MillLine - Tungaloy Corporation · MillLine ... special insert geometry that reduces cutting force....

DOFEED

MillLine

Innovative high-feed cutters offerincredible productivity!

Tungaloy Report No. 403-USwww.tungaloyamer ica .com

2 DOFEED22222222 DODODOFEFEFEFF EDEDEDED

A C C E L E R A T E D M A C H I N I N G

www.t u nga l oyame r i c a .c om 3

MillLine

www. t unga l o y ame r i c a . com

High-feed cutters reduce machining time for a wide

range of applications.

4 DOFEED

0 1 2 3

Excellent chip evacuation prevents chip packing

Chipbreaker for general machining

Chipbreakerfor lowercutting force

Competitor

Reduced chatter due to double-sided insert with low cutting forces

· Large inclination forms ideal chips and controls the direction

chips flow.

· Air hole removes all chips away from the insert

and cutter body.

Crushed or unstable

Curl consistently at ideal length10 mm

10 mm

Competitor

Competitor

Spindle current (A)

MJ chipbreaker

ML chipbreaker6%

lower

9%lower

Comparison of spindle load

Good

Poor

Close pitch cutters for high productivity!

Coarse-pitch cutters minimize vibration for tools on low-powered machines.

Innovative high-feed cutters! DoFeed offers outstanding productivity with close-pitch cutters and special insert geometry that reduces cutting force. The rich lineup of items meets a wide variety of application needs.

Outstanding productivity

ø0.750 3 4 3ø1.000 4 5 4ø2.000 4 5 4ø3.000 4 6 4

: TXN06R200U0075A05

: LNMU06X5ZER-MJ

: AH725

: Carbon steels (1055)

: Vc = 590 sfm

: fz = 0.070 ipt: ap =0.039"

: Dry

: Vertical M/C, CAT50

: EXN03R100U0100-05

(ø1.000", z = 5)

: LNMU0303ZER-MJ / ML

: AH725

: Carbon steels (1055)

: Vc = 820 sfm

: fz = 0.020 ipt (1 insert)

: ap = 0.020"

: ae = 1.000" (Slot milling)

: Dry


Tool dia.

øDc (in)Productivity improvement compared to competitor

1.3 times

1.3 times

1.3 times

1.5 times

Cutter

Insert

Grade

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Coolant

Machine

Competitor

No. of inserts (z)

Cutter

Insert

Grade

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Width of cut

Coolant

Machine

Coarse pitch Close pitch

· ø0.750 and ø1.000 are based on EXN03 and HXN03 type · ø2.000 and ø3.000 are based on TXN06 type


A CC E L E R A T E D M A C H I N I N G

New

0 10 20 30 40 50

22%

39%39%

0 3.05 6.10 9.15 12.2 15.25 18.3

Ra0.8Ra0.8

Ra2.5Ra2.5

MJ General machining ML Low cutting force

Stainless SuperalloysSteel Cast iron

Hard Materials

Optimal rake angle

Large rake angle

Large landSmall land

4 cutting edges· Excellent combination of sharpness and

strength· Ideal for machining steel, cast iron, and

hardened steel

4 cutting edges· Exceptional sharpness· Suitable for cutting stainless steel, titanium

alloys, and other exotic materials· Reduces chattering when cutting with low

rigid set-ups

2 cutting edges· Excellent surface finish while

maintaining high productivity

Three chipbreakers for all machining needs

W Wiper insert

LNGU06-W

Extensive application coverage with a large variety of items

Stainless SuperalloysSteel Cast iron

Hard Materials

Stainless SuperalloysSteel Hard Materials

MH Robust cutting edges

CutterInsertGradeWorkpiece materialCutting speedFeed per toothDepth of cutWidth of cut CoolantMachine

: EXN03R125U0125-06: LNGU0303ZER-MH : AH8015: D2 (45HRC): Vc = 492 sfm: fz = 0.016 ipt: ap = 0.020": ae = ~ 1.250": Wet: Vertical M/C, CAT50

Competitor Competitor

Failure ratio (%)

Large radius

4 cutting edges· Robust cutting edges· Suitable for hardened steel

MH chipbreaker features:

•Robust cutting edge design

•Large radius on the wiper edge

•Modest inclination angle of the cutting edge decreases the impact to the cutter when entering the workpiece, reducing premature insert failures and extending tool life.

