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Full Catalog Catalog Contents: Profile and Copy Milling Program Inch 6 • Metric 58 Graphite Machining Program Inch 8 • Metric 60 PCD & CBN Inserts Inch 18 • Metric 72 Copy Milling / Button Insert Cutters Inch 24 • Metric 77 APKT Square Shoulder Cutters Inch 28 • Metric 82 Aluminum Milling Cutters Inch 30 • Metric 83 High Feed Indexable Milling Program Inch 32 • Metric 87 Solid Carbide End Mill Program Inch 39 • Metric 97 SD Collet & HM Milling Chucks Inch 50 • Metric 117 Catalog Contents Catalog Millstar is an industry leader in producing die and mold profile tooling and solid carbide tools. Millstar tools are designed for conventional profile machining, and high speed and hard milling with modern machine tools and methods. Millstar Profile Milling Tools represent the latest in profile and contour milling technology, resulting in shorter machining and lead times, higher machining accuracy and true contouring results. Customers include die and mold machining companies, aluminum extrusion companies, high speed machining mold makers, and aerospace and medical component industries. Insert tooling is typically used in roughing and finishing applications. The Millstar product line is manufactured in the USA, and all tools are fully traceable. Nearly six decades of cutting tool design and manufacturing for automotive, aerospace and many other industries, as well as special design capabilities using 3-D CAD allow us to respond quickly to requests for special designs. The Millstar Story The 1 Insert Overview The Inserts • Choose from side-cutting ball nose Rock Solid Insert Millstar inserts are fully ground inserts with 180 degree nose radius, Clamping and popular ball nose inserts with a precision inserts for better chip control, Cutting insert clamping is highly cutting edge covering 230 degrees faster metal removal and higher surface accurate and rigid. Unique V-pocket for steep wall up-and-down ramping, accuracies. They are far more accurate design gives a truly positive seat for the profiling, contour milling and blending, than pressed and O.D. sharpened insert and will not allow insert and for a wider range of applications inserts. movement when milling with a compared to conventional ball • Positive ground chipbreaker or side thrust. “Sandwiched” nose tools. strong negative cutting edge designs insert clamping with single guarantee outstanding cutting • Select from a variety of flat bottom, locking screw is unsurpassed performance in a wide variety of back draft and toroid inserts for steep for rigidity. The advanced ferrous and non-ferrous materials. or straight wall milling with long design of Millstar inserts extensions on hard to reach cores, • A choice of state-of-the-art insert eliminates heat-seizing of cavities or fillets. Milling with small grades, designs and tool coatings allow locking screws or insert radii prevents deflection and results for optimum speed and feed rates in movement due to costly in superior finishes and contour wet and dry machining. Reduced locating screws or pins of accuracies. Available with or without machining times by 25% to 60% are less advanced design. chipbreaker and coating in a variety not uncommon. Positive V-pocket seating of corner radii and sizes. • Economical one-piece inserts eliminates mismatch when with two cutting edges are changing to fresh inserts. It cost-effective for contour milling. True also eliminates the need radius geometry is fully CNC-ground to program new length or for higher machining accuracy and diameter offsets. greatly reduced manual finishing and polishing time. Inch Insert Overview Insert Overview 2 Page 2 Ball Nose Inserts BS-N Ball Nose Insert Back Draft Inserts CBN Tipped Sidecutting, non- For high speed chipbreaker. Side machining or MBT SuperFinisher cutting insert BD-R Back Draft Insert milling of high Ball Nose Insert used in cavity Precision ground, with hardness Precision ground, and core positive ground materials with harder grade, for profiling, for chipbreaker and longer tool life semi-finish and blending of fillets 7 degree back- and superior finish milling. on medium and hard materials. taper. Used for finishes. Excellent choice milling of cores, for unattended cavities, fillets finish milling Flat Bottom Inserts with straight or PCD Tipped at small depth and high speeds very steep walls of softer material. For carbon milling and feed rates. with longer tool BDS Flat Bottom Insert life. Precision ground, non- VBD Small MB Ball Nose Insert chipbreaker. Unique Back Draft Insert Unique cutting edge allows crossover design Used for semi and performance in all operations in between flat bottom finish-milling small material below 42 HRc; FB and back draft radius or detail work, Toroid in semi, & finishing BD inserts. Allows and surface milling in operations above. straight walls with soft and hard steel, Significant a larger step down than BD, but cast iron, aerospace TO Toroid Bull Nose Insert benefits in chip less cutting forces than FB; allows and non-ferrous Precision ground, large corner evacuation. Insert higher cutting speeds and feed alloys, aluminum radius & back taper