Milling

CoroMill 200
Robust facemilling and profiling cutter
A concept for secure roughing
A
Roughing
CoroMill 200 / CoroMill 300
Semi finishing
CoroMill 300 / CoroMill Ball Nose
Finishing
B
CoroMill Plura /
CoroMill Ball Nose Finishing

Pitch:

E L M H

Condition: General

F
Geometries:

-L -M -H 10 12 16 20

G fz
0.05 0.6 mm
Condition: General

H
ISO application areas:

Tool options designed to individual customer

requirements are available.

D 70
 Milling

CoroMill 200 round insert milling cutter

Facemilling for roughing and in difficult conditions.
For facemilling and profiling.

Available as coarse, close and extra close pitch for maximum

performance in different conditions.
Secure insert geometries and grades optimized by application, A
make high removal rates a reality.
Inserts self locating into their seats.
Tough carbide shim for cutter body protection.
Roughing of pockets by ramping or helical interpolation.

Cutter bodies are machined from hardened steel resulting in B

close tolerances and high strength.
Long, consistent and predictable insert life.

Ceramic inserts and CBN inserts for milling cast-iron and hard-
ened steel.
C

Cylindrical shank
Diameter 25 – 160 mm

Arbor
E

F
Effective top rake angle
L: +17° M: +12° H: +5°
l1 = programming length

Operations: More information on the next page

G

Facemilling Shoulder milling Full slot milling Rest milling Profiling H

Helical interpolation Ramping Plunge milling Turn milling

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 Milling

Inserts and grades for CoroMill 200

Cemented carbide/Cermet Ceramic Boron nitride

Light Medium Heavy

A
Four insert sizes available in three geometries covering depths of
M cut up to 10 mm, with a feed range of 0.05 - 0.6 mm/insert.
Medium
Facet on the base of the insert prevent insert movement during
L H the cutting action.
Light Heavy
B
Insert are centre screw located for easy chip evacution and
mounted on carbide shims for good cutter body protection.
General use in
most materials.

C Light machining. Heavy machining.

Low cutting forces. Highest edge security.
Low feed rates. High feed rates.

Cemented carbide/Cermet Ceramic Boron nitride

ISO Insert geometry
L M H

E Steel P
Stainless
fz 0.05 - 0.6 steel M
Feed range, mm/tooth Cast iron K
Non-ferrous
material N
F Heat resistant
material S
Hardened
material H

Basic grades for CoroMill 200

G
Wear resistance

01 P CT530 M K CB50
N S H CB50

Good H13A
10 GC CC
Aluminium / Non-ferrous

6090
Heat resistant and

GC 1025
GC GC GC
Hardened materials

4020 CT
titanium alloys

1025 1025 530 1025

H GC
Stainless steel

20 GC
CT
530 3020
Cast iron

GC GC GC
4030 H13A
Steel

2030 2030 4020

GC GC GC1025
Average 30 SM
30 2040 3040
conditions
GC
40 4040
H10F

Difficult
50

Toughness

D 72
 Milling

Nominal feed values per insert

Cemented carbide/ Cermet
Feed recommendations for insert size 10 (iC)
fz (mm/insert)
ap -PL/-ML/-KL -PM/-MM/-KM/-WM -PH/-KH/-WH
(mm) rec. (min.–max.) rec. (min.–max.) rec. (min.–max.)
0.1 0.40 (0.25–0.60) 0.85 (0.50–1.01) 1.26 (0.50–1.51)
0.5 0.18 (0.11–0.28) 0.39 (0.23–0.46) 0.57 (0.23–0.69)
1 0.13 (0.08–0.20) 0.28 (0.17–0.33) 0.42 (0.17–0.50) A
1.5 0.11 (0.07–0.17) 0.24 (0.14–0.28) 0.35 (0.14–0.42)
2 0.10 (0.06–0.15) 0.21 (0.13–0.25) 0.31 (0.13–0.38)
3 0.09 (0.05–0.13) 0.19 (0.11–0.22) 0.27 (0.11–0.33)
4 0.08 (0.05–0.12) 0.17 (0.10–0.20) 0.26 (0.10–0.31)
5 0.08 (0.05–0.12) 0.17 (0.10–0.20) 0.25 (0.10–0.30)

B
Feed recommendations for insert size 12 (iC)
fz (mm/insert)
ap -PL/-ML/-KL -PM/-MM/-KM/-WM -PH/-KH/-WH
(mm) rec. (min.–max.) rec. (min.–max.) rec. (min.–max.)

0.1 0.44 (0.28–0.66) 0.94 (0.55–1.10) 1.38 (0.55–1.65)

0.5 0.20 (0.13–0.30) 0.43 (0.25–0.50) 0.63 (0.25–0.75) C
1 0.14 (0.09–0.22) 0.31 (0.18–0.36) 0.45 (0.18–0.54)
1.5 0.12 (0.08–0.18) 0.26 (0.15–0.30) 0.38 (0.15–0.45)
2 0.11 (0.07–0.16) 0.23 (0.13–0.27) 0.34 (0.13–0.40)
3 0.09 (0.06–0.14) 0.20 (0.12–0.23) 0.29 (0.12–0.35)
4 0.08 (0.05–0.13) 0.18 (0.11–0.21) 0.27 (0.11–0.32)
5 0.08 (0.05–0.12) 0.17 (0.10–0.20) 0.25 (0.10–0.30)
6 0.08 (0.05–0.12) 0.17 (0.10–0.20) 0.25 (0.10–0.30)
D

Feed recommendations for insert size 16 (iC)

fz (mm/insert)
ap -PL/-ML/-KL -PM/-MM/-KM/-WM -PH/-KH/-WH
(mm) rec. (min.–max.) rec. (min.–max.) rec. (min.–max.)
0.1 0.51 (0.32–0.76) 1.08 (0.63–1.27) 1.59 (0.63–1.90) E
0.5 0.23 (0.14–0.34) 0.49 (0.29–0.57) 0.72 (0.29–0.86)
1 0.17 (0.10–0.25) 0.35 (0.21–0.41) 0.52 (0.21–0.62)
1.5 0.14 (0.09–0.21) 0.29 (0.17–0.34) 0.43 (0.17–0.51)
2 0.12 (0.08–0.18) 0.26 (0.15–0.30) 0.38 (0.15–0.45)
3 0.10 (0.06–0.15) 0.22 (0.13–0.26) 0.32 (0.13–0.38)
4 0.09 (0.06–0.14) 0.20 (0.12–0.23) 0.29 (0.12–0.35)
5 0.09 (0.05–0.13) 0.18 (0.11–0.22) 0.27 (0.11–0.32) F
6 0.08 (0.05–0.12) 0.18 (0.10–0.21) 0.26 (0.10–0.31)
7 0.08 (0.05–0.12) 0.17 (0.10–0.20) 0.25 (0.10–0.30)
8 0.08 (0.05–0.12) 0.17 (0.10–0.20) 0.25 (0.10–0.30)

Ceramic and cubic boron nitride Feed recommendations for insert size 20 (iC)
Insert Grade (min – max) fz (mm/insert) G
fz mm/tooth
ap -PL/-ML/-KL -PM/-MM/-KM/-WM -PH/-KH/-WH
rec. (mm) rec. (min.–max.) rec. (min.–max.) rec. (min.–max.)
RCHT 12 04 M0 CB50 0.14 (0.07 – 0.21) 0.1 0.57 (0.35–0.85) 1.21 (0.71–1.42) 1.77 (0.71–2.13)
RCKT 12 04 M0 6090 0.28 (0.10 – 0.42) 0.5 0.26 (0.16–0.38) 0.54 (0.32–0.64) 0.80 (0.32–0.96)
RCKT 16 06 M0 6090 0.28 (0.10 – 0.42) 1 0.18 (0.11–0.28) 0.39 (0.23–0.46) 0.57 (0.23–0.69)
1.5 0.15 (0.09–0.23) 0.32 (0.19–0.38) 0.47 (0.19–0.57)
2 0.13 (0.08–0.20) 0.28 (0.17–0.33) 0.42 (0.17–0.50) H
3 0.11 (0.07–0.17) 0.24 (0.14–0.28) 0.35 (0.14–0.42)
4 0.10 (0.06–0.15) 0.21 (0.13–0.25) 0.31 (0.13–0.38)
5 0.09 (0.06–0.14) 0.20 (0.12–0.23) 0.29 (0.12–0.35)
6 0.09 (0.05–0.13) 0.19 (0.11–0.22) 0.27 (0.11–0.33)
7 0.08 (0.05–0.13) 0.18 (0.10–0.21) 0.26 (0.10–0.31)
8 0.08 (0.05–0.12) 0.17 (0.10–0.20) 0.26 (0.10–0.31)
Torx Plus screws have been designed to ensure the correct 9 0.08 (0.05–0.12) 0.17 (0.10–0.20) 0.25 (0.10–0.30)
torque value is always obtained. 10 0.08 (0.05–0.12) 0.17 (0.10–0.20) 0.25 (0.10–0.30)

D 73
 Milling

Ramping and helical interpolation – CoroMill 200

lm Hole

tan α ap

ap

A
iC
D3

Ramping Helical interpolation

In penetrating operations ramping is preferred. The maximum By using helical interpolation it is possible to produce a hole in
B ramping angle is dependent on insert size and cutter diameter. a solid workpiece.
The angle α for each cutter is presented in table below. This is a good solution when required to produce large diameter
holes on small machines having limited power availability.

