavitywallincontrasttoroidal tool.Inmillingcavitiesbyhelicalinterpolation, holes ofdifferent diameters.Inadditiontothementionedadvantages,aHFMtoolhasfarless In thecaseofablindhole,holebottomwillbeflat.Moreover, thesameHFMtoolcanproduce production oflarge-diameter holesdirectly from solid,orenlargingapreviously madehole. if theyhavesufficiently largesizes.Naturally, HFMtechniqueissuccessfullyappliedtorapid HFM isespeciallyeffective formachiningdiecavitiesorrecesses byhelicalinterpolation,principally semi finishing.Allthesefeatures makeHFMasignificanttimesaver. produce thecontourthatwillbeveryclosetofinalshapeandthusdiminishoreveneliminate for machiningdiecavities,punchesandrams.Third, shallowdepthofcutmakesitpossibleto and enablesstablerough millingathighoverhangs–theproperty oftheutmostimportance rates. Second,thecuttingforce actingmainlytowards tothespindleaxisminimizesvibrations cycle time.Firstofall,itallowsforfastmaterialremov al, duetoconsiderablyincreased feed Generally HFMrelates torough millingoperations,butitcansubstantiallyreduce overallmachining- 1 26: Fig. 3 26: Fig. operational performance. operational #40 taper, which can be enough for proper for enough be can which taper, #40 a with spindles required corresponding powerful machine tools. Today HFM leads to the same the to leads HFM Today tools. machine powerful corresponding required and possible size smaller much by reached is that result past, the classical approach for rough milling dictated using as large-size as using dictated milling rough for approach classical the past, the In st rd pass pass tools. No wonder many machine tools for HFM have HFM for tools machine many wonder No tools. d 2 26: Fig. 4 26: Fig. ly securing HFM tools and good and tools HFM securing th nd pass pass cutter as cutter d

combined combined

MULTI-MASTER shanks) interchangeable MULTI-MASTER heads(thelatterare intendedformountinginthe ISCAR’s HFMlinecomprisesfamiliesofindexablemillingtools,solidcarbideendmillsand small dimensions. roughing facesurfacesor relatively large-sizedshapes,aswelltovariousprofiles ofmediumto important forthedieandmoldindustry;sincethatmomentHFMtechniqueisappliedto interchangeable headsofless nominaldiameters.SuchasecondbirthoftheHFMtoolswasvery the HFMtoolsnotonlyimproved theshapeoftheirinsertsbutwere replenished bysolidtools and production ofverycomplicatedcuttinggeometriesintoolsdifferent , evensmallsizes.Eventually and 2inFig.28).Theprogress inmultiaxisCNCgrindingandsharpeningmachinesallowedfor A cuttingedgeoftheinsertbasicallywasanarc ortwoarc chords (correspondingly profiles 1 replaceable insertscarried bythetoolstraditionallyhadtrigonorquadrihedralshapes(Fig.27). Originally theHFMtoolswere indexable millingcuttersofrelatively largenominaldiameters.The

Fig. 28 Fig. Fig. 30 Fig. Fig. 27 Fig. “ for suitable method HFM the Is mold materials. mold and die “ and HFM rpm? These machines are still common in many die and mold shops. mold and die many in common still are machines These rpm? 6000-7000 normally is answer The and the and rates; feed normal with 1 old-type because the typical feed drive of the machine ensures ne ensures machine the of drive feed typical the because “yes” generally of the spindle speed are enough for rough milling of most of milling rough for enough are speed spindle the of values mentioned CNC machine tools machine CNC ” at shallow depth of cut. of depth shallow at speed cutting tooth, per feed incresed is removal material high for key the HFM, In 2 old-type with tools machine CNC ”

Fig. 29 Fig. spindle speeds spindle c e ss ary Die andMold 79 Milling Tools 80 Milling Tools *

Number offlutesforsolidcarbidemillsandMULTI-MASTER

manufacturing partsfrom corresponding materials. Hence, theT-type insertsare more commonthere; however, theHP-typeinsertsare alsousedfor withsteelworkpieces . Referring toHFM,thedieandmoldindustryisgenerallyconcerned on theirtopsurfacesforvisualidentification(Fig.30). machining austeniticstainlesssteelandhightemperature alloys.TheT-type insertshave“I”marks T andHP. The T-type isdesignedformillingsteelandcastiron, whiletheHP-typerelates mostlyto In accordance withthecuttinggeometry Table 55 various adaptations. available indifferent configurations:shellmills,millswithshanksandmillingheadsfor high feedsformetalremoval. Tools ofthefamilyhavea17°cuttingedgeangleandare The mentionedadvantagesoftheHELIDOUPFEEDfamilyallowseffective rough millingatvery portion adjoiningtheminoredge–concave. For betterchipformation,theinsertrakefaceportionadjacenttomajoredgeisconvex;and performance especiallyinrampdownmilling,whentheminorcuttingedgeplaysakeyrole (Fig.31). cuttingedge.Thisconfigurationimproves cuttingedgeandtheminor(internal) atool or external) provides veryfirmclamping. Acuttingedgeoftheinsertcomprisestwosections:major(main that feature 6cuttingedges(Fig.30).Theinsertissecured intoadovetailinclinedpocket,which FEEDMILL’s strength and The questforexcellenceoftheHFMtoolsledtocombiningHELIDO’s most oftheforces usuallyexertedontheclampingscrew (Fig.29). mounted intothecorresponding hole oftheinsertpocketprovides veryrigidclamping,absorbing clamped inthetoolbody. Theinsertshaveacylindricalprotrusionwhen attheirbottom,which FEEDMILL, thefirst-everfamilyofindexabletools,produced by ISCAR, feature thetrigoninserts 3.2.1. IndexableT HELIDO UPFEED Family FEEDMILL 16FEEDMILL FEEDMILL MULTI-MASTER at fast feed for high productivity in rough milling operations! operations! milling rough in productivity high for feed fast at faster Run FF in the designation of ISCAR tools, inserts or heads for HFM mean HFM for heads or inserts tools, ISCAR of designation the in FF letters Two Run faster Run Main Tool FamiliesforHFM geometry Indexable Type Indexable Indexable Solid heads Solid , creating theHELIDOUPFEED familywiththetrigondouble-sidedinserts Shell mills configuration Tool Shell mills adaptation MULTI-MASTER FLEXFIT adaptation Shank-type mills Shell mills FLEXFIT adaptation CLICKFIT adaptation Shank-type mills Solid carbideendmills Assembly: shanks with replaceable heads ools forHFM , there are twotypesoftheHELIDOUPFEEDinserts: 40-125 mm diameters, Range of 40-125 16-20 20-40 16-40 80 25-40 25-40 25-40 6-20 10-25 8-25 heads cutting edges No. ofinsert 16 4* 2* 4* 6 3

designation Tool (shank) FF EWX…MMT… FF EWX…M… FF EWX… FF FWX… FF EW…M… FF EW…CF… FF EW… FF FW… FF NM… EFF S4… MM… “ s Fast Feed Fast designation Insert (head) H600WXCU… FFWO… ONMU…

MM FF… MM EFF… ” .

Table 56 HELIDO UPFEEDFF…millingtools. Table 56showsthedepthofcutranges,dependingonsizesH600WXCU…Tinsertsfor a) DepthofCutAp Starting CuttingData Fig. 31 Fig. Fig. 32 Fig. – a mismatch produced by such specification (correspondingly t in the same figure). same the in t (correspondingly specification such by produced mismatch a – cusp a of in ISCAR catalogs and technical leaflets. The radius defines the maximal thickness maximal the defines radius The leaflets. technical and catalogs ISCAR in found be can called is that radius The programming, a programming, CNC In programming for Radius Insert size 08 04 05 ∝ Depth ofCutApforFF…Tools withH600WXCU…TInserts Minor cuttingedge A H600 WXCU08…T H600 WXCU05…T H600 WXCU04…T designation D “ as Insert HFM tool is often specified as a with a corner radius. radius. corner a with cutter milling a as specified often is tool HFM n 1 radius for programming (R in Fig.32), relates to reference data and data reference to relates Fig.32), in (R programming for radius Major cuttingedge A 0.25 min. 0.4 0.2 Rotated andenlarged A-A Ap, mm R max. 0.8 1 2 t Die andMold 81 Milling Tools 82 Milling Tools * **

Incaseofmachininginunstable conditions, thestartingfeedshouldbereduced by30% ISCAR materialgroup inaccordance withVDI3323standard the tabledatashouldbereduced by30%. overhang, millingnearthinwallsandinothercasesofnon-sufficient operationalstability applied. More precisely The valuesare enoughforquickestimationofafeedper toothandgivesatisfactoryresults when Table 57. Normally, feedspertoothforthemajorityofdieandmoldmaterialslaywithinvaluesshownin c) StartingFeedPerT passes afterstepdown(Fig.33). tooth overloading,becauseofexcessmachiningallowanceincuspsproduced onthefurther It isstrongly recommended thatawidthofcutbenomore thandiameterD1inorder toprevent b) Width ofCutAe Table 58 Table 57 DIN/ISO 513 Fig. 33 Fig. Class Insert ISO M size H K P 08 05 04 Commonly OccurringFeedsforFF…Tools withH600WXCU…TInserts Average StartingFeedfzoforFF…Tools withH600WXCU…TInserts Nodular castiron Hardened steel Martensitic s.s. Grey castiron Plain carbon Alloy steel tool steel Type steel and

Workpiece material , thefeedfzcanbedefinedwith Table 58.Forpoorworkholding,high H600 WXCU08…T H600 WXCU05…T H600 WXCU04…T Stepdown designation Insert ooth fz Material Group* 12, 13 17-18 15-16 38.2 38.1 8, 9 6, 7 1-4 11 10 5 H600 WXCU04 A D with H600 e 1 >D 0.7 0.8 0.9 0.8 0.3 0.4 0.9 1 1 1 1 1 Feed fzo,mm/toothforFF…tools H600 WXCU05 WXCU…T… a Cusp e >A 1.1 1.2 1.2 1.3 1.1 0.3 1.3 1.3 0.5 1.2 1 mm/tooth p Feed Fz, 0.5…1.5 0.6…2 0.4…1 H600 WXCU08 Inserts** , 1.2 1.3 1.4 1.5 1.6 1.3 0.4 1.6 1.7 0.6 1.4 * –Recommendedcarbidegrade ISCAR materialgroup inaccordance withVDI3323standard

drives, proper workholding,andshortoverhangofthetool. The machiningconditionscanbeestimatedasstable: a machinetoolwithpowerfulmainandfeed plane surfaceofalarge-sizeblock.Theblockmaterial is AISI/SAED2toolsteel,HB190…210. mill toolFFFWXD080-06-32-08withinsertsH600WXCU080612TIC830 for rough millinga In order tocutcycletimeforforgingdiemanufacturing,aprocess plannerdecidedtoapplyface Example Table 59 or toolholding,etc.)thevaluesshouldbereduced by20-30%. carbide grades.Ifthecuttingconditionsare estimatedasunfavorable(highoverhang,poorwork- Table 59comprisestheaveragedvaluesofstartingcuttingspeedVcinrelation totheinsert d) StartingcuttingspeedVc DIN/ISO 513 ISO Class tool cuts downward, ramps to material, demands reduced feed per tooth; and the values the and tooth; per feed reduced demands material, to ramps downward, cuts tool the when to recommended is it Additionally, 30-40%. by decreased be should 58 Table in shown edge angle of a FF tool with H600 inserts is practically cons practically is inserts H600 with tool FF a of angle edge cutting The of cut that is specified in Table 57 by 20%. by 57 Table in specified is that cut of depth maximal the cause not does cut of depth a reducing Therefore, tool. the in mounted insert an of edge cutting solid workpiece and then starts profile milling by helical interpolation. Keep in mind that in that mind in Keep interpolation. helical by milling profile starts then and workpiece solid a to maximum for work cut: of Depth for allow not does and effect thinning chip machine your If cycle time cycle gain you feed milling of cavities and pockets and cavities of milling feed high Starting ramping down directly to solid solid to directly down ramping care: Particular M H K P FF… Tools withH600WXCU…TInserts:StartingCuttingSpeedVc Nodular castiron Hardened steel Martensitic s.s. Grey castiron Plain carbon Alloy steel tool steel cut – cut of depth maximal for work rigid, is workholding and power enough has Type steel Workpiece material and and reach higher productiv higher reach and Mat. group* 12, 13 17-18 15-16 38.2 38.1 8, 9 6, 7 1-4 11 10 5 inscreasing feed per tooth and then run faster. run then and tooth per feed inscreasing IC808 120 180 200 120 130 150 150 150 150 60 80 i ty. ,

an HFM tool performs the first cut by ramping down ramping by cut first the performs tool HFM IC810 Vc, m/minforGrades 200 220 120 125 130 135 140 150 50 70

is tant (17°) along the main the along (17°) tant IC830 120 200 220 115 115 120 125 135 150

reduc IC330 120 100 110 115 120 125 135 e case,

the Die andMold 83 Milling Tools 84 Milling Tools

Heads andSolidCarbideEndmillsIntendedforHFM Table 60 60 and61. solid carbideendmills.Generaldataregarding theseheadsandsolidendmill s isshowninTables “economy” typeandmultifluteMMEFF…headswithcuttinggeometrysimilartotheFEEDMILL There are twogroups oftheMULTI-MASTER headsforHFM:two-fluteMMFF…ofthe endmills forHFM 3.2.2. MULTI-MASTER millingheadsandsolidcarbide Metal removal rateQ≈1.3×62×3572=287.9(cm Feed speedV Spindle speedN=1000×115/(π×80)=458(rpm). chosen tool(D1=64mm). ofcutAe”andcatalogdatathe ofcutAe=62mm-refer toabove paragraphb)“Width Width cutting speedVc=115m/min(Table 59). The materialrelates tomaterialgroup No.10.Startingfeedfz=1.3mm/tooth(Table 58),starting maximum”) 2mm(Table 56). conditions allowthepropose d maximaldepthofcut(refer toremark “Depthofcut:workfor Assuming thatcalculationsshowthemachinehasenoughpower, thecurrent manufacturing

S.C. Endmills MULTI-MASTER MULTI-MASTER Type recommended when that inserts customer the offers ISCAR technique HFM the If new positive results. positive new in result inserts HELIOCTO the for intended are that OFMW…FF Inserts cutters. HFM into 16-edged standard carries diameter nominal mm 80 with D080-06-27-R08 NM FF mill face Further, cutting tool (2) and …cutting insert …cutting and (2) tool cutting of Versatility slot full milling care: Particular HELIMILL the for designed are which …FF, APKT and FF … ADCT FF, 0806…. The insert orientation features similar capabilities to HFM tools. By using the using By tools. HFM to capabilities similar features orientation insert The 0806…. ONMU insert catalog main ISCAR The the mentioned lines for high-efficiency rough milling using the HFM method. The inserts The method. HFM the using milling rough high-efficiency for lines mentioned the of ranges rough face milling, the material removal rate can be increased by 1.5 to 2 times, when times, 2 to 1.5 by increased be can rate removal material the milling, face rough in tool on the principle of versatility of principle the on based solutions require any new tools and are secured in secured are and tools new any require not do the standard tool with this insert. By the way, due to its 16 cutting edge insert edge cutting 16 its to due way, the By insert. this with tool standard the with compared solution economical winning a 0806…is ONMU Number ofFlutesZandMaximalDepthCutApmaxforMULTI-MASTER F =1.3×6×458=3572 (mm/min). and 59 should be reduced by 30%. 30%. by reduced be should 59 and 58 Tables in EFF… MM EFF… MM FF… Designation is appl and technical leaflets co leaflets technical and ied for ied of flutesZ Number rough milling a full slot, starting feeds and cutting speeds cutting and feeds starting slot, full a milling rough 4 4 2 where , mounted in mounted 0.3

6 for high feed milling of large-size of milling feed high for 3 to /min). ntain pockets of the standard tools of the families. the of tools standard the of pockets the 0.4 0.4 necessary information regarding these regarding information necessary 8 ation combin right Apmax, mm,fornom.diam.D,mm to the exist the 0.5 0.5 0.6 10 ing tools 0.6 0.6 family, expand the application the expand family, 12 1 of indexable tools and tools indexable of family and inserts ADKT… inserts and family , they , 0.8 0.8 1.1 16 plane surfaces. plane d turn these tools these turn 1.5 20 1 1 1.2 25

* * * * * * * * *

4 3 2 1 4 3 2 1 HRC56-63 HRC50-55 HRC45-49 HRC56-63 HRC50-55 HRC45-49

With theassumptionthatdepthofcutisApmax,showninTableWith 60 Average DepthofCutAp,mm Solid Carbide Table 63 Table 62 defining startingcuttingdata. be obtainedfrom Tables 62-64.Thetablescontainaveragevaluesthatworkwellwhenappliedto A more accurateestimatwe fordepthandwidthofcutwithrespect toaworkpiecematerialcan Table 61 ISCAR materialgroup inaccordance withVDI3323standard ISCAR materialgroup inaccordance withVDI3323standard DIN/ISO 513 DIN/ISO 513 and EFF… endmills EFF… MM heads MM FF MM Designation ISO Class ISO Class M M H K H K P P … heads S.C. EndmillsEFF…andMULTI-MASTER HeadsMMEFF…: MULTI-MASTER HeadsMMFF…:Average DepthofCutAp,mm Maximal WidthofCutAemax*forMULTI-MASTER Headsand 10-11 39 38.2 38.1 15-18 12, 13 1-9 Material Group 38.1 15-18 12, 13 1-9 Material 38.2 39 10-11 *4 *4

Endmills IntendedforHFM *3 *2 *3 *2 Group 4.5

6 *1 *1 ~0.02 D ~0.03 D ~0.035 D Relation Apmax ~0.04 D ~0.045 D ~0.04 D 0.05 D Apmax 0.05 D ~0.06 D ~0.02 D ~0.03 D ~0.045 D Relation 6.1 8 0.25 0.25 0.1 0.2 0.2 0.3 0.3 6 Max. Aemax,mm,fornom.diam.D,mm 0.5 0.6 0.5 0.6 0.2 0.3 0.4 10 7.7 7.7 10 0.15 0.25 0.25 0.35 0.4 0.3 0.3 8 0.35 0.45 9.1 9.1 12 0.2 0.3 0.5 0.4 0.4 10 0.25 0.6 0.8 0.7 0.4 0.5 12 1 ApforD,mm Ap forD,mm 0.45 0.25 0.55 0.4 0.6 0.5 0.5 12 12.5 13.6 16 0.75 0.65 0.65 0.8 1.1 0.8 0.3 0.5 0.7 16 0.6 0.3 0.5 0.8 16 1 15.5 17.5 20 0.7 0.4 0.6 0.9 0.8 0.8 20 1 1.2 1.4 0.4 0.6 0.9 20 1 1 19.5 25 0.75

0.9 0.5 1.1 1.2 25 1 1 Die andMold 85 Milling Tools 86 Milling Tools * * * * * *

5 4 3 2 1 HRC56-63 HRC50-55 HRC45-49 ISCARmaterialgroup inaccordance withVDI3323standard reference With todepthofcut,ApshowninTable 63

ISCAR materialgroup inaccordance withVDI3323standard

S.C. EndmillsEFF…:StartingSpeedVc,m/min S.C. EndmillsEFF…:Average WidthofCutAe,mm Table 65 Table 64

Reduce Reduce • Decrease Decrease • Reduce Reduce • DIN/ISO 513 DIN/ISO 513 ISO Class ISO Class heads intended heads MULTI-MASTER the and s endmill carbide solid the of application about Speaking it should be noted that all additional limitations regarding table values of starting cutting cutting starting of values table regarding limitations additional all that noted be should it HFM, for milling full slot slot full milling care: Particular HELIDO for considered data M M H H K K P P

feed by 30% in case of poor stability poor of case in 30% by feed feed and cutting speed b speed cutting and feed MULTI-MASTER HeadsMMFF…/MMEFF…and MULTI-MASTER HeadsMMFF…/MMEFF…and feed by 30-40% and maximal depth of cut by 20% for ramping down to solid to down ramping for 20% by cut of depth maximal and 30-40% by feed 39 38.2 10-11 38.1 15-18 12, 13 1-9 Material Group *5 *4 *3 Material Group* *2 ~0.25 D ~0.3 D ~0.45 D Relation ~0.6 D ~0.7 D ~0.6 D ~0.7 D UPFEED 12, 13 17-18 15-16 38.2 38.1 39** 7-9 5-6 2-4 11 10 1 30% when milling full slot full milling when 30% y cutters are also valid here: valid also are cutters 1.5 2.5 3.5 3.5 2 4 4 6 2.5 3.5 5.5 4.5 5.5 4.5 2 8 *1 2.5 4.5 10 3 7 6 7 6 AeforD 3.5 5.5 8.5 8.5 12 3 7 7 Vc, m/min 120 100 160 180 180 140 150 160 120 130 11.5 11.5 60 80 4.5 9.5 9.5 16 4 7 12 14 14 12 20 6 5 9 17.5 17.5 7.5 11 15 15 25 6 • Approximately • Feed • Spindle Calculations: Example * * * * * * * * 4 3 2 1 4 3 2 1 HRC56-63 HRC50-55 HRC45-49 HRC56-63 HRC50-55 HRC45-49