Insert failure ratio is significantly reduced, improving tool life stability!

Small rake angle

Nega Land

Modest inclination angle

CutterInsert

GradeWorkpiece materialCutting speedDepth of cutWidth of cut CoolantMachineMetal removal rate Q (in3/min)

Feed per tooth: Feed per tooth: ff z z == 0.039 ipt 0.039 ipt

Feed per toothFeed per tooth: : ffz z == 0.012 ipt 0.012 ipt

+ Wiper insert+ Wiper insert

Competitor Competitor Face milling cutter Face milling cutter

+ Wiper insert+ Wiper insert

Performance of wiper insert

: TXN06R300U0100A05: LNMU06X5ZER-ML x 3: LNGU06X5ZER-W x 2 : AH725: 1055 : Vc = 492 sfm: ap = 0.059" : ae = 2.362": Dry: Vertical M/C, CAT50

Wiper insert

LNGU06X5ZER-W

0.142" (Wiper length)

Metal removal rate comparison: DoFeed+wiper inserts vs face mill cutter with wiper inserts

Superb surface quality is achieved by high-feed motion

3 3 timestimesproductivity!productivity!

6 DOFEED

T U N G A LOY

AH725 AH120AH130AH3035

0 50 100 150 200

AH801515.0 92.0 3.0

3.5H10-H20

AH800515.0 93.0 2.0

H05-H15

AH8015New

AH8005New

: EXN03R075U0075-03

: LNMU0303ZER-MJ

: AH8015

: H13 (50HRC)

: Vc = 492 sfm

: fz = 0.020 ipt

: ap = 0.020"

: ae = 0.375"

: Dry


Cutter

Insert

Grade

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Width of cut

Coolant

Machine

・Exceptionally wear resistant in cast iron machining

Special Surface Technology

Stainless StainlessSuperalloys SuperalloysSteel Steel Cast iron Cast ironHard Materials

・Superior resistance to wear and fracture in cast iron milling

・High chipping resistance ・Ideal for titanium alloy

machining

Smooth insert surface prevents chip adhesion!・High wear and chipping

resistance and minimized built up edge due to nano multi-layered AlTiN coating with high Al content

・Well-suited for difficult

materials of 45-55 HRc

Extremely hard layer of nano multi-layered AlTiN coating with high Al content

Wear resistant substrate

Competitor

Machining length (ft)

Superior wear resistance and eliminates built up edge

Application

Specification of AH8015

Features

Grade Substrate Coating layer

Applicationcode

Relativedensity

MainComposition

Hardness(HRA)

T.R.S.(GPa)

Thickness(μm)

Hard Materials

Steel

Flash-Coating

(Ti, Al)N, base

Grades with long tool life for a wide range of materials

・Wear and fracture resistant for high-feed application

・Most suitable for steel and stainless steel machining

Hard Materials

Steel Cast iron

Cast iron

・High wear and chipping resistance and minimized built-up edge due to nano multi-layered AlTiN coating with high

Al content

・Ideal for hardened steel of 55HRc and above

Hard Materials

Hard Materials



TXN03Super h igh feed mi l l ing cutters wi th double s ided inserts wi th 4 edges

Inch Max. ap øDc z øDc1 øDc2 øDb ød ℓ Lf b a κ° lb Air hole Insert

TXN03R150U0050A05 0.039 1.500 5 1.248 1.247 1.460 0.500 0.750 1.575 0.160 0.252 17 0.530 with LNMU03...

TXN03R150U0050A06 0.039 1.500 6 1.248 1.247 1.380 0.500 0.600 1.575 0.160 0.252 17 0.510 with LNMU03...

TXN03R200U0075A05 0.039 2.000 5 1.718 1.757 1.693 0.750 0.750 1.969 0.197 0.315 17 1.100 with LNMU03...

TXN03R200U0075A08 0.039 2.000 8 1.718 1.757 1.693 0.750 0.750 1.969 0.197 0.315 17 1.100 with LNMU03...

