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Milling products – in one book!

We have the BEST tool – no matter what your Milling
application, workpiece, or equipment – to reduce your
machining time, while providing you superior surface
finishes!

Kennametal‘s newest easy selection
guide system guarantees you:
Ř 1st choice milling solution for your application.

Ř 1st choice cutting conditions for your application.

Ř Milling process optimization for improved productivity.

Ř Most importantly, the benefits of maintaining constant
mean chip thickness (hm), especially for applications
involving radial engagements (AE) less than 50% of the
cutter diameter (D1).

Ř Kennametal your proven productivity booster.

THINK MILLING, THINK KENNAMETAL.

Indexable Milling – New Product Highlights NEW! TM Dodeka Best in class in face milling. Get consistent. circular and helical interpolation. Boost your productivity with 12 cutting edges per insert! Provides smooth cutting action! TM Mill 1 Boost your performance to the top. Improved stability with consistent performance and reliability. One tool for face and shoulder milling. 18 mm and 25 mm axial depth of cut! TM KSCM Precise. Excellent Tool Life and surface finishes! TM KDMB 1st choice for Die & Mold. measurable performance at high speeds – and long tool life! 4 . easy & productive solution for Aluminum milling. ramping and 3D-milling. Available in 14 mm.

Harvi style Prevent chip packing.ideal for cast and ductile iron! TM KSSM Helical Cutter . Indexable Milling Highlights TM KenFEED Reach feed rates of .118" per tooth! TM KSSM Slotting Cutters Perform right-hand.PERFECT Finisher PERFECT surface for finishing and reduced cycle time! 5 . left-hand. with unique helical design! TM KSSR Increased productivity and higher metal removal rates due to optimum cutter density! FIX . and full slotting with one cutter! TM HexaCut Achieve unbeatable efficiency and surface finish with 12 cutting edges . reduce harmonics.

178" Page 218 Dia: 2.12.00" 6 .00" Page 214 Dia: 2.00" .00" Page 268 Dia: 3.Application Selection Steps – Choose the right cutter 1) Choose your application: Ř Face Mills Ř 0° Square Shoulder Ř Die and mold Ř Ceramics Ř Chamfer Mills Ř Slotting Ř Thread milling Face Mills Ř k = 15° Ř k= 0° FIX .6.00" Ř Ř Ř Ř Ř k = 43° Ř Ř Ř Ř k=45° KSOM Mini Dodeka KSHR NEW! 8 cutting edges NEW! 12 cutting edges AP1 = .354" (4 cutting edges) AP1 = 0.00" .00" .6.138" (8 cutting edges) AP2 = .PERFECT Finisher KSCM PCD Shell Mills Cast Iron 4 cutting edges NEW! 1 cutting edges AP1 = 0.8.118" Page 246 Dia: 4.04" AP1 = .00" .

Application Selection Steps – Choose the right cutter Ř Ř k = 6° Ř k=20° KSSR FIX .Cast Iron KSSM 45° 12 cutting edges 4 cutting edges AP1 = . 7 .12.30" milling book 6050 Inch on page 76-79.275" (4 cutting edges) Page 264 Dia: 2.PERFECT 70° IC 12 8 cutting edges Cast Iron 8 cutting edges AP1 = .6.10.87" Ř Ř Ř Ř Ř k = 15° P = Steel KSSM 15° 4 cutting edges M = Stainless Steel K = Cast Iron N = Non-Ferrous Materials S = High-Temp Alloys H = Hardened Materials Please find entire application AP1 = .10.50" .213" (8 cutting edges) AP1 = .00" Page 238 Dia: 2.15" .15" .260" Page 250 Dia: 3.7.26" .00" Ř k = 45° Ř Ř Ř Ř Ř k=45° HexaCut 45° .200" AP2 = .00" Page 230 Dia: 1.00" .256" AP1 = .314" Consult selection guide in the new Page 234 Dia: 3.

Tools that become before the selected AP1 value in that Application section are not applicable to your operation.6.178" 3) Find the Appropriate Application and AP1: Example: Face milling and .Application Selection Steps – Choose the right cutter 2) Choose the depth of cut (AP1): Ř Example . Any tool located after selected AP1 value in that application section is suitable for your operation.178" AP1.26" . Material grid Approach angle Ř Ř Ř Ř k = 45° Dodeka KSHR NEW! 12 cutting edges Max depth AP1 = .00" Link to catalog 6050 Inch with all details Available Standard offering 8 .178" of cut Page 214 Dia: 1. 4) Choose the Material: Each tool has a material grid marked with a solid dot for appropriate for that tool.