(Table 67). The startingcuttingspeedis150m/min(Table 65)andthestartingfeedis0.48mm/tooth as 0.55mm(Table 63)andthewidthofcutas8.5mm(Table 64). The tooldiameteris12mm.materialrelates tomaterialgroup No.6.Definethedepthofcut Find startingcuttingdata. stability isgoodenough. 045/34C12R2.0M. ThepartmaterialisAISIP20moldsteel,HRC32…35.operational In amoldmakingshopthere is aparttobemachinedbyfour-fluteendmill EFF-S4-12 solidcarbide Tables 65-67showrecommended valuesforstartingcuttingspeedandfeedpertooth. Starting Feedfzo,mm/tooth Table 67 Table 66 ISCAR materialgroup inaccordance withVDI3323standard ISCAR materialgroup inaccordance withVDI3323standard DIN/ISO 513 DIN/ISO 513 ISO Class ISO Class M M H K H K P P speed 0.48×4×3980=7641.6(mm/min) speed 1000×150/(π×12)=3980(rpm) MULTI-MASTER HeadsMMFF...: StartingFeedfzo,mm/tooth S.C. EndmillsEFF…andMULTI-MASTER HeadsMMEFF…: 10-11 39 38.2 39 38.2 11 10 17-18 8, 9 6, 7 38.1 15-16 12, 13 5 1-4 Material Group 38.1 15-18 12, 13 1-9 Material *4 *4 metal removal rate0.55×8.5×7641.6/1000=35.7(cm *3 *2 *3 *2 Group *1 *1 0.05 D Apmax 0.05 D ~0.06 D ~0.02 D ~0.03 D ~0.045 D Relation 0.12 0.16 0.22 0.25 0.28 0.34 0.25 0.33 0.35 0.1 0.2 0.3 6 0.16 0.12 0.25 0.28 0.38 0.33 0.45 0.43 0.48 0.2 0.3 0.3 8 0.5 0.6 0.5 0.6 0.2 0.3 0.4 10 0.22 0.25 0.16 0.33 0.35 0.45 0.52 0.35 0.57 0.3 0.4 0.5 10 fzo, forD,mm 0.25 0.6 0.8 0.7 0.4 0.5 12 1 0.33 0.16 0.35 0.38 0.43 0.52 0.48 0.43 0.57 0.67 0.3 0.6 12 Ap forD,mm 3 /min) 0.38 0.43 0.48 0.52 0.57 0.52 0.65 0.75 0.4 0.2 0.6 0.7 16 0.8 1.1 0.8 0.3 0.5 0.7 16 1 0.45 0.48 0.52 0.57 0.67 0.75 0.2 0.6 0.7 0.8 0.6 0.9 20 1.2 1.4 0.4 0.6 0.9 20 1 1 0.52 0.55 0.25 0.62 0.67 0.78 0.87 0.7 0.8 0.9 0.7 25 1 Die andMold 87 Milling Tools a pmax

88 Milling Tools

Fig. 35 Fig. 34 Fig. feed) (pick stepover and cut of Depth exceed when the depth of cut is defined by corresponding data in Tables 60, 62 60, Tables in data corresponding by defined is cut of depth the when exceed to recommended with stepover passes, the depth of cut and the stepover are interrelated quantities. interrelated are stepover the and cut of depth the passes, stepover with HFM In If not, the produced cusp shape can lead to the tool (head) overloading in further milling further in overloading (head) tool the to lead can shape cusp produced the not, If 63. and endmill carbide solid EFF a of edge cutting the Because It is clear that decreasing the stepover reduces the cusps (Fig. 35) and improve improve and 35) (Fig. cusps the reduces stepover the decreasing that clear is It stepdown. with arc of large-diameter circle, the maximal stepover is limited by chord length t defined by depth by defined t length chord by limited is stepover maximal the circle, large-diameter of arc an is surface condition. surface ap (Fig. 34). Therefore, the width of cut in Tables 61 and 64 specifies the values that are not are that values the specifies 64 and 61 Tables in cut of width the Therefore, 34). (Fig. ap cut of machining large-size machining in Generally, of cut, HFM with maximal corresponding width of cut will be the most the be will cut of width corresponding maximal with HFM cut, of depth recommended case when the allowance is divided between stepdown passes, the stepover the passes, stepdown between divided is allowance the when case In productive. more careful examination careful more requires definition Stepover 2 Stepover 1 d , mostly plane, surfaces with an allowance no more than the than more no allowance an with surfaces plane, mostly , t Stepover max in order to avoid overload after stepdown. stepdown. after overload avoid to order in , Stepover h 1 or a MM FF/EFF milling head actually actually head milling FF/EFF MM a or ≤ t h 2 a pmax a pmax

walls andenablesforincreasing stepdownfor millingpasses(compare casesaandbinFig.41). cylindrical cuttingportion.Theportionallowsforbettersurfacefinish,whilemachiningnearstraight The ballnosemillingtoolswiththeball-shapedcuttingedgeasahemisphere oftenhavealsoa making. (taper ortapered ballnosecutters,Fig.40),basically 80°-89°,are commonindieandmold hemisphere (bulb-typecutters,Fig.39),typically 220°-250°,andtheedgelessthanhemisphere shaped cuttingedge.Usuallyitis180°(hemisphere, Fig.38);buttoolswiththeedgemore than In theballnosecutters,oneofimportantengineeringfactorsisangularvalueaball- and thetoroidal cuttingprofiles. about specificfeatures ofthecuttingtoolsindieandmoldmaking, reference istotheballnose excellently meettherequirements formachiningtheseparts.Itislittlewonderwhenspeaking The dieandmoldindustryfeature nolackofcomplexshapedparts-theballnosemillingtools surface. Thusthetooldoesnotcausedeformationofneededshapewhilemilling(Fig.37). actually onlyasphericalcuttingtoolcanensure theoretical pinpointcontactwitharequired 3-D is apartofsphere (Fig.36).Nothingotherthanaballhasthecommonnormaltosurface;and A ballnosemillingtoolhasaball-shaped(spherical)cuttingedge.Thismeansthattheedge 3.3. Ballnosemillingtools

Fig. 36 Fig. material removal by milling by removal material to not to time (especially in shoptalk of the die and mold professional environment) the ball nose nose ball the environment) professional mold and die the of shoptalk in (especially time to time From “ be to said are cutters Ball mill Ball of the specific design principle and relate to grinding materials into powder into materials grinding to relate and principle design specific the of devices grinding ball mills ball SR... ” definition should be avoided because ball mills refer to refer mills ball because avoided be should definition a Such . . SR... SR... but , Die andMold 89 Milling Tools 90 Milling Tools Fig. 38 Fig. Fig. 37 Fig. Contact points 180º 180º 180º Required shape Profile ofmachinedworkpiece Fig. 40 Fig. 39 Fig. Fig. 41 a 41 Fig. a 1 a e ϕ ϕ SR ϕ<180° ϕ>180° Fig. 41 b 41 Fig. ϕ ϕ a e Cylindrical edge SR Die andMold 91 Milling Tools 92 Milling Tools 68 showsthemostpopularISCARfamiliesofballnoseendmillcutters. (types BandD).Usuallytypefeatures anoperatingangleαequalto5°,andtypeD–2°.Table (Fig.44), there are different designconfigurationswithstraight(typeA)andtapered (conical)neck cutting headswithaFLEXFITorMULTI-MASTER adaptation.Forthetoolswithintegralbody indexable typesare availablenotonlyastools withintegralbodybutinmostcasesasreplaceable they varyindimensionsandobtainableaccuracy. Inaddition,thecuttersofsingle-insertand insert andwithinterchangeable solidcutting heads. Normallytheseare endmillswithshankand ISCAR carriesawiderangeofballnosemillingcuttersdiversetypes:indexableandsolid,single- planning requires takingtheproperties intoconsideration. some particularproperties associatedwiththe ballnosecuttinggeometry. Thecorrect process machining specificpartscandemandvariousmillingstrategies;andtheexamplesonlyillustrate much bettersituationwhenamore acceptablecuttingspeedcorresponds tothisarea. Ofcourse, low cuttingspeeds;whileincaseb),theedgearea, whichcarriesthemainload,isina case a),themoststressed portionofthecuttingedgeisarea nearthecuttertipthatfeatures the cuttingconditionsforbetter. Underthesameprogrammed spindlespeedandfeedin a, Fig.43)onrampupmilling(caseb,thesamefigure) inamachiningprocess atoncechanges loading onthecuttingedgemore uniform.Anotherexample:replacing rampdownmilling(case milling withatoolwhenitsaxisisnotperpendiculartomachinedsurface(“tilting”,Fig.42)makes improve theperformanceof theballnosetoolsandmakesthemmore effective. Forinstance, geometry ofaballnosetool.Additionally, machiningpracticeadvancesdifferent methodsthat Cutting toolengineerstakeintoaccountthementionednegativeeffect whendesigningthecutting harder andintensifieswear inthecertainareas ofthecuttingedge. substantial difference inloadingthepointsofcuttingedgealongitsprofile, whichmakescutting place here. Thecombination ofunequalcuttingspeedsanddissimilarchipthicknessleadstoa speeds. Thechipthinningeffect considered intheprevious sectionsoftheguidealsotakes corresponding sphere. Suchavariationmeansthatthepointscutwere withdifferent cutting edge layonunequaldistancefrom atoolaxisvaryingfrom zero (thetip)totheradiusof phenomenon makescuttingneartothetipdifficult. Further, thepointsofaball-shapedcutting one seriousweakpoint:thezero velocity(andhencethezero cuttingspeed)ofacuttertip.That tools. However, theball-shapedcuttingedge,whichpredetermines thisimportantfeature, has The abilitytogenerateexact,trueformsurfacesistheprimeadvantageofballnosemilling

copy mill copy background: Historical “ called are tools milling nose ball the cases many In mills “copy plainly copying arrangement – the copy milling milling copy the – arrangement copying a of machines milling conventional on produced were machines, operated manually or having a follow-up drive of hydraulic, electric hydraulic, of drive follow-up a having or manually operated machines, The machines. CNC machines dramatically changed the technology of generating the contoured the generating of technology the changed dramatically machines CNC the of Introduction the ability to follow a master model (template) and thus to generate the contoured contoured the generate to thus and (template) model master a follow to ability the feature type, cutting. In contrast to the traditional copy milling that allowed machining for the most the for machining allowed that milling copy traditional the to contrast In cutting. by surfaces cutting. As a matter of course, the copy milling machines use mainly the cutters of cutters the mainly use machines milling copy the course, of matter a As cutting. by surfaces profiles, modern CNC technology is capable of producing very complicated 3-D shapes 3-D complicated very producing of capable is technology CNC modern profiles, 2-D part toroidal cutting profile that were called were that profile cutting toroidal or ball-shaped “ today and cutting; metal by is software CAD/CAM of use the with built model The “ terms used sometimes Therefore programs. CNC from their original meanings. original their from differ substantially now ” . These terms trace their history to not so long-ago when the contoured surfaces contoured the when long-ago so not to history their trace terms These . template ” , which defines tool paths, is a computer solid model. solid computer a is paths, tool defines which , copy milling copy copy milling cutters milling copy “ intended for generating corresponding generating for intended copy mills copy “ correspondingly and ” accordingly. ” ” “ , copying style mills style copying copy mills copy or ” etc. , ” , Fig. 44 Fig. Fig. 43 a 43 Fig. Fig. 42 Fig. a ∝ V F R Type A Type δ A ∝ B Fig. 43 b 43 Fig. Type D Band R n V F α° ∝ a Die andMold 93 Milling Tools 94 Milling Tools * Forproduction ofthestandard line

equation 15.Table 69showshowtodefinetheeffective diameter, dependingonacuttingpath. in Fig.45)where theareas ofthecuttingedgehavingdiametersmore thanDedetermined from However, theequationwillnotworkforrampingandmillingnearstraightwalls(casesb)c) following equation: which relates tothepointofcuttingedgewithmaximalspeed,canbedefinedfrom the For aballnosemillingtooltheeffective cuttingdiameter(seethemarginalnoteonpage58)De, conditions andshouldbeavoided. and b)inFig.43.Thelatteristhecorrect choice,whilethefirstcaseshowscuttinginunfavorable the area withthepossiblymaximalcuttingspeed.Compare, forexample,thementionedcasesa) section. Acorrectly selectedmillingmethod demands removing mostofamachiningallowanceby engages directly inmilling.Duetothechipthinningeffect thechipthicknessalsovarieswithin As already stated,thecuttingspeedvariesalongsectionofaball-shapededgethat Starting CuttingDataandTool Selection Where Table 68

allowance allowance

SOLIDMILL MULTI-MASTER HELIBALL DROPMILL BALLPLUS Family with a ball nose cutter, tilting the cutter axis prevents the non-cutting effect of the of effect non-cutting the prevents axis cutter the tilting cutter, nose ball a with milling When its zero cutting speed. cutting zero its to due tip cutter case study case action: Tilting Fig. 42. Section AB of the cutting edge performs milling operation milling performs edge cutting the of AB Section 42. Fig. to Turn on can be found as R∙sin as found be can axis the speed within the section is directly proportional to a distance from a point of the section the of point a from distance a to proportional directly is section the within speed cutting The not difficult to see that if the angle is 5°, the cutting speed in point A is approximately 9% of 9% approximately is A point in speed cutting the 5°, is angle the if that see to difficult not is It cutter axis cutter the to if 10° - 17%; and for the angle 15° the speed is already 26% of the maximum. the of 26% already is speed the 15° angle the for and 17%; - 10° if maximum, the from the axis, where R – the radius of the cutter sphere. The distance from point A to A point from distance The sphere. cutter the of radius the – R where axis, the from R distance Ball NoseEndmillCutters:MainFamilies δ . ap D minimal in point A. The cutting speed has a maximum in the point spaced spaced point the in maximum a has speed cutting The A. point in minimal is it and –tooldiameter –axialdepthofcut Solid carbide Interchangeable solidheads Single-insert Indexable Single-insert Type De =2x√(D×ap-ap²) α – a tilting angle. tilting a – α where ,

tools 6…25 8…10 12…50 12…25 Diameter Range,mm* 0.4…25 (15) removing machining removing ,

** * be asource ofseriousinaccuracy. result. Nevertheless,thisequationshouldbeappliedforrough calculationonlyduetothetruncationerror thatcan The simplifiedequationisoftenusedforestimatingeffective diameter. Inmanycasesitgivesamore orlesssuitable α -rampingangle,amachiningallowance(stocktoberemoved) perpass.

by substitutionzero valueforangleα. diameter ofaballnosemilling cutterinrampingapplicationsandissimplyobtained from the latter One caneasilyseethatequation(15)isnothingbutaparticular caseoftheformulaforeffective The truncationerror here isonly6% andthatistotallyacceptable. simplified equation-25×sin70°=23.5(mm). De=(25-2×1)×sin70°+2×√(25-1) ×cos70°=24.96(mm) ≈25 mm;andinaccordance withthe On thecontrary, for70°ramping witha25mmdiameterballnosecutter1allowance gives only1.7mm!Thetruncationerror inthiscasereaches 80%! diameter De=(10-2×2)×sin10°+2×√(10×2-2²)×cos10°=8.9 (mm),whilethesimplifiedequation If forthesamecutterrampinganglewillbe10°and theallowance2mm,calculatedeffective By comparison,thesimplifiedequationwillgive10×sin30°=5(mm)-truncationerror is37.5%. De=(10-2×0.4)×sin30°+2×√(10×0.4-0.4²) ×cos30°=7.99(mm)≈8mm. In accordance withTable 69(caseb)inFig.45): by onepass. ramp upmillingwitharampingangleof30°.Themachiningallowance0.4mmshouldberemoved Calculate theeffective diameterforaballnose cutterof10mmdiameter, whichisappliedto Example Table 69 Cutting Path Milling straight The cutter Ramping, milling Fig. 45 a 45 Fig. a better performance. performance. better of the effective diameter. Precise calculation leads to correct cutting action and action cutting correct to leads calculation Precise diameter. effective the of computation in with ball nose cutters, especially in ramping operations, it is very important to be accurate be to important very is it operations, ramping in especially cutters, nose ball with milling In with effective diameter effective with accurate Be p axis is normal to a machined surface amachined to normal is axis Effective DiameterforBall Nose MillingCutters walls inclined surfaces n D e + V F Fig. 45 b 45 Fig. α a Case in b) c) a) D e Fig. 45 Fig. n (D-2×a)×sinα+2×√(D×a-a²) ×cos* Effective DiameterDe D 2×√(D×ap-ap²) V F Fig. 45 c 45 Fig. Stepdown (a p ) a e D n e ≈D×sinα** Notes

V Die andMold F 95 Milling Tools 96 Milling Tools operation willbeapproximately 30%less! V spindle speedn=1000×100/(π×16)=1990(rpm)andprogrammed feedspeed As acomparison,ignoringsuchfactorsaseffective diameterandchipthinningresults in Normally, chipthinningfactorKTHcanbefoundfrom thefollowingequation: factor isafunctionofthecuttersphericdiameterDandaxialdepthcutap(Fig.47). order toobtaintheplanned maximalchipthickness,shallbetakenintoaccount.Thethinning important tore-emphasize thatthechipthinningfactorincreases theprogrammed feedpertoothin the sectionrelated tothetoroidal tools;anditisnotnecessarytorepeat itagain.Howeverisvery maximal cuttingangle.Thechipthinningeffect hasbeenalready considered inreasonable detailin tools withtoroidal cuttingprofile, foraballnosecutterthevariationofdepthcutchanges The ball-shaped(spheric)cuttingedgeisthecauseofchipthinning(Fig.46).Justasmilling V Thus feedpertoothfz=0.12×1.2=0.14(mm/tooth)andprogrammed feedspeed Chip thinningfactorKTH=1/sinχmax=1/sin55.8°=1.2 Maximal cuttingedgeangleχmax=arccos (1-(2×3.5/16))=55.8° Correspondingly, programmed spindlen=1000×100/(π×13.2)=2411(rpm) Effective diameterDe=2×√(16×3.5-3.5²)=13.2(mm) maximal chipthickness0.12mm?Theaxialdepthofcutis3.5mm. diameter two-fluteballnosecutter, ifthe required cuttingspeedis100m/minandtheexpected What feedandspindlespeedshouldbeprogrammed foramillingoperationperformedby16mm Example Maximal cuttingedgeangleχmax,asitfollowsfrom equation(4),isdeterminedby F F Fig. 46 Fig. = 0.12×2×1990=477.6(mm/min).Underthisprogrammed data,productivity ofthe =0.14×2×2411= 675(mm/min) χ max =arccos(1-(2xap/D)) KTH = 1/sin h m χ f z max

a p (16) (4a)

Ball Nose Table 70 cutting data. can alsobefoundfrom Table 70.Justaswell,thetabledataisveryusefulforquicklyestimating In additiontoequations(15)and(16),effective cuttingdiameterDeandchipthinningfactorKTH 8 7 6 5 4 3 2 1 0.7 0.5 0.3 0.2 mm ap, Fig. 47 Fig. out can lead to to poor operational performance and less productivity. less and performance operational poor to to lead can out them Leaving diameter of a cutter and the chip thinning factor defined by application. application. by defined factor thinning chip the and cutter a of diameter effective corresponding with ball nose cutters, correct feed and speed calculations sh calculations speed and feed correct cutters, nose ball with milling In 3.5 2.6 2.1 1.7 De — — — — — — 4 3 SØ4