TXN03R200U0075A10 0.039 2.000 10 1.718 1.757 1.693 0.750 0.750 1.969 0.197 0.315 17 1.100 with LNMU03...

SPARE PARTS

Designation Clamping screw Lubricant Wrench

TXN03... CSPB-2.5 M-1000 IP-8D

A.R. = +6°, R.R. = +12° ~ 13°

TXN03

EXN03

HXN03CAT30

0.625 0.750 1.000 1.250 1.500 2.000 2.500 3.000 6.000

CAT40

CAT50 TXN06EXN06

øDcøDc1

Rb

Lf

øDbøda

κ ° ap

øDc2øDc

Mach

ine s

ize

Tool dia. : øDc (in)

Applicable area

Rich lineup of cutter bodies from ø0.625" to ø6.000"

TXN03 (øDc = 1.500" - 2.000")

TXN06 (øDc = 2.000" - 6.000")

EXN03 (øDc = 0.625" - 1.250")

EXN06 (øDc = 1.250" - 1.500")

HXN03 (øDc = 16 - 32 mm

0.630" - 1.260")

Max. ap = 0.039"

Max. ap = 0.059"

LN*U06

LNMU03

Bore typeInsert Shank type Modular type

With LNGU03-MH

With LNMU03-MJ/ML

8 DOFEED

EXN03

Inch Max. ap øDc z øDc1 øDc2 øDs L Lf ℓs κ° lb Air hole Insert Fig.

EXN03R062U0062-02 0.039 0.625 2 0.372 0.381 0.625 4.000 1.250 2.750 15 0.310 with LNMU03... 1

EXN03R062U0062-02L 0.039 0.625 2 0.372 0.381 0.625 6.000 2.000 4.000 15 0.460 with LNMU03... 1

EXN03R068U0062-02 0.039 0.688 2 0.434 0.436 0.625 4.000 1.250 2.750 17 0.310 with LNMU03... 1

EXN03R068U0062-02L 0.039 0.688 2 0.434 0.436 0.625 6.000 1.000 5.000 17 0.490 with LNMU03... 1

EXN03R075U0075-02 0.039 0.750 2 0.495 0.498 0.750 5.000 2.000 3.000 17 0.550 with LNMU03... 1

EXN03R075U0075-03 0.039 0.750 3 0.495 0.498 0.750 5.000 2.000 3.000 17 0.550 with LNMU03... 1

EXN03R075U0075-03L 0.039 0.750 3 0.495 0.498 0.750 6.500 3.500 3.000 17 0.710 with LNMU03... 1

EXN03R075U0075-03-C 0.039 0.750 3 0.494 0.498 0.750 5.000 2.000 3.000 17 0.660 with LNMU03... 2

EXN03R087U0075-02 0.039 0.875 2 0.621 0.623 0.750 5.000 2.000 3.000 17 0.570 with LNMU03... 1

EXN03R087U0075-03 0.039 0.875 3 0.621 0.623 0.750 5.000 2.000 3.000 17 0.570 with LNMU03... 1

EXN03R087U0075-03L 0.039 0.875 3 0.621 0.623 0.750 6.500 1.250 5.250 17 0.750 with LNMU03... 1

EXN03R087U0075-03-C 0.039 0.875 3 0.634 0.623 0.750 5.000 2.000 3.000 17 0.660 with LNMU03... 2

EXN03R100U0100-04 0.039 1.000 4 0.746 0.748 1.000 5.500 2.500 3.000 17 1.080 with LNMU03... 1

EXN03R100U0100-04L 0.039 1.000 4 0.746 0.748 1.000 7.000 4.000 3.000 17 1.340 with LNMU03... 1

EXN03R100U0100-05 0.039 1.000 5 0.746 0.748 1.000 5.500 2.500 3.000 17 1.080 with LNMU03... 1

EXN03R100U0100-05-C 0.039 1.000 5 0.756 0.748 1.000 5.500 2.500 3.000 17 1.100 with LNMU03... 2

EXN03R112U0100-04 0.039 1.125 4 0.871 0.872 1.000 5.500 2.500 3.000 17 1.120 with LNMU03... 1

