Workhorse for Rough Machining Operations ! Application Range of Roughing Series

Tungaloy Report No. 415-US

Shoulder milling cutter NEW

Workhorse for rough machining operations ! Application range of roughing series

High

ø2.000" ~ ø2.500"

Machine and work rigidity ø1.000" ~ ø2.000"

ø.750" ~ ø1.000" Low

Light machining Heavy machining

Suitable for roughing operations on BT40 spindle taper machines

Optimum edge position prevents Comparison of metal removal rate chatter Optimum cutter design allows High helix angle distributes and reduces the load high productivity with large for smoother cutting depth of cut 6 Best solution for preventing chip Improved recutting 5 by 33%! • Small inserts create small chips 4

• Through tool air blast blows chips from the /min)

3 3 cutting area

Q (in 2

Metal removal rate Metal removal 1

0 Proven insert from Competitor A standard range ELD05R075U0075W021 2 • 4 cornered insert offers Condition Competitor 1 higher operating proﬁ t Work material 1055 • Positive rake chipbreakers Tool diameter øDc (in) .750 4 Effective number of cutting edge line 23 MJ: for general purpose Cutting speed Vc (sfm) 490 3 including exotic material Feed per edge line fz (ipt) .004 AJ: for machining of Depth of cut ap (in) .8 .4 aluminum Width of cut ae (in) .3 Machine Vertical M/C CAT40

2 Versatile cutters for various work materials

Optimized angular positioning Comparison of metal removal rate prevents chatter Higher number of ﬂ utes guarantees high productivity Cutters with high insert density 15 delivers higher productivity Improved 12 by 50%!

Air blast through tool blows off 9 /min) chips 3 6 Q (in

Metal removal rate Metal removal 3 Proven insert from 0 standard range Competitor A • Suitable for roughing ELS11R125U0125W03 operation of various Condition Competitor materials Work material 1055 • Tough cutting edge and low Tool diameter øDc (in) 1.250 cutting force chipbreakers Effective number of cutting edge line 3 2 Cutting speed Vc (sfm) 330 MJ: for general purpose Feed per edge line fz (ipt) .006 MS: for stainless steel and Depth of cut ap (in) 1.25 exotic material machining Width of cut ae (in) .55 AJ: for machining of Machine Vertical M/C CAT50 aluminum

New solution for roughing operations on large machines

Tangential insert with tough Comparison of metal removal rate edge allows high feed Tough cutting edges provide stable machining even in heavy machining roughing operations

Highly rigid body, suitable for 50 Improved heavy machining 40 by 40%! • Large core thickness increases body 30

rigidity /min) 3 20

Air blast through tool to blow Q (in

off chips rate Metal removal 10

0 4 Competitor A Proven insert from 1 TLM11R200U0075A03 standard range Condition Competitor • 4 cornered insert offers Work material 1055 3 higher operating proﬁ t Tool diameter øDc (in) 2 2 Effective number of cutting edge line 34 Cutting speed Vc (sfm) 330 Feed per edge line fz (ipt) .008 Depth of cut ap (in) 2 1.6 Width of cut ae (in) 1.2 .8 Machine Vertical M/C CAT50

3 Cutters c s D D ø ø

90° 0D[ap Replacement parts Lf Rs Description Cat. No. L Clamping screw CSPB-2L043 Shank type Wrench IP-6DB No. of eff. Dimensions (in) Weight Air No. of Cat. No. Stock edge Inserts lines øDcøDs rs Lf L Max.ap (Ib) hole inserts ELD05R075U0075W02 ᭹ 2 .750 .750 2.031 1.219 3.250 .800 .33 with 10 SDMT050204PN-MJ ELD05R100U0100W03 ᭹ 3 1.000 1.000 2.250 1.500 3.750 .969 .69 with 18 SDHT050204FN-AJ

Inserts A T

rε

Grades Dimensions (in) Cat. No. Accuracy Honing Coated Carbide Cutters AH725 AH140 TH10 ATrε SDMT050204PN-MJ M with ᭹᭹ .200 .094 .016 ELD05… SDHT050204FN-AJ H without ᭹ .200 .094 .016

Standard cutting conditions Brinell hardness Cutting Speed Feed per tooth Work material Grades HB Vc (sfm) fz (ipt) Low carbon steels (1015 etc.) < 200 330 - 820

High carbon steels (1045 etc.) 200 - 300 .0015 - .004 AH725 330 - 660 Alloyed steels (4140 etc.) 150 - 300

Tool steels (W1-8 etc.) < 300 330 - 430 .0012 - .0035

Stainless steels (304 etc.) − AH140 300 - 490 .0012 - .0035

Gray cast irons (No35B etc.) 330 - 820 .002 - .005 150 - 250 AH725 Ductile cast irons (60-40-18 etc.) 260 - 660 .002 - .005

Aluminum alloys (Si < 13%) − 660 - 1650 TH10 .002 - .006 Aluminum alloys (Si ≥ 13%) − 330 - 660