C
Dia. iC = 10 mm — ap ≤ 5 mm iC = 12 mm — ap ≤ 6 mm

Max. ramp Min. dist.1) Hole dia. (mm) Max. ramp Min. dist.1) Hole dia. (mm)
D3 angle α° lm (mm) Min. Max. angle α° lm (mm) Min. Max.
25 13 22 32 38 – – – –
32 – – – – 13 26 42 50
D 40
50
–
–
–
–
–
–
–
–
9.5
6.5
32
49
58
78
66
86
63 – – – – 4.5 68 104 112
80 – – – – 3.5 98 138 146
100 – – – – 2.5 137 178 186

iC = 16 mm — ap ≤ 8 mm iC = 20 mm — ap ≤ 10 mm

Max. ramp Min. dist.1) Hole dia. (mm) Max. ramp Min. dist.1) Hole dia. (mm)
E angle α° lm (mm) Min. Max. angle α° lm (mm) Min. Max.
40 13 35 50 62 – – – –
50 11 35 70 82 13 43 62 78
63 7 48 96 108 11 45 88 104
80 5 70 130 142 7 67 122 138
100 3.5 102 170 182 5 95 162 178
125 2.5 131 220 232 3.5 127 212 228
160 – – – – 2.5 191 282 298

F 1)
Maxmimum α and ap

ae max rec. max rec.

iC ae, mm iC az, mm

10 9 10 2.9
G 12 10.8 12 3.7
16 14.4 16 4.9
20 18 20 6.1

Plunge milling Peck drilling

For long tool overhangs and unstable conditions, plunge milling Pocketing can also be performed to a limited extent, by peck-
H might be the only possible solution. drilling at depths of up to 1.5 mm depending on insert size.

True finishing
0.03
The close diameter tolerance, never on the plus side, allows the tool to be used for true
+0 0.03 finishing operations when copy milling.
–0.2

D 74
 Milling

CoroMill round insert cutter Standard insert:

RCKT 10 T3 ..., max. ap 5 mm
R200 RCKT 12 04 ..., max. ap 6 mm
A
RCKT 16 06 ..., max. ap 8 mm
RCKT 20 06 ..., max. ap 10 mm

Arbor mounting Arbor mounting Arbor mounting

acc. to ISO 6462 acc. to ISO 6462 acc. to ISO 6462 Varilock 50, 63, 80 B

C
Style Dc2 Style Dc2 Style Dc2
A22 50-68 B27 75-100 C40 118.7-250 Dc2 25-125
A27 63-100 B32 80-125 C60 175.3-254
B40 86-160

D
Cylindrical 20, 25, 32

Weldon 20, 25, 32, 40 Morse 02, 03, 04, 05

F
Dc2 =25-50 Dc2 =25-50
Dc2 =25-50

G
Options
Insert size 10, 12, 16, 20 Mounting Cylindrical,Weldon,Morse taper, Arbor mounting,
type Varilock
Dc2 Diameter—25-254 mm
dmm/D5m Mounting size—see above
Dc1 Diameter—15-234 mm
Shim yes or No
l3 Reach length—30-150 mm H
l2 Total length—81-240 mm
Pitch type Even or Differential
l1 Programming length—40-183 mm,
No of inserts 2-16
Coolant For Varilock—l1 max 80 mm
hole

D 75
 Milling

CoroMill 300
Light cutting face and profile milling cutters
Versatile concept for roughing to high
feed semi-finishing
A Roughing
CoroMill 200/CoroMill 300
Semi-finishing
CoroMill 300/CoroMill Ball Nose
Finishing
CoroMill Plura /
B CoroMill Ball Nose Finishing

• High feed semi-finishing

E Extra close pitch version

F Geometries:

Pitch:

G
General

05 07 08 10 12 16 Condition:
Unstable General Stable
fz
H 0.1 0.5 mm

ISO application areas: Tool options designed to individual customer

requirements are available.

D 76
 Milling

CoroMill 300 round insert milling cutter

Light-cutting round-insert cutter for facemilling, profiling, action in all materials. Pitch and insert
pocketing by ramping or helical interpolation. options combined for productivity in
Designed for high speed machining. many operation. Cutter bodies manu-
factured from pre-hardened steel,
Long, consistent and predictable tool-life. resulting in close tolerances and high
Excellent surface finish achieved at high feeds. strength. Light cutting action promotes A
Precision ground inserts for even greater accuracy. high feed rates even in weaker ma-
chines and unstable condtions.
High performance and versatility. Power effciency for both
stable and weak powered machines. High and vibration-free
metal removal with both short and long tools. Smooth cutting
B

Diameter 10 – 42 mm Cylindrical Weldon Morse taper Threaded

coupling
Neutral design

Machines: All types

Materials: All types
Insert geometry M-xM E-xM M-xH D
Effective top
rake angle +20 0 +5 l1 = programming length

Diameter 25 – 125 mm Cylindrical Coromant Capto Arbor

Positive design
E

Machines: All types

Materials: All types
Insert geometry M-xM E-xM M-xH
F
Average effective
toprake angle +24 +4 +9 l1 = programming length

Operations:

Facemilling Shoulder milling Full slot milling Rest milling Profiling

H

Helical interpolation Ramping Contouring Plunge milling Turn-milling

Type of tool shown on the applications above is the recommended first choice. Other tool alternatives are also recommended, but only as a second choice.

D 77
 Milling

Feed recommendations

Feed/tooth, mm Feed recommendations for insert size 08 (iC)

fz
fz (mm/insert)
0.5
ap E-xM M-xM M-xH
0.4 R300-0517E-PM
(mm) rec. (min.–max.) rec. (min.–max.) rec. (min.–max.)
R300-1240E-PM
0.3 0.1 0.59 (0.23–0.90) 0.59 (0.32–0.90) 0.68 (0.32–1.13)
0.2 0.5 0.27 (0.10–0.41) 0.27 (0.14–0.41) 0.31 (0.14–0.52)
A 1 0.20 (0.08–0.30) 0.20 (0.11–0.30) 0.23 (0.11–0.38)
0.1 1.5 0.17 (0.06–0.26) 0.17 (0.09–0.26) 0.19 (0.09–0.32)
0 2 0.15 (0.06–0.23) 0.15 (0.08–0.23) 0.17 (0.08–0.29)
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 ae, ap 3 0.13 (0.05–0.21) 0.13 (0.07–0.21) 0.15 (0.07–0.26)
Radial and/or axial depth of cut, mm
4 0.13 (0.05–0.20) 0.13 (0.07–0.20) 0.15 (0.07–0.25)

B
High feed face milling Feed recommendations for insert size 10 (iC)
fz (mm/insert)
Feed per insert ap E-xM M-xM M-xH
ap IC (mm) rec. (min.–max.) rec. (min.–max.) rec. (min.–max.)
8 10 12 16
C 0.1 0.90 (0.25–1.26) 0.75 (0.35–1.26) 1.01 (0.35–1.51)
0.5 0.62- 0.92- 1.00- 1.44- 0.5 0.41 (0.11–0.57) 0.34 (0.16–0.57) 0.46 (0.16–0.69)
-0.83 -1.15 -1.75 -2.01 1 0.30 (0.08–0.42) 0.25 (0.12–0.42) 0.33 (0.12–0.50)
1.5 0.25 (0.07–0.35) 0.21 (0.10–0.35) 0.28 (0.10–0.42)
1.0 0.67- 0.72- 1.03- 2 0.23 (0.06–0.31) 0.19 (0.09–0.31) 0.25 (0.09–0.38)
0.45 0.83 -1.27 -1.45 3 0.20 (0.05–0.27) 0.16 (0.08–0.27) 0.22 (0.08–0.33)
1.5 0.60- 0.86- 4 0.18 (0.05–0.26) 0.15 (0.07–0.26) 0.20 (0.07–0.31)
0.56 -0.76 -1.20 5 0.18 (0.05–0.25) 0.15 (0.07–0.25) 0.20 (0.07–0.30)
D
2.0 0.54 0.76

Feed recommendations for insert size 12 (iC)