for spiral geometry allows alloys, graphite, etc. Suitable for and pocket smoother cutting high speed and hard milling. milling, motion-diminishing heat build up FB-R Flat Bottom Insert milling of & tool deflection, reduces vibration Precision ground, pre-hard and caused by cutting action. with positive ground BD-N Back Draft Insert hardened Precision ground, non- chipbreaker. Flat flat surfaces chipbreaker and 7 bottom insert for at higher VRBS Small Ball Nose Insert degree backtaper. shoulder milling, speeds than Used for semi and finish-milling Used for milling fillet finishing tools with small radius or detail work, of cores, cavities, and long reach smaller corner radii. Good choice and surface milling in soft fillets with straight angular wall for HS milling of Aluminum and hard steel, cast iron, finishing of softer materials or very steep walls aerospace and non- of harder material. ferrous alloys, graphite, etc. Suitable for high HF (High Feed) Inserts speed and hard milling. Millstar’s new HF insert is TOBD-NF Back Draft Inserts designed for High for Non-Ferrous Materials RB-N Ball Nose Insert Speed and High Feed Millstar’s new TOBD-NF insert machining. The is specifically designed for Precision ground, non- HF is designed to high speed and high feed chipbreaker. Best choice run at high cutting roughing of Aluminum, for cavity, core and speeds and feed but also has the profile milling of rates with shallow versatility to be used for pre-hard and depth of cut. The fine finishing as well. This unique fully hard die/ NEW curved cutting edge design allows the mold steels, cast geometry allows the chip to flow chips to flow freely up the flute steels and cast up and out of the cut quickly and allowing higher speeds and feeds. iron. Strongest smoothly allowing for the use of The TOBD-NF comes in diameters cutting edge design. heavy chip loads. The geometry from 1/2 inch (12mm) up to 1 inch of the new HF insert generates (25mm) and fits into our standard RBT Insert cutting forces upward, toward flat type tool holders making the Precision ground for the spindle, which helps eliminate holders more versatile than ever. semi-finish and vibration and deflection, allowing finish milling. for very high chip loads. The HF Excellent choice insert is designed to fit into Metric for unattended Millstar’s standard flat holders, Insert Overview finish milling at style 4 (CYF, TAF and CBCYF) small depth and making these holders more high speed and feed versatile than ever. rates. Page 3 33 Holder Overview Indexable Milling Holder Identification System Tool Body Measurement Denotes Diameter System Shank Material Shank Type Size Length Diameter Imperial CB SFCY 0500 - 6.0 - 0500 Metric CB SFCY 12 - 150 - 12 Imperial = Imperial = SFCY = Cylindrical Hundredths Imperial = Hundredths Inches CY = Cylindrical of an Inch of an Inch “CB” = Carbide Spike “ ” = Steel SFTA = Taper Metric = Metric = Millimeters Metric = TA = Taper Spike Millimeters Millimeters Holder Overview Holder Overview 4 The Tool Holders Cylindrical and tapered toolholders include • Minimized cutter run out – improved the longest reach profiling tools available milling results in soft to fully hardened Button Cutter as standard catalog items. Tool holders (to 65 HRc) materials. High Performance Milling from Heavy are inherently balanced for high spindle • Smaller shank to cutter diameter – Roughing to Fine Finishing. speeds. Machine with confidence at the several sizes have full-length side increased speeds and velocities dictated clearance to machine straight walls. by modern high velocity machining. Super Millstar face mills are equally useful • Safe high speed milling – highest tool on newer high velocity machines and intelligent machine controls with high stiffness and least deflection when speed data transfer, rapid advances in older slower equipment and will optimize compared with steel and heavy metal milling performance of all your machine cutting edge materials and coating tool shanks result in process reliability technologies enable ever faster machining tools. The hardened tool bodies can be and highest safety for operator run at aggressive spindle speed and feed speeds and increased productivity. and machine. Millstar tools are designed to keep pace. rates, when used with Millstar’s precision • Shank diameters (h6) – all tool shanks ground, strong and thick, round inserts are heat shrink-fit tool adapter compatible. with proven hard, high performance TLN Carbide Long Reach or HSN tool coating. Long Reach + Stiffness = High Speed Precision Milling MILLSTAR® Solid Carbide The tools provide for precision finish Long Reach Tool Shanks and Precision results, minimal tool deflection and Profile Milling Inserts are designed for run-out. Excellent milling results can aggressive and high speed milling of a wide be achieved in roughing, semi finishing variety of materials. They provide the perfect and fine finishing in Z-level, profiling or solution for difficult milling operations in raster cuts, as well as in linear or circular die and mold making, aerospace and many interpolation milling or ramping.
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