EXN03R112U0100-04L 0.039 1.125 4 0.871 0.872 1.000 7.000 1.500 5.500 17 1.460 with LNMU03... 1

EXN03R112U0100-05 0.039 1.125 5 0.871 0.872 1.000 5.500 2.500 3.000 17 1.120 with LNMU03... 1

EXN03R125U0125-05 0.039 1.250 5 0.997 0.997 1.250 6.000 3.000 3.000 17 1.870 with LNMU03... 1

EXN03R125U0125-05L 0.039 1.250 5 0.997 0.997 1.250 8.000 5.000 3.000 17 2.430 with LNMU03... 1

EXN03R125U0125-06 0.039 1.250 6 0.997 0.997 1.250 6.000 3.000 3.000 17 1.850 with LNMU03... 1

EXN03R125U0125-06-C 0.039 1.250 6 1.008 0.997 1.250 6.000 3.000 3.000 17 1.760 with LNMU03... 2

SPARE PARTSDesignation Clamping screw Lubricant Wrench

EXN03... CSPB-2.5 M-1000 IP-8D

Super h igh feed endmi l ls wi th double s ided inserts wi th 4 edges

LLf

øDc

øDc 1

øDs

κ°

apRs

øDc

øDc 2

With LNGU03-MHWith LNMU03-MJ/ML



A.R. = +6°, R.R. = +5° ~ +11°

Metric Max. ap øDc z øDc1 øDc2 L6 Lf C T øD3 κ° Ts Ib Air hole Insert

HXN03R016MM08-02 1 16 2 9.6 9.8 42 25 8 10 12.8 15 M8 0.07 with LNMU03...








HXN03R028MM12-04 1 28 4 21.5 21.6 57 35 10 17 23 17 M12 0.26 with LNMU03...

HXN03R028MM12-05 1 28 5 21.5 21.6 57 35 10 17 23 17 M12 0.26 with LNMU03...





HXN03-M

Super h igh feed endmi l ls wi th TungFlex


HXN03... CSPB-2.5 M-1000 IP-8D

øD3

L6Lf

øDc

øDc 1

ap

TTs

CA

Aκ° A-A cross section

øDc

øDc 2

P � � �

M � �

K � �

N

S � �

H � � �

LNMU03-MJ（汎用ブレーカ） B

AT

rε

ap

LNMU03-ML（低抵抗ブレーカ）

BA

Trε

ap

rε Max. ap A B T

AH

13

0

AH

72

5

AH

30

35

AH

80

15

AH

80

05

LNMU0303ZER-MJ 0.047 0.039 0.126 0.236 0.169

LNMU0303ZER-ML 0.047 0.039 0.126 0.236 0.169

LNGU0303ZER-MH 0.047 0.039 0.126 0.236 0.169

New

BA

Trε

ap

New

INSERT

With LNGU03-MH

With LNMU03-MJ/ML

LNMU03-MJ (for general purpose) LNMU03-ML (for low cutting force)

Steel

Stainless

Cast iron

Non-ferrous

Superalloys

Hard materials : First choice : Second choice

Designation

Coated

: Line up

LNGU03-MH (Robust cutting edges)

10 DOFEED

Inch Max. ap øDc z øDc1 øDc2 øDb Lf ød ℓ a b lb Air hole Insert

TXN06R200U0075A04 0.059 2.000 4 1.513 1.485 1.850 1.969 0.750 0.750 0.315 0.197 0.970 with LN*U06...

TXN06R200U0075A05 0.059 2.000 5 1.513 1.485 1.850 1.969 0.750 0.750 0.315 0.197 0.990 with LN*U06...

TXN06R250U0075A04 0.059 2.500 4 2.012 1.983 2.323 1.969 0.750 0.750 0.315 0.197 1.740 with LN*U06...

TXN06R250U0075A06 0.059 2.500 6 2.012 1.983 2.323 1.969 0.750 0.750 0.315 0.197 1.760 with LN*U06...

TXN06R300U0100A05 0.059 3.000 5 2.512 2.481 2.835 2.480 1.000 1.049 0.374 0.236 3.130 with LN*U06...