000 6.178 1.000 3326924 KSHR300HN5345C4 6 1.250 4.Right Hand .431 3.219" . 2) Find the (hm) value in the chart. This will help you in defining the feed rate per to tooth. 4) Determine the insert grade.006" ŘŘŘ 9 .500 5. How to Determine Speeds and Feeds STEP 1: Choose the Milling Cutter NEW! TM Dodeka Shell Mills . The black dot in the material grid indicates first-choice grades of machining those materials.000 3326850 KSHR200HN5345C3 4 .570 .750 .178 2. Max RPM 2.047" .433 2.722 1.000 3326930 KSHR600HN5345C8 12 2.000 3326928 KSHR500HN5345C6 10 1.Coarse Pitch D1 order number catalog number Z D D1max D6 L Ap1max lbs. 3) Determine the workpiece material.750 .432 4.432 2.178 1.380 .722 2.652 2.625" S . See pages 516-520 of catalog 6050 Inch for material descriptions.570 .79 8300 4.81 12500 2.93 6300 5.000 3.000 3326926 KSHR400HN5345C5 8 1.750 2.219" L10 .178 5.178 .10 4100 STEP 2: Choose the Inserts 1) Choose the insert style.593 1.94 5000 6.178 9. H S ŘŘ 3 N K Ř Ř M ŘŘ P Ř Ř KC520M KC522M KC725M KC915M KC935M 2 4 1 catalog number HNGJ535ANENLD cutting edges 12 D .189 1.338" .380 .933 1.500 3326852 KSHR250HN5345C3 6 .434 1.32 10000 3.986 1.338" Rε .047" hm .750 2.625" .004" ŘŘŘŘŘ HNGJ535ANSNGD 12 .

The bold-type value that corresponds to the material on the left is your starting sfm value. 3) To determine the sfm for the chosen grade. 2) Choose the grade.How to Determine Speeds and Feeds STEP 3: Determine the Cutting Speed 1) Choose the material group. go to the bold-type center column for that grade. Recommended Starting Speeds (sfm) 45° approach angle Material Group KC520M KC522M KC725M KC915M KC935M P1 1030 900 840 1550 1360 1260 P2 640 580 520 960 960 780 P3 580 520 470 860 780 710 P4 380 360 320 430 400 360 650 600 540 P5 530 480 430 590 530 480 890 790 720 P6 320 280 360 310 540 470 M1 600 530 490 670 590 540 1010 890 820 M2 550 490 460 610 550 500 920 830 760 M3 410 370 460 410 680 610 K1 1060 960 850 650 590 530 1440 1310 1310 1010 910 820 K2 830 740 700 800 720 660 520 460 430 1140 1020 950 800 720 660 K3 700 620 560 670 600 550 430 380 350 960 850 780 670 600 550 N1 N2 S1 130 110 140 120 S2 110 110 120 120 S3 140 140 160 160 S4 180 170 200 180 H1 10 . 4) Move down the bold-type column until you reach the value that is directly in line with the appropriate material in the first column on the left. These are first-choice recommended starting speeds.

How to Determine Speeds and Feeds STEP 4: Determine the Feed Rate 1) Choose the (hm) value in the feed chart that matches the (hm) value in the insert chart you selected in Step1. 2) Define the radial width of cut as a percentage. To determine this. divide the radial width by the cutter diameter to achieve the percentage of the engagement. Recommended Starting Feeds Programmed Feed Rate fz (Inch) 45° Approach Angel Feed-Per-Tooth Compensation (Radial Width-of-Cut Dependent) Percentage of the Cutter Diameter in Cut 11 .

Influence of radial cutter engagement (0° lead angle – Mill 1-14) Radial Width of Cut Ae Constant feed rate fz Average chip thickness hm 100% fz Full = Slot hm Milling 50% fz hm1 20% fz hm2 10% fz hm3 Radial cutter engagement fz = constant less then 50%. Tool life hm > hm1> hm2 > hm3 Surface quality Chip forming Productivity 12 .