Effective CuttingDiameterDe,mm,andChipThinningFactorKTHfor Milling Cutters KTH 1.1 1.3 1.5 1.9 2.3 — — — — — — 1 4.9 3.5 2.4 1.9 De — — — — — — 4 3 SØ5 KTH 1.2 1.4 1.7 2.1 2.5 — — — — — — 1 5.6 4.5 3.8 3.3 2.6 2.1 De — — — — — 6 SØ6 KTH 1.1 1.3 1.5 1.8 2.3 2.8 — — — — — 1 V F 6.9 6.3 4.9 4.2 3.6 2.8 2.3 De — — — — — SØ7 KTH 1.1 1.4 1.7 1.9 2.5 — — — — — 1 3 D,mm a p 7.7 6.9 5.3 4.5 3.9 2.5 De — — — — 8 3 SØ8 KTH 1.1 1.5 1.8 2.1 2.6 3.2 — — — — 1 1 9.8 9.1 5.1 4.3 3.4 2.8 De 10 — — — ∝ 8 6 SØ10 ould V KTH 1.1 1.2 1.7 1.9 2.3 2.9 3.6 — — — F 1 1 be based on the on based be 11.8 11.3 10.4 8.9 6.6 5.6 4.8 3.7 3.1 De 12 a — — p SØ12 a KTH 1.1 1.1 1.3 1.8 2.1 2.5 3.2 3.9 — — 1 1 15.9 15.5 14.8 13.8 12.5 10.6 7.7 6.5 5.6 4.3 3.5 De 16 SØ16 KTH 1.1 1.1 1.3 1.5 2.1 2.4 2.9 3.7 4.5 Die andMold 1 1 1 97 Milling Tools 98 Milling Tools for BallNoseMillingCutters than theassembledone. but itismore exceptionthantherulethatsays: themonolithicintegraltoolcanbemore precise MULTI-MASTER ballnoseheadswithaccuracyrequirements more strictthanforthesolidmills, their accuracyordimensionalsizes.Itisworthytonotethatthere are high-precision of theMULTI-MASTER familyare typicallyfoundin-betweentheindexable andsolidtoolseitherin cutters ofthesingle-inserttypeandmillingtoolswithinterchangeable solidcarbideheads accuracy requirements; howeverthediameterofsuchamillrarely exceeds20mm.Theballnose will belimited;atthesametimeasolidcarbideendmillusuallyismostsuitablesolutionforhigh cutter: basingontheindexable-typeprinciplecuttercanreach largediametersbutitsaccuracy cutter accuracyanditsnominaldiameter. Insomemeasures thechartcanhelpinchoosing The chartinFig.48showssimplifiedformthetypeofaballnosecutterasfunction milling cuttersspecifically. part manufacture makesdifferent demandsfortherequired toolsingeneralandfortheballnose accuracy; theydiffer inprocessing chainandspecificationof rough andfinishpasses.Therefore the a largemachiningallowance.Themachineddieandmoldpartsare notequalintheir sizeand Normally, theballnosecuttersfeature semi-finishtofinishmillingofthe3-Dsurfaceswithout Apart from everythingelse,definingcuttingdatadependsonthetypeofballnosecutters. Table 70(cont.) 25 20 16 12 10 8 5 3 1 0.5 0.3 mm ap, Fig. 48 Fig. 19.6 17.3 14.3 8.7 6.2 4.9 De 20 — — — — SØ20 KTH 1.1 1.4 2.3 3.2 4.1 — — — — Effective CuttingDiameter De,mm,andChipThinningFactorKTH 1 1 diameter Nom. 24.5 23.3 16.2 9.8 5.4 De 25 20 — — — 7 SØ25 KTH 1.1 1.2 1.5 2.5 3.6 4.6 — — — 1 1 Indexable 30.1 29.7 27.7 23.2 18.6 11.1 7.9 6.2 De 32 — — B.N. Cutters One Insert D,mm SØ32 Interchangeable Solid Heads KTH 1.1 1.1 1.4 1.7 2.9 5.2 — — 1 1 4 Carbide Solid 39.2 36.7 34.6 26.4 12.5 8.9 6.9 De 40 32 21 — Accuracy SØ40 KTH 1.1 1.1 1.2 1.5 1.9 3.2 4.5 5.8 — 1 1 46.6 42.7 36.7 23.7 9.9 7.7 De 49 40 30 14 50 SØ50 KTH 1.1 1.2 1.2 1.4 1.7 2.1 3.6 6.5 1 5 1

accuracy (Table 71). The BALLPLUSinsertsdiffer inangularvaluesoftheircuttingedge,geometryand throwaway, isprovided withonlyonecuttingedge. insert, however, isindexable andthere are twocuttingedgesonit;butthe8mminsert,atypical one cuttingedgeinthiscaseandisintendedmostlyfor rough millingoperations.The10mm for thecuttersare shapedbysinteringonlywithoutanygrindingoperation.Acutterhas replaced byit,isrepresented todayonlyby thecuttersofsmallerdiameters:8-10mm.Inserts The HELIBALLfamily, theimmediatepredecessor oftheBALLPLUSandnowalmostcompletely 12-25 mm. edges whichare theedgesofinsert.The rangeofdiametersfortheBALLPLUScuttersis against twocontactsurfaceswithintheslotofcutterbody(Fig.19).Thehascutting A BALLPLUSmillingcuttercarriesoneballnoseinsertwiththeV-shaped rear partthatismounted nose millingcutters BALLPLUS andHELIBALL:familiesofsingle-insertball calculation. cutter andcontainthetableswithbasicspeedsfeedsnecessaryforcuttingdata The subsectionsbelowemphasizethecharacteristicproperties ofthefamilies the ballnose connected withdesignfeatures ofthecutterfamily. Defining thebasicstartingspeedandfeeddependsontypeofaballnosecutteris rigid workholding,etc.). estimated cuttingstabilityisinsufficient (millingthinwalls,highoverhang,poortoolholding,non- The stabilityfactor, asalready noted,istakentobe1fornormalconditionsand0.7ifthe The chipthinningfactorisdefinedbyequation(16)orin Table 70. The toollifefactorisshowninTable 8. Where:

the already knownequations (1)and(6): The startingcuttingspeedVcandfeedpertoothfzusedforCNCprogramming canbefoundfrom Ks KTH fz Kt Vo 0 –basicstartingfeed –toollifefactor –stabilityfactor –basiccuttingspeed –chipthinningfactor fz = Vo xKsKt Vc =Vo 0 x KTHKs (1) (6) Die andMold 99 Milling Tools 100 Milling Tools *

ISCAR materialgroup inaccordance withVDI3323standard

Table 72 Basic startingfeedfzoandbasiccuttingspeedVo are showninTables 72and73. Table 71

HCR…-QP HCR…-QF HBF… HBR... Insert DIN/ISO 513 ISO class earlier, in milling with ball nose cutters, the machining tolerance (stock) typically is not is typically (stock) tolerance machining the cutters, nose ball with milling in earlier, mentioned As For quick estimation of the depth of cut/width of cut relation, a rule of thumb may be used. be may thumb of rule a relation, cut of cut/width of depth the of estimation quick For large. so t of rule A “ as named rule, The martensitic stainless steel by ball nose cutters of one-insert type or with interchangeable with or type one-insert of cutters nose ball by steel stainless martensitic and steel In accordance with the rule, if a depth of cut is the half of a cutter diameter (D/2), diameter cutter a of half the is cut of depth a if rule, the with accordance In heads. solid of cut should be no more than D/6; for the depth of cut D/3 the maximal width of cut cut of width maximal the D/3 cut of depth the for D/6; than more no be should cut of width a D/4, etc. D/4, be should not difficult to see that 2×6=3×4=12. that see to difficult not is It H M K P BALLPLUSandHELIBALLBallNoseMillingCutters:BasicFeedfzo,mm/tooth BallNoseInsertsoftheBALLPLUSFamily (hemisphere) humb 11 10 8, 9 39 6, 7 38.2 17-18 5 38.1 15-16 12, 13 1-4 (bulb-type) Spheric ~220° Material Group* 180° Cutting Edge the rule of 12 of rule the Cylindrical yes no 0.06 0.07 0.07 0.03 0.08 0.04 0.08 0.08 0.05 0.09 0.07 0.09 8 ” , gives quite acceptable results for milling soft and pre-hardened pre-hardened and soft milling for results acceptable quite gives , Accuracy normal normal Grade high 0.07 0.08 0.08 0.03 0.09 0.05 0.09 0.09 0.06 0.08 0.1 0.1 10 sintered sintered ground Rake Face 0.09 0.09 0.04 0.06 0.11 0.11 0.07 0.09 0.12 0.12 0.1 0.1 12 fzo,forD,mm ground Flank Material type 0.11 0.04 0.12 0.06 0.12 0.12 0.07 0.13 0.13 0.1 0.1 0.1 16 range wide soft Application 0.11 0.12 0.05 0.13 0.07 0.14 0.14 0.08 0.11 0.15 0.15 0.1 20 rough tofinish rough tofinish Operation finish 0.11 0.12 0.13 0.06 0.15 0.08 0.16 0.16 0.12 0.17 0.17 0.1 25 ** *

In thiscaseHSMrecommended ISCAR materialgroup inaccordance withVDI3323standard Table 73 DROPMILL BCR…Inserts:BasicCuttingSpeedVo, m/min Programmed feedspeedV Spindle speed1000×Vc/(π×De)=1000×168/(π×17.3)=3090 (rpm). Cutting speedforestimatedtoollife60min.Vc=210×1×0.8=168 (m/min). Programmed feedpertoothfz=0.15×1.1=0.16(mm/tooth). Basic cuttingspeedVo=210 m/min(Table 73). Basic feedfzo=0.15mm/tooth(Table 72). The workpiecematerialrelates tothematerial group No.1. Table 70:17.3mmand1.1respectively. Effective diameterDeandchipthinningfactorKTHcanbecalculatedorfounddirectly from the widthofcut(stepover)–3.5mm.Operationalstabilityissufficient. HCM D20-A-L150-C20,withinsertHCRD200-QFIC908.Theaxialdepthofcutis5mm, A partmadefrom carbonsteelAISI/SAE1020 ismachinedbyballnoseendmillcutter Example this grade. sintering non-ground CR…insertsfor8and 10 mmdia.HELIBALLtoolsare produced justfrom milling inunstableconditionsandforcaseswithconsiderableimpactloading.Thefullyshapedby workpieces from hardened steelsandnodularcastiron. ThetoughergradeIC328issuitablefor be considered tobethepreferred option.Inmanycasesitistheuniquesolutionforprofiling finish milling,gradeIC908,thehardest one,hasbecomeincreasingly more popular, andcan that themainpartofapplicationone-insertballnosecuttersrelates tosemi-finishand and shouldbethefirstchoiceformillingsoftpre-hardened steel.However, duetothefact IC908, IC928andIC328.From thesethree grades,IC928isconceptuallythemostgeneral-duty Three carbidegradesare availablefortheBALLPLUS/HELIBALLinsertsofstandard line: DIN/ISO 513 ISO Class H P M K BallNoseCutterswithBALLPLUSHCR…/HBR…,HELIBALLCR…and Material Group* 12, 13 15-16 17-18 38.1 38.2 39** 2-4 5-6 7-9 10 11 1 F = 0.16×2×3090=988.8(mm/min)≈990mm/min. IC908 210 220 155 100 200 200 190 180 160 140 70 55 Vc, forGrade IC928 180 200 130 170 180 150 140 125 120 80

IC328 160 125 140 130 125 120 110

Die andMold 101 Milling Tools 102 Milling Tools

• • overhang. Example π×12×3804/1000=143 (m/min),whilethereal cuttingspeedisnobetterthan49m/min. Comparison ofthecuttingspeedwithrespect tothenominaldiameterwillbeasfollows: Programmed feedspeedV Spindle speed1000×Vc/(π×De)=1000×49/(π×4.1)=3804(rpm) Cutting speedfor20min.toollifeVc=70×0.7×1=49(m/min) Programmed feedpertoothfz=0.06×3.9×0.7=0.16(mm/tooth) Basic cuttingspeedVo=70 m/min(Table 73) Basic feedfzo=0.06mm/tooth(Table 72) The machinedmaterialrelates tomaterialgroup No.38.2,hence: The hightooloverhangrequires definingstabilityaspoorandusing factorKs=0.7. Chip thinningfactorKTH=1/sin Maximal cuttingedgeangle Axial depthofcut(equation17)ap=12/2+[(0.2-12/2)×cos5°+√(12×0.2-0.2²)×sin5°]=0.36(mm). De=(12-2×0.2)×sin5°+2×√(12×0.2-0.2²) ×cos5°=4.1(mm). Effective diameterinaccordance withTable 69,caseb): Find cuttingdataiftherequired toollifeperiodis20minutes: angle of5°andmachiningallowance0.2mm.Thecutterworkswithreasonably high AISI P20moldsteelhardened toHRC50-52.Theoperationisrampupmillingwitharamping IC908 isappliedtofinishinganinclinedbottomsurfaceofaplasticmoldpartmadefrom 12 mmdiameterballnoseendmillcutterHCMD12-D-L160-C16withinsertHBFD120-QF

ap=D/2+[(a-D/2)×cos

factor KTH, as a function of cutter diameter D and axial depth of cut ap, is defined defined is ap, cut of depth axial and D diameter cutter of function a as KTH, factor thinning Chip (16) and (4a). In ramping with ball nose cutters, ap often is not specified directly specified not is often ap cutters, nose ball with ramping In (4a). and (16) equations by w one and mathematics Ramping and machining allowance (stock to be removed) be to (stock allowance machining and α angle ramping via implicitly defined is it but depth of cut can be calculated from the following equation: following the from calculated be can cut of depth axial the of a ball-shaped cutting edge during ramping. during edge cutting ball-shaped a of loading non-uniform practice the result of calculation according to equation (17) is often increased by 10-20% by increased often is (17) equation to according calculation of result the practice shop In a. part per any case the final value shall not exceed D/2). This working rule provides a sort of safety of sort a provides rule working This D/2). exceed not shall value final the case any in (clearly, phrase in the square brackets is positive, ap s ap positive, is brackets square the in phrase the If the programmed feed a little bit smaller. The safety factor takes into account into takes factor safety The smaller. bit little a feed programmed the making factor, Of course, CAD/CAM systems allows very quick finding ap in such case. In addition, addition, In case. such in ap finding quick very allows systems CAD/CAM course, Of α +√(D×a-a²) ×sin +√(D×a-a²) F = 0.16×2×3804=1217(mm/min) χ max =arccos (1-(2×0.2/12))=14.8°. χ max=1/sin14.8°= 3.9. r orking α (17) ] ule be taken equal to the cutter radius or D/2. or radius cutter the to equal taken be hould Table 74 reduces actingcuttingforces andimproves chipevacuation. large depthsofcut,duetoitschipslittingcuttingeffect thatprevents theformationoflongchips, CS withchipsplittinggrooves. Thelatterisprincipally intendedforheavydutyrough millingwith There are twotypesoftheDROPMILLinserts:peripherallyground QTandfullysintered modular toolswithFLEXFITorMULTI-MASTER connections. relatively smalldepth.Thecuttersare produced asintegraltoolsandalsomillingheadsfor removal ofsignificantmachiningstock.Inaddition,theyare suitablefordrillingoperationswith are especiallyadvantageousforsemi-finishingthecontoured surfaces;allowingforproductive die andmoldcavitiesbyrampinglineorhelix(helicalinterpolation),etc.TheDROPMILLcutters The mainapplicationofthefamilyisformilling3-Dsurfacesusingvarioustechniques,machining the insertpocket,allowstowithstandhighforces resulting from considerableloading. a shoulderwithround corner. Aprotrusion from theinsertbottomthatfitsintoamatchingslotin 60-70% ofasphericalradiusgeneratedbythecorner, whichenablesmachiningastraightwalland round withastraightsidearea corner tangenttothecorner. Thearea hasarelatively largelength: teeth forthecutter(Fig.49).Theinsertfeatures twocuttingedgesandeachofthemcombinesa A DROPMILLcuttercarriestwoindexableinsertsofateardrop shape,ensuringtwofullyeffective DROPMILL: aFamilyofIndexableBallNoseMillingCutters Insert BCR D…-QT BCR D…-CS Fig. 49 Fig. BallNoseInsertsofDROPMILLFamily sintered Rake Face Straight Area sintered ground Flank R A p Splitter Chip yes no QT semi-finishing Application roughing Main CS 12

16

20

Tool Ø,mm 25

30

32

40

Die andMold 50

103 Milling Tools 104 Milling Tools *

ISCAR materialgroup inaccordance withVDI3323standard

Table 75 and chipthinningfactorKTH =1. The cutterradiusis25mm.Hence,theeffective diameteronthefirstpasswillalready be50mm; cut, thesecond–with10mm,andthird –with8mmdepthofcut.Findcuttingdata: A process plannerdecidedtomilltheslotbythree step passes:thefirst–with25mmdepthof is alloysteelAISI/SAE6150,HB250…260.Thetechnological systemhassufficient stiffness. nose endmillcutterBCMD50-A-W50-CwithinsertsBCR D500-CSIC908.Theworkpiecematerial A slotwitharounded bottomof50mmwidthand43depthisplannedtobemachinedbyball Example by 20-30%. CS-type insertsandforheavy-dutyshouldermilling,thespecifiedvaluesshouldbe reduced quarter ofthediameterforQT-type insertsandmore thanthethird partofthediameterfor Basic feedpertoothisshowninTable 75.Formillingafullslotwithdepthofcutmore thana values shouldbereduced by10-20%. QT-type insertsandmore thanthethird partofthediameterforCS-typeinserts,table width ofcutormillingafullslotwithdepthmore thanaquarterofthediameterfor less insemi-finishtofinishpasses.Therefore, incaseofheavy-dutyapplicationswithasizable cut usuallydoesnotexceed30%ofthecutterdiameterinrough operationsanditisconsiderably Table 73containsdataforbasiccuttingspeeds.InmillingwiththeDROPMILLcutters,awidthof the samecarbidegrades:IC908,IC928andIC328. Similar tothefamiliesofone-insertballnosecutters,DROPMILLinsertsare produced from

DIN/ISO 513 ISO Class operations, using the CS-type inserts is the preferred way. The CS-type geometry should geometry CS-type The way. preferred the is inserts CS-type the using operations, such For or grooves (especially the deep ones by step passes), milling shoulders with large with shoulders milling passes), step by ones deep the (especially grooves or slots Milling as a first choice in any case when it comes to heavy-duty milling and problems and milling heavy-duty to comes it when case any in choice first a as considered be milling cavities and pockets with high stock removal rate – all these operations these all – rate removal stock high with pockets and cavities milling rough allowance, evacuation. chip with d splitting Chip DROPMILL the by performed P M H K DROPMILLBallNoseMillingCutters:BasicFeedfzo,mm/tooth 11 10 8, 9 39 6, 7 38.2 17-18 5 38.1 15-16 12, 13 1-4 Material Group* rop 0.08 0.09 0.04 0.05 0.11 0.11 0.07 0.11 0.09 0.11 0.1 0.1 12 re-cutting. chip and loading tool heavy feature cutters 0.09 0.11 0.04 0.11 0.06 0.12 0.12 0.08 0.13 0.13 0.1 0.1 16 0.12 0.13 0.05 0.13 0.07 0.14 0.14 0.09 0.15 0.15 0.12 0.1 20 fzo, forD,mm 0.11 0.13 0.14 0.06 0.15 0.08 0.16 0.16 0.17 0.17 0.13 0.1 25 30/32 0.12 0.14 0.15 0.07 0.16 0.09 0.17 0.17 0.11 0.18 0.18 0.14 0.13 0.15 0.16 0.07 0.17 0.09 0.18 0.18 0.12 0.21 0.21 0.15 40 0.15 0.17 0.18 0.08 0.19 0.21 0.13 0.25 0.25 0.17 0.1 0.2 50 • •

Programmed feedspeedV Spindle speed1000×Vc/(π×De)=1000×122/(π×50)=776(rpm)≈770rpm tool life-180×0.85×0.8=122(m/min). programmed feedpertooth willbe0.18×0.75=0.13(mm/tooth);thecuttingspeedfor60min. values by10-20%forthespeedand20-30%feed.Itmeansthatonaverage Taking intoaccounttheaboveremarks regarding millingafullslotweshouldreduce these Basic cuttingspeedVo=180 m/min(Table 73) Basic feedfzo=0.18mm/tooth(Table 75) The machinedmaterialrelates tomaterialgroup No.8,therefore: for thefirstpassand115m/minwith0.12mm/tooththird pass. one becausethechipevacuationbecomesproblematic. Letsay, 135m/minwith0.14mm/tooth approach demandslessdecrease forthefirstpassandgreater reduction forthethird, thelast We tooktheaveragefactor forreducing thespeedandfeed.Amore correct Remark family, Table 76). helix angleis30°.Thediameterhasaccuracytolerancee8(h10fortheeconomicalSOLIDECO the solidcarbideballnoseendmilltoolsis1…25mm(0.4…2forminiature cutters); andthe intended foralltypesofthedieandmoldmaterials.Generally, therangeofcuttingdiametersfor in short,medium,longandextralengthversions(Fig.50),withstraightortapered neckand geometry andnumberofflutes.Thecuttersare produced from variouscarbidegrades(Table 10) SOLIDMILL, theISCARlineofsolidcarbideendmills,containsballnosecuttersvaryingincutting Solid CarbideBallNoseEndmillCutters Fig. 50 Fig.