TXN06R300U0100A07 0.059 3.000 7 2.512 2.481 2.835 2.480 1.000 1.049 0.374 0.236 3.280 with LN*U06...

TXN06R400U0150A06 0.059 4.000 6 3.512 3.481 3.819 2.480 1.500 1.610 0.626 0.394 4.850 with LN*U06...

TXN06R400U0150A10 0.059 4.000 10 3.512 3.481 3.819 2.480 1.500 1.610 0.626 0.394 4.850 with LN*U06...

TXN06R500U0150A08 0.059 5.000 8 4.512 4.481 3.819 2.480 1.500 1.610 0.626 0.394 7.050 with LN*U06...

TXN06R500U0150A12 0.059 5.000 12 4.512 4.481 3.819 2.480 1.500 1.610 0.626 0.394 7.280 with LN*U06...

TXN06R600U0200A10 0.059 6.000 10 5.512 5.480 4.331 2.480 2.000 1.496 0.748 0.433 9.480 with LN*U06...

TXN06R600U0200A14 0.059 6.000 14 5.512 5.480 4.331 2.480 2.000 1.496 0.748 0.433 9.260 with LN*U06...

TXN06

Super h igh feed mi l l ing cutters wi th double s ided inserts wi th 4 edges

SPARE PARTSDesignation Clamping screw Grip Lubricant Torx bit

TXN06R200U - 500U CSPB-5 H-TB2W M-1000 BLDIP20/S7

TXN06R600U... CSPB-5 H-TB2W M-1000 BLDIP20/M7

Lf

ℓ

øDcøDc1

15°

øDbøda b

ap

øDcøDc2

ød

b

a

R

ø101.6 mm

ø17 mm

øDb

ød

b

a

R

ø101.6 mm

ø18 mm

øDb

TXN06R200M47.6... TXN06R200M60.0...

A.R.=+10°,R.R.=+2°~+6°

With LNGU06-MHWith LN*U06-MJ/ML/W

Fig.1 Fig.2 Fig.3



EXN06

Inch Max. ap øDc z øDc1 øDc2 øDs L Lf ℓs lb Air hole Insert

EXN06R125U0125W02 0.059 1.250 2 0.766 0.745 1.250 5.281 3.000 2.281 1.540 with LN*U06...

EXN06R125U0125-02L 0.059 1.250 2 0.766 0.745 1.250 8.000 5.000 3.000 2.360 with LN*U06...

EXN06R150U0125W03 0.059 1.500 3 1.014 0.989 1.250 5.781 3.500 2.281 1.830 with LN*U06...

EXN06R150U0125-03L 0.059 1.500 3 1.014 0.989 1.250 10.000 2.000 8.000 3.310 with LN*U06...

Super h igh feed endmi l ls wi th double s ided inserts wi th 4 edges

A.R. = +10°, R.R. = -2° ~ +6°


EXN06... CSPB-5 M-1000 IP-20D

LLf Rs

øDc

øDc 1

øDs

ap

15°

øDc

øDc 2

P � � �

M � �

K � � �

N

S � �

H � � �

rε Max. ap A B T bs

AH

12

0

AH

13

0

AH

72

5

AH

30

35

AH

80

15

AH

80

05

LNMU06X5ZER-MJ 0.079 0.059 0.236 0.472 0.276 -

LNMU06X5ZER-ML 0.079 0.059 0.236 0.472 0.276 -

LNGU06X5ZER-MH 0.079 0.059 0.236 0.472 0.276 -

LNGU06X5ZER-W 0.079 0.059 0.236 0.472 0.276 0.142

B

A

T

rε

ap

rε

B T

A

ap

B

Abs

T

rε

ap

New

B

A

T

rε

ap

New

INSERT

With LNGU06-MHWith LN*U06-MJ/ML/W

Steel

Stainless

Cast iron

Non-ferrous

Superalloys

Hard materials

Designation

Coated

: First choice : Second choice

: Line up

LNGU06-MH

LNMU06-MJ LNMU06-ML

LNGU06-W (2 cutt ing edges)

12 DOFEED

w

rε

R

t117°

R

t2

t1

max.

ap

max ap (in) rε (in)

W (in)t1 (in) t2 (in)