M-xH first choice for high feed milling with
fz (mm/insert)
CM 300.
E ap E-xM M-xM M-xH
(mm) rec. (min.–max.) rec. (min.–max.) rec. (min.–max.)
E-xM for lower cutting forces. Use the lower
0.1 0.99 (0.28–1.38) 0.83 (0.39–1.38) 1.10 (0.39–1.65)
range of feed rate. 0.5 0.45 (0.13–0.63) 0.38 (0.18–0.63) 0.50 (0.18–0.75)
1 0.33 (0.09–0.45) 0.27 (0.13–0.45) 0.36 (0.13–0.54)
1.5 0.27 (0.08–0.38) 0.23 (0.11–0.38) 0.30 (0.11–0.45)
2 0.24 (0.07–0.34) 0.20 (0.09–0.34) 0.27 (0.09–0.40)
High feed milling with a round insert cutter 3 0.21 (0.06–0.29) 0.17 (0.08–0.29) 0.23 (0.08–0.35)
F 4 0.19 (0.05–0.27) 0.16 (0.07–0.27) 0.21 (0.07–0.32)
5 0.18 (0.05–0.25) 0.15 (0.07–0.25) 0.20 (0.07–0.30)
• Small ap (5-15% of iC) makes high feed 6 0.18 (0.05–0.25) 0.15 (0.07–0.25) 0.20 (0.07–0.30)
rates possible - Vf is favourable cutting
force direction.

G Feed recommendations for insert size 16 (iC)

• Avoid machining against a vertical face fz (mm/insert)
- large contact (large ap) excessive ap E-xM M-xM M-xH
(mm) rec. (min.–max.) rec. (min.–max.) rec. (min.–max.)
vibration.
0.1 1.27 (0.32–1.90) 1.14 (0.44–1.59) 1.59 (0.44–2.54)
0.5 0.57 (0.14–0.86) 0.52 (0.20–0.72) 0.72 (0.20–1.15)
H 1 0.41 (0.10–0.62) 0.37 (0.14–0.52) 0.52 (0.14–0.83)
1.5 0.34 (0.09–0.51) 0.31 (0.12–0.43) 0.43 (0.12–0.69)
• Move gradually away from the vertical 2 0.30 (0.08–0.45) 0.27 (0.11–0.38) 0.38 (0.11–0.60)
3 0.26 (0.06–0.38) 0.23 (0.09–0.32) 0.32 (0.09–0.51)
face for every new z-level.
4 0.23 (0.06–0.35) 0.21 (0.08–0.29) 0.29 (0.08–0.46)
Waterline milling 5 0.22 (0.05–0.32) 0.19 (0.08–0.27) 0.27 (0.08–0.43)
6 0.21 (0.05–0.31) 0.19 (0.07–0.26) 0.26 (0.07–0.41)
7 0.20 (0.05–0.30) 0.18 (0.07–0.25) 0.25 (0.07–0.40)
8 0.20 (0.05–0.30) 0.18 (0.07–0.25) 0.25 (0.07–0.40)

D 78
 Milling

CoroMill 300 insert geometries and grades

Medium Medium Heavy

M-xM E-xM M-xH

M-xM E-xM M-xH

A

General use in most For highest edge sharpness First choice for roughing
materials. and precision in combination applications in all materials.
with security.
First choice for semi-finishing
applications.
B

C
Max. rpm (nmax) in relation to the protrusion Insert sizes 10, 12 and 16 mm
of the tool on cylindrical shanks Insert sizes 5, 7 and 8 mm
Facet on insert prevents movement during
machining
nmax
D3 = 12
35 000 D
D3 = 10
Cemented carbide
30 000 D3 = 15
ISO Geometry
D3 = 16 l L
25 000 D3 = 20 Steel P x
D3 = 25 E
20 000 Stainless
steel M x
15 000 Cast iron K x
10 000 Non-ferrous
material N x
5 000 l mm Heat resistant
material S x F
50 100 150 200 Hardened
material H x

G
Wear resistance

01 P M K N S H
Good
10 GC
Aluminium / Non-ferrous

1025 GC
GC GC GC
Hardened materials

1025
Heat resistant and

CT 4020 CT 4020
1025
H
titanium alloys

530
20
Stainless steel

530 CT GC
530 3020
Cast iron

GC GC
Steel

4030 2030
Average 30 GC
2040
GC
3040
GC
3040

GC
40 4040

Difficult
50
Toughness

D 79
 Milling

Ramping and helical interpolation – CoroMill 300

lm Hole Helical interpolation
By using helical interpolation it is pos-
tan α ap sible to produce a hole in a solid work-
piece.
ap This is a good solution when required to
produce large hole diameters on small
A Ramping machines having limited power availability.
In penetrating operations ramping is preferred. The
maximum ramping angle is dependent on insert size iC
and cutter diameter. The angle α (alpha) for each cutter D3
is presented in table below.

B
Insert 8 10 12 16
D3 α lm min Flat max α lm min Flat max α lm min Flat max α lm min Flat max

25 8.0 28.5 36.4 42.0 49.0 13.5 20.8 32.4 40.0 49.0
32 5.0 45.7 50.4 56.0 63.0 7.5 38.0 46.4 54.0 63.0 12.0 28.2 42.6 52.0 63.0
34 11.5 29.5 46.6 56.0 67.0
C
35 4.0 57.2 56.4 62.0 69.0 6.5 43.9 52.4 60.0 69.0 10.5 32.4 48.6 58.0 69.0
40 3.5 65.4 66.4 72.0 79.0 5.0 57.2 62.4 70.0 79.0 8.0 42.7 58.6 68.0 79.0
42 3.0 76.3 70.4 76.0 83.0 4.5 63.5 66.4 74.0 83.0 7.5 45.6 62.6 72.0 83.0
50 2.5 91.6 86.4 92.0 99.0 5.5 62.3 78.6 88.0 99.0
52 2.0 114.5 90.4 96.0 103.0 5.0 68.6 82.6 92.0 103.0 7.0 65.2 75.6 88.0 103.0
63 1.5 152.8 112.4 118.0 125.0 3.5 98.1 104.6 114.0 125.0 5.0 91.4 97.6 110.0 125.0
D 66 1.5 152.8 118.4 124.0 131.0 3.5 98.1 110.6 120.0 131.0 4.5 101.6 103.6 116.0 131.0
80 1.0 229.2 146.4 152.0 159.0 2.5 137.4 138.6 148.0 159.0 3.5 130.8 131.6 144.0 159.0
100 2.5 183.2 171.6 184.0 199.0
125 1.5 305.5 221.6 234.0 249.0

Cutters with threaded coupling (neutral design)

E
iC = 10 mm — ap ≤ 5 mm iC = 12 mm — ap ≤ 6 mm
Dia. Dia.
Max. ramp Min. dist.
1)
Hole dia. (mm) Max. ramp Min. dist.1) Hole dia. (mm)
angle α° lm (mm) angle α° lm (mm) Flat
Flat D3
D3 Min. Max. Min. bottom Max.
bottom
32 12.0 23.5 47 54 63 32 20.0 16.5 46 52 63
34 10.3 27.5 51 58 67 34 16.9 19.7 50 56 67
F 40 8.3 34.3 63 70 79 40 13.2 25.6 62 68 79
42 7.7 37.0 67 74 83 42 12.1 28.0 66 72 83
1)
Maxmimum α and ap 1)
Maxmimum α and ap

max rec.
Plunge milling ae iC
ae, mm
G For long tool overhangs and unsta-
8 7.2
ble conditions, plunge milling might 10 9
be the only possible solution. 12 10.8 max rec.
16 14 iC
az, mm

8 1.7
10 3.3
12 3.3
H 16

Good practice for plunge milling

with round inserts is to use radial Peck drilling
depths of cut, ae, of approx. 80% of Pocketing can also be performed to a limited extent, by peck-
insert diameter, iC. That will give a drilling at depths of up to 1.5 mm depending on insert size.
stabilising effect of the tool.

D 80
 Milling

CoroMill 216
Robust ball nose endmill
A metal remover for semi-finish profiling
A
Roughing
CoroMill 200/CoroMill 300
Semi-finishing
CoroMill 300/CoroMill Ball Nose
Finishing B
CoroMill Plura/
CoroMill Ball Nose Finishing

inserts for higher Peripheral location E

M security

Identical inserts
inserts with sharper edges
E and higher precision
F
Central location

Flexibility and long reach

0.05 0.05 0.08 0.10 0.12 0.15 0.15 0.20 0.25

0.10 0.10 0.16 0.20 0.24 0.30 0.30 0.40 0.50 H

Modular cutting heads
in combine with a variety
of shanks
ISO application areas:

D 81
 Milling

CoroMill 216 Ball Nose milling cutter

General contouring and profiling.
Pocketing by ramping or helical -interpolation.
Suitable for HSM, high speed machining.