Short Overhang F = 0.13×2×776=202(mm/min)≈200mm/min Medium Long Extra Long Extra Die andMold 105 Milling Tools 106 Milling Tools ** D-thediameterofaballnosecutter(head) * * ** Asubgroup of2fluteEB…A…cuttersisintendedformaterialswithHRC55…70

ISCAR materialgroup inaccordance withVDI3323standard machining formaindieandmoldmaterialscorresponding machiningallowance. different typesofmachiningare notsoclear. Table 77canhelpinestimationofthetype In machiningwithlowallowances,evenarough stockissmallenough;andtheborders between allowance orstock(Fig.45),butthecuttersare usedsuccessfullyinroughing applicationstoo. finish andsemi-finishmillingofthe3-Dsurfaces;theyprimarilyoperateundersmallmachining indexable mill.Therefore, themainapplicationofsolidcarbideballnosecuttersrelates to Obviously, anintegralsolidcutterprovides amore accuratemachiningsolutionrelative toan

Table 77 Number offlutes Table 76 carbide gradeshouldbechosen from Table 10. Basic cuttingspeedsandfeeds canbedefinedfrom Tables 78and79.Asalready stated,the only

Heads: Type ofMachiningandApproximate MachiningAllowance

EBRF ESB EB Cutter DIN/ISO 513 ISO Class ISCAR solid carbide ball nose milling cutters have 2 or 4 flutes, that is - 2 or 4 cutting 4 or 2 - is that flutes, 4 or 2 have cutters milling nose ball carbide solid ISCAR the Classically are more suitable for rough milling, ensuring better chip evacuation. In addition, using the using addition, In evacuation. chip better ensuring milling, rough for suitable more are gullet chip to choose the number of flutes for a tool? a for flutes of number the choose to How teeth. cutters is a workable method for fine finishing due to less accumulated error, which depends which error, accumulated less to due finishing fine for method workable a is cutters flute 2 our? f or Two 4 flute ball nose cutters give a universal robust and productive solution for various for solution productive and robust universal a give cutters nose ball flute 4 all-purpose The number of teeth. of number the on for semi-finish and finish milling. Opposite milling. finish and semi-finish for especially applications, 4 flute cutters, traditionally only two teeth produce the central cutting area near the near area cutting central the produce teeth two only traditionally cutters, flute 4 the Concerning “ a by action cutting and not four. Then in finish milling with shallow depth of cut, calculation of the feed per feed the of calculation cut, of depth shallow with milling finish in Then four. not and tip cutter of the non-central teeth and accuracy errors. accuracy and teeth non-central the of wear intensive by marked multi-flute a of advantages the and teeth; effective two only consideration into take should tooth cutter M H K P Spherical The 2 flute tool is a more preferable means for such a case. Also, it prevents it Also, case. a such for means preferable more a is tool flute 2 The diminished. are ~220° 180° 180° SolidCarbideBallNoseCuttersandMULTI-MASTER MMEB…BallNose SolidCarbideBallNoseMillingCutters Cutting Edge Mat. Group* 1, 2,4,6,10 5, 8,9,11 Cylindr. ISCAR 12, 13 15-18 yes yes no 9-11 38.2 38.1 3, 7 39 conversion zone conversion 2; 3;4 3; 4 2; 4 Z* martensitic s.s. pre-hardened 0.4…25 Range, 6…20 3…16 Diam. hardened soft steel mm cast iron steel steel Machined material between 2 and 4 teeth 4 and 2 between ” ECO Line yes no no IC900; IC300;IC08 HB 250…300 HRC 38-44 HRC 30-37 HRC 56-63 HRC 50-55 HRC 45-49 HB< 300 HB<250 HB<250 Standard IC903 IC903 IC903 Carbide Grades specific for the 4 flute tools that is is that tools flute 4 the for specific , IC900; IC08 Roughing 0.12×D** 0.08×D 0.05×D 0.06×D 0.08×D 0.15×D 0.1×D 0.1×D 0.1×D ECO ly – – – , the 2 flute cutters with greater with cutters flute 2 the , Type ofmachining hard materials hard materials Main Milling general-duty Semi-finishing Application roughing 0.04×D 0.05×D 0.05×D 0.07×D 0.03×D 0.04×D 0.04×D 0.08×D 0.05×D up toHRC65** up toHRC55 up toHRC45 up toHRC65 Workpiece Hardness Finishing 0.015×D 0.01×D 0.01×D 0.02×D 0.01×D 0.01×D 0.01×D 0.03×D 0.01×D ** ISCARmaterialgroup inaccordance withVDI3323standard *

Carbide gradeselectorforsolidcutters–refer toTable 10 Programmed feedspeedV Spindle speed1000×Vo/(π×De)=1000×50/(π ×3.3)=4822(rpm). Cutting speedfor20min.toollifeVc=Vo=50 m/min. Programmed feedpertoothfz=0.011×3.5×1=0.038(mm/tooth). Table 79andremarks toit). speed is50m/min(Table 78);thebasicfeedpertoothis0.011mm/tooth (0.013×0.85–refer to Consequently, formaterialgroup No.38.2,towhichrelates themachinedsteel,basiccutting From Table 70chipthinningfactorKTH≈3.5. ap=D/2-0.5×√(D²-De²)=12/2-0.5××√(12²-3.3²)=0.23 (mm) Axial depthofcutapcanbereadily calculated(Fig.47)as: De=(12-2×0.15)×sin3°+2×√(12×0.15-0.15²) ×cos3°=3.3(mm) According toTable 69,caseb)effective diameterDe: Find startingcuttingdata. The machineisinagoodcondition;thehobproperly clampedintoafixture onthemachinetable. Machining stocktoberemoved duringthismilling operationis0.1…0.15mmonside. EB-A2 12-12/24C12H110903.Thehobwallsare inclined3°. vertical machinecenter, usinga12mmdiametersolidcarbideballnosecutter It issuggestedtomillamasterhob,whichmadefrom AISIA6toolsteelhardened toHRC55,ona Example

Ball NoseHeads:BasicCuttingSpeedVo* Reminder Table 78 will be:VcD=π×12×4822/1000=182(m/min) It isinteresting thatthecuttingspeedcalculatedrelative tothenominaldiameterofcutter(12mm) DIN/ISO 513 ISO Class how a report, technical paper or guide specifiies a cutting speed cutting a specifiies guide or paper technical report, a how check Always nominal diameter (Fig. 51)! (Fig. diameter nominal or effective M H K P Solid CarbideBallNoseCuttersandMULTI-MASTER Mat. Group** ISCAR 12, 13 15-16 17-18 38.1 38.2 2-4 7-9 39 10 11 1 5 6 F = 0.038×2×4822=366(mm/min). Roughing 160 180 110 150 150 125 130 120 115 100 70

Vo, m/min,forType of Semi-finishing 180 220 110 170 170 140 150 135 130 110 80 40 30

Machining with respect to respect with , Finishing 220 280 100 150 200 200 170 190 170 165 120 50 40 Die andMold 107 Milling Tools 108 Milling Tools *** ** * Ball NoseHeads:BasicFeedfzo* Table 79 For cutterswiththediameterlessthan1mm,refer tocorresponding ISCARuserguidesandcatalogs D -thediameterofacutter(head),mm ISCAR materialgroup inaccordance withVDI3323standard Carbide gradeselectorforsolidcutters–refer toTable 10 For semi-finishtofinishapplications,thetablevaluesneedbe reducedby10-20% The tablereflects rough tosemi-finishmillingoperations DIN/ISO 513 ISO Class Fig. 51 Fig. H P M K Solid CarbideBallNoseCuttersandMULTI-MASTER MMEB… Group** ISCAR 12, 13 17-18 15-16 Mat. 38.2 38.1 8, 9 6, 7 1-4 11 10 39 5 0.006 0.007 0.007 0.004 0.007 0.005 0.007 0.007 0.006 0.008 0.007 0.008 1 0.009 0.013 0.015 0.004 0.018 0.005 0.021 0.018 0.007 0.021 0.013 0.02 2 0.015 0.005 0.006 0.031 0.025 0.008 0.031 0.015 0.01 0.02 0.02 0.03 3 0.015 0.022 0.025 0.005 0.028 0.007 0.042 0.032 0.012 0.042 0.022 0.04 4 0.027 0.032 0.006 0.035 0.007 0.052 0.038 0.017 0.052 0.027 0.02 0.05 5 fzo, mm/tooth,forD*** 0.025 0.035 0.007 0.008 0.058 0.043 0.021 0.058 0.055 0.03 0.04 0.03 6 0.028 0.032 0.038 0.007 0.048 0.009 0.065 0.025 0.065 0.032 0.062 a 0.05 8 0.035 0.038 0.045 0.008 0.057 0.073 0.027 0.073 0.038 0.01 0.06 0.07 10 0.038 0.042 0.009 0.062 0.013 0.085 0.068 0.085 0.042 0.05 0.03 0.08 12 0.045 0.009 0.072 0.015 0.095 0.075 0.035 0.095 0.05 0.06 0.05 0.09 16 D a p 0.055 0.082 0.117 0.085 0.117 0.06 0.07 0.01 0.02 0.04 0.06 0.11 20 0.013 0.025 0.137 0.137 0.06 0.07 0.08 0.09 0.11 0.05 0.07 0.13 25 * Numberofflutes of for allow reducers and extensions shanks, with combined accuracy. heads and The shapes Table 80 The cutting Similar to The MULTI-MASTER MULTI-MASTER: Interchangeable ball nose heads are called “ called are heads H… nose MM ball cutters. solid the for method the as same the is EB… heads MM data for cutting to finding approach The lengths. cutting have smaller usually however heads the ball nose heads: multi-flute MM EB… heads and twoflute “ and MM multi-flute heads: EB… heads nose ball other pressed and sintered “ sintered and pressed other (h7). tolerances as HRF… MM heads, diameter and HBR… The MM closed precision have very heads The machinedThe material represents material group No. =1. (10 factor KTH diameter thinning chip Then case. mm) worst –the Assume that edge all cutting found. be must data Cutting good. is stability Operational 0.2 max. mm allowance machining with 40…42.HRC passes of several consists cycle restmilling The H11 AISI tool is steel material part of die. The the hardness with of apart corners the of restmilling S-B-L125-C16-T06 MM shank HCR100-2T06 MM head subject the nose is ball with IC908, assembled cutter, nose comprises die, aball which casting adie manufacturing for process aplanned Within Example Table tooth from Tablefound per –from feed 78 basic the 82. and be can speed cutting basic H… The MM heads. of MULTI-MASTER use tools carrying the nose ball with of milling types Table data, different for cutting Concerning allowance 81 machining average shows used. is IC903 grade carbide which steel, for HRF…hardened finishing precise for intended MM except heads the for IC908, grade carbide from made are MULTI-MASTER heads The nose ball EB… MM and heads. cutters nose ball carbide solid the with compared when less steel.much However, is heads of the hardened angle milling and helix the profiling rough for important is which loading; considerable against up stands successfully and strong tooth extremely is of head the A others. and heads HBR… MM bulb-type in edge of spheric the area increased HCR… heads, MM in edge cutting of spheric the part most the along rake angles positive tip with head the near rake angles of negative features: combination the unique for allows technology Such manufacturing. their during MM EB MM HBR MM HRF MM HCR Head numerous ball nose endmill cutters that meet the requirements of the die and mold maker. mold and of die the requirements the meet that cutters endmill nose ball numerous head shapes (square, toroidal, etc.), MULTI-MASTER of the the shapes head types main two are there economy (pressed ground to size) Ball NoseHeadsofMULTI-MASTER Family Type geometry of MM EB… heads is not different from the solid carbide ball nose cutters; cutters; nose ball carbide solid the from not different is EB… of MM heads geometry Spherical ~240° 180° 180° Cutting Edge family offers a rich choice of ball nose milling heads with various dimensions, dimensions, various with heads milling nose of ball choice arich offers family to shape and size and to shape perform cutting and the effective diameter De is equal to the nominal to nominal the equal is De diameter effective the and cutting s perform Cylindr. yes yes no economy sintered ground Rake Face ground ground Flank ” ” heads of this type, require minimum grinding operation , but not due to lesser accuracy. contrary, the high- to On not due lesser , but 2; 4 Z* 10. 2 Ball Nose Milling Nose Ball Heads tol. h7 h9 h7 e8 Ø economy Carbide Grade IC908 IC908 IC908 IC903 MM H… heads (Table H…” MM 80). heads

6 Head Ø,mm

8 10

12

16

20

rough tofinish rough tofinish finish +milling Main Milling Application assembl hard steel Die andMold y 109 Milling Tools 110 Milling Tools *** ** * Recommended carbidegrade-IC903 D -thediameterofahead ISCAR materialgroup inaccordance withVDI3323standard

Type ofMachiningandApproximate MachiningAllowance

Table 81

DIN/ISO 513 ISOClass Fig. 52 Fig. rule, productive milling passes, especially rough, propose applying more durable and rigid rigid and durable more applying propose rough, especially passes, milling productive rule, a As of smaller diameter cuts the areas with residual stock. In speaking about restmilling, about speaking In stock. residual with areas the cuts diameter smaller of tool a high metal removal rate. In many cases the form and dimensions of the tool do not allow allow not do tool the of dimensions and form the cases many In rate. removal metal high for tools a finishing operation that is a part of the whole finish milling cycle. milling finish whole the of part a is that operation finishing a is this Restmilling cut in some areas; for example, the corners of a die cavity (Fig. 52). The remainder of the of remainder The 52). (Fig. cavity die a of corners the example, for areas; some in cut a for ball nose heads is the is heads nose ball MULTI-MASTER the and cutters nose ball carbide solid the of use Making the areas is removed by restmilling – a method under a technological process whe process technological a under method a – restmilling by removed is areas the in material for restmilling tools. restmilling for choice excellent M H K P by restmilling ( removed to be Material MULTI-MASTER MMH…BallNoseHeads: Mat. Group* 1, 2,4,6,10 5, 8,9,11 ISCAR residual 12, 13 15-18 9-11 38.2 38.1 3, 7 39 stock) r< a a D 2 with diameter D diameter with cutter milling Rough R - x - Finising allowance Martensitic s.s. Rough allowance Pre-hardened Hardened Soft steel Cast iron steel*** steel Machined Material ∅ D HB 250…300 HRC 38-44 HRC 30-37 HRC 56-63 HRC 50-55 HRC 45-49 HB< 300 HB<250 HB<250 A Roughing 0.14×D** 0.09×D 0.11×D 0.12×D 0.05×D 0.06×D 0.09×D 0.17×D 0.11×D R≥ D 2 Type ofMachining Semi-finishing Final shape 0.04×D 0.05×D 0.06×D 0.08×D 0.03×D 0.04×D 0.04×D 0.08×D 0.05×D a R Finishing 0.015×D 0.01×D 0.01×D 0.02×D 0.01×D 0.01×D 0.01×D 0.03×D 0.01×D a re X A *** ** * D -thediameterofahead ISCAR materialgroup inaccordance withVDI3323standard For machininghardened steel-carbidegradeIC903isrecommended For roughing byacutterwithMMHBR…head,thetablevaluesneedtobereduced by10% For semi-finishtofinishapplicationsthetablevaluesneedbe reducedby10-20% The tablereflects rough tosemi-finishmillingoperations Programmed feed speed V feed Programmed 1000×Vo/(π×De)=1000×165/(πSpindle speed ×10)=5252 remark). the with (rpm) 0.06 (Table mm/tooth 82: 0.07 value by 10% table reducing with mm/tooth accordance in 20 for 165 min. is tool life speed (Table m/min 78); tooth cutting per is basic the So feed basic the of Table values the with 81, allowance machining the milling. into fits finish Comparing operation the Table 81 DIN/ISO 513 ISO class H M K P MULTI-MASTER MMH…BallNoseHeads:BasicFeedfzo* Mat. Group** ISCAR 12, 13 17-18 15-16 38.2 38.1 8, 9 6, 7 1-4 11 10 39 5 F = 0.06×2×5252=630 (mm/min) 0.06×2×5252=630 = 0.05 0.06 0.06 0.08 0.08 0.07 0.07 0.08 0.02 0.03 0.04 0.06 8 0.025 0.037 0.06 0.07 0.07 0.09 0.09 0.08 0.08 0.09 0.05 0.07 10 fzo, mm/tooth,forD*** 0.045 0.07 0.08 0.08 0.09 0.11 0.06 0.08 0.03 0.1 0.1 0.1 12 0.055 0.035 0.08 0.09 0.09 0.11 0.12 0.12 0.11 0.07 0.09 0.1 16 0.065 0.09 0.12 0.11 0.13 0.13 0.12 0.08 0.04 0.1 0.1 0.1 20 Die andMold 111 Milling Tools 112 Milling Tools

do do

• • •

High High High HSM can mean: can HSM notObviously, exist. does machining speed high of definition accepted toEven up now agenerally up-to-date die mold and manufacturing? for relevant so HSM is Why it? is what machining, speed High making. mold and die particular, in operations HSM many and speed; spindle high with of note not aprocess always worthy HSM that It is time. cycle cut dramatically can HSM process to manufacturing applied tools,wi that cutting tools, of course, and toolholding devices ball nose “Solid carbide 55to HRC section the hardness with steel of machining example the In speed? etc.cutting How tothe define feed =more speed spindle More interrelated. are speeds feed and spindle cutting, that clear It is speeds… feed and a metalcutting method, demands very specific cutting techniques and cutting specific a method,techniques metalcutting as HSM, very demands machining. speed of high attributes classical are speeds Shallow, spindle high with light combined cuts m/min,40 m/min 60 m/min and80 correspondingly! 815 be will speed 0.04 feed mm/tooth. mm/min, The 1222 speed 1630 and mm/min cutting for mm/min Table feed in with cuts it cutter 2teeth and nose has 83 Assume ball that diameter 4mm to fast. run acutter causes turn in which speed, spindle considerable require can speeds cutting of cut, small even depths shallow milling with profile in that (Table distinctly shows 83). diameters table The nose of cutters different 0.1 –182the with nominal diameter of milling acase is illustrative m/min. More ball by of cut depth mm respect with to speed the 50 m/min, was and diameter to related effective the speed cutting real the and MillingofHardened Steel 3.4. SpecialMethods:HighSpeedMachining(HSM) The term “ term The “ is it that emphasized often is HSM

twenties-thirties Dr.-Ing. Carl Salomon, a German researcher, did a series of experiments for experiments of series a did researcher, German a Salomon, Carl Dr.-Ing. twenties-thirties the In temperatures against the corresponding cutting speeds during machining of machining during speeds cutting corresponding the against temperatures cutting measuring History: HSM History: materials. The results, which have been represented graphically, allowed the allowed graphically, represented been have which results, The materials. engineering some the area related to speeds is 5-10 times as much as common values. common as much as times 5-10 is speeds to related area the hypothesis By assume that the cutting temperature rises with increasing the cutting speed cutting the increasing with rises temperature cutting the that assume to researcher reaches some specific critical value, and then comes down, in spite of further the speed the further of spite in down, comes then and value, critical specific some reaches speed the 53). Hence, Salomon concluded, there is an area of cutting speeds much more than more much speeds cutting of area an is there concluded, Salomon Hence, 53). (Fig. growth which the cutting temperature is similar to those that are observed in conventional cutting. conventional in observed are that those to similar is temperature cutting the which for usual need high rotational need not velocity. feed speed machining machining speed feed machining speed spindle machining speed cutting High Speed MachiningHigh Speed various advantages various for allows ” that and the abbreviation “ abbreviation the ” and …amethod high-efficiency machining of modern with high . HSM ll ensure ll are well-known in industry, and in industry, in and well-known ” are acceptable tool life. Being acceptable dedicated machine until until , spindle cutters” cutters” speed, Vc rpm -spindle speed De diameter to effective respect with speed cutting Vc -the 0.1 for cut of depth diameter mm effective De, mm,-the cutter nose aball of diameter D -the competition on the die and mold markets dictates of work manual low is a very likelihood, which presents additional problems for production. Intense Repeatability processes. time-consuming are very polish and finish manual and EDM polishing. and steel hardened on finishing and (EDM) machining discharge electro steel, soft on operations of cutting Traditionally, share aconsiderable expected making mold die and nominal diameters. small with by tools especially and steel hardened of milling speed high with all of first connected practice mold and die in machining speed high HSM by Therefore time 40-50%. cycle the out; cutting allowing machining for starting processes, making mold and die It changed successful. maker. mold very was and method HSM The to to aroad HSM die the opened geometries and tool materials cutting new of course, and toolholders technology, drives, and bearings other components of machine tool, balanced high-precision spindle control,high-speed CNC in Success polish. and finish manual eliminate and possible as in aerospace or in aerospace branch Today, penetrated into mainly has enough HSM deeply the following processes: machining Table 83 of Different Diameterswith0.1mmDepthofCut 80 60 40 m/min Vc, Fig. 53 Fig. D - the cutting speed with respect to diameter of a cutter D acutter of to diameter respect with speed cutting , m/min,-the the entire the in tochanges led drastic advantages , HSM Temperature ComparativeExample:MillingbyBallNoseCutters 9094 6820 4547 Cutting T rpm T cr c De= 2.8 SØ 20 in die and mold making. E making. mold and die in steel and automotive industries Vc 572 429 286 D Conventional Cutting 12732 9549 6366 rpm of SØ 10 De= 2 Critical Point already hardened workpieces, and left manual finish and polishing polishing and finish manual left and workpieces, hardened already Vc 400 300 200 V cr D 14386 10789 7193 rpm De= 1.77 SØ 8 that Vc 362 271 181 D D, mm manufacturers cut cycle time as much 16976 12732 8488 rpm manufacturing approach. manufacturing De= 1.5 SØ 6 High Speed V Machining h and then manual smooth finish finish smooth manual then ; and Vc 320 240 160 D 20372 15279 10186 xactly in the die and mold mold and die the in xactly rpm De= 1.25 SØ 4 Vc 256 192 128 D 29270 21952 14635 rpm of Cutting Speed De= 0.87 aluminum aluminum SØ 2 Vc 184 138 92 Die andMold D , 113 Milling Tools 114 Milling Tools ISCAR * ISCAR