0.039 0.047 0.118 0.039 0.018 -

0.039 0.047 0.118 0.059 0.014 -

0.039 0.047 0.118 0.079 0.008 0.004

0.039 0.047 0.118 0.098 0.003 0.011

max ap (in) rε (in)

W (in)t1 (in) t2 (in)

0.039 0.047 0.118 0.039 0.018 -

0.039 0.047 0.118 0.059 0.014 -

0.039 0.047 0.118 0.079 0.008 0.004

0.039 0.047 0.118 0.098 0.003 0.011

When chips stay in the cutting zone during slotting or pocketing, use air blast to remove chips from the work area.

Tool overhang length must be as short as possible to avoid chatter. When the tool overhang length is long, decrease the number of revolutions and feed.

0.020 　 0.030 　0.040 0.060

0.040

0.028

0.020

0.012

0

Vc = 330 - 980 sfm

Vc = 260 - 650 sfm

The use of a standard or long shank

Tool dia.: øDc = ø0.625 - 1.250"

Workpiece material: 1055

(200HB)

When using a long shank, please lower the cutting conditions (Vc, fz, ap) to 70% of the maximum conditions for the standard shank.

L/D ratio of overhang

Standard shank: L/D ≤ 3

Long shank: L/D = 4

Standard shank

Long shank

Dep

th o

f cu

t: a

p (in

)

Feed per tooth: fz (ipt)

CAUTIONARY POINTS IN USE

STANDARD CUTTING CONDITIONS TXN03/EXN03/HXN03

Tool geometry on programming

When programming for CAM, the tool should be considered as

a radius cutter. Usually, the corner radius should be set as R

= 1.5 mm. If a larger radius is used, overcutting will occur. The

following table shows the amount left uncut (t1) and overcut (t2).

Amount left overcut

Amount left overcut

Max. d

ep

th o

f cut

Corner R when programming

Amount leftuncut

Max. depth of cut Corner radius

Amount leftuncut

Corner R whenprogramming

Each value in table is calculated theoretically at the maximum condition.

Amount left overcut

Max. depth of cut Corner radius

Amount leftuncut

Corner R whenprogramming

LNGU03-MH

LNMU03-MJ/ML

ISO

ø0.625", z=2 ø0.688", z=2 ø0.750"

Vc (sfm)

ø0.620~ 0.870 ø1.000~ 2.000 n Vf n Vf n Vfz = 2 z = 3

Carbon steels

1045, 1055, etc.- 300HB

First choice AH3035 MJ330 - 990

0.020 - 0.047

0.020 - 0.059

0.0044,040 240 3,670 220 3,360 200 300

for wear resistance AH8015 MJ Vc = 660 sfm, fz = 0.030 ipt

Alloy steels

4140, SCr415, etc.- 300HB


0.020 - 0.047

0.020 - 0.059

0.0044,040 240 3,670 220 3,360 200 300


Prehardened steels

NAK80, PX5, etc.

30 - 40HRC

First choice AH3035 ML 330 - 6600.020 - 0.039

0.020 - 0.039

0.0043,060 180 2,780 170 2,550 150 230

Vc = 500 sfm, fz = 0.030 ipt

30 - 40HRC

for impact resistance AH3035 MJ 330 - 660

0.020 - 0.047

0.020 - 0.059

0.0043,060 180 2,780 170 2,550 150 230

Vc = 500 sfm, fz = 0.030 ipt

30 - 40HRC

for wear resistance AH8015 ML 330 - 660

0.020 - 0.039

0.020 - 0.039

0.0043,060 180 2,780 170 2,550 150 230

Vc = 500 sfm, fz = 0.030 ipt

Stainless steels

304, 316, etc.- 200HB

First choice AH3035 ML330 - 490

0.012 - 0.031

0.012 - 0.031

0.0032,510 100 2,280 90 2,090 80 130

for impact resistance AH3035 MJ Vc = 410 sfm, fz = 0.020 ipt

Gray cast irons

No.250B, etc.