Dia. 10 – 50 mm
A – Depth of cut up to 44 mm
– Feed per tooth up to 0.6 mm
– Self locating inserts with two cutting edges
– Shank protection insert on large diameters
– Permanent marking of insert and cutter body with important
product information.
B – Start values in feed per insert should be adjusted depending
on tool length, overall stability and engagement of the cutter.

Two effective cutting edges give smooth cutting action and up

to twice the table feed of a single edge cutter.
The M-inserts are designed for a high security level and effec-
C tive transportation of the heat generated by heavy cuts.
The E-inserts are designed for highest edge sharpness and
precision.

Cylindrical Weldon Weldon Threaded coupling

Morse Taper

Machines: All types

G Materials: All types
Inclination angle -10° l1 = programming length

Operations:
H

Profiling Ramping Helical interpolation Full slot milling

D 82
 Milling

Main inserts Shank protection insert

M-M E-M M

E = Highest edge sharpness and precision

A
M = Highest edge security

GC = Coated carbide/Cermet (ISO = HC)

CT = Cermet (ISO = HT)
– = Uncoated carbide (ISO = HW)

For Dimensions, mm
cutter
rε
dia. ➚ la l s iW Εr rε1 rε2 B
Central and peripheral
10 5
R216-10 02 E-M 8.6 9.8 1.7 – – – –
12 6
R216- 12 02 E-M 10.8 12.0 2.38 – – – –
12 02 M-M
16 8 R216- 16 03 E-M 14.4 16.0 3.18 – – – –
16 03 M-M
20 10 R216- 20 T3 E-M 17.9 20.0 3.97 – – – – C
20 T3 M-M
25 12,5 R216- 25 04 E-M 22.3 24.9 4.76 – – – –
25 04 M-M
30 15 R216- 30 06 E-M 26.9 29.9 6.35 – – – –
30 06 M-M
32 16 R216- 32 06 E-M 28.6 31.8 6.35 – – – –
32 06 M-M
40 20 R216- 40 07 E-M 36.5 39.9 7.94 – – – – D
40 07 M-M
50 25 50 07 E-M 44.6 49.7 7.94 – – – –
50 07 M-M
Shank protection insert
30 - 50 – APMT 160408-M – 16.4 4.76 9.25 85º 0.8 0.4

Insert location
The insert has two cutting edges, one for periphery location and one F
for central. Follow the marking on insert and cutter body.

Periphery location

G
Identical
inserts

Central location

Torx Plus screws have been designed to ensure

the correct torque value is always obtained.

D 83
 Milling

Machining recommendations
Edge tolerance
-M -E
R A B R A B
5 – – 5 0.15 <0.01
6 1.4 0.07 6 0.15 <0.01
8 1.7 0.09 8 0.15 <0.01
M D3 +0.07
–0.23
10 2.2 0.12 10 0.15 <0.01
A 12.5 3.0 0.1 12.5 0.15 <0.01
15 3.9 0.20 15 0.15 <0.01 D3 E D3 +0.0
–0.20
16 3.5 0.22 16 0.15 <0.01
20 3.6 0.24 20 0.15 <0.01
25 3.8 0.26 25 0.15 <0.01

B
Machined form Insert tolerances for highest precision or
The form error occuring at the centre point according to the highest security
table is minimized by using the -E type inserts. The M-inserts are designed for a high security level and effec-
tive transportation of the heat generated by heavy cuts.
The new E-inserts are designed for highest edge sharpness
and precision.
C

D Contouring
The preferred method is to use contouring. This allows the ef-
fective cutting speed to be controlled more easily, utilise high-
er feed rates and machine in the preferred climb mode. The
overall result being higher productivity, increased security and
longer insert life.
E

Copy milling
G The traditional technique – mainly linked to older types of copy
milling machines.
This method of production can dramatically reduce the tool life
of the inserts, caused by the heavy load on the insert centre
point. To improve the insert life it is recommended to reduce
the feed rate according to the following graph.
H
100%
100%
100%
20º 50%
Typical problem area 45º 40% 60%
45º

90º

D 84
 Milling

CoroMill 216F
Ball Nose Finishing endmill
A cutter for high finish profiling
A

Roughing
CoroMill 200/CoroMill 300
Semi-finishing Carbide shank option
CoroMill 300/CoroMill Ball Nose
B
Finishing
CoroMill Plura/
CoroMill Ball Nose Finishing

Constant stock allows C

near net shape milling

CoroGrip

Sharp –L geometry

-L
-adds precision E

HSM 10-15° F
P10A

Genera
P20A Dc
Vc
G
ap

De ve

Use Shallow axial and radial cuts for safe productivity. Always calculate H
the true cutting speed (Ve) based on the effective diameter in cut (De)

ISO application areas:

D 85
 Milling

CoroMill Ball Nose 216F Finishing endmill

High speed finishing to super finishing of profiles is possible
with indexable insert tools. A surface finish equal to that pro-
duced by a solid carbide tool, is with the CoroMill Ball Nose
Finishing endmill – equipped with Coromant P10A inserts.

A The inserts are screw clamped in high security seats allowing

safe milling with high speed machining performance.

The CoroMill finishing cutter with the P10A insert is developed

for finish milling of a range of materials used for die and mould
making as well as for manufacturing of turbine blades within
B the aerospace industry. Its sharp edges easily cut hardened
steel up to HRC 60 as well as stainless steel, grey or nodular
cast iron, aluminium, Kirksite and graphite.

With the CoroMill ball nose endmill series of tools, mirror finish-
ing is possible using either smaller CoroMill Plura solid carbide
C endmills – from diameter 0.4 mm – or larger indexable insert
cutters – up to 32 mm. Both versions exist in the intermediate
diameter range from 8 up to 20 mm.

Both the CoroMill ball nose high precision cutter and CoroMill
Plura provide their optimum performance when clamped in
Coromant CoroGrip precision chucks.
D
By applying accurate programming techniques, the finishing cut-
ters may, in many operations, replace conventional ball nose
endmills and greatly improve the surface quality, very often, at
ten times higher feed.

Dimensions, mm

Cutter Dc mm s iC ap max
8 R216F-08 24 E-L 2.4 8 1.2
H 10 R216F-10 26 E-L 2.6 10 1.5
12 R216F-12 30 E-L 3.0 12 1.8
16 R216F-16 40 E-L 4.0 16 2.4
20 R216F-20 50 E-L 5.0 20 3.0
25 R216F-25 60 E-L 6.0 25 3.7
30 R216F-30 70 E-L 7.0 30 4.5
32 R216F-32 70 E-L 7.0 32 4.5

D 86
 Milling

P10A is first choice for: P20A is first choice for:

- high effective cutting speed (HSM) applications. - copy milling applications or all applications where the centre of the
- contouring applications (not cutting with centre point of insert) insert is cutting (zero vc). B
- hardened steels and cast iron. - machines with limited rpm (non HSM).
- non hardened materials.
- semi-finishing applications.

C
Cutting data recommendations
Material Cutting speed ve Cutting Feed per tooth, fz (mm/z)
m/min depth
Insert diameter
CMC
No HB P10A P20A ap or ae 8 10 12 16 20 25 30 32
D
P
Unalloyed steel
01.1 125 300–500 150–375
01.2 150 250–450 125–340 0.07x Dc 0.15-0.20 0.15-0.20 0.15-0.20 0.20-0.25 0.20-0.25 0.25-0.30 0.25-0.30 0.25-0.30

Low alloy steel

02.1 175 200–400 100–300 0.05x Dc 0.10-0.15 0.10-0.15 0.15-0.20 0.20-0.25 0.20-0.25 0.25-0.30 0.25-0.30 0.25-0.30
02.2 330 180–330 80–200
High alloy steel
03.11 200 200–330 100–230 0.05x Dc 0.10-0.15 0.10-0.15 0.15-0.20 0.20-0.25 0.20-0.25 0.25-0.30 0.25-0.30 0.25-0.30 E
M
Stainless steel
05.11 200 150–200 100–200 0.05x Dc 0.10-0.15 0.10-0.15 0.15-0.20 0.15-0.20 0.15-0.20 0.20-0.25 0.20-0.25 0.20-0.25
05.21 200 120–170 80–120
Malleable cast iron

K 07.1
07.2
130
230
200–450
300–450
130–330
100–330
0.10x Dc 0.15-0.20 0.15-0.20 0.20-0.25 0.25-0.30 0.25-0.30 0.30-0.35 0.30-0.35 0.30-0.35