006" + Tool life fz compensation for 20% radial engagement (Ae) + Surface quality Increase fz to fz2 = .013" = 215% + Productivity booster fz compensation for 10% radial engagement (Ae) Increase fz to fz3 = .006" to .006" to .019" = 315% 13 . Influence of radial cutter engagement (0° lead angle – Mill 1-14) Radial Width of Cut Ae Constant average chip Feed rate fz thickness hm 100% fz Full = Slot hm Milling 50% fz1 hm 20% fz2 hm 10% fz3 hm hm = constant BEST fz < fz1 < fz2 < fz3 SOLUTION Assume that the chip thickness value is .

KC935M. 2) Inserts with tolerance class G.K.Insert edge preps Finishing Semi-roughing Roughing F – edge prep E – edge prep S – edge prep Small Sharp Hone „T“land + Hone E – edge prep T – edge prep Small Small Hone „T“land S – edge prep Small „T“land + Hone Periphery ground inserts 1) 1st choice for finishing. 3) For example: Insert catalog number OFKT53AFEN4GB.H are periphery ground. KC725M. Pressed and sintered to size inserts (PSTS) 1) 1st choice for semi-roughing and roughing applications. 3) For example: Insert catalog number EP1408EHD. high precision applications and machining of non ferrous materials.C. 14 . 2) Inserts with tolerance class P are pressed and sintered to size (PSTS or molded).

002" SDET43.004" SNXF43...002" EC1408EGD ...ER8LD2 .SN4HB .FJ ..EHD .002" SNXF43.005" EP18.E .006" SPHX12.. EN4GB ...002" OFKT53.SNGD ..002" 291 Mill 1-18 EP18..E ..004" 219 KSOM Mini OFKT53.008" 265 KSSR SNXF43....008" OFKT53.003" SDPT43.SR8GN .006" SDCT43..005" EC18.004" OFPT53...ENLD .SN6LB ...SN4HB .002" SDET43.003" SDCT43.008" OFKT53..004" HNGJ53..FR8LE ....003" EC18..005" EC18.ENLD2 .003" KSCMCA75HR ..004" 368 KSSM Slotters SDPT43...005" EP18.SRGPB .004" SDCW43...002" SDPT43...SR8GB2 ..ER8GB2 .008" OFKT53. 15 ...002" OFPT53.004" SPHX12.TRGPBK .ENLD .SNHE ....EN6LB ....SR8GB2 .004" SDET43..ER8GB2 .SNGP .TRGPB ..SR8GB2 .SR8GN .003" KSCMCA75UN EC1408FLDJ .ERGPB ..006" HNGJ53.003" SDCT43.005" Ensure always that the feedrate (fz) is higher than the edge prep.SR8GB2 .004" 329 Fix Perfect 90° SPHX12.SNHD ...S ..ER8GB2 .EN4GB ..... Recommended starting hm-values Finishing Semi-roughing Roughing Page Milling Platform hm hm hm 215 Dodeka HNGJ53.004" 318 KSSM 90° SDPT43..AFFN4LNJ .003" SDCT43....ER8GB2 .FR8LE .003" 269 KSCM AluMill KSCMCA75QF .003" EP1408EHD .005" 285 Mill 1-14 EC1408ELD .003" SPHX12.005" SDCW43.004" SDET43.004" KSCMCA75UN .003" KSCMCA90UN .002" EP1408SGD .E .

00" fz = hm Řfz = .16"/min Refer to Catalog 6050 for lead angle compensation on Feed Per Tooth (fz) Page 289 of the Inch milling catalog. 16 .Milling Strategy Full width cutting with 100% radial engagement (0° lead angle) Ae = 100% of D1  Ř Material 1045 (P2) Ř ŘMID300E14085100L175 (Mill 1-14) ŘEP1408SGD KC935M ŘDiameter (D1) = 3.006 x 8 x 920 = 44.006" (according feed chart for 100% radial engagement (Ae) and lead angle compensation for 90°) ŘFeedrate (Vf) = Feed Per Tooth (fz) x Number of Teeth (Z) x Spindle Speed (n) Vf = .00" ŘNumber of teeth (Z) = 8 ŘAverage Chip Thickness (hm)= .006" ŘCutting Speed (Vc) = 720 sfm ŘSpindle Speed (n) = 920 rpm ŘAxial Depth of cut (Ap1) = .390" ŘRadial Width of Cut (Ae) = 2.