Table 84 4…25 diameter with MULTI-MASTERand mm. cutters of matter the initial For field. this in ISCAR specialists contacting we recommend and examination; deep more data require cutting starting and tool suitable more a defining Therefore, steel. of soft HSM from and conditions conventional under steel hardened milling from essentially It differs process. of whole the part acritical and participant tool, amandatory is cutting the course of and toolholder the software, and tool, hardware CNC the machine the components: involved the of one every which for Conceptually, method integrated technological an is steel HSM of hardened advantages. real in results together means the of all combination –the devices toolholding and systems tools, control machine dedicated also tools but cutting not only is HSM course, Of problem. this tool overcoming for agood maker mold and gave die the days’ technique HSM time. The several during to cut be need sometimes that molds and die large-sized for especially manufacturing, makes machining operations unpredictable. Such is vagueness simply unacceptable for die and mold of accuracy, tool of life, stability, of reduction etc. poor loss asource It is take place. that vibration difficult-to are -which steels In machining hardened cutting speed with respect to effective diameter De diameter to effective respect with speed Vc -cutting (stepdown) cut of -depth ap (stepover) cut of -width ae diameter D -cutter

Milling Finish Milling finish Semi- Milling Rough Steel ConditionalGroup is at the same time hard-to-machine steel. Not so long ago a workpiece of hardness of workpiece a ago long so Not steel. hard-to-machine time same the at is steel Hardened of hardened steel, starting feed per tooth feed per tooth is often estimated as 0.5-1% of of 0.5-1% as estimated often is tooth per feed tooth per feed starting steel, hardened of HSM In was considered to be the limit for metal cutting; and for more hard materials grinding materials hard more for and cutting; metal for limit the be to considered was 45 HRC diameter. The l The diameter. cutter a context of such steels HSM is an effective instrument that makes their cutting possible. cutting their makes that instrument effective an is HSM steels such of context the In steel Hard of thumb of rule A be applied. Progress in cutting tool technology seriously shook the understanding the shook seriously technology tool cutting in Progress applied. be should operations and more. and 60 HRC to hardened steel to refers often steels” “hard Today limits. hardness the of Material Group* Hardness, HRC material group in accordance with VDI 3323 standard 3323 VDI with accordance in group material Average StartingCuttingDataforHSMofSteelParts fz, mm/tooth fz, mm/tooth fz, mm/tooth , T Vc, m/min Vc, m/min Vc, m/min able 84 below contains typical average data referring to the square end solid carbide carbide solid end to square the referring data average typical contains below 84 able ap ap ap ae ae ae ower Pre-hardened (0.40-0.70)D (0.05-0.12)D (0.40-0.70)D (0.07-0.15)D (0.40-0.70)D (0.04-0.1)D 0.03-0.22 0.03-0.24 0.03-0.2 150-230 140-200 120-190 feed values correspond to more hard steel. hard more to correspond values feed 38-44 11 (0.03-0.08)D (0.40-0.55)D (0.04-0.09)D (0.40-0.60)D (0.06-0.12)D (0.40-0.60)D 0.03-0.18 0.03-0.22 180-220 0.03-0.2 130-180 100-170 45-49 38.1 - cut materials - intensive heat generation and and generation heat -intensive materials cut (0.02-0.06)D (0.35-0.50)D (0.03-0.07)D (0.35-0.55)D (0.05-0.08)D (0.40-0.60)D 0.02-0.15 0.03-0.17 170-190 120-170 0.03-0.2 90-150 50-55 38.2 estimation and a general knowledge knowledge ageneral and estimation Hardened (0.35-0.45)D (0.03-0.05)D (0.35-0.45)D (0.04-0.07)D (0.35-0.55)D 0.1-0.4 mm 0.02-0.13 0.03-0.14 0.03-0.17 130-200 90-150 70-100 56-60 39.1 (0.30-0.40)D (0.02-0.05)D (0.30-0.45)D (0.03-0.07)D (0.30-0.50)D 0.1-0.3 mm 0.015-0.11 0.02-0.12 0.02-0.14 110-160 70-130 60-80 39.2 >60 Feed speed =0.03×4×7000=840 speed Feed (mm/min) =1000×130/(π×6)=6896Spindle speed (rpm)≈7000 rpm =0.03Feed mm/tooth =130 speed m/min Cutting =0.15 cut of Depth mm =0.4×6=2.4 of cut Width mm 39.1: material group No. extract 6mm,is we can 4…25 range diameter mill diameter the and within mm cutters for data Table to mostly typical relates 84 Taking stable. are that into account conditions machining that toWe assume basis have agood test milling passes. for data cutting center. machining starting the Find speed high new acquired arecently on machined in hardened condition (HRC O1 AISI from be tool made steel, is will plate, the which process, the with accordance In test milling. by introducing HSM in

of “ boundaries lays within speed spindle The Remark adieIn and mold shop a technologist plans Example spindle speed) is twice as little! as twice (and is correspondingly, speed) spindle “ which for hardness, high with tool steel to refers machining above case cutting speed data which is not actual. Please check thorougly which diameters which thorougly check Please actual. not is which data speed cutting use steel, papers and advertising leaflets related to HSM and in particular to HSM of hardened of HSM to particular in and HSM to related leaflets advertising and papers technical Some when the stepover will be equal to the feed per revolution. per feed cutter the to nose equal ball a be of will use the stepover with the HSM when for that reached shows be research Various m in Keep to. refer values these nominal or effective Reminder ind the from the table the following starting data referr data starting following the table the from finalmachining steps.The checkstechnologist a proposed process by 58…60) by solid carbide endmill EC-A4 060-13C06-50 endmill 58…60) IC903 carbide by solid to conventional chang e the values. However,” values. the that not forget do process of manufacturing a cavity plate acavity of manufacturing process ing . the best surface finish can finish surface best the , normal to finish milling for ISCAR for milling to finish cutting speed speed ” cutting , Die andMold 115 Milling Tools 116 Milling Tools

rigidity of a machine tool – allowing productive milling and excellent straightness of machined surfaces. of machined straightness excellent and milling productive tool –allowing of amachine rigidity milling for better finish. additional requires usually surface the nevertheless stepover; but alinear by decreasing reduced be can that cusps with surface aserrated produces technique machining this that clear It is again. cycle noise automatically lead to reducing cutting data and decreasing productivity. and tool. Vibration machine of the tool, the and adapter the damage and machining inaccurate causes which deviation, cutter the and noise vibration, is result The forces. of radial the part most the up takes tool of amachine spindle the Furthermore, forces. of cutting component radial of considerable the because moments bending great the not withstand can often quite adapter its and cutter the passes, layer-by-layer cutter, material removes milling which aconventional on in applied is overhang high When forces. bending minimal with overhang at high to machine ability the is of plunging advantage main ISCAR offers In addition In plunging, Plunging had In plunging, Plunge milling 3.5. Special

more popular representatives. flat surface at bottoms and HFM at high overhang, boring operation, etc.operation, boring overhang, high HFM at and bottoms at surface flat a obtaining for of cut depth limited with milling face to perform plungers), often is or cutters plunge-in plungers) are able to produce holes, their main function is to machine straight walls or slots. or walls straight to is machine function main their holes, to produce able are plungers) the fact despite But into workpiece. the toolthe plunges (Fig. 54). tool like the axis drilling: It looks along directed feed with downward into aworkpiece directly Fig. 54 Fig. is not a feature incidental to plungers. Some other milling cutters (for example, (for cutters milling other Some plungers. to incidental feature a not is capacity Plunge-in use as plunging tools has some limitations and should be considered as only optional. only as considered be technique. should milling and this limitations perform also some has can HT…) tools MM plunging heads as use toroidal their with tools However, MULTI-MASTER options cutting Plunge-in to plunging ability, the main intended purpose of the plunge milling cutters (also called (also called cutters milling of plunge the purpose intended ability, main the to plunging the main component of the cutting force acts axially – exactly in the direction of the highest of highest the direction the in –exactly axially acts force of cutting the component main the this continues then and linearly out, stepwise moves in, lifts plunges toolthe classically a great variety of the plunge milling cutters. Table 85 shows general characteristics of the characteristics Table cutters. general shows 85 milling of plunge the variety a great spurted into popularity among die and mold makers due to one important feature: the to important due one makers mold and die among into popularity spurted or simply “plunging”, is a productive rough milling method during which atool moves which during method “plunging”, milling rough simply or aproductive is Methods: Sculpturing by Milling Sculpturing Plunge Methods: that some plunge milling tools (usually called called tools (usually milling plunge some that Plunging in Lifting out Stepover * Heads with FLEXFIT with Heads

TANGPLUNGE the from …LN-type of HTP the family. plungers side popular most the for data cutting initial specify below tables and explanations the of subject, the understanding However, better for properly. process your to plan order in specialist ISCAR milling an contact and/or to papers technical or guides corresponding studying advise we strongly Therefore features. have unique plunging for programming CNC and strategy machining time, correct At same the shapes. and slots walls, cavities, deep machining for method economical and effective an Plunge milling is Table 85

Family PLUNGER HELITANG TANGPLUNGE Fig. 55 Fig. of a plunging cutter bring to mind a working stone in stone sculpturing stone in chisel stone working a mind to bring cutter plunging a of movements Axial it. removes and series a in material into plunges also which stages), rough early, its on (especially “ called sculptor Plunging “ called sometimes is milling plunge That “ the called sculptured MainISCARPlungeMillingCutters sculptured surface sculptured PLX …-12 HTP …LN16 Designation PH …-13 FTP …LN10 HTP …LN10 or adaptation ” ). 32…80 50…100 mm Range Dia. 40…63 50…63 25…52 (Fig. 55, but be careful – in general every 3-D shape also can be can also shape 3-D every general in – careful be but 55, (Fig. ” Radial Tangential Clamping Insert Tangential Tangential Tangential sculpturing Endmill

Configuration ShellMill and a 3-D shape obtained by plunging is plunging by obtained shape 3-D a and ” FLEXFIT*

Side Plunger Center Cutting Plunger Side Features Main Milling Face

Options HFM

Ramping

Die andMold 117 Milling Tools 118 Milling Tools relationship between L1max and ae is given by the following formula: L1max =2×√D× formula: -ae² ae following by the L1max given is ae and between relationship * The Table 87 Table 86 (17) equations following the from found be tooth (18): can Vc and per fz feed and speed cutting Starting

Where: Maximal StepoverL1maxandWidthofPlungeaeforCutterDiameterD*(Fig.56) as theFunctionofRatioOverhangHtoCutterDiameterD 14 13 12 11 10 9 8 7.5 7 6 5 4.5 4 3 2 1 mm ae, KH H/D Fig. 56 Fig. 14.3 13.8 12.4 10.5 7.7 16

fzo Kt KH Vo TANGPLUNGE HTP…LNPlungers: OverhangCoefficient KHfortheTANGPLUNGE Cutters HTP… 06 –toollifefactor –basiccuttingspeedfor20min.toollife –basicstartingfeed 17.3 16.7 14.2 –overhangcoefficient 8.7 16 12 20

19.2 18.3 16.2 13.5 9.8 20 25

to 4 1 22.9 22.4 21.3 19.2 18.3 16.2 13.5 9.8 20 25

Vo xKHKt Vc =Vo 27.7 27.1 26.4 23.3 22.2 21.2 18.7 15.4 11.1 25 32

fz = 29.4 28.7 26.4 24.5 23.4 22.3 19.6 16.2 11.7 28 35

fzo over 4to6 31.2 30.3 28.6 26.5 25.2 17.4 12.5 32 24 21 40 HTP…10

0.9

x L1max, mm 32.2 31.3 29.4 27.2 25.9 24.6 21.6 17.8 12.8 33 42 KH

D, mm 36.7 35.7 34.7 32.5 28.6 27.1 23.8 19.5 L 30 14 50

1

(Table 89) (Table 88) (Table 8) (Table 86) 37.5 36.5 35.5 33.2 30.7 29.2 27.7 24.3 14.3 20 52

(18) over 6to8 ∆ae 43.8 42.7 41.4 38.5 36.6 35.7 34.7 32.5 28.6 27.1 23.8 19.5 (17) 40 30 0.8 14 50

43.8 42.5 39.3 37.5 36.5 35.5 33.2 30.7 29.2 27.7 24.3 14.3 45 41 20 52

52.4 49.5 47.8 43.1 41.9 40.8 39.6 32.4 30.7 26.8 15.7 51 46 37 34 22 63 HTP…16 53.9 52.5 50.9 49.2 47.3 45.3 41.8 40.6 37.9 34.9 33.2 31.4 27.5 22.6 16.1 over 8to10 43 66 0.7 60.8 57.1 55.1 52.9 50.5 46.6 45.2 42.1 38.7 36.8 34.8 30.4 24.9 17.8 59 48 80 69.4 67.3 62.6 57.2 54.3 52.6 47.5 43.6 41.4 39.1 34.1 19.9 100 65 60 51 28 - ISCAR ** * For material group in accordance with VDI 3323 standard 3323 VDI with accordance in group material * ISCAR

More suitable grade

Table 89 Table 88

DIN/ISO 513 DIN/ISO 513 ISO Class milling plunge In Horizontal machines have good conditions for removing chips, however the however chips, removing for conditions good have machines Horizontal important. highly cause serious problems and thus significantly reduce tool life. tool reduce significantly thus and problems serious cause can which c in Plunge vertical machines is worse. For the latter it is very important to use the machining the use to important very is it latter the For worse. is machines vertical with situation a tool route that ensures collecting the chips away from the tool cutting movement cutting tool the from away chips the collecting ensures that route tool a with strategy bottom of a cavity, for example) in order to prevent compressing and re-cutting the chips, the re-cutting and compressing prevent to order in example) for cavity, a of bottom the (at be a good solution for unstable and low-power milling machine tools. machine milling low-power and unstable for solution good a be can Plunging Please note Please 20 min. tool life tool 20 min. Class ISO P M M H K H K P material group in accordance with VDI 3323 standard 3323 VDI with accordance in group material TANGPLUNGE HTP…LNPlungers:BasicCuttingSpeedVo, m/min* TANGPLUNGE HTP…LNPlungers:BasicStartingFeedfzo,mm/tooth Mat. Group** hips ISCAR Material 12, 13 15-16 17-18 Group* ISCAR 12, 13 38.1 15-16 17-18 6, 7 8, 9 2-4 pockets and cavities, especially those with considerable depth, chip evacuation is evacuation chip depth, considerable with those especially cavities, and pockets 38.1 10 11 8, 9 6, 7 2-4 1 5 11 10 1 5 IC808 190 105 145 210 175 175 155 150 150 140 130 IC808 0.08 0.07 0.12 0.11 0.08 0.08 0.09 0.13 0.11 0.1 0.1

IC810 175 230 155 180 145 140 140 140 125

IC810 0.13 0.11 0.11 0.11 0.09 0.09 0.15 0.12 0.1

IC830 135 165 210 150 170 140 135 135 135 125 95 Vo forGrades fzo forGrades IC928 130 155 200 140 165 135 130 130 130 120 90 IC928 IC830 0.08 0.14 0.12 0.12 0.12 0.11 0.16 0.13 0.1 0.1 0.1 IC330 125 150 135 130 125 125 125 115

IC328 IC330 0.15 0.12 0.12 0.12 0.13 0.11 0.1 0.1

IC328 120 145 135 130 120 120 120 110

Die andMold 119 Milling Tools 120 Milling Tools Feed speed fz speed Feed Example conditions.cutting heavy for and steel hard-to-cut and hardened machining for LNHT…ETR recommended are –that Starting feed Starting speed Therefore: Overhang/cutter diameter Basic starting Basic cutting The material Estimate starting The width Side accepted as 110 as accepted m/min) endmill shell in mounted be will 100 depth cutter the mm plunging P20, AISI steel 30…35. HRC necessary For pre-hardened is material cavity tool. The machine anew on cavity adie machining for proposed is There two Spindle speed =1000×108/(π×40)≈860Spindle speed (

• •

•

Processing Processing •

Accommodates Accommodates Quick Quick Tool Advisor, is a parametric search engine that takes computer-aided tool and process and tool computer-aided takes that engine search parametric a is Advisor, Tool Iscar ITA, – ITA “ It level. new entirely an to selection a huge knowledge base of best practice worldwide. practice best of base knowledge huge a on resting features separate ITA from the other available tooling search engines: search tooling available other the from ITA separate features key Three best starting ideas and processing strategies, with priority by productivity. productivity. by priority with strategies, processing and ideas starting best the provides Search Option takes more comprehensive application input, helps the user narrow user the helps input, application comprehensive more takes Option Search Advanced The and delivers a fully developed optimum solution. optimum developed fully a delivers and down choices tooling, tool brand/family as well as productivity/tool cost and power and cost productivity/tool as well as brand/family tool tooling, indexable vs. Variables include machine power and condition, type of cut, available available cut, of type condition, and power machine include Variables priorities. management shape/rigidity, setup stability, overhang, secondary operations and many more. many and operations secondary overhang, stability, setup shape/rigidity, part speed, spindle feature makes ITA valuable for job shops as well as dedicated applications. dedicated as well as shops job for valuable ITA makes feature Variables The that most shops want to be able to use a tool for more than one job. one than more for tool a use to able be to want shops most that recognizes ISCAR and see the ITA the see and www.iscar.com/ITA Visit parameters for a given shop environment, as well as a short list of list short a as well as environment, shop given a for parameters machining recommended tooling solutions. tooling by shell milling cutter HTP D040-4-16-R-LN10 HTP cutter 1006 milling ER IC830 LNHT plunging by HTP shell inserts with holder DIN69871 holder 16X100; SEMC 40 of 140 haveoverhang an will mm. tool assembly this and Your Search/Advanced Search Option – With just three application facts, the Quick Search Search Quick the facts, application three just With – Option Search Search/Advanced of plunge and the stepover are 5 mm and 20 mm and 5mm stepover are the and of plunge kinds of inserts intended for the HTP plungers: general-duty HTP LNHT…ER HTP HTP general-duty and plungers: HTP the for intended of inserts kinds

h in the mentioned conditions represents ISCAR material group No. for elper Solutions, Not Just Tooling Solutions – With Advanced Search, the user can get can user the Search, Advanced With – Solutions Tooling Just Not Solutions, = 0.11×1= 0.11 ( 0.11 0.11×1= = = 0.11×4×860≈378= (mm/min) speed Vo =135speed (Table m/min 88). feed fz feed for estimated tool life 60 min. (Kt=0.8, 60 tool life estimated for Table 8) Vc =135×1×0.8=108 ( cutting data for 60 min. tool life. 60 for data cutting Shop Preferences and Variables – The user can stipulate such preferences as solid as preferences such stipulate can user The – Variables and Preferences Shop fi o =0.11 (Table mm/tooth 89). m the nding = 140/40 < 4, then overhang coefficient KH = 1 (Table= 140/40KH =1 86). coefficient <4, overhang then ) mm/tooth e ost fficient c fficient thinks rpm ’s true value! true like a process engineer and allows finding the right tool right the finding allows and engineer process a like ” ) t utting ool , respectively. 9. m/min ) (may be contains general data regarding the most often used drilling families drilling used often most the regarding data Table general contains 90 edges. cutting to directly supply coolant provide channels coolant Internal range. of tolerance H7 hole applications with their unique quick-change bayonet for mechanism the securing heads are suitable for reaming The of productivity. increase considerable for allows heads, carbide interchangeable with with conventional reaming methods comparison In replacement – it can be done inside the machine. head for drill to need remove the no is There materials. workpiece various for designed profiles head of drill types different carry can body drill quality. Asingle surface good with machining high-precision CHAMGUN adjusting the drill for plates of aset ashim with supplied is drill Each inserts. indexable square with cartridges carries SUMODRILL constructed bodies with excellent chip evacuation properties. stably and durable exhibit and coolant for nozzles twisted with designed are shanks The parameters. cutting high exceptionally with machining for allows mechanism clamping unique The diameters. hole eight half to a and one depths: from of various holes drilling for tools efficient produces lengths different of into shanks steel clamped Being materials. of engineering types main for intended geometries cutting four in (Fig. 57). available are heads heads The carbide interchangeable with of drills family new SUMOCHAM is of drilling depth short-to-medium for products effective of most the One various of countersinks and reamers, of drills, variety arich includes ISCAR’s line making hole broad making. hole for ISCAR tools popular some profile of to ashort add necessary it we consider Hence, making. hole without relate to However, production milling. mold process this and die to hard is imagine it during operations machining most and manufacturing mold and die for specific so tools are milling the all of we first making, mold and tools die for When speaking cutting about Tools Making Hole Fig. 57 Fig. kinds: solid, indexable or with interchangeable heads. family of deep hole drills with replaceable heads (Fig. 59), heads productive for intended is replaceable with drills hole of deep , afamily a family of relatively large diameter drills (more than 60 mm). It features a drill body that that mm). body 60 (more than adrill drills It features diameter large of relatively afamily is ’ s diameter within a corresponding range if it will be necessary (Fig. 58). necessary be will it if range acorresponding within s diameter , BAYO T-REAM , a family of high speed reamers reamers speed of high , afamily mean milling tools. Indeed, tools. Indeed, milling mean – a relatively –arelatively Die andMold 121 Hole Making Tools 122 Hole Making Tools * D Table 90

SOLIDDRILL SUMOCHAM Family DR-TWIST ISCAR DR-DH CHAMGUN SUMODRILL - drill nominal diameter Fig. 59 Fig. Fig. 58 Fig. v and Modularity setup time for increasing productivity and profitability in die and mold manufacturing. mold and die in profitability and productivity increasing for time setup no with SUMOCHAM as such various carries that body One – such a principle is successfully applied to the hole making line. Versatile robust Versatile line. making hole the to applied successfully is principle a such – cutters milling with interchangeable cutting heads designed in accordance with this principle this with accordance in designed heads cutting interchangeable with reamers and drills External Cartridge External Shim Plate Cartridge Internal SelectedISCARDrillingFamilies Designation DR…CA-N DR-DH… SCCD… STGT… DCN… SCD… DR…

ersatility CHAMGUN , Set ofShimPlates With interchangeable With With indexableinserts With With indexableinserts With With interchangeable heads With indexableinsertsincartridges With heads and one head suitable for different bodies – similar to the the to similar – bodies different for suitable head one and heads BAYO T-REAM BAYO and carbide Type Solid heads Screw andWasher Cartridge Clamping Diam. Range, Drill Body , give the die and mold maker effective tools tools effective maker mold and die the give , 25.4…69.5 0.8…20 6…25.9 12…60 10…16 61…80 3…20 5…10 3…10 mm deep hole Max. Drilling 5×D andup ~2.5×D Depth 20×D 12×D 5×D* 5×D 8×D 5×D Shim PlateScrew drilling semi-standard semi-standard adjustable three-flute Remarks two-flute

, In Summation

We hope that ISCAR’s reference guide will provide you with brief but necessary information, that will help you to select the most suitable cutting tool and define relevant initial cutting data.