Grey cast iron

08.2 245 200–400 100–300 0.10x Dc 0.15-0.20 0.15-0.20 0.20-0.25 0.25-0.30 0.25-0.30 0.30-0.35 0.30-0.35 0.30-0.35 F
Nodular cast iron
09.1 160 400–500 150–350
09.2 250 200–350 100–260 0.07x Dc 0.15-0.20 0.15-0.20 0.20-0.25 0.25-0.30 0.25-0.30 0.30-0.35 0.30-0.35 0.30-0.35

N Aluminium
30.22 90 1000 1000 0.15x Dc 0.20-0.25 0.20-0.25 0.25-0.30 0.30-0.35 0.30-0.35 0.35-0.40 0.35-0.40 0.35-0.40

S
Heat resistant alloys
20.22 350 40–80 20–60 0.03x Dc 0.10-0.15 0.10-0.15 0.15-0.20 0.15-0.20 0.15-0.20 0.20-0.25 0.20-0.25 0.20-0.25
Titanium alloys G
23.22 350 70–120 35–90 0.03x Dc 0.15-0.20 0.15-0.20 0.20-0.25 0.25-0.30 0.25-0.30 0.30-0.35 0.30-0.35 0.30-0.35

H
Hardened steel
04 55 HRC 150–250 75–190
0.03x Dc 0.10-0.15 0.10-0.15 0.15-0.20 0.20-0.25 0.20-0.25 0.25-0.30 0.25-0.30 0.25-0.30
04 63 HRC 90–150 40–110

Note: 1. fn = 2 x fz
2. When using periphery of insert, reduce the feed by 50%.
H

D 87
 Milling

Machining recommendations
Shallow cuts provide security in high perform-
ance milling
The capability of the ball nose finishing cutter can be demon-
strated by applying it to shallow depths of cut e.g. considerably
smaller axial and radial depths of cut - ap and ae - than used
in general milling with round inserts, for example when using
A CoroMill 200 cutters.
Down milling is preferred method for best performance of the tool.

Cutter body selection

Steel shank cutter bodies are generally first selection.
Carbide shank cutter bodies are recommended for applications
B with the highest demands on precision. Carbide shank cutters
are also recommended for finishing of bi-metal surfaces.

Shallow cut allows higher table feed

At radial and/or axial depths of cut between 0.2–3 mm (depending
on insert size) both the feed per tooth and cutting speed can be
C increased by up to 5 times compared with general milling, re- Compensated cutting speed, vc,
sulting in very high table feeds and metal removal rates without due to low ae or ap
any reduction of security or tool life.
vc 1 400
For both security and tool life an effective evacuation of the
chips is essential – preferably executed by compressed air. m/min 1 200
1 000
800
D Calculate the cutting speed
600
Particularly when using round insert cutters at small depths of
400
cut, it is always important to calculate the true cutting speed
200
(ve) based on the effective – or true diameter in cut (De).
0
The De value deviates considerably from the Dc value for shal- 0 1 2 3 4 5 6 7 8 9 10
low depths of cut. ae , ap mm
If these factors are not taken into consideration, there will be
E severe miscalulations of feed rate, as this is dependant on the
spindle speed. Such miscalculations will lead to conditions in
which the finishing cutter will be operating under its capacity.
To avoid the zero cutting speed appearing at the tool centre, it
is recommended to move the cutting zone away from this area
by tilting spindle or work piece.
F

Effective cutting speed ( ve )

ve = π × n × De m/min
1000

D 88
 Milling

CoroMill 210
Versatile cutter for both high feed milling and plunging
Highly productive roughing cutter
A

Plunge milling High feed helical High feed facemilling

interpolation E

F
ap
F
ae 10° entering angle results in favourable
cutting forces directed towards the
spindle. G
l ap ae
l 09 1.2 8
14 2.0 13

ISO application areas:

Tool options designed to individual customer
requirements are available.

D 89
 Milling

CoroMill high feed facemill and plunge

milling cutter
The CoroMill 210 is a very productive roughing cutter. It is
suitable fo many operations where high metal removal is a
priority. The 210-cutter is first choice especially for rough
A
machining involving high feed facemilling and plunge milling,
with or without long tool overhangs.

The CoroMill 210 combines a plunge mill and face mill cutter in
one tool. This is made possible through the design of the cut-
ter body, insert seat and the inserts themselves. A ten degree
B entering angle allows extreme feed rates at small axial depths
of cut when the tool is fed tangentially – and also high radial
depths of cut when fed axially in roughing operations. In both
cases the major part of the cutting force is directed towards
the spindle, providing a stable cutting action practically free of
vibration or deflecting side forces.
C
The inserts are avalible in two sizes, and have four cutting edg-
es. The CoroMill 210 programme includes modular tools with
Coromant Capto or screw mounted couplings, as well as arbor
mounted cutters and cylindrical shank cutters.

Diameter 25 — 100 mm Threaded

coupling
Cylindrical Coromant Capto

E Arbor

F
Machines: All types
Materials: All types
κr 10°
l1 = programming length

G Operations:

H
High-feed Plunge Shoulder Profiling Ramping Helical Slot milling
milling milling milling interpolation

D 90
 Milling

High feed machining

Speed and feed values
Material Cutting speed, Grade Feed per tooth, fz (mm/z)
vc (m/min) recommendations
Insert size 9 Insert size 14
CMC
No HB fz rec fz min — fz max fz rec fz min — fz max

P
Unalloyed steel
01.1 125 180 – 280 2030 1.5 (0.4 – 2.0) 2.0 (0.4 – 3.0)
01.2 150 180 – 280 3040 1.5 (0.4 – 2.0) 2.0 (0.4 – 3.0)
Low alloy steel A
02.1 175 150 – 250 3040 1.5 (0.4 – 2.0) 2.0 (0.4 – 3.0)
02.2 330 120 – 200 3040 1.0 (0.4 – 1.5) 1.5 (0.4 – 2.0)
High alloy steel
03.11 200 130 – 220 3040 1.5 (0.4 – 1.7) 2.0 (0.4 – 2.5)
03.21 300 100 – 180 3040 1.0 (0.4 – 1.3) 1.5 (0.4 – 2.0)
Stainless steel
M 05.11 200 150 – 250 2040 1.5 (0.4 – 1.7) 2.0 (0.4 – 2.5)
B
05.21 200 140 – 210 2040 1.0 (0.4 – 1.5) 1.5 (0.4 – 2.0)
Grey cast iron
K 08.2 245 130 – 220 4020 1.5 (0.4 – 2.0) 2.0 (0.4 – 3.0)
Nodular cast iron
09.2 250 120 – 200 4020 1.5 (0.4 – 2.0) 2.0 (0.4 – 3.0)

S
Heat resistant alloys
20.22 350 25 – 35 2030 0.8 (0.6 – 1.2) 1.0 (0.6 – 1.5) C
Titanium alloys
23.22 350 30 – 50 2030 0.8 (0.6 – 1.2) 1.0 (0.6 – 1.5)

H
Hardened steel
04 45 HRC 70 – 140 3040 0.8 (0.4 – 1.2) 1.0 (0.4 – 1.5)
04 55 HRC 50 – 90 3040 0.8 (0.4 – 1.2) 1.0 (0.4 – 1.5)

D
Grades
Wear resistance

01 P M K S H
Good
10 GC E
4020 Hardened materials
Heat resistant and
Conditions

GC
Stainless steel

20
titanium alloys

3040
Cast iron

GC GC GC GC GC
GC
Steel

2030 2030 4020 4020 2030

GC GC 2030 GC GC
Average 30 2040 3040 2040 3040

40 GC
2040

F
Difficult
50
Toughness

Grade recommendation
High feed milling Plunge milling G
Grade Grade

ISO Good Difficult ISO

conditions1) conditions

P 3040 2030 P 2040

H
M 2040 M 2040

K 4020 3040 K 3040

S 2030 S 2030

H 3040 2030 H 2030

1)
Good conditions = recommended machining strategies are used, tool overhang = ≤3 × Dc

D 91
 Milling

Standard inserts:
CoroMill 210 R210-09 ..., max. ap 1.2 mm
R210-14 ..., max. ap 2.0 mm
A

Arbor mounting Coromant Capto

Style D3 l1 Size D3 l1
B A22 50- 72 48.4-85 C3 25- 40 50-133
A27 63-102 48.4-85 C4 32- 50 45-163
A32 72-127 48.4-85 C5 32- 72 46-163
C6 40- 82 55-163
C8 50-127 60-200

Cylindrical Cylindrical shank for Weldon

shank power chuck

Size D3 l2 Size D3 l2 Size D3 l1

F 20 25-32 84.4-254 32 32-50 112.4-254 20 25-32 85.4-229.5
25 25-40 90.4-254 42 42-63 132.5-254 25 25-40 94.4-218.5
32 32-50 90.4-254 32 32-50 90.4-222.5

Coolant holes on all cutters up to diameter 102 mm

G
Options
Insert size 9, 14 Mounting type Arbor mounting, Coromant Capto,
D3 – 9, Diameter 25-82 mm Cylindrical, Cylindrical power chuck
–14, Diameter 50-127 mm Weldon
H No of inserts 2–8 dmm/D5m Mounting size—see above
depending on cutter diameter l3 Reach length—34-192 mm
and size of inserts l2 Total length—see above
l1 Programming length—see above

D 92
 Milling

High feed milling

High feed face milling with CoroMill 210 is the most productive roughing method. Hole
Extremely high chip volumes can be removed, at feed rates far above those possible
with conventional face milling, as the cutting forces are directed towards the spindle
even when the tool is operating tangentially. This is true despite the limited depths
of cut allowed by the ten degree entering angle – max 2.0 mm with the larger 14 mm
insert, and 1.2 mm with the smaller. In very favourable conditions feed per insert, fz,
up to 4 mm/tooth can be used and metal removal rate values, Q, up to 1400 cm3/min A
can be achieved.
Due to the low entering angle maximum chip thickness, hex, is dramatically reduced.
This allows extremely high feed rates to be used without over-loading the inserts.