006" ŘVf = fz x Z x n fz = .84"/min Example: 13% radial width of cut in contact with the workpiece.006 x 8 x 920 ŘVf = fz x Z x n = 44.315" Without feedrate (fz) compensation With feedrate (fz) compensation ŘSince no compensation is considered. the feed per ŘAccording to the feed chart for 10% radial engage- tooth (fz) does not vary with the radial engagement ment (Ae) and a lead angle compensation for 90° (Ae). (refer 6050 catalog). For calculation purposes use 15% 316% Time savings to get the new feed rate per tooth.019" x 8 x 920 = 139. 17 .006" Řhm = .16"/min Vf = . Milling Strategy Partial width cutting with 10% radial engagement (0° lead angle) Ae = 10% of D1  Ř Material 1045 (P2) Ř ŘMID300E14085100L175 (Mill 1-14) ŘEDPT1EDPT1408SGD KC935M ŘDiameter (D1) = 3.00" ŘNumber of teeth (Z) = 8 ŘAverage Chip Thickness (hm)= .006" ŘCutting Speed (Vc) = 720 sfm ŘSpindle Speed (n) = 920 rpm ŘAxial OPTIMUM Depth of cut (Ap1) = . fz = Constant hm = Constant fz fz hm hm Řfz= .019" Vf = .390" SOLUTION ŘRadial Depth of Cut (Ae) = .

ŘFeedrate (Vf) = Feed Per Tooth (fz) x Number of Teeth (Z) x Spindle Speed (n) Vf = .008" (according feed chart for 80% radial engagement (Ae) and lead angle compensation for 45°) Anything above 50% radial engagement.170" ŘRadial Depth of Cut (Ae)= 3.006" ŘCutting Speed (Vc) = 1310 sfm ŘSpindle Speed (n) = 1250 rpm ŘAxial Depth of cut (Ap1) = .120" fz hm Řfz = .008 x 8 x 1250 = 80"/min 18 .Milling Strategy Cutting with 80% radial engagement (45° lead angle) TM Dodeka Ae = 80% of D1  Ř Material Class 35 Cast Iron (K1) Ř ŘKSHR400HN5345C5 (Dodeka) ŘHNGJ535ANSNGD KC915M ŘDiameter (D1) = 4"  ŘNumber of teeth (Z) = 8 ŘAverage Chip Thickness (hm) = . always use the 100% engagement value.

170" OPTIMUM SOLUTION ŘRadial Depth of Cut (Ae) = 1.008 x 8 x 1250 ŘVf = fz x Z x n = 80"/min Vf = .015" Vf = . fz = Constant hm = Constant fz fz hm hm Řfz = .015 x 8 x 1250 = 150"/min 187% Time savings 19 . the feed per tooth (fz) does not vary with ment (Ae) and a lead angle compensation for 45° the radial engagement (Ae).008" Řhm = .006" ŘVf = fz x Z x n fz = . Milling Strategy Partial width cutting with 30% radial cutter engagement (45° lead angle) TM Dodeka Ae = 30% of D1  Ř Material Class 35 Cast Iron (K1) Ř ŘKSHR400HN5345C5 (Dodeka) ŘHNGJ535ANSNGD KC915M ŘDiameter (D1) = 4" ŘNumber of teeth (Z) = 8 ŘAverage Chip Thickness (hm) = .2" Without feedrate (fz) compensation With feedrate (fz) compensation ŘSince only lead angle (k) compensation is consi. (refer 6050 catalog). Ř According to the feed chart for 30% radial engage- dered.006" ŘCutting Speed (Vc) = 1310 sfm ŘSpindle Speed (n) = 1250 rpm ŘAxial Depth of cut (Ap1) = .

stainless steel. TM HARVI Solid Carbide Endmills ŘUnequal flute spacing delivers smooth. cast iron. and high- temp alloys! THINK MILLING. chatter-free machining! ŘYields superior surface finishes. even at high speed! ŘRougher and finisher in one tool! ŘEasy to regrind! ŘMaximize performance in steel. THINK KENNAMETAL. .