We consider the guide to be a practical supplement to our catalogs and technical papers, and will be pleased if you will find it useful for solving real tooling problems.

The scope of the guide has allowed us only to touch upon some themes related to the cutting tools used for die and mold making. Therefore we are waiting for your response. Do you find the guide to be useful? What do you want to add? Delete? What is you own experience with ISCAR tools in die and mold manufacturing?

We are waiting for your comments in order to improve the guide and change it in cooperation with you, in order to become more effective.

3P (3): Productivity, performance, and profitability Triple P not only emphasizes the newest products, but reflects 3 main principles, “3 pillars” of ISCAR’s philosophy regarding the aim of cutting tools for the customer. By advanced tools to higher productivity for improving the work performance and to increase profitability – this is the real way for fruitful collaboration and partnership between ISCAR and the customer.

123

Die and Mold 124 Technical Information 22.0 18.0 15.0 11.0 7.5 Motor PowerP Values for Motor Power P Machining power milling forb/D>0.1 Average chipthicknessinshoulder milling forb/D≤0.1 Average chipthicknessinshoulder Specific cuttingforce Machining time Metal removal rate Feed perrevolution Feed pertooth Feed speed Spindle speed Cutting speed Max. Machine Power (kW) Calculations 5.5 0.4 m hasavalueofapproximately 7to12%MaximumMachinePower N D P = Th = f f

K h

hm = V π N = 1000min Vc = Q = N z Motor Power P = m f c =fz =f = ≈f V 6

(a Vc

f

N

π K z z V

* * a π ( * √ *

c1 1000 Z L p f Z [mm/rev] p

Z * V * * * * * w D 10 b * f b N [mm/min] h

*

b D D * * [mm/tooth] 1000 [rev/min] * * m m [mm] V arcsin ( 0.4-0.6 D 7

V * [min] * -mc f * z 180 N [m/min] f f * h

2.5 2.2 1.5 1.0 k

c [cm κ ) * b [kW]

* b/D) a f 3 p /min] Z m ) (kW) [mm] h P k mc Hm Kc Kc [N/mm Lw Th b ap f Z fz Vf N D Vc Q N

[RPM]

[cm

P Pc P P 1 (1) m [N/mm

- - = - V f N Net Power=Cutting Power Net Power=Cutting Total MachiningPower Pc + P Motor Power(whilenotcutting) [kW] [degrees] [mm] [mm] [min] [mm] [mm] [mm/tooth] [mm/min] [mm] [m/min] [mm/rev] 3 /min] 2 2 ] ] m hm Machine efficiency Machining power Cutting edgeangle Chip thicknessfactor Average chipthickness for 1mm Specific cuttingforce Specific cuttingforce Machining length Machining time ofcut Width Depth ofcut Metal removal rate cutting edges Number of Feed pertooth Feed speed Spindle speed Tool diameter Cutting speed Feed perrevolution f z b 2 chipsection Endmill Shank Styles l l l l l d d d Bridgeport Morse (Clarkson) Combined Shank Weldon Cylindrical CM 4 CM 3 CM 2 40 32 25 20 16 50 40 32 25 20 16 12 40 32 25 20 16 10 Diameter (d) Shank 101.6 102.5 81 64

75 54 53 — 39 80 70 60 56 50 48 45 1.5xd 1.5xd 1.5xd 1.5xd 1.5xd 1.5xd Min. l Value Recommended Die andMold 125 Technical Information 126 Technical Information Face Mills Arbor Hole Styles E E E E b b b b d d a 1 d d a 1 d d 1 a d a Style D Style C Style B Style A d 60 60 40 40 32 27 22 27 22 16 d E 38 38 33 E 33 25 25 20 23 20 19 d — — 65 1 d 101.6 — 66.7 2 d 56 46 38 31 38 18 13.5 1 d 177.8 — — 3 16.4 14.4 12.4 10.9 12.4 10.4 8.4 a a 25.7 25.7 16.4 b 7.0 6.5 5.6 9.0 8.0 7.0 6.5 b 14.0 14.0 9.0 Chip thicknessfactor. Specific cuttingforce for1mm According toDIN/ISO513 andVDI3323 MATERIAL GROUPS ISO M N K H S P Steel Nonferrous Material alloying elements (less than5%of and caststeel Low alloysteel free cuttingsteel and caststeel, Non-alloy steel Cast iron Chilled castiron Hardened steel alloys Ti and Titanium High temp.alloys Non-metallic Copper alloys alloyed Aluminum-cast, wrought alloy Aluminum- Malleable castiron nodular (GGG) Cast iron Grey castiron (GG) cast steel Stainless steeland cast steel,andtoolsteel High alloysteel, Stainless Steel

based Ni orCo Fe based

>= 0.55%C >= 0.25%C < 0.25%C High Temp. Alloys < 0.55%C <=12% Si 2 >12% Si chipsection. >1% Pb High temperature Alpha+beta alloyscured Cast Cured Annealed Cured Annealed Hard rubber Electrolyitic copper Brass Cured Cured Pearlitic Pearlitic/martensitic Pearlitic Austenitic Martensitic Ferritic/martensitic Quenched andtempered Annealed Quenched andtempered Annealed Hardened Condition Quenched andtempered Annealed Quenched andtempered Annealed Annealed Hardened Cast Hardened Duroplastics, fiberplastics Not cureable Not cureable Ferritic Pearlitic/ferritic Ferritic Free cutting Cast Iron Hardened Steel RM 1050 [N/mm Strength RM 400 Tensile 1200 1100 1000 1000 930 600 820 680 680 600 750 850 650 420 2

]

[N/mm Kc 1350 1225 1350 1150 4500 4600 4700 4600 3300 3300 3300 3100 2600 1420 1225 1800 1675 2150 1875 1875 2450 1775 2500 1725 1700 2110 1700 1675 1500 1350 1900

700 700 700 750 700 700 800 700 2 ] m 0.28 0.25 0.28 0.20 0.24 0.24 0.24 0.24 0.24 0.25 0.27 0.27 0.27 0.25 0.25 0.25 0.25 0.25 0.20 0.21 0.21 0.23 0.23 0.23 0.22 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.22 0.21 0.3 c HB Hardness 55 HRC 60 HRC 55 HRC 250 160 260 180 320 350 250 280 200 230 130 400 100 110 130 100 350 300 275 200 180 240 200 200 325 300 220 250 190 125 90 90 75 60 No. Material 18 17 16 15 35 34 33 32 31 20 19 40 28 27 26 25 24 23 22 21 30 29 14 13 12 10 11 36 37 41 39 38 9 8 7 6 5 4 3 2 1 Die andMold 127 Technical Information 128 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1008 A 366(1012) AISI/SAE A 570Gr. 33,36 A 570Gr.50 A 570Gr. 40 1115 A 572Gr. 65 A572 Gr.50 A 284Gr.D A 570Gr36;C A 573Gr.58 A 619(1008) A 621(1008) A 573Gr. 70 A 611Gr. C A 621(1008) M 1010 A 611Gr.D 1.0035 1.0034 1.0028 0.0030 Material No. 1.0036 1.0050 1.0045 1.0044 1.0038 GS-CK16 1.0037 1.0060 1.0116 1.0114 1.0112 1.0070 1.0060 1.0333 1.0330 1.0144 1.0143 1.0130 1.0334 1.0301 1.0226 1.0149 St 33 St185 (Fe310-0) RSt 34-2(S250G2T) Ust 34-2(S250G1T) C10 DIN S235JRG1 (Fe360B) E295 (Fe490-2) S355JR St44-2 S275JR (Fe430B) St 37-2 S235JR (Fe360B) Ust 37-2 E335 (Fe590-2) St 50-2 S235J2G3 (Fe360D1) S235JU;St 37-3U P235S St 70-2 E360 (Fe690-2) St60-2 St 60-2 St 37-3 Ust 13 Ust 3(DC03G1) St 2;12 DC 01 S275J2G3 (Fe430D1) S275J0; St44-3U P265S UStW 23(DD12G1) C10 DX51D; St02Z S275JOH; RoSt44-2 St 44-3 1449 15HR,HS Fe 310-0 HS,CR,CS 1449 34/20HR, 1449 10CS 045 M10 040 A10 BS Fe 360B 030A04 Fe 490-2FN 4360-50 B 4360-43 B 1449 43/25HR,HS Fe 430BFN 4360-40 B Fe 360B 4360-40 B Fe 60-2 4360-50 B Fe 360D1FF 4360-40C 1501-164-360B LT20 Fe 690-2FN 4360-55 E;55C 4360-40 D 144937/23CR 1449 2CR;3CR 1449 3CS 1449 4CR 1449 10CS 045 M10 Fe 430D1FF 4360-43C 1501-164-400B LT 20 040 A10 Z2 4360-43C 4360-43 C;43D EN 1A

A 34-2NE A 34-2 XC 10 AF 34C10 AFNOR A 33 E 36-2 E 28-2 E 24-2 A 50-2 E 24-3 A37AP A 60-2 E 24-3 A 70-2 E 24-4 E TC XC 10 E 28-3 A 42AP E 28-3 S C AF 34C10 GC E 28-4

SS 1142 1151 10 1412-04 1414 1411, 1412 1414-01

1313 1312 1655 2172 1650 1550 2172 1412 1325 1311 1312 1311 1300 FeP 12 FeP 02 FeP 01 FeP 00 1 C10 C 10 FeP 02G Fe 430C Fe 430D(FF) Fe 430B,C(FN) Fe 430D

Fe 37-2 Fe 360DFF Fe 360CFN Fe 360D1FF Fe 360C Fe 360C Fe 690 Fe 70-2 FE60-2 Fe 590 Fe 60-2 Fe 490 Fe 510B Fe 430BFN Fe 430B

1449 37/23HR Fe 360B

FE37BFU Fe 320 Fe 330BFN Fe 330,Fe330BFU 1 C10 C 10 UNI AP 12 AP 02 AP 11 F.151.A F.1511 FeP 02G Fe 430C Fe 430D1FF AE 275D AE 275D SPH 265

Fe 360D1FF AE 235D AE 235C AE 235C Fe 690-2FN A 690-2 Fe 590-2FN A 590-2 Fe 490-2FN a 490-2 AE 355B Fe 430BFN AE 275B

Fe 360B AE 235B Fe 360B AE 235B Fe 310-0

F.151.A F.1511 UNE SPHE SPCD SPHD S 10C

SM 400A;B;C

SM 570 SS 490

SM 400A;B;C

STKM 12A;C

SS 330

S 10C JIS 10kp

15 kp 10

St4kp; ps;sp

16D St3kp; ps;sp

St6ps; sp St5ps; sp

St3ps; sp

St3Kp 16D, 18Kp St0 St2sp

10 GOST Die andMold 129 Technical Information 130 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 A 620(1008) A 622(1008) AISI/SAE A 515Gr. 65;55 A 516Gr. 65;55 A 414Gr. C A 442Gr.55 12 L14 1215 11 L08 11 L08 1109 1108 12 L13 1213 1213 1 M 1023 (M) 1020 A 588 A 633Gr.C A27 65-35 1020;1023 1020 1.0338 1.0335 Material No. 1.0345

1.0982 1.0976 1.0972 1.0737 1.0736 1.0722 1.0722 1.0721 1.0718 1.0715 1.0715 1.0570 1.0566 1.0565 1.0425 1.0402 1.0562 1.0553 1.0549 1.0547 1.0546 1.0545 1.0539 1.0443 1.0402 1.0402 St4; St14 DC04 DD13; StW24 DIN H I P235GH

S460MC; QStE460TM S355MC; QStE360TM S315MC; QStE300TM (11SMnPb37) 9 SMnPb36 9 SMn3611SMn37) 10 SPb20 10 SPb20 10 S20 (11SMnPb30) 9 SMnPb28 9 SMn28 9 SMn28(1SMn30) St 52-3 S355J2G3 P355NL1; TStE355 P355NH; WStE355 P265GH Hll C22 StE 355 P355N S355JO;St 52-3U S355 NLH;TStE355 S355JOH S355NL;TStE 355 S355N; StE355 S355NH;StE 335 GS-45 C22 C22 1449 1CR;2CR 1449 1HR BS 1501 Gr. 161-360;151-360 1501 Gr. 141-360 1501 Gr. 161-400;154-360 1501 Gr. 164-360;161-360 1501-50F45 1501-43F35 1501-40F30 (210 M15) 230 M07 230 M07 4360-50 D 1449 50/35HR>HS Fe 510D1FF 1501-225-490A LT 50 1501-225-490B LT 20 1501 Gr. 164-400;154-400 1501 Gr. 164-360;161-400 1501 Gr. 161-400;151-400 1499 22HS,CS 055 M15,07020 1501 Gr.225-490A LT 20 4360-50C 4360-50C 4360-50EE 4360-50E A1 055 M15;07020 050A20 EN 2C/2D 2C 2C/2D ES 3 C AFNOR A 37CP;AP E 355D E 315D S 300Pb S 300 10 PbF2 10PbF 2 10F 2 10S20 S 250Pb S 250 S 250 E 36-4 A 510FP A 510AP A 510AP XC 25;1C22 AF 42C20; E 36-3 A 42CP;AP XC 25;1C22 E 355R/FP; E 36-3 TSE 355-3 E 355FP E 355R TSE 355-4 E 23-45M AF 42C20; CC20 FeE 355KGN SS

1330 1331 1147 1914 1912 1912 1450 2174 2135 2172-04 2135-01 2334-01 2134-04 1305 1432 1430 1431 1450 1450 2134, 2132, 2133 2107-01 2106 2106 2642 1926 UNI Fe 3602KW;KG FeE235, Fe3601KW;KG FeP 04 FeP 13 CF 9SMnPb28 CF 9SMn28 CF SMn28 C 20 Fe 510D Fe 510C FeE 355KT FeE 355KG Fe 510B KT Fe4102KW; KG Fe 4101KW; KG; C 20; C20C21 C 21,25 CF 10S20 17G1S 17GS FeE 355-3 FeE 355-2 FeE 355KG;KW Fe 510C C 21;C25 CF 10SPb20 CF 10SPb20 FeE 355TM CF 9SMnPb36 CF 9Mn36 UNE RA II A 37RCI AP 04 AP 13 F.2112-11 SMnPb28 11 SMn28 F.2111 -11SMn28 1 C22F.112 FeE 355KTM Fe 510C AE 355KT AE 355KG Fe 355KGN A 42RCII A 42RCI 1 C22F.112 F.112 F. 2121-10S20 Fe 510,D1FF AE 355D AEE 355KG;DD F.2122-10 SPb20 10 SPb20 F.2114- 12SMnPb35 F.2113 -12SMn35 JIS SGV 48,SPV450; SGV 410,450 SPCE SPHE SUM 22L SUM 22 SUM 22 S20C SPV 480 SUM 23L,24L SGV 450;480 SG 295;SGV410 SPV 315;355 S 20C;S22C S22 C SM 490A;B;C;YA;YB SM 490A;B;C;YA;YB

SUM 25 GOST 08Ju; JuA 08kp 20 17G1S 20K 16K 20 17GS 15GF

Die andMold 131 Technical Information 132 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material

1 1 1 1 1

1

1 1 1 1 2 2 2

2

2 2 2 2 2 2 2 2 2

2 2 2 2 2 2 2

AISI/SAE

1010

1015 1020 1023 D 3 A36

A572-60 (M) 1025

A 537CI.1 A 612 A 414Gr. G 1035 1045 1040

A27 70-36 A148 80-40 1140 A738 1146 1035 1041 1025 1536 1330 1330 1330

1035 Material No. 1.0984 1.0986 1.1121 1.1121 1.1141

1.1151

1.2080

1.8900 1.0406 1.0416 1.0473

1.0501

1.0503 1.0511 1.0540 1.0551 1.0553 1.0726 1.0577 1.0727 1.1157

1.1158 1.1166 1.1170 1.1170 1.1170 1.1178 1.1180 DIN S500MC; QStE500TM S500MC; QStE500TM (C10E) CK 10 St 37-1 CK 15 (C15E) C22E CK 22 X 210Cr12 St 44-2 StE 320-3Z StE 380 C 25 GS-38 P355GH 19Mn6

C35

CF 45 C40 (C45G) C 50 GS-52 GS-60 35 S20 S355J2G4 (Fe510D2) 45 S20(46S20) 40Mn4

CK 25 C25E 34Mn5 28Mn6 28 Mn6 28Mn6 C30E; CK30 Cm 35 C35R 080A35 BS

1501 -60F55 040 A10 4360 40A 040 A1532C 080 M15 055 M15 (070 M20) BD 3 4360 43A 1 501160 4360 55E 070 M26

080 A32,35 1449 40CS 080 M36, 060 A47 080 M40 080 M46

A2 A3 212 M36 1501 Gr. 224-490 1501 Gr.224-460 Fe 510D2FF

150 M36

(070 M25)

(150 M28),18) 150 M5

080M30

EN

8M

15

14A

AFNOR E 490D E 560D XC 10

XC 1215 XC 18 2 C22XC18 XC 25 Z 200C12 NFA 35-501E28

1 C25 20-400 M A 52CP 1 C35 XC38 AF 55C35 XC 42H1TS AF 60C40 1 C40

280-480 M 320-560 M 35MF 6 A 52FP 45 MF4 35 M5 40 M5 XC 25 2 C25

20 M5,28Mn6 20 M5 20M5 XC 32 XC 32 3 C35 SS

1370 1300 2662 1450 1265 2145 1421 1411 1672 2102 2101 1306 2107 1606 1505 1674 1550 1572 1973 1957

1572 C 1516 FeE 490TM UNI C 2025 2 C15 C 10,210F-1510-CK FeE 560TM

FeE390KG C 46 C 43 Fe E355-2 C 251 C 50 C40 1 C35 C 35

C25

C 28Mn C28Mn C 30 F.1110-C 15K UNE F.1120-C 25K F.1511-C 16K S10C

A 52RCIRAII A 52RBII 1 C50 1 C40 F.113 F.210.G AE 355D F.1120 -C25K TO.B 28 Mn6

F.1135-C 35K-1 2 C30 S 15 S 9CK JIS S 20C,CK S15CK

S 22C S 45C S25C SGV 450 SGV 410 F.114.A S 35C SGV 480

S 25C SMn 433H S 28C SCMn 1 SCMn1

08;10 15 GOST

45 Ch12

35 40G 25

30G

Die andMold 133 Technical Information 134 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material

2

2 2 2

2 2 3 3

3 3 3 3 3 3 3

3

3

3 3 3 3 3 4 4

4

AISI/SAE 1035 1038 1035 1042 1049 1050 1050 4520 1055

A 516Gr.70 A 515Gr. 70 1074 1043 A 414Gr.F; G 1086 1095 1036 1335 1330 1040 1045 1049

A 387Gr. 12CI A 387Gr. 12CI.