Ramping
B
In penetrating operations ramping is preferred. The maximum ramping angle is de-
pendent on insert size and cutter diameter. The angle α (alpha) for each cutter is
Widening cavity
presented in table below.
- Smooth entry and exit
- Correct strategy for machining corners
Helical interpolation
By using helical interpolation it is possible to produce a hole in a solid workpiece. This C
is a good solution when required to produce large hole diameters on small machines
having limited power availability.
Helical interpolation is also one preferred method to change to new Z-level in constant
Z-level milling.
On holes larger than 50 mm this method with CoroMill 210 is comparable to the pro-
ductivity of a Coromant U-drill. D

Open up a cavity
max - Helical interpolation to reach a new E
iC
ap, mm z-level
9 1.2 - Use correct strategy for machining
14 2.0 corners.

ap
F
Do not exceed max ap during high feed rate!

Cutter dia. iC = 9 mm iC = 14 mm
ap ≤ 1.2 mm ap ≤ 2 mm G
Max. ramp Hole dia. (mm) Max. ramp Hole dia. (mm)
D3 Insert
angle α° Min. Max. angle α° Min. Max.
size
25 9 14.5 32 49 – – –
32 9 8 46 63 – – –
35 9 7.0 52 69 – – –
36 9 7.0 54 71 – – –
42 9 5.0 66 83 – – –
50 9 3.5 82 99 – – – H
52 9 3.3 86 103 – – –
52 14 – – – 5.8 76 103 When machining a flat surface, max-
63 9 2.6 108 125 – – – imum width of cut, ae, is determined
63 14 – – – 3.8 98 125
by Dc. If a larger width of cut is used
66 9 2.4 114 131 – – –
66 14 – – – 3.2 104 131 the cutter will produce a surface
80 14 – – – 2.4 132 159 with scallops.
82 14 – – – 2.0 136 163
100 14 – – – 1.6 172 199

D 93
 Milling

High feed milling

Caution should be exercised Do not exceed the max. ap val-
when high feed milling against ue when high feed milling. Any
high shoulders. Depending excess depth of cut above the
upon the tool overhang, an ex- hex = fz main cutting edge will result in
cessive feed rate can result in extreme hex-values.
vibrations which can damage If the max. recommneded value
A the periphery of the insert. The has to be exceeded, the feed
feed rate should be reduced if rate should be reduced by ap-
fz
any such risk prevails. hex = prox. 80%.
5.8 max. ap
fz

B
Kr : 10º
iC Dc ap Dc
9 D3-14.1 0.25 Dc+2.8
14 D3-24 0.5 Dc+5.7
ap
1.0 Dc+11.3
Dc
1.2 Dc+13.6
C De
1.5 Dc+17.0
D3 2.0 Dc+22.7

Machining of corners

D Programming
CM CM
210 300

iC Dimensions, mm
Uncut
material
E R b ap x
Special care needs to be taken when machining corners to
avoid vibration from maximum contact between cutter and ma-
9 2.5 7.05 1.2 0.79
terial. Best practice is to program a radius by circular interpola-
14 3.5 12.0 2.0 1.48
tion, considerably bigger than the cutter radius (alternatively
a cutter radius considerably smaller than corner radius). If
When using CoroMill 210 in high feed applications, program as recommended machining strategy is not followed, reduce feed
F a round insert cutter with insert radius R. rate by approximately 50%.

Plunge milling
G
Plunge milling with CoroMill 210 is the fastest way to mill away The considerable axial forces experienced in rough plunge mill-
large volumes of metal in the axial direction. ing mean that optimum performance is obtained with ISO 50
Repeated plunging of the cutter to a predetermined depth, fol- machine tools, or similar.
lowed by retraction and repositioning for the next plunge re-
moves metal rapidly through overlapping passes, cutting with
H the front face of the tool.
It is a highly productive method for internal milling of deep cavi-
ties, and milling externally along deep shoulders.
Compared to conventional milling using tool paths in the X-Y
plane, the increased rigidity experienced when moving in the
Z direction can allow the tool to cut through a larger cross
section of material for the same feed rate, resulting in faster
metal removal.

D 94
 Milling

ae
Plunge milling Programming
For long tool overhangs and Avoid using a drilling cycle.
unstable conditions, plunge Programme path to move away from the wall
milling might be the only pos- prior to rapid feed.
sible solution.
Best performance is achieved if a smooth exit
s from workpiece is programmed prior to retrac-
tion.
max recom- max recom- A
iC mended ae, mm mended s = programme table feed
= rapid traverse
9 8
<0.75 × D3
14 13

Recommended overhang
When using long tool overhangs, vibration
B
Plunging can occur which will be detrimental to
Feed values both the machine tool spindle bearings,
<6 × Dc the tool and the quality of the finished re-
Insert fz mm/ tooth
size sult. CoroMill 210 reduces this risk when
rough milling as the major cutting forces
iC Starting value min - max
act in the Z-plane where the machine tool
9 0.10 0.08 - 0.15
spindle is generally the strongest, and is a real problem-solver C
14 0.15 0.10 - 0.20
for operations where extended tooling is required.

Alternative method for milling with extra

Recommended method long tools D
• Most effective plunge milling strategy. • Plunge millling with tool overhang longer than 4 x D3
• Step, s, recommendation approximately 0.75 x D3 • Smaller engagement – less risk of vibration
• Recommended for L<4 x D3 • Gradually decrease plunge depth to minimize vibration
• For a longer tool an alternative method is
recommended.
E

8
7
6
5 iC Max ae
L ≥ 4 x D3
9 7
F
14 12

9
8
7
6
4
3
2 G
1

5
4
3
2
1

For example, the main part of a deep die can be roughed out using high feed milling H
method, three-axis helical engagement for a continuous transition from one Z-level to
another and two axis pocketing (constant Z-level) leaving corner radii larger than cutter
radius.
• The corners can, thereafter, be roughed out using a plunge milling method.
• Due to the nature of these two CoroMill cutters they can often be combined for one
and the same workpiece, reducing tool inventory considerably.

D 95
 Milling

CoroMill Century
Facemill for non-ferrous materials
Designed for High Speed Machining
A

Steel body

B High alloy
aluminium body

C
Coromant Capto, HSK or
arbor mountings

Intensified chip evacuation

D by accelerated cutting fluid

HSM-security by design
E

F
0.1
Serrated location gives a very high
Easy micro precision seating speed security against insert mevement
within 0.1 mm setting range

G
PCD and carbide insert Wiper insert option for
high feed finishing

Key for correct tightening

H torques delivered with the tool
CD10 H10 CD10 H10

ISO application areas: Tool options designed to individual customer

requirements are available.

D 96
 Milling

CoroMill Century
Light weight cutters in aluminum and durable • To suit differ-
steel for high speed machining of non-ferrous ent demands
metals caused by the
Cutters in larger diameters – 80 to 200 mm - are arbor mount- property of the
ed and available in high alloy aluminium for light weight and in aluminium to be
hardened steel for durability, both designed for best possible machined, arbor A
high speed performance. mounted cutters
Smaller cutters are manufactured in steel - either arbor mount- bodies are avail-
ed in diameters 50 and 63 mm or integrated with Coromant able in aluminium and hardened steel.
Capto in the diameter range 40-80 mm. Alternatively HSK cou- - aluminium bodies for light machining.
plings in diameters from 40 up to 125 mm are available. - steel for more demanding operations and in high abrasive
aluminum. B
Larger cutters can be made on request with inserts mounted in • The cutter is built up of a minimum of parts and inserts are
adjustable cassettes. securely fixed against radial forces.
• Max. revolution per minute is marked on the cutter body.
• Close tolerances and consistent surface finish. • Extremely light cutting performance with high positive
• Delivered with built in precision – which can be improved still edge geometries transfer a minium load to the spindle
further by easy use of the setting screw. assembly and component fixturing. C
• Wiper insert option for superior surface finish at high • Minimal run-out contributes to smooth, stable and vibration
removal rate. free cutting action.
• No burr formation. • Light weight cutter body prevents excessive load on spindle
• Balanced cutter body, few parts and inserts with edges for bearings.
high speed located in serrated seats for minimum run out. • Easy to handle – easy to use.
Features that contribute to the cutter’s excellent high speed • Indexable inserts eliminates reconditioning costs.
D
performance providing reduced, costly production time. Its
simplicity and easy handling also makes it possible to re-
duce non production delays.