.. Ř Plain and weldon shank... general engineering. 21 . Catalog 6050 Inch: Product Page 28 Application Data 44 Operations Ř Side cutting. and automotive applications. 1/2" to 1" ∅ Features Ř Factory standard. Application Data 44 Operations Ř Side cutting. slotting and ramping. Ř Sharp and Corner chamfer - Catalog 6050 Inch: Product Page 30 center cutting. medical. P M K N S H Features ŘŘŘ Ř 1/8" to 1" ∅ Ř Plain and weldon shank. Ř For aerospace and medical. slotting and ramping. Ř For aerospace. slotting and ramping. Ř For aerospace and automotive applications. Ř Weldon shannk. Catalog 6050 Inch: Product Page 29 Application Data 44 Ř Sharp and Corner chamfer - center cutting. Ř Sharp and Corner chamfer - center cutting. Solid Carbide / End Mills Highlights HARVI Square End Finishers HPHV. HPHVT – HARVI FOR TITANIUM P M K N S H Features Ř 1/2" to 1" ∅ Ř Factory standard. Operations Ř Side cutting. HARVI Long Reach Finishers P M K N S H ŘŘŘ Ř HPRSHV.

and 3-dimensional milling.Solid Carbide / End Mills Highlights HARVI Ball Nose Finishers HPHUBN. 22 . P M K N S H Features ŘŘŘ Ř 1/8" to 1" ∅ Ř Factory standard. Ř Ball nose. Catalog 6050 Inch: Product Page 64 Application Data 70 Operations Ř Side cutting.. slotting. Ř For general engineering. Ř Plain and weldon shank.. aerospace applications and medical.

. SQ milling Slotting Ř [7473] 1) Workpiece Material (S) 2) Type of Application (Slotting) 3) Diameter (Ø 10) 4) No.first choice See Page .125-1.000 4 38 CH.500-1..000 4 38 CH.500-1.alternative Range of choice Diameter Type Tool (inch) No. Tool selection guide 3 4 5 2 Ř.. SQ milling Slotting ŘŘŘ Ř [3733] Side HPRSHV . of Helix Special Type of Workpiece of Tool Style Min-Max Flutes Angle Features Application Material R-Radius CH-Chamfer N-Neck C-Coolant KW-Keyway 1 Mic-Micro TR-Toriodal SQ-Square End P M K N S H Side HPHV . of Flutes and Helix Angel (4 and 38°) 5) Special Features (Radius) 23 .. SQ milling ŘŘŘ Ř [3751] Side HPHVT .000 4 38 CH.

0 WELDON HPHV625S4125 Ř 5/8 5/8 1 1/4 3 1/2 — WELDON HPHV625S4125CH Ř 3/4 3/4 7/8 3 1/2 .020" 45° 1/4" and larger +. D1 BCH KCH D1 D1 Tolerance D Tolerance ≤ 5/16" .0000" to –.0005" ≥ 3/8" .0 WELDON HPHV1000S4150 Ř 1 1 1 1/2 4 — WELDON HPHV1000S4150CH Ř 1/8 1/8 1/2 2 .. Ř For aerospace.003" +.. medical. Ř Side cutting and slotting.015" 45° < 1/4" +.002" +. Ř Sharp and chamfered corner .0 WELDON HPHV625S4075 Ř 5/8 5/8 3/4 3 — WELDON HPHV625S4075CH Ř 5/8 5/8 1 1/4 3 1/2 .first choice K Ř M Ř . and automotive center cutting.0 PLAIN HPHV312S4075CH Ř 3/8 3/8 7/8 2 1/2 — PLAIN HPHV375S4088 Ř 3/8 3/8 7/8 2 1/2 .0 PLAIN HPHV375S4088CH Ř 1/2 1/2 5/8 2 1/2 — WELDON HPHV500S4063 Ř 1/2 1/2 5/8 2 1/2 .0 PLAIN HPHV250S4075CH Ř 5/16 5/16 3/4 2 1/2 — PLAIN HPHV312S4075 Ř 5/16 5/16 3/4 2 1/2 .0 WELDON HPHV750S4150 Ř 3/4 3/4 1 1/2 4 — WELDON HPHV750S4150CH Ř 24 .0 WELDON HPHV750S4088 Ř 3/4 3/4 7/8 3 1/2 — WELDON HPHV750S4088CH Ř 3/4 3/4 1 1/2 4 .0 WELDON HPHV500S4063CH Ř 1/2 1/2 1 3 — WELDON HPHV500S4100CH Ř 1/2 1/2 1 1/4 3 .000" to –. general engineering.0000" to – .0 WELDON HPHV500S4125 Ř 1/2 1/2 1 1/4 3 — WELDON HPHV500S4125CH Ř 5/8 5/8 3/4 3 .0 PLAIN HPHV125S4050 Ř 1/8 1/8 1/2 2 — PLAIN HPHV125S4050CH Ř 3/16 3/16 5/8 2 1/4 .0 PLAIN HPHV188S4063 Ř 3/16 3/16 5/8 2 1/4 — PLAIN HPHV188S4063CH Ř 1/4 1/4 3/8 2 . applications.0 PLAIN HPHV250S4038CH Ř 1/4 1/4 3/4 2 1/2 — PLAIN HPHV250S4075 Ř 1/4 1/4 3/4 2 1/2 .alternative choice P Ř KC633M D1 D Ap1 max L Rε mounting style catalog number 1 1 1 1/2 4 .Tool selection guide HPHV – Unequal Flute Spacing Features Application Ř Kennametal standard. die and mold. 38° Helix H Ř Chamfer Table S Ř N Ř End Mill Tolerances Ř... Ř Plain and Weldon shanks.000" to – .0005" Ř 4-Flute.