᭹ : Stocked items 4 øDb Cutters ød s a c ø D ø D

Bore type b Shank type

R ap ˚ Lf Rs L f L Replacement parts a p Description Cat. No. Cutter TLS11R... ELS11R... Clamping screw CSPB-2.5 Wrench IP-8D øDc 90º Bore type Center bolt CM10X40H - No. of eff. Dimensions (in) Weight Air No. of Cat. No. Stock edge lines Max. Inserts øDcøDbød r Lf baap (Ib) hole inserts TLS11R200U0075A04 ᭹ 4 2.000 1.875 .750 .750 2.356 .197 .315 1.921 1.22 with 20 ASMT11T3..., ASGT11T3... Shank type Dimensions (in) Weight Air No. of Cat. No. Stock No. of eff. Inserts edge lines øDcøDs rs Lf L Max. ap (Ib) hole inserts ELS11R100U0100W02 ᭹ 2 1.000 1.000 2.250 1.500 3.750 1.197 .67 with 6 ASMT11T3… ELS11R125U0125W03 ᭹ 3 1.250 1.250 2.250 2.250 4.500 1.535 1.24 with 12 ASGT11T3… ELS11R150U0125W03 ᭹ 3 1.500 1.250 2.329 2.171 4.500 1.551 1.47 with 12

Inserts

A T A T A T B B B

rў rў rў Fig. 4 MJ Fig. 5 MS Fig. 6 AJ

Grades Dimensions (in) Cat. No. Coated Cermet Carbide Shape Cutters

Honing AH725 AH120 AH130 AH140 T3130 T1115 DS1100 NS740 KS05F ABTrε Accuracy ASMT11T304PDPR-MJ with ᭹᭹ ᭹᭹ ᭹ .016 Fig.4 ASMT11T308PDPR-MJ with ᭹᭹ ᭹᭹ ᭹ .031 Fig.4 ASMT11T312PDPR-MJ with ᭹᭹ ᭹ .047 Fig.4 ASMT11T316PDPR-MJ M with ᭹᭹᭹᭹ .063 Fig.4 ELS11R ASMT11T320PDPR-MJ with ᭹ .457 .264 .146 .079 Fig.4 TLS11R ASMT11T330PDPR-MJ with ᭹ .118 Fig.4 ASMT11T304PDPR-MS with ᭹᭹ .016 Fig.5 ASGT11T304PDFR-AJ with ᭹᭹ .016 Fig.6 G ASGT11T308PDFR-AJ with ᭹᭹ .031 Fig.6 Cautionary point in modifying cutter bodies

R When using inserts with corner radius rε Corner radius rε (in) The dimension of modifying (in) ≥ .079", standard cutter bodies have to be .016 ~ .063 No modiﬁ cation required modiﬁ ed “R”. .079 ~ .118 .080 • From 2nd row onwards, please use insert with rε = .016" or .031".

᭹ : Stocked items

5 Standard cutting conditions Brinell Cutting speed Feed per tooth: fz (ipt) Work material hardness Priority Grade HB Vc (sfm) MJ MS AJ First choice AH725 .004 - .007 - - Low carbon steels < 200 330 - 820 (1010, 1015 etc.) For wear resistance T3130 .004 - .007 - - First choice AH725 .003 - .006 - - High carbon steels and 200 - 300 330 - 660 alloy steels (1045, 4140 etc.) For wear resistance T3130 .003 - .006 - - First choice AH725 .003 - .006 - - 150 - 300 330 - 490 Tool steels (H13 etc.) For wear resistance T3130 .003 - .006 - - Stainless steels (304,316 etc.) --AH130 330 - 490 - .003 - .006 - Gray cast irons First choice AH120 .004 - .007 - - 150 - 250 330 - 820 (No.250B, No.300B etc.) For wear resistance T1115 .004 - .007 - - First choice AH120 .004 - .007 - - Ductile cast irons 150 - 250 260 - 660 (65-45-12, 80-55-06 etc.) For wear resistance T1115 .004 - .007 - - Aluminum alloys (Si < 13%) - - DS1100 660 - 1650 - - .002 - .007

Aluminum alloys (Si ≥ 13%) --DS1100 330 - 660 - - .002 - .007

Titanium alloys - - AH130 60 - 200 - .003 - .006 - (Ti-6AI-4V etc) Nickel-based alloys --AH725 60 - 130 .003 - .005 - - (Inconel718 etc.)

øDb Cutters ød a b R

Replacement parts Description Cat. No. a p f

L Applicable cutter TLM11R200… TLM11R250… Clamping screw CSTB-3.5L110 Torx bit BT15S Grip H-TB Wrench Mono block type substitution wrench T-15T Bore type øDc 90º Center bolt SD06-A2 SD08-52 No. of eff. Dimensions (in) No. of Stock Weight Cat. No. edge Max. Air holeinserts Inserts lines øDcøDbød r Lf baap (lb) TLM11R200U0075A03 ᭹ 3 2.000 1.850 .750 .750 2.750 0.157 .315 2.323 1.85 with 21 LMMU1107** TLM11R250U0100A04 ᭹ 4 2.500 2.323 1.000 .750 3.250 0.197 .374 2.654 3.33 with 32