Diameter 40 – 200 mm

*) *) *) G
κr 90°
l1 = programming length

Operations:
H

General Facemilling to Demanding intermittent

facemilling mirror finish machining

D 97
 Milling

Inserts geometries and grades for CoroMill Century

PCD grade CD10 Coromant grade H10

Wiper Wiper

B
Example:
Dimensions, mm Max
BALANCE PROTOCOL
l iW rε bs ap
Coromill Century
11 R/L590- 1105H-PS2-NL 11 11.5 0.25x45° 2.2 2
1105H-PR2-NL 11 11.5 0.4 2.2 2 nmax : 20800 rpm
C 1105H-PC2-NL 11 11.5 1x45° 1.5 2 Art Nr. : R590-125Q40A-11M
1105H-PS5-NL 11 11.5 0.25x45° 2.2 5 Mass : 0.88 kg
1105H-PR5-NL 11 11.5 0.4 2.2 5 Unbalance : 8.1 gmm
1105H-PC5-NL 11 11.5 1x45° 1.5 5 Order Nr. : 00257433
110504H-NL 11 11.5 0.4 2.2 10 Date : 03-12-17

R/L590- 1105H-RS2-NW 11 11.5 0.25x45° 7.0 2

1105H-RR2-NW 11 11.5 0.4 7.0 2
D 1105H-RC2-NW 11 11.5 1x45° 6.3 2
110504H-NW 11 11.5 0.4 7.0 2

Inserts
E Cemented carbide Polycrystalline
ISO Geometry diamond
L Wiper Wiper

Non-ferrous
material N

Cutting data for CoroMill Century

G PCD CMC No. Cutting speed, m/min Feed per tooth, mm
Corner geometries
CD10 vc fz
min rec rec max rec
PR, RR, NL, NW
min rec rec max rec
First choice
Al alloy non cast 30.1 1000 4000 8000 0.05 0.15 0.3
Al alloy cast 30.2 1000 4000 8000 0.05 0.15 0.3
Al >99% 30.3 1000 2000 4000 0.05 0.15 0.3
Al Si 13-22%
H 30.4 1000 2000 4000 0.05 0.15 0.3 PS, RS
Carbide Cutting speed, m/min Feed per tooth, mm Against burr
H10 vc fz formation

min rec rec max rec min rec rec max rec
Al alloy non cast 30.1 500 2500 6000 0.1 0.2 0.4 PC, RC
Highest security
Al alloy cast 30.2 500 2000 4000 0.1 0.2 0.4
Al >99% 30.3 500 1500 3000 0.1 0.2 0.4
Al Si 13-22% 30.4 500 750 1500 0.1 0.2 0.4

D 98

Insert edges for cutting of aluminium are very sharp and fragile.
The polycrystalline diamond – PCD – edges are particularly sen-
sitive to mishandling.
Measuring equipment
All measuring procedures where the insert edges are positioned
in direct contact with the point of a dial indicator carry an inher-
ent risk of insert damage.
The maximum acceptable contact pressure between the contact
point and the edge should not exceed 0.25N – the quality pro-
vided by qualified linear gauges.
However, optical setting by projecting the cutting edge is recom-
mended.
High radial accuracy by design and axial by
easy setting.
① ②
③ ④
B E
⑤ A
⑥ ⑦
C
⑧ ⑨
Milling
Setting of wiper inserts
When mounting a wiper insert, resetting is necessary since it is
manufactured to the same size as the conventional inserts and
is recommended to set 0.05 mm below the milling inserts.
Depending on the work material and whether edge frittering oc-
curs in the workpiece, a reduction of this dimension to about
0.03 mm might be necessary.
A
B
① The axial position of the inserts can be adjusted by an easily operated
setting screw. The maximum setting range is 0.1 mm/.004 in.
② Measuring equipment.
All measuring procedures where the insert edges are positioned in direct contact
with the point of a dial indicator carry an inherent risk of insert damage.
Optical setting by projecting the cutting edge is recommended.
C
③ Insert edges for cutting of aluminium are very sharp and fragile.
The polycrystalline diamond - PCD - edges are particulary sensitive to all unskilful
handling.
The maximum acceptable contact pressure between the contact point and the
edge should not exceed 0.25N/.06 lbf - the quality provided by qualified linear
gauges.
④ Lubricate the insert screws (A) with Molykote – included in the tool box. D
Make sure the serrations in the insert seats are free from dirt and damage.
Keep the serrations dry.
⑤ Mount the inserts.
Make sure the correct corner geometry has been selected.
Tighten the insert screw to 3Nm/26.6 lbf.in using the Torx Plus torque key
included in the tool box.
⑥ Check,
insert.
using the measuring equipment, the position of the parallel land of each
⑦ Determine the highest positioned insert.
Raise the position of this insert by approximately five microns/.02 µin, by turning
the adjusting screw (B) carefully clockwise.
⑧ Zero set the indicator at this level. F
⑨ Adjust the position of all remaining inserts to this zero level in same way as
indicated above.
If the zero position is exceeded, return to a level of about five microns/.02 µin
below zero and repeat the setting again.
G
Indexing inserts/Changing to new inserts.
• Untighten the setting screw.
• Undo the insert screw and remove the insert.
• When changing to new PCD inserts, always change to new insert screws.
Setting of the wiper insert.
• When using a wiper insert, resetting of the system is normally required. H
• Setting follows the same procedure as given above.
• The parallel land of the wiper insert should be adjusted to a level 0.05
mm/.002 in below the zero position of the conventional inserts.
• Depending on the workpiece material and whether edge frittering occurs in the
workpiece, a reduction of this dimension to about 0.03 mm/.001 in might be
necessary.
• A CoroMill Century cutter with inserts mounted should always be protected with
the cover (C) included in the package see fig. 6 when not in use.
D 99
 Milling

CoroMill Century inserts

A CD03, CD10, CD30, H10, H13A, 1025, K20W, 4020
CD03 – Fine grained. Recommended when sharp edges are needed.
CD10 – Medium grained. First choice.
CD30 – Course grained. Recommended for extremely abrasive materials. R S C
H10 – Uncoated fine grained carbide gives excellent sharp edges
H13A – Uncoated carbide for medium to finishing milling of
B aluminium alloys
1025 – PVD-coated carbide grade for light milling of steel
K20W – Coated carbide for milling under wet conditions of gray cast iron
4020 – Coated carbide grade for light milling of cast iron

Only radius options on

HM-inserts.
C
Std; Rb0 = 200
A1 ; Rb0 = 80
A2 ; Rb0 = 40

A3 ; = 5°

Wiper Std; Rb0 = 500

A1 ; Rb0 = 300
A2 ; Rb0 = 100
F

Options
G
Insert grade CD03, CD10, CD30, H10, H13A, 1025, K20W, ER treatment Small, Medium, Large
4020
Axial depth of Parallell land, N = No
cut ap ap Max = 2.0 / 5.0 / 9.0 / 10.0 mm radius and type Std / A1 / A2 / A3
Negative land on
Corner parallell land Y = Yes or N = No
H modification R = Radius, S = Sharp or C = Chamfer
Length of Length Bs= 0.1 - 7.5 mm
Corner radius R Radius: rε = 0.2 - 2.8 mm parallell land
Height: ch = 0.1 - 2.0 mm
Chamfer C ( Angle: κε = 45° ) Hand of tool R = Right or L = Left

Negative land on Y = Yes or N = No

main cutting edge

D 100
 Milling

CoroMill 790
Shoulder milling cutters for non – ferrous materials
High Speed Machining performance
with high security
A

Insert size 22 mm
Insert size 16 mm

Torque wrench to be
Torque wrench delivered
ordered separately
together with the tool E

Ground
– for precision
F

Serrated location reduces effect

G
of inset tolerances by half

16
rε = 0,5 0,8 1,6 2,0 2,4 3,1 4,0 5,0 mm

22 H
rε = 0,5 0,8 1,6 2,0 2,4 3,1 4,0 4,8 5,0 6,0 6,4 mm

ISO application areas: Tool options designed to individual customer

requirements are available.