0022 .0016 .0014 .0026 ..0021 .0034 .5XD 1xD 225~275 .0016 . reduce fz by 20%.3XD 65~90 .0014 .0016 .0034 .0022 .0010 .0036 . 304) Austenitic stainless steel M2 1xD 0.0026 .0029 .0010 .0036 .0031 .0034 .0016 .2XD 0.0026 .0040 steels <330HB.5XD 1xD 275~375 .0014 .5XD 1xD 125~200 .0018 .0016 .0014 .0008 .2XD 0.0022 resistant alloys Cobalt based heat S2 1xD 0. KC633M For slotting operations.0014 . 303. Tool selection guide Application data HPHV.0016 .0008 .0036 .0020 .0012 .0012 .0040 <330HB.2XD 0.0040 carbon steels > 0.5XD 1xD 400~500 .0026 .0028 .0008 .0022 .0012 .5XD 135~175 . 316L) Austenitic stainless steel: M3 Duplex (Ferritic and 1xD 0.0020 .0015 .0018 .0020 .0036 (302.0008 .5XD 1xD 200~275 .0004 . <35HRC Austenitic stainless steel M1 1xD 0.Diameter (Inch) Group Material ap ae ap SFM 1/8" 3/16" 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 1" Medium and high P2 1xD 0.0008 .0012 . Side Milling Slotting D1 . 36-48HRC Ferritic.0050 Iron based heat S1 1xD 0.0010 .0010 .0016 .0016 .450HB. Martensitic P5 and PH Stainless steels 1xD 0.0016 .0026 .0031 .0022 resistant alloys Nickel based heat S3 1xD 0.0039 .0020 .0010 .0034 .0004 .0034 Titanium alloys For Material Group Selection see Material Grade Table Page 546-551 (Catalog 6050 Inch).0021 .0034 .0017 .5XD 1xD 425~525 .0036 .0008 .0012 .0010 .0018 .0014 .3% Alloy steels and Tool P3 1xD 0.0031 .0021 .0014 .0031 (316..0031 .0004 .3XD 65~90 .0026 .3XD 0.0014 .0034 .0031 .5XD 1xD 300~400 .0026 .0012 .0004 .0021 .0022 resistant alloys Alpha-Beta S4 1xD 0. Cutting Reduce conditions speed by for: 20% for HPHV slotting applica- tions Recommended fz .0021 .Feed Per Tooth (Inch/th) Application Vc for side cutting operations.0004 .0014 .0016 .0036 340.0014 .0016 .3XD 65~90 .0012 .0026 .0012 . <35HRC Alloy steels and Tool steels P4 1xD 0.0008 .5XD 1xD 500~600 .0020 .0031 Austenitic Mixture) K1 Grey Cast Iron (GG) 1xD 0.0008 .0020 .0012 .0012 . 25 .0022 .

but small plunge depth max. combined machining more efficient Face milling Smaller chip chambers Roughing/finishing With two cutting edges in the center Helical end milling Plunging possible.Technical Notes Number of Cutting Edges Main Application Comment Plunging (drilling) Very suitable for full slot milling. (0.1 x d) Steps Contouring Helical end High form and positioning milling Finishing tolerance. greater dimensional accuracy in feather key slot milling (F2AU … DK30. F3AU … DK30) Full slot (Feather key slot) Better for fill slot milling and helical end milling. feed rates (efficiency) (small ae with increasing Higher ae number of teeth) Poor chip evacuation Chip cahmbers become clogged 26 . Surface quality.