A572-60 1055 1060 107 Material No. 1.1181

1.1181 1.1191 1.1206

1.1213 1.5423 1.0050 1.0481

1.0614 1.0503 1.0616 1.0618 1.1165 1.1167 1.1186

1.1191

1.1201

1.7242 1.7337 1.7337 1.7362

1.0535 1.0601

1.0603

DIN C35E CK 35 C35E GS- Ck45 CK 35 C50E CK 50 Cf 53 22Mo4 (C53G) St50-2 P295GH 17 Mn4 C 76D;D75-2 C35 C 86D;D85-2 C 92D;D95-2 30Mn5 36Mn5 C40E CK 40 C45E CK 45 C45R 080M46 Cm 45 18 CrMo4 16 CrMo4 16 CrMo4 12 CrMo195 17 MnV6 C55 C60

C67

BS 080 A35 (080 M36) 080 A35 080 A46 (080 M36 080 M50

070 M55 1503-245-420

1501 Gr. 224

1449 50HS,CS 080 M46 060 A47

120 M36 150 M36 (150 M28) 060 A40,08040 080 M40 080 M46 060 A47

3606-625 436055 E 070 M55 060 A6243D 1449 HS,CS 080 A67 1449 70HS EN

AFNOR 2 C35,XC32 XC 38H1 XC 38 XC 45 2 C50 XC 50H1 XC 48H1; XC 48HTS

a 48Cp;AP XC 75 AF65C45 1 C45 XC 80 XC 90 35 M5 40 M5 2 C40 XC 42H1 2 C45 XC 48H1 XC 45 XC 42H1 3 C45 XC 48H1 XC 42H1

Z 10CD5.05 NFA 35-501E36 AF 70C55 1 C55 1 C60 AF70C55 XC 65

1572 SS 1655 2142 18 CrMo4 1660 1672 2120 C 85 1650 1672 1674 1674 1660 1572 1550 C 67 1C60 C 60 1 C55 C 55 16 CrMo205 A 18CrMo45KW A 18CrMo45KW C 45 C 46 C 45 C 40 1 C45 C 45 FeE 295 Fe 510-2KG;KT;KW Fe 510KG;KT;KW FE50 16 Mo5KG;KW C 53 C 50 C45 C36 C 35 UNI

F.1147C 48K-1 F.1145-C 45K-1 F.1142-C48 K F.1140-C 45K F. 8212-36Mn5 F. 1203-36Mn6 f.8311-AM 30Mn5 F.8211-30 Mn5 F.114 A 47RCIRAII F.2602- 16Mo5 F-1140 F.1130-C 35K UNE S 58C S 55C S 50C S48C S 45C S 40C SCMn 3 ssmN 438(H) SCMn 2 SMn 433H S 45C SGV 480 SGV 450 SG 365,SGV410 SB 450M;480M S 50C S35C S 35C JIS 60(G) 55 15ChM 45 40 35GL 35G2 30GSL 27ChGSNMDTL 85 75 45 14G2 50 50 45 35 GOST Die andMold 135 Technical Information 136 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material

4

4 4

4 4 4

4 4 4 4 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

AISI/SAE 1074 1075 1055 1055 1060 1070 1064 1074 1075 1086 1078 1095 W 112

A573-81 65 A515 65 5120 9255 9254 9262 L3 L1 L2

4135

0 1 S1 S1 L6 L6 O2 E 50100 52100

Material No. 1.0605

1.1203 1.1209

1.1221 1.1231 1.1248 1.1269 1.1274 1.1663

1.0070 1.7238 1.7701 1.0116 1.0345 1.0841 1.0904 1.0904 1.0961 1.2067 1.2108 1.2210 1.2241 1.2311 1.2330 1.2419 1.2510 1.2542 1.2550 1.2713 1.2721 1.2842 1.3501 1.3505 1.5024

DIN C75

CK 55 C55E C55R Cm 55 C60E (C67E) Ck 67 CK 60 CK 75 (C75E) CK 85(C85E) Ck 101(C101E) C 125W

St70-2 49 CrMo4 51 CrMoV4 St 37-3 H1 St 52-3 55 Si7 55 Si7 60SiCr7 100Cr6 90 CrSi5 115CrV3 51CrV4 40 CrMnMo7 35 CrMo4 105WCr6 100 MnCrW4 45 WCrV7 60WCrV7 55NiCrMoV6 50NiCr13 90MnCrV8 100 Cr2 100Cr6 46Si7

BS 1449 80HS

070 M55 060 A57 070 M55

060 A62 060 A67 060 A78

436040B 1 501161 150 M19 250A53 250 A53

BL3

708 A37

BO1 BS1

BO2

535 A99 2 S135

EN

43D XC60H1

45

31

AFNOR XC 55H1 2 C55 3 C55 XC 55H1 2 C60 XC 68 XC 75 XC 90 XC 100 Y2 120

E 24-U A 37CP 20 MC5 55S7 55 S7 60SC6 Y100C6

100C3

34 CD4 105WC13 8 MO

55WC20 55NCDV7 55 NCV6 90 MV8

100 C6 45 S7;Y46 7;46 SI7 SS

1312

2234 2140

1655 1770 1678 1665 774 2223 1870

2092 60SiCr8 2090 2085 2172 1330

2140 2258 2550 2710 2710 UNI C 55 C 75 C70 C 60 C 55 C 75 C 100 C 90 FE70-2 105WCR 5 100Cr6 60SiCr8 55Si8 Fe 52 51 CrMoV4 107CrV3KU Fe37-3 35 cRmO8KU 10WCr6 35CrMo4 100Cr6 58WCr9KU 45 WCrV8KU 10WCr6 UNE F.1150-C 55K F.1155-C 55K-1

F-5117

56Si7 F-431

105WCr5 34CrMo4 F. 1451-46SI7 F.1310 -100Cr6 f-528 F.520.S 45WCrSi8 105WCr5 JIS S 55C S 58C

SUP 4

SCM435TK SUJ2 SKT4 SKS31 GOST 55 75 65GA 60G, 60GA 60 75(A) 68GA ,70 85(A)

Ch

ChWG SchCh 15 5ChNM 5ChW25F Die andMold 137 Technical Information 138 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material

6

6 6 6 6 6

6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 AISI/SAE 9255 9255 9260 H 9260

A 204Gr.A 4017 4419 A 350-LF5 3415 3310; 3314

5015 5140 5140 5132 5115

5155 4135; 4137 4142 4140

ASTM A182F-12 A 182-F11;12 ASTM A182F.22 A182 F-22

A355A A570.36 3135

8620 8740 4130

Material No. 1.5025

1.5026 1.5028 1.5027 1.5120 1.5415

1.5419 1.5622 1.5732 1.5752 1.6587 1.6657 1.7015 1.7045 1.7035 1.7033 1.7131 1.7139 1.7176 1.7220 1.7223 1.7225 1.7228 1.7262 1.7321 1.7335 1.7335 1.7380 1.7380 1.7715 1.8509 1.0038 1.5710 1.5755 1.6523 1.6546 1.7218 1.7733 1.7755 DIN 51Si7

55Si7 65Si7 60Si7 38 MnSi4 16Mo3 15 Mo3 20Mo4 14Ni6 1 NiICr10 14NiICr14 17CrNiMo6 14NiCrMo134 15Cr3 42Cr41 41Cr4 34Cr4 16MnCr5 16MnCr5 55Cr3 34CrMo4 41CrMo4 42CrMo4 55NiCrMoV6G 15CrMo5 20 mOcR4 13CrMo4 4 13 CrMo4 10CrMo9 10 10 CrMo9 14MoV6 3 41CrAlMo 7 S235JRG2 (Fe360B) 36NiCr6 RSt 37-2 31 NiCr14 2 NiCrMo2 40 NiCrMo22 25CrMo4 24 CrMoV5 GS-45 CrMOV104 BS

251 a58 251 H60 251 A60

1503-243 B 1503-243-430

655M13 820A16

523 M15 530 A40 530M40 530A32 527 M17

527 A60 708 Aa37

708 M0 823M30

1501-620Gr27 1 501620Gr. 27 1501-622gR31; 45 1501-622 1503-660-440 905 M39 Fe 360BFU 640A35 4360-40 B 1449 27/23CR 653 M31 805M20 311-Tyre 7 CDS 110

EN

36A

18 42C4 18B 32C4

48

33

41B

362

AFNOR 51 S7 51 Si7 55 S7 60 S7 60 S7

15 D3

16N6 14 NC11 12NC15 18NCD6

12 C3 42 C4TS 16 MC5

55 C3 35 CD4

42 CD4

12 CD4

15 CD4.5

12 CD9.10

40 CAD6.12 E 24-2NE 35NC6 18 NC13 20 NCD2

25 CD4 20 CDV6 SS

2506

14Ni6KG;KT 2225 25CrMo4(KB)

2245

1312 2940 2218 2090

2085 2090 -2512 2912 16NiCr11 2234 2253 2127 2511 2625 2216 2512 2244 2216 Fe 360BFN 41CrAlMo7 12CrMo9,10 21 CrMoV511 48 Si7 UNI

55 Si7 50 Si7 20NiCrMo2 G 20Mo522Mo5 16Mo3(KG;KW) 60 Si7 40NiCrMo2(KB) 14NiCrMo131 14NiCrMo13 15NiCr11 F.2641 -15Ni6 34Cr4(KB) 41Cr4 16MnCr5 41Cr4 653M31 41CrMo4 14CrMo4 5 AE 235BFN;FU 41CrAlMo7 13MoCrV6 TU.H F.1450-50 Si7 UNE Fe 360BFN;FU F.1440 -56Si7 20NiCrMo2 F. 2601-16Mo3 F. 1441-60Si7 55Cr3 40NiCrMo2 SNC815(H) SNC415(H) 35Cr4 42Cr4 16MnCr5 42Cr4 12CrMo4 42CrMo4 12CrMo4 14CrMo45

JIS

SNCM220(H) SCPH 11 50 P7SUP6 SCM420/430 SNCM240 SCr415(H) SCr430(H) SCr440(H) SUP9(A) SCr440 SNB 22-1 SCM415(H) 20ChM; 30ChM 12ChM; 15ChM

GOST St3ps; sp 55S2 20ChGNM 60S2 38ChGNM 15Ch 35Ch

35ChM 50ChGA 40ChFA

Die andMold

139 Technical Information 140 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material

7 9 9 8 10 10 9 9 8 8 8 8 8 8 8 8 8 10 11 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 AISI/SAE

3135 4142 A 619 A573-81 6150 4340 9840 3435 A128(A) M 1015 2515 2517 ASM A353 ASTM A353 N08028 D3 H 12 H 21 D 4(D6) HNV3 D 2 A 2 H 13 H 11 (12L13) 12L13 M 1017 M 1016 Material No. 1.8070 1.5864 1.5710 1.2332 1.0347 1.0144 1.4882 1.8523 1.8515 1.8161 1.8159 1.7361 1.6582 1.6511 1.5736 1.3401 1.0401 1.3202 1.5680 1.5680 1.5662 1.5662 1.4563 1.3343 1.2606 1.2601 1.2581 1.2436 1.2379 1.2379 1.2363 1.2344 1.2343 1.2083 1.0723 1.0718 1.0718 1.0570 DIN 21 CrMoV511 35 niCr18 36NiCr6 47 CrMo4 DCO3 ST 44-3 31 NiCrMo134 X 50CrMnNiNbN219 39CrMoV13 9 32 CrMo12 58 CrV4 50 CrV4 32 CeMo12 35CrNiM 6 36CrNiMo4 36 NiCr10 G-X120 Mn12 15 S20 C15 RSt;RRSt 13 S 12-1-4-5 12 Ni19 12Ni19 X8Ni9 X8Ni9 S 6-5-2 X 37CrMoW51 X 165CrMoV12 X 30WCrV93 X 210CrW12 X210Cr12G X 155CrVMo121 X100 CrMoV51 X 40CrMoV51 x 38CrMoV51 15 S22210A 9 SMnPb28 9SMnPb28 ST 52-3 BS

640A35 708 M40 1449 3CR 4360 43C 830 m31 897M39 722 M24 735 A50 722 M24 817 M40 816M40 210 M15 080 M15 1449 2CR 1449 17CS BT 15 12Ni19 502-650 1501-509;510 BM2 BH 12 BH 21 BD6 BD2 BD2 BA 2 BH 13 BH 11 4360 50B 080 M15 EN

111A 35NC6 21.09 19A 40C 40B 47 40B 24 110

AFNOR 42 CD4 E 28-3 Z 50CMNNb 30 CD12 50CrV4 30 CD12 35 NCD6 40NCD3 30 NC11 Z 120M12 E AF 37C12 Z 18N5 Z18N5 9 Ni Z1NCDU31-27-03 Z200C12 Z 35CWDV5 Z 30WCV9 Z 200CD12 Z160CDV12 Z 160CDV12 Z 100CDV5 Z 40CDV5 Z 38CDV5 S 250Pb S250Pb E 36-3 XC 18

2584 2715

2310 2260 2242

SS

2310 2312 2736 2314 1922 1412 1914 2534

1914

2132 2240 2230 2183 1350 2240 2541 2244 HS 12-1-5-5

X10Ni9 14 Ni6KG;KT X210Cr13KU X 35CrMoW05KU

X30WCrV 93KU X215CrW 121KU

X165CrMoW12KU X100CrMoV51KU X40CrMoV511KU X 37CrMoV51KU

CF 9SMnPb28

CF9SMnPb28 36nIcRmO4(KB)

Fe52BFN/Fe52CFN 36CrMoV12 1 C15 32CrMo12 50CrV4 GX120Mn12 C16 C15 30CrMo12 35NiCrMo6(KB) 42CrMo4 Fep 02 35 NiCr9 UNI 12-1-5-5

F-2645 XBNiO9 X210Cr12 F.537

F-526 F-5213

X160CrMoW12KU F-5227 F-5318

F.210.F 11 SMnPb28 f-1270

11SMnPb28 35NiCrMo4

F.124.A 51CrV4 F. 8251-AM-X120Mn12 F.111 F.124.A 42CrMo4 AP 02 UNE

SL9N60(53) SUH3

SKD5

SKD12 SKD61

SUM 32 SM 400A;B;C 12 L13 SNC236

SUP10

SM490A;B;C;YA;YB

SCMnH 1,SCMnH11 S 15C SNCM 447 SCM (440) JIS

R6M5 5ChNM

3Ch2W8F

4Ch5MF1S 4Ch5MFS

17G5

110G13L

08JU GOST 50ChGFA 38Ch2N2MA 40ChN2MA St4KP; ps;sp Die andMold 141 Technical Information 142 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material 11 11 11 11 11 12 12 12 439 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 11 11 11 11 11 11 11 T 1 M 2 M 42 409 430tI 430 Ti XM 8 S31500 S31500 434 440B 430 F 420 430 430 410; CA-15 416 405 405 (410S) 403 422 HNV 3 630 M 7 T 4 T 15 AISI/SAE 1.3355 1.3343 1.3249 1.3247 1.3246 1.4512 1.4511 1.4510 1.4510 1.4418 1.4417 1.4417 1.4340 1.4113 1.4112 1.4104 1.4086 1.4028 1.4027 1.4027 1.4016 1.4016 1.4006 1.4005 1.4002 1.4002 1.4001 1.4001 1.4000 1.4935 1.4718 1.4548 1.3348 1.3255 1.3243 1.3207 Material No. (X2CrTi12) S 18-0-1 S6-5-2 S 2-9-2-8 S 2-10-1-8 S 7-4-2-5 X 6 CrTi 12 X 6CrTi X 6CrNb17(X17 17 X6 CrTi X4 CrNiMo165 X2 CrNoMoSi1853 X2CrNiM0Si19 5 G-X40CrNi27 4 X6CrMo 17 X90 CrMoV18 X12CrMoS17 G-X120Cr29 X30 Cr13 G-X 20Cr14 G-X20Cr14 X6 Cr17 X8Cr17 (G-)X10 Cr13 X12CrS 13 X6 CrAl13 X6CrA12 X7 Cr13 X6Cr14 X6Cr13 x20 CrMoWV121 X45CrSi 93 S2-9-2 S 18-1-2-5 S 6-5-2-5 S 10-4-3-10 DIN

409 S19 BT 1 BM2 BM 34 BM 42 LW 19 434 S17 420 S37 452C11 420 S45 420 C29 420C29 430 S15 Z8C17 410S21 416 S21 405 S17 405S17 (403 S7) 403 S17 401S45 BT 4 BT42 BS 09-04-02- 18-05-04-0 09-08-04 07-05-04 06-05-05-04-02 60 56A 52 EN Z 80WCV18-4-01 Z 85WDCV Z110 DKCWV Z110 WKCDV Z 3CT12 Z 4CNb17 Z 4CT17 Z 4CT17 Z6CND16-04-01 Z 8CD17.01 Z 10CF17 Z 30C13 Z 20C13M Z20C13M Z 8C17 430S15 Z10 C13 Z11 CF13 Z6CA13 Z8CA12 Z 8C13 Z 6C13 Z45CS9 Z7CNU17-04 Z 100DCWV Z 80WKCV KCV Z130WKCDV AFNOR SS R18 R6M5

2383

2782 2722 2-10-1-8 7-4-2-5 2723 2301 2301 2304 2320 2320 2302 2380 2302 2387 2376 2376 2325

HS 29 HS 652 2-9-2-8 HS 2-9-1-8 HS 7-4-2-5 HS 6-5-2-5 UNI X6Cr13 X45CrSi8 X8Cr17 X8Cr17 X12Cr13 X12 CrSC13 X6CrAI13 X6CrAI13 X8CrMo17 X10CrS17 17 X 6CrTi

X 6CrNb17 X 6 CrTi 12 X 6CrTi F-5607 F-5604 M 41 M 35 6-5-2-5 UNE F8401 F.3110 F322 F3113 F.3113 F.3401 F-3411 F.3117 F.3115 17 -X5CrTi

F.3122-X 5CrNb17

SKH 51 SKH55 JIS SUS403 SUH1 SUS430 SUS410 SUS 416 SUS434 SUS430F SUS 430LX

SUS 430LK SUH 409 R6M5K5 GOST 08Ch13 08Ch13 08Ch13 40Ch9S2 20Ch13 20Ch13L 20Ch13L 12Ch17 12Ch17 12Ch13

08Ch17T 08Ch17T

Die andMold 143 Technical Information 144 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material 14

14 14 14 14 14 14 14 14 14 14 14 14 14 13 13

13

13 13

13 13 13 13 13 13 12 12 12 12 12 12 12 12 12

316 202 S32304 304

305

304 LN 301 CF-8 304L 304L 303 304

348

630 CA6-NM

431

420 420 429 302 EV 8 446 446 HNV6 430 405 AISI/SAE 1.4401

1.4371 1.4362 1.4350 1.4332 1.4312 1.4312 1.4311 1.4310 1.4308 1.4306 1.4306 1.4305 1.4301 1.4922 1.4923

1.4546

1.4544 1.4542

1.4313 1.4125 1.4057 1.4034 1.4031 1.4021 1.4871 1.4762 1.4749 1.4747 1.4742 1.4724 1.4720 Material No.