D 101
 Milling

CoroMill 790
Shoulder milling cutter for non-ferrous materials
The CoroMill 790 cutter is first choice for ISO N material. For mould makers for mill-
shoulder operations as a “super remover” is designed de- ing deep cavities and
signed, for high security demands and also high precision in prototyping and oth-
work. er industries manu-
A facturing pockets and
The cutter is available in two insert sizes cavities.
– large, 22 mm inserts for extreme metal removal rates in ma- However, although de-
chines with very high power. veloped for alumini-
– and a smaller version with 16 mm inserts for machines with um, the concept is
somewhat moderate spindle power. also suitable for Kirk-
B site and other non fer-
• The inserts and its support faces are designed for high centri- rous materials.
fugal forces generated at excessive speeds. The unique, ser-
rated design is the most reliable on the market – provided To take best advantage,
the insert screws are tightened correctly. this tool is most effec-
• The design guarantees accurate location of the cutting edges tively used for roughing
C and practically eliminates the effect of the insert tolerances to finish ramping and
and the resulting run out. circular interpolation in
• This design also allows the tool to take up forces from all a helix form. It generates deep straight shoulders with minimal mis-
directions and to perform high ramping operations without match. CoroMill 790 is extremely good for boring operations,
feed reductions. both roughing and finishing.
• As no contact points against the insert seats are required to
D support the inserts, it has been possible to give these an Besides its capability for safe, high speed machining, the cutter
open location for undisturbed chip flow at heavy cuts. is also a “power effective” tool, capable of high metal removal
• The stiff cutter body is hardened before machining – a guar- rates per kW.
antee for maintained precision.
HSK tool mounting = first choice for machines with HSK interface
The CoroMill 790 cutter concept is primarily developed to fulfil in spindle.
the extreme demands from manufacturers of frame compo- (Other mountings, see CoroMill 390)
E
nents for the aerospace industry, but will also satisfy die and

F Diameters 25 – 100 mm

G
κr 90°
l1 = programming length

Operations:
H

Repeated Shoulder Facemilling Slot milling Helical Ramping Plunge milling Helical boring
shoulder milling milling interpolation

D 102
 Milling

Inserts Insert Cemented carbide

25° (R790-22…) ISO size, mm Insert geometry
20° (R790-16…) M

16
Aluminum N 22
Medium -NM

The cutter is available in two insert sizes

A
• large, 22 mm inserts for extreme metal removal rates in machines with
16 very high power.
0.5 0.8 1.6 2.0 2.4 3.1 4.0 5.0 (mm)
rε =
• and a smaller version with 16 mm inserts for machines with somewhat
moderate spindle power.
22 • The inserts and its support faces are designed for high centrifugal forc-
0.5 0.8 1.6 2.0 2.4 3.1 4.0 4.8 5.0 6.0 6.4 (mm)
es generated at excessive speeds. The unique (pat.pend.), serrated B
rε =
design is the most reliable on the market – provided the insert screws
are tightened correctly.
• The design guarantees accurate location of the cutting edges and prac-
tically eliminates the effect of the insert tolerances and the resulting
run out.
• This design also allows the tool to take up forces from all directions and
C
to perform high ramping operations without feed reductions.
• As no contact points against the insert seats are required to support
the inserts, it has been possible to give these an open location for un-
disturbed chip flow at heavy cuts.
• The stiff cutter body is hardened before machining – a guarantee for
maintained precision.
D

Recommended feeds
Insert hex, fz ( feed in mm/tooth)
size Insert geometry Starting value E
16 Medium H-NM 0.3
22 Medium H-NM 0.6

1 2
F
16 < 3 Nm 16 3 Nm 16 > 3 Nm
22 < 5 Nm 22 5 Nm 22 > 5 Nm

OK
3 4 Torque:
Insert size 16 3 Nm G
Insert size 22 5 Nm

Warning!
At elevated rpms, the weight of insert and clamping elements Correct insert clamping is received by tightening the 16 mm screw H
increase rapidly, all manufacturing at high speed therefore, should to a torque of 3 Nm and the 22 mm insert to 5 Nm.
only take place in a well protected machine tool set up.
Make sure before mounting the insert, that the insert and its seat Note: A 19 gram insert weighs 350 kg at 37500 rpm!
are in perfect condition and free from burrs or any particles which
may seriously affect the clamping arrangement.

D 103
 Milling

Helical interpolation and ramping for pocketing Circular interpolation

and cavity milling
Blind or through hole
ap
lm =
tan α
Pitch

P = Max ap

Ramping Helical interpolation

B
Depending on the diameter of the cutter For wider pockets, helical interpolation Preferably apply down milling.
a ramping angle of up to 28 degrees can can be an advantage.
be used.

C Cutter diameter Ramping angle 1) Hole diameter 1)

Minimum 2)
distance
max D max Max pitch D min Max pitch
Dc, mm ap α° lm
(mm) (mm/rev) (mm) (mm/rev)
Insert size 16
25 12 19 45.7 49.8 12 28.8 4.32
D 32 12 13 66.0 63.8 12 42.8 8.15
36 12 11 78.1 71.8 12 50.8 9.29
40 12 9 89.5 79.8 12 58.8 10.20
44 12 8 101.4 87.8 12 66.8 10.83
50 12 7 118.7 99.8 12 78.8 11.59
54 12 6 130.8 107.8 12 86.8 11.92

Insert size 22
E 40 18 18 74.2 79.8 18 51 11.50
44 18 16 84.0 87.8 18 59 13.69
50 18 13 100.6 99.8 18 71 15.72
54 18 12 111.7 107.8 18 79 16.69
63 18 9 134.7 125.8 18 97 18.00
66 18 9 141.8 131.8 18 103 18.00
80 18 7 176.8 159.8 18 131 18.00
84 18 7 188.6 167.8 18 139 18.00
100 18 5 233.6 199.8 18 171 18.00
F 1) Maximal ramping angle, valid for min. corner radius, 0.5 mm. See diagram below for other radii.
2) Maximum α° and maximum ap

Ramping angle

30°
Maximum linear ramping angle rε = 0.5 mm
G The curves in the diagram are valid for rε = 6.35 mm
25°
min. and max, radii. For intermediate ra-
dii, please interpolate.
20°
rε = 0.5 mm
rε= 5.0 mm
15°

H
10°

5°
= Insert size 22
0°
= Insert size 16 20 30 40 50 60 70 80 90 100 110 120 130
Tool diameter, mm

D 104
 Milling

CoroMill R790 Al endmill Standard insert,

R790 22 ..., rε= 0.5-6.4 mm
in steps of 0.1 mm
Cylindrical A
Cylindrical power chuck Weldon Coromant Capto

Size Dc Size Dc Size Dc Size Dc C

25 38 - 50 32 38 -65 25 38 - 50 C4 38 - 51
32 38 - 65 42 38 -80 32 38 - 65 C5 38 - 65
40 38 - 80 40 38 - 80 C6 38 - 80
50 38 -100 50 38 -100 C8 38 -127
1 38 - 50 1 38 - 50
11/4 38 - 65 11/4 38 - 65
11/2 38 - 80 11/2 38 - 80
2 38 -101.6 2 38 -101.6 D
Arbor mounting Arbor mounting
HSK type A/C acc. to ISO 6462 acc. to ISO 6462 Cat V 50

Style Dc Style Dc
A16 52 - 64 B27 78 -125 F
A22 57 -105 B32 85 -165
A27 60 -125 B40 95 -200
Size Dc
A32 66 -165 B1 75 -118.6
50 38 - 65 Size Dc
A3/4 57 - 84.5 B11/4 86 -165
63 38 - 80 50 38 -150
A1 60 -118.6 B11/2 100 -200
80 38 -101.6
38 -150 A11/4 86 -165
100
A11/2 72 -200
G
Options
Insert size 22 l3 Reach length — 46 mm – 3 × Dc
Dc 38 – 200 mm l2 Total length — 105 – 409 mm
Pitch type Even l1 Programming length — 49 mm – 3 × Dc or 150 mm
H
zn 2–5 Coolant hole Available for all except arbor coupling
Mounting Cylindrical, Cylindrical power chuck, Weldon, Balance Always for HSK-A/C, Cat V 50
type Coromant Capto, HSK-A/C, Arbor mounting, Available for all coupling types
Cat V 50
dmm/D5m Mounting size — see above

D 105
 Milling

CoroMill 331
Multi-purpose side and face milling cutter
High precision capability
A

Full slot
Half side Cassette version

ap = <14 mm ap = 6-26.5 mm

Double half side

Tailor Made
Full slot
Fixed pocket version
D

ap Wide setting
range
ap = 6-10 mm
E

ISO application Geometries:

G areas:
-L -M -H
mm

General
H
-NL

Tool options designed to individual customer

requirements are available.

D 106