54 0.34 d eff 0.30 0.28 0.25 0.01 0.6 = .917 0. the end mill diameter used to determine speed and feed rate is smaller than the cutting diameter (D1).04 0.03 0.08 0.19 27 .6 Step 4: Effective cutting diameter = .5 = .3" Depth of cut ratio Diameter factor = ap/D1 0.1 Step 3: Diameter factor = . Step 1: Determine the following values from your application: D1 = end mill cutting diameter.05“ axial depth of cut? Step 1: D = 1/2" ap = .15 0. ap = axial depth of cut Step 2: Determine the depth of cut ratio: depth of cut ratio = ap/D1 Step 3: Determine the diameter factor from the table below using the depth of cut ratio from Step 2: Step 4: Calculate the effective cutting diameter (Deff): Deff = D1 multiplied by the diameter factor Example: What is the effective cutting diameter for a 1/2"-diameter ball nose end mill running at a .39 0.20 0.05" Step 2: Depth-of-cut ratio = .6 0.5D1).40 0. This effective cutting diameter can be calculated using a simple 4-step process.44 0. Technical Notes Ball Nose – Effective Cutting Diameter Calculation When the axial depth of cut is less than half of the cutting diamter (ap < .87 0.02 0.10 0.05 0.5 x .71 0.8 0.05/.98 0. This smaller end mill diameter is known as the effective cutting diameter (Deff).

73 = . follow the simple 4-step process. Step 1: Determine the following values from your application: D1 = end mill cutting diameter. ae = radial width of cut fz = desired chipload per tooth at the cutting edge Step 2: Determine the radial width engagement ratio: radial width engagement ratio = ae/D1 Step 3: Determine the chipload factor from the table below using the radial width engagement ratio from Step 2: Step 4: Calculate what the programmed chipload should be to get the desired chipload at the cutting edge: fz programed = fz * chipload factor Example: What is the programmed chipload to achieve a desired chipload of .25 0.05 2.25 1.33 0.Technical Notes Square End – Radial Width of Cut Factor If the radial width of cut (ae) is less than .0 0.1 1.15 1.15 0.1 radial width engagement ratio = 1.73 0.05" fz = .73 Step 4: The programmed chipload = fz x chipload factor = .2 1.500" = .03 2.002" x 1.002"/tooth using a 1/2"-diameter end mill with a radial width of cut of .1 Step 3: Chipload factor for a .500" ae = . To obtain the correct chipload at the cutting edge.002" Step 2: Radial width engagement ratio = ae/D1 = .41 0. the actual chipload at the cutting edge is less than the programmed chipload.05"? Step 1: D1 = .5 x D1.93 0.07 2.05"/.0 28 .1 0.6 0.0034" Radial Width Chip Load Factor Engagement Ratio = ae/D1 0.02 3.01 5.3 1.

Technical Notes Application hints Suggested solutions in solid carbide milling Splintering of the cutting edge Ř Decrease feed per tooth (thermal load) Ř Increase cutting speed Crumbling of the cutting edge Ř Check rigidity of machine. (mechanical load) workpiece. workpiece clamping Ř Reduce feed per tooth Ř Shorten protrude length Ř Climb milling Ř Check tool clamping Ř Check spindle movement Mill breakage Ř Ensure free cutting process Ř Increase cutting speed Ř Reduce feed rate and cutting depth Ř Check tool clamping Ř Shorten protrude length Ř Reduce cutting depth Ř Improve chip evacuation Heavy crater wear Ř Reduce cutting speed Ř Use more wear-resistant carbide grade Heavy flank wear Ř Increase feed per tooth Ř Reduce cutting speed Ř Use coated version Ř Use more wear-resistant carbide grade 29 .

Technical Notes Application hints Suggested solutions in solid carbide milling Edge build-up Ř Increase cutting speed and/or feed rate Ř Improve cooling Vibrations (chatter) Ř Check damping and machine stability Ř Select a different cutting geometry Ř Check alignment of milling cutter and workpiece Ř Climb milling Inadequate surface on Ř Reduce feed per tooth the on the workpiece Ř Check clamping and machine stability Ř Increase cutting speed Ř Select a different cutting geometry with larger twist angel Ř Use milling cutter with more of teeth Splintering on the workpiece Ř Reduce feed per tooth Ř Use milling cutter with more teeth Chip buildup Ř Use tool with larger chip chambers (less teeth) Ř Modify cutting geometry Ř Modify cutting values Ř Reduce cutting depth Ř Use milling cutter with less teeth 30 .

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