T B Inserts

rε

Stock Dimensions (in) Cat. No. Accuracy Honing Coated grades Cutters AH725 T3130 AH140 AH120 T1115 ABTrε LMMU110708PNER-MJ M with ᭹᭹᭹᭹᭹.413 .280 .461 .031 LMMU110716PNER-MJ M with ᭹᭹᭹᭹᭹.413 .280 .453 .063 TLM11… LMMU110724PNER-MJ M with ᭹᭹᭹᭹᭹.413 .280 .445 .094 LMMU110732PNER-MJ M with ᭹᭹᭹᭹᭹.413 .280 .437 .125 ᭹ : Stocked items 6 Standard cutting conditions Brinell Work material hardness Priority Grade Cutting speed Feed per tooth HB Vc (sfm) fz (ipt) First choice AH725 330 - 820 Low carbon steels < 200 AH140 260 - 590 .004 - .009 (1010, 1015 etc.) Priority for impact resistance Priority for wear resistance T3130 330 - 820 First choice AH725 330 - 660 High carbon steels 200 - 300 Priority for impact resistance AH140 260 - 490 .003 - .008 (1045, 1055 etc.) Priority for wear resistance T3130 330 - 660 First choice AH725 330 - 660 Alloy steels 150 - 300 AH140 260 - 490 .003 - .008 (4140, 5120 etc.) Priority for impact resistance Priority for wear resistance T3130 330 - 660 First choice AH725 330 - 490 Tool steels < 300 AH140 260 - 390 .003 - .008 (D-2, M3-1 etc.) Priority for impact resistance Priority for wear resistance T3130 330 - 490 Stainless steels (304, 316 etc.) - First choice AH140 300 - 490 .003 - .008 Gray cast irons First choice AH120 330 - 820 .004 - .010 (No.250B etc.) Priority for wear resistance T1115 150 - 250 First choice AH120 Ductile cast irons 260 - 660 .004 - .010 (65-45-12 etc.) Priority for wear resistance T1115 Super alloys (Inconel718, Ti-6AL-4V etc.) - First choice AH725 70 - 160 .002 - .006 • From 2nd row onwards, please use insert withrε = .031" Practical examples

Work piece type Cover of machine Machine part Cutter ELD05R075U0075W02 (ø.75", z = 2) TLS11R200U0075A04 (ø.2", z = 4) Insert SDMT050204PN-MJ ASMT11T308PDPR-MJ Grade AH725 AH725 4140 Low carbon steel

.4" Work material

1.575" Cutting speed: Vc (sfm) 330 490 Feed per tooth: fz (ipt) .003 .007 Feed speed: Vf (in/min) 10 26.2 Depth of cut: ap (in) .4 1.575 Width of cut: ae (in) .24 × 3 passes .2 Method of machining Shoulder milling Shoulder milling Coolant Wet Dry Cutting conditions Machine Flexible machine BT40 Vertical M/C CAT50 2.5 5

2.0 Machining 4

time ) Productivity 1.5 reduced 3 1.3 times! /min 3 (min) 1.0 20%! 2 in (

Results 0.5 Q 1 Machining time

0 rate Metal removal 0 Competitor Competitor Higher productivity achieved than with competitor TungRec can machine at a 30% higher table speed solid end mills. Reduction of inventory with the with no chatter, even when machining on machine reduction of regrinding costs. tools and components with low rigidity levels.

7 Work piece type Power generator part Base of machine Cutter TLS11R200U0075A04 (ø2", z = 4) TLM11R200U0075A03 (ø2", z = 3) Insert ASMT11T308PDPR-MJ LMMU110708PNER-MJ Grade AH725 AH120 Inconel 718 No.250B

1.6" Work material 1.65"

Cutting speed: Vc (sfm) 100 490 Feed per tooth: fz (ipt) .003 .008 Feed speed: Vf (in/min) 2.3 22 Depth of cut: ap (in) 1.65 1.6 Width of cut: ae (in) .080 .8 Method of machining Shoulder milling Shoulder milling Coolant Wet Dry Cutting conditions Machine Horizontal M/C CAT50 Vertical M/C CAT50

160 140 Machining 30 120 time ) Productivity 100 25

reduced /min 20 80 3 1.6 times!

(min) %! 15

60 60 cm

40 ( 10

Results Q

Machining time 20 5

0 rate Metal removal 0 Competitor Competitor Machining with large depth of cut with TungRec can TecMill allows more stable machining drastically reduce machining time. Achieves stable tool without chipping on the cutting edges, this improves life due to no chipping on cutting edges. productivity by 60%.

3726 N Ventura Drive, Arlington Heights, IL 60004, U.S.A. Phone: +1-888-554-8394 Fax: +1-888-554-8392 Tungaloy Canada 432 Elgin St. Unit 3, Brantford, Ontario N3S 7P7, Canada Distributed by: Phone: +1-519-758-5779 Fax: +1-519-758-5791 Tungaloy de Mexico S.A. C Los Arellano 113, Parque Industrial Siglo XXI Aguascalientes, AGS, Mexico 20290 Phone:+52-449-929-5410 Fax:+52-449-929-5411 www.tungaloyamerica.com Scan for instant web access Jan. 2013 (TJ)