X 5CrNiMo17122

X3 CrMnNiN18887 X2 CrNiN234 X5CrNi18 9 X2 CrNi18-8 X8 CrNi1812 G-X10CrNi18 8 X2 CrNiN1810 X12CrN i177 X6 CrNi189 X2 CrNi1810 X2CrNi18 9 X10 CrNiS189 X 5CrNi189 x20cRmV12-1 X22 CrMoV121

X5CrNiNb 18-10

X 5CrNiCuNb174 (X5CrNiCuNb 16-4) G-X4 CrNi134 X 105CrMo17 X20CrNi172 X46Cr13 X40 Cr13 X20Cr13 X10 CrNi15 x12 CrNi189 X 53CrMnNiN219 X10CrA124 x18 cRn28 X80CrNiSi20 X10CrA118 X10CrA113 X20CrMo13 (X4 CrNiMo17-12-2) DIN

302 S31 349 S54 443S65 439S15 403S17 316 S13

284 S16

304S15

305 s19 302C25 304 S62 301 S21 304 C15 304 S11 304S12 303 S21 304 S15

S.525/527 2 S.143/144/145 2 S.130 347 S31 S. 526 S. 524

425 C11

431 S29 420 S45

420S37 316 S19 316 S17 BS 316 S33 316 S31

58E

58E

58M

57

59 Z80CSN20.02 60 Z10CAS18 EN

18- 08-05 Z 8CMN Z 2CN23-04AZ Z6CN18.09

Z10CN18.9M Z 2CN18.10 Z 12CN17.07 Z 6CN18-10M Z 3CN19-11 Z2CrNi18 10 Z 8CNF18-09 Z 5CN18.09

Z 4CND13-04M Z 100CD17 Z 15CN16.02 Z40 C14 Z 40C14 Z 20C13 Z 10CN18-09 Z 52CMN21.09 Z10CAS24 Z10C13 AFNOR Z 6CND17-11 Z 6CND17-11-02 Z 3CND17-11-01 Z 7CND17-12-02 Z 7CND17-11-02

SS

X80CrSiNi20

X40Cr14

2346

2322 -2304 2303 2330 2321 2385 2332;2333 2317 2371 2331 2333 2352 2352 2327 2332 2347 UNI X10CrA112 X8Cr17 X16Cr26 F.320B 14210 X53CrMnNiN21 9 X16CrNi16 F.3405 (G)X6CrNi304 X 105CrMo17 X 6 CrNiTi 1811 X 6CrNiTi x20cRmOnI 1201 X 6CrNiNb1811 X2CrNiN18 10 X2CrNi18 07 X2CrNi18 11 x2cRnI18 11 X10CrNiS18.09 X5CrNi18 10 X 5CrNiMo1712

UNE F.311 F.3113 SUH4

F.3427 SUS420J2

F.3517 F.3503 F.3508 F.3551 F.3534-X 5CrNiMo 17 122 JIS

SUS430 SUH446 SUH35,SUH36 SUS431 SCS5

SUS304LN SUS304L SCS19 SUS303 SUS304 SUS 316 GOST 10Ch13SJu 15Ch18SJu

40Ch13 20Ch13 55Ch20G9AN4 20Ch17N2 95Ch18 08Ch 18N12T 08Ch18N10 10Ch18N9L 30Ch18N11 10Ch18N9L Die andMold 145 Technical Information 146 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material

14 14 14 14 14 14

14 14

14 14 14

14

14

14

14 14 14

14 14

14

321 CN-7M 443 UNS N08904 444 17-7PH

329 329 317

(s31726) 317L 316 316L 316 Ln

CF-8M 316LN 316L AISI/SAE

1.4541 1.4539 1.4521 1.4539 1.4504 1.4500

1.4462 1.4460

1.4460 1.4449 1.4440

1.4439

1.4438

1.4436

1.4435 1.4429 1.4410

1.4408 1.4406

1.4404 Material No.

Z 6 CrNiTi 18-10 Z 6CrNiTi (G-)X1 NiCrMoCu25205 X2CrMoTi18-2 X1NiCrMoCuN25-20-5

G-X7NiCrMoCuNb25 20

X2CrNiMoN22 53 X8CrNiMo27 5 (X3CrNiMo27-5-2) X 4CrNiMo2752 X5 CrNiMo17133 X 2CrNiMo1813

X2 CrNiMoN17135 (X2CrNiMo 18-15-4) X2 CrNiMo18164

(X4CRNIMO 17-13-3 X 5CrNiMo17133

X2 CrNiMo18143 X2 CrNiMo17-13-3 G-X10CrNiMo18 9 G-X 6CrNiMo1810 GX 5CrNiMoN7122 (X2CrNiMoN 18-10) X2 CrNiMoN17122

GX 2CrNiMoN18-10 (X2 CrNiMo17-12-2)316S14,31; X2 CrNiMo17132 DIN LWCF 24 LW 24 321 S51(1010;1105) 321 S31

316S111

318 S13

317 S16

317 S12 LWCF 23 LW 23 316 S33 316 S19;31 LWCF 22 LW 22 316 S14;31631Z3CND18-14-03 316 S11;31613Z3CND17-12-03 316 S62

ANC 4B 316 C16(LT 196) 316 S63 316 S61

C 12,T.75, S.161 316 S42,S.537;316 316 S11,13 BS

Z 2CND18-13 EN Z 6CNT18-10 Z1 NCDU25-02M Z 2NCDU25-20 23NCDU25.20M (Z 3CND25-06-03Az) (Z 2CND24-08Az) Z 3CND22-05Az

Z 5CND27-05Az (Z 3CND25-07Az)

18-14-06 AZ Z 3CND z 3cnd19-15-04 Z 2CND19-15-04

Z 7CND18-12-03 Z 6CND18-12-03

Z 2CND17-13Az Z5CND20.12M

Z2 CND17-12AZ Z 3CND19.10M Z 3CND18-12-03 17-12-02 FF Z 3CND Z 3CND17-11-02 Z 2CND17-12 AFNOR SS

2343 2328 2375 2375 2348 2343 2367

2324

2337 2564 2562 2326 2377 2324

UNI X2CrNiMoN 1713 X 2CrNiMoN1713 X 2CrNiMo1712

X 5CrNiMo11713 G-X 2CrNiMo1911 X2CrNiMo18 16 X 8cRnImO1713

X 5CrNiMo1815

X 2CrNiMoN1712

X 6 CrNiTi 1811 X 6CrNiTi Z8CNA17-07

F.8414-AM-X 7 CrNiMo 2010 UNE F.3533-X 2CrNiMo F.3543-X 2CrNiMoN17133 F.3533 -X2CrNiMo 17 132 17 132 F.3543-X 5CrNiMo171223 F.3537 -X2CrNiMo f.3539-x 2cRnImO18164 F.3538-X 5CrNiMo1713

17 133

F.3309-X 8CrNiMo17122 F.3542-X 2CrNiMoN F.3552-X 8CrNiMo18164 F.3523 -X6CrNiTi F.3123-X 182 2CrMoTiNb X2CrNiMo1712 17 122 18 10

SCS 14 JIS (SUS 316LN SUS 316L SUS 316 SUS317L

SUS316L SUS 317 SUS 329J1 SUS 444 SUS 329J3L SUS316LN SUS 321

GOST

O3Ch17N14M3

06Ch18N10T

08Ch18N10T 09Ch18N10T 12Ch18N10T 07Ch18N; 18N10G2S2MSL Die andMold 147 Technical Information 148 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material 17 16 16 16 16 16 16 15 14 15 14 15 14 15 14 15 14 14 15 14 14 15 14 14 14 15 14 14 15 14 14 14 14 14 15 14 14 14 14 14 14 14 14

100/70/03 A48-60 B A48-50 A48-45 B CLASS45 CLASS30 No 20B 660 60-40-18 304H A436 Type 2 S30815 NO 30B Ss30415 A48-30B 321 316tTi A48 25B 310 S 17-7PH CLASS25 309S NO 25B 309 347 A48-20B 17-4PH S31254 CLASS20 S31753 17-4PH 630 318 316 Ti AISI/SAE 0.7033 0.7070 0.6040 0.6035 0.6030 0.6030 0.6020 1.4980 0.7040 1.4948 0.6660 1.4893 0.6020 1.4891 0.6020 1.4878 1.4571 0.6015 1.4845 1.4568 1.4829 0.6015 1.4833 1.4552 0.6015 1.4828 1.4550 0.6010 1.4823 1.4548 1.4821 1.4547 0.6010

1.4585 1.4581 1.4542 1.4542 1.4583 1.4571 Material No. GGG35.3 GGG-70 GG40 GG-35

GG30 GG20 GG 10 2515 X5 NiCrTi GGG 40 X6 CrNi1811 GGL-NiCr202 X8 CrNiNb11 GG 20 X5 CrNiNb1810 GG-20 189 X6 CrNiTi 17122 X6 CrNiMoTi GG 15 X12 CrNi2521 X 12CrNi22 GG15 X6 CrNi2213 G-X7CrNiNb18 9 GG 15 X15CrNiSi20 12 X6 CrNiNb1810 GG-10 G-X40CrNiSi27 4 X2 CrNiMoN25227 X20CrNiSi25 4 X1 CrNiMoN20187 GG10 (X5 CrNiChNb16-4) X2 CrNiMoN18134 G-X7CrNiMoCuNb18 18 G-X 5CrNiMoNb X5 CrNiCuNb174 X5 NiCrN3525 X 10CrNiMoNb1812 17122 x 6CrNiMoTi DIN

SNG700/2 GRADE400 GRADE 350 Grade 300 GRADE300 GRADE220

SNG 420/12 304 S51 L-NiCuCr202 Grade 220 Grade 220 32 1S20 320 S31 Grade 150 310S24 316S111 GRADE150 309 S13 Grade 150 309 S24 347 S17

318 C17 303 S21 320 S31 BS

58B

58C 58F

58J EN FGS 700-2 Ft 40D Ft35D Ft 30D Ft30D Ft20D Ft 10D FCS 400-12 Z 5CN18-09 L-NC 202 Ft 20D Ft 20D Z 6CNT18-12(B) Ft 15D Z 12CN25-20 Ft15D Z 15CN24-13 Z4CNNb19.10M FT 15D Z15CNS20.12 Z 6CNNb18.10 FT 10D Z7CNU17-04 Z20CNS25.04 Ft10D Z7CNU17-04 Z 7CNU17-04 Z15CNS20.12 Z 6NDT17.12 Z 7CNU15-05 AFNOR Z 4CNDNb18.12M Z 6CNDT17-12002 Zz 8nctv25-15bff SS

110 2570 07 37-01

2338 2378 2350 2350 0717-02 0523-00 120 0120-00 01 15-00 115 0115-00 0110-00 110 2333 2368 2372 2337 2361 07 17-15 140 135 01 30-00 130 120

UNI X6CrNiNb18 11 12 X6CrNiMoTi17 Z8CNA17-07 x15cRnIsI2 12 GS 370-17 G 20 G14 G 15 G 15 G10 11 X6CrNiTi18 X6CrNi25 20 12 X6CrNiMoTi17 G 35 G 30 G 20 GGG 70 UNE F.3552 F.3535 X2CrNiMo1712

FGE 38-17 FG15 FG 15 FG 15 F.3553 F.331 F.8414 FG 35 FG 30 FG 20 GGG 70 SCS 24 JIS SUS347 SUS 630

FCD400 FC200 FC150 SUS321 SUH310 SCS17 FC350 FC300 FC100 FCD700 GOST 08Ch18N12B 10Ch17N13M2T 10Ch17N13M2T 09Ch17NJu1 VCh42-12 SCh20 SCh20 SCh15 SCh15 SCh15 SCh10 SCh10 20Ch23N18 20Ch20N14S2 SCh40 SCh30 SCh30 SCh20

Die andMold 149 Technical Information 150 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material 23 23 23 22 22 22 22 21 21 21 20 20 20 20 20 20 20 20 20 20 20 20 20 20 19 19 19 19 19 19 19 18 18 18 18 17 17 17 17 17 17 17 17

7050

1000 Al99 70003 400 10 1035 1518 1022

A220-90001 90001 70003 50005 A220-50005

32510

A220-40010 A47-32510 32510

A48 40B 80/55/06

A48-40 B

A43D2

65-45-12 80-55-06 60/40/18 60-40-18

AISI/SAE 3.2581 3.2382 3.2381 3.4345 3.2315 3.1655 3.1325 3.3315 3.0255 3.0205

1.1183 1.1133 0.817 0.8170 0.8170 0.8165 0.8155 0.8155 0.8065 0.8045 0.8040 0.8035

0.8145 0.8135 0.8135 0.8055

0.7060 0.7060 0.6025

0.7660 0.7652 0.7050 0.7050 0.7043 0.7040 0.7033 Material No. G-AISi12 GD-AISi10Mg G-AISi10Mg AIZnMgCuO,5 AlMgSi1 AICuSiPb AlCuMg 1 AIMg1 AI99.5

GTS-65 GTS-45 Cf 35(C35G) 20Mn5 GTS-70-02 GTS-70-02 GTS-70-02 GTS-65-02 GTS-55-04 GTS-55-04 GTMW-65

GTW-40 GTM-35 GTS-35

GTS-35 GTS-45-06 GTS-35-10 GTS-35-10 GTW55

GGG-60 GGG60 GG25 GGG 40.3 GGG-NiCr 202 GGG-NiMn 137 GGG-50 GGG50 GGG-40.3 GGG-40 GGG-35.3 DIN

L 86

L31/34/36

P 570/3 P440/7 080 A35 120 M19 IP 70-2

P 690/2 P 570/3 P510/4 P 510/4

W410/4 W340/3 B340/12 8 290/6 B 340/12 P 440/7 B 340/2 B 340/12

600/3 SNG600/3 Grade260 SNG 370/17 Grade S6 S-NiMn 137 SNG 500/7 SNG500/7 370/7 SNG 420/12 350/22 L40 BS

EN

AZ 4GU/9051

A59050C

MP 60-3

XC 38H1TS 20 M5

Mn 700-2 Mn 700-2 Mn 650-3 MP 50-5 Mn 550-4

MB40-10 MB35-7 MN 35-10 MN 32-8

Mn 450-6 Mn 35-10 MN35-10

FGS 600/3 FGS600-3 Ft 25D FGS 370-17 S-NC 202 S-Mn 137 FGS 500-7 FGS 500/7 FGS 370/17 FGS 400-12 FGS 370/17 AFNOR SS 0727-02

VCh50-2

0717-15 0717-02 0717-15 0815-00 810 0727-03 07 32-03 125 0717-12 0776-00 0772-00 852 08 15 814 0810-00 858 08 52 1572 811-04 2132 0864-00 0862-00 0856-00 0854-00 0854-00 UNI GGG 50 GGG 60 G 25 0727-02 0852-00 GMB40 GMB45 C 36;38 20 Mn7 G 22Mn3 GMN 70 GMN 65 GMN 55

UNE

GTS 35 GTW 55 GGG 60 FG 25 GTM 35 GMN 45 GTM 40 GTM 45 F.1515-20 Mn6 GTW 65

JIS

FCD600 FC250 FCD500 FCMW330 AC4A FCMW370

FCMP540 S 35C SMnC 420 FCMP690 FCMP590 FCMP490

VCh42-12 VCh42-12 GOST VCh50-2 KCh35-10 KCh35-10 VCh60-2 SCh25

35 KCh55-4 AD35 D1 AD0 35 AK9 20G KCh70-2 KCh70-2 KCh70-2 KCh60-3 KCh55-4 AK12 Die andMold 151 Technical Information 152 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material 27 27 26 26 26 26 26 23-24 23-24 23-24 23-24 23-24 23-24 23-24 31 24 31 24 28 31 24 28 24 28 24 28 24 28 24 28 24 28 23 28 23 28 23 27 23 27 23 27

27 27 C 27200

C 93800 C 23000 C 83600 C 83600 C 93200 A380.1 A413.0 A413.1 A413.2 356.1 A356-72 A360.2 N 08028 GD-AISI12 N 08031 QE 22

N 08800

C 81500 SC64D C 90800 4218 B C 90700

B-148-52

C 63000

C 94100 AZ 91

AZ 81

EZ 33 C 18200 ZE 41 C 86200

C 86500 AISI/SAE C 27700 2.0321 2.0240 2.1182 2.1182 2.1098 2.1096 2.1090

3.2383 1.4563

1.4562 3.5106 2.4764 1.4558 3.2373 2.1292 3.2373 2.1052 3.2371 2.1050 3.2163 2.0975 3.1754 2.0966 2.1871 2.0596 3.5912 2.0375 3.5812 2.0060 3.5103 2.1293 3.5101 2.0596 3.3561 2.0592 Material No. 2.0590 2.0321 CuZn 37 CuZn 15 G-CuPb15Sn G-CuPb15Sn G-CuSn 2Znpb G-CuSn5ZnPb G-CuSn 75pb GD-AlSi8Cu3 GD-AlSi12 G-AlSi 12(Cu) G-AlSi12

G-AISi0Mg(Cu) X 1NiCrMoCuN31274 G-ALMG5 X 1NiCrMoCu32287 G-MgAg3SE2Zr1 CoCr20W15Ni X 2 NiCrAITi 3220 X 2NiCrAITi G-AISi 9Mg G-CuCrF 35 G-AISI9MGWA G-CuSn 12 G-AISi 7Mg G-CuSn 10 G-AISi9Cu3 G-CuAI 10Ni G-AICu5Ni1,5 CuAI 10Ni5Fe4 G-AICu 4TiMg G-CuZn 34AI2 G-MgAI9Zn1 CuZn36Pb3 G-MgAI8Zn1 E-Cu57 MgSE3Zn27r1 CuCrZr G-MgZn4sE1Zr1 G-CuZn 34AI2 G-AIMg 5 G-CuZn 35AI1 DIN G-CuZn40Fe CuZn 37 CZ 108

LB1

LG 2

LM24

LM 20 LM 6 LM25 2789;1973 LM9

LM5

MAG 12 NA 15

CC1-FF

pb 2

CT1

Ca 104

HTB 1 MAG 7

NMAG 1

MAG 6 CC 102 MAG 5 HTB 1

U-Z 36N3 BS CZ 108

EN

Uu-PB 15e8 U-pb 15E8

U-E 7Z5pb4

NF A32-201

A-SU12

A-S7G UE 12P

U-A 10N

U-Z 36N3

G-TR3Z2 U-Cr 0.8Zr

U-Z 36N3

HTB 1 AFNOR

CuZn 36,37 CuZn 36,37 SS

4250 4247 4260 4261 4244 4253 4252 4251

2584 UNI C 2700 C2720

UNE

A7075 A6061 ADC12 A5052 C4BS JIS

AK12 AK7 AK9 AK8 VAL8 GOST L63 L63 EK77 BrAD; N10-4-4 LS60-2 LTs23AD; ZMts Die andMold 153 Technical Information 154 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material 37 37 37 37 37 37 37 37 37 36 36 36 35 35 35 35 35 34 34 34 34 34 34 34 34 34 34 34 33 33 33 33 33 33 33 33 33 32 31 31 31 31 31

AMS R56401 AMS R56400 AMS R54520

R 54620

AMS 5397 R 52250 R 50250

AMS 5399 Hastelloy C Hastelloy B lnconel X-750 AMS 5772 5537C 5660 5391 5383

lnconel lnconel 718

4676 Monel k-500 lncoloy 825 5666 lnconel 625 lnconel 690

Nimonic 75 Hastelloy C-4 5390A Monel 400

AMS 5544

330 N 08330 AISI/SAE

3.7195 3.7185 3.7165 3.7145 3.7124 LW2 4674 3.7225 3.7025 3.7115 2.4973 2.4810 2.4685 2.4669

LW2.4964 LW2.4662 LW2 4670 LM2.4668 2.4955 2.4694 2.4668 2.4631 2.4375 2.4375 2.4858 2.4856 2.4856 2.4642 2.4630 2.4630 2.4610 2.4603 2.4360 1.4977 LW2.4668 1.4958 1.4865 1.4864 1.4864 Material No. TiAl6V4ELI TiAl6V4 TiAl5Sn2.5 TiAl4Mo4Sn4Si0.5 TiAl 3V2.5 TiAl TiAl4Mo4Sn2 TiAl6V4 TiAl6Sn2Zr4Mo2Si TiCu2 NiCo15Cr10MoAITi Ti 1pd Ti Ti 1 Ti TiAl5Sn2 NiCr19Co11MoTi G-NiMo30 G-NiMo28 NiCr15Fe7TiAl C0Cr22W14Ni CoCr20W15Ni NiFe35Cr14MoTi S-NiCr13A16MoNb NiCr19Fe19NbMo NiFe25Cr20NbTi NiCr16fE7TiAl NiCr19FeNbMo NiCr20TiAI NiCu30Al NiCu30 Al NiCr21Mo NiCr22Mo9Nb NiCr22Mo9Nb NiC29Fe NiCr20Ti NiCr20Ti NiMo16cR16Ti

NiCu30Fe X 40CoCrNi20 NiCr19NbMo X 5 NiCrAITi 3120 X 5NiCrAITi G-X40NiCrSi38 18 X12 NiCrSi3616 X 12NiCrSi3616 DIN TA11 TA10-13/TA28 TA14/17

TA 45-51;TA 57 TA 10-13;TA 28

2 TA 21-24

TP 1 2 TA 1

3146-3 HR8

Hr40;601 3072-76 NA 18 NA 16

NA 21

HR5,203-4 HR 5,203-4

NA 13

330 C40 NA 17 NA 17 BS

EN

T-A6V T-A5E

T-A 6V

NC19KDT

NC 15TNbA KC22WN KC20WN ZSNCDT42 NC12AD NC19eNB

NC 19FeNb NC20TA

NU 30AT NC 21FeDU Inconel 625 NC 22FeDNb Nnc 30Fe NC20T NC 20T

NC22FeD NU 30 Z 42CNKDWNb NC20K14

Z 12NCS37.18 Z 12NCS35.16 AFNOR SS

UNI XG50NiCr39 19 UNE

SUH330 JIS SCH15 GOST VT6 VT1-00 VT5-1 KhN77TYuR KhN38VT Die andMold 155 Technical Information 156 Technical Information ISCAR MATERIAL GROUPS According toVDI3323Standard Group Material 41 41 41 40 40 40 40 40 40 40 40 38 38 38 38 38

310

A 532lll25%Cr A 532lll25%Cr

Ni-Hard 4 Ni- Hard 1 Ni- Hard 2

440C

W210 W 1 AISI/SAE 0.9655 0.9645 0.9635 1.4841 1.2419 0.9655 0.9650 0.9640 0.9630 0.9625 0.9620 1.6746 1.4125 1.2762 1.1545 1.1545 Material No. G-X 300CrNMo271 G-X 260CrMoNi2021 G-X 300CrMo153 X15 CrNiSi2520 105 WCr6 G-X 300CrNMo271 G-X 260Cr27 G-X 300CrMoNi1521 G-X 300CrNiSi952 G-X 330NiCr42 G-X 260NiCr42 32 nIcRmO145 X105 CrMo17 75 CrMoNiW67 C105W1 C 105W1 DIN

314 S31 105WC 13 Grade 3E Grade 3D

Grade 2B Grade 2A 832 M31

BW2 BW 1A BS

EN

Z 15CNS25-20

35 NCD14 Z 100CD17

Y120 Y1 105 AFNOR SS 2900

1880

C 100KU UNI C120KU 0512-00 0513-00 0466-00

F-5118 UNE CF.515

107 WCr5KU SK 3 JIS SUP4

U10A GOST 95Ch18 U10A ChWG 20Ch25N20S2

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