150 - 250HB

First choice AH725 MJ 330 - 9900.020 - 0.047

0.020 - 0.059

0.0044,040 240 3,670 220 3,360 200 300

Vc = 660 sfm, fz = 0.030 ipt

150 - 250HB

First choice AH725 MJ 330 - 9900.020 - 0.047

0.020 - 0.059

0.0044,040 240 3,670 220 3,360 200 300

Vc = 660 sfm, fz = 0.030 ipt

Ductile cast irons

65-45-12, etc.150 -

250HB


0.020 - 0.047

0.020 - 0.059

0.0043,610 220 3,280 200 3,010 180 270


Titanium alloys

Ti-6AI-4V, etc.- 40HRC


0.012 - 0.028

0.012 - 0.028

0.002920 37 830 33 760 30 46


Heat-resistant alloys

Inconel, Hastelloy, etc.- 40HRC

First choice AH8015 MH70 - 170

0.004 - 0.012

0.004 - 0.012

0.003730 12 670 11 610 10 15

for wear resistance AH8005 MH Vc = 120 sfm, fz = 0.008 ipt

Hot mold steel

HB, etc.40

-55HRC


0.004 - 0.020

0.004 - 0.020

0.0022,320 56 2,110 51 1,940 47 70

for impact resistance AH8015 MH Vc = 380 sfm, fz = 0.012 ipt

Hot mold steel of D.T.C

materials

(DAC**, DH**, DIEVER, etc)

40-55HRC


0.004 - 0.012

0.004 - 0.012

0.0021,530 24 1,390 22 1,270 20 30


Cold mold steel

D2, etc.

55- 60HRC

for impact resistance

AH8015 MH 160 - 2300.002 - 0.008

0.002 - 0.008

0.0021,220 12 1,110 11 1,020 10 15

Vc = 200 sfm, fz = 0.005 ipt55 -

65HRCfor impact resistance

AH8015 MH 160 - 2300.001 - 0.004

0.001 - 0.004

0.0011,220 7 1,110 7 1,020 6 9

Vc = 200 sfm, fz = 0.003 ipt

Plunging Chip-

breaker

Cutting speed


Tool dia.: øDc (in)Workpiece material Hardness Priority Grade


The above table shows the conditions for standard shank type cutters. When using long shank type cutters, the number of teeth may be diff erent. In this case, the cutting conditions should be changed by referring to: “The use of standard or long shanks” shown on previous page.

Cutting conditions are generally limited by the rigidity and power of the machine and the rigidity of the workpiece. When setting the conditions, start from half of the values of the standard cutting conditions and then increase the value gradually while making sure the machine is running normally.

Tool dia. Max. depthof cut

Max. rampingangle

Max. plungingdepth

Min.machinablehole dia.

Inch øDc Max ap θ° A W øD1 øD2 ae

EXN03R062U0062... 0.625 0.039 1.7 0.012 0.118 0.897 1.181 0.492

EXN03R068U0062... 0.688 0.039 1.7 0.012 0.118 0.991 1.339 0.571

EXN03R075U0075... 0.750 0.039 1.2 0.012 0.118 1.132 1.496 0.650

EXN03R087U0075... 0.875 0.039 1 0.012 0.118 1.371 1.654 0.728

EXN03R100U0100... 1.000 0.039 0.9 0.012 0.118 1.610 1.890 0.846

EXN03R112U0100... 1.125 0.039 0.8 0.012 0.118 1.857 2.126 0.965

EXN03R125U0125... 1.250 0.039 0.7 0.012 0.118 2.104 2.441 1.122

TXN03R150U0075... 1.500 0.039 0.5 0.012 0.118 2.750 3.070 1.437

TXN03R200U0075... 2.000 0.039 0.4 0.012 0.118 3.540 3.858 1.830

· For øDc above 1.300", slot milling, ramping or contouring is not recommended as chips may be re-cut.

øD1, øD2

θ°a p A

Wae

a p

Shoulder milling Slotting

Traversing

Small depth plungingRamping

Plunging Drilling(Helical feed)

Enlarged hole

APPLICATION RANGE

Max.machinable

hole dia.

Max. cutting width in plunging

Max. cutting width in enlarged

hole

ø.875" φ1.000" φ1.125" φ1.250" φ1.500" φ2.000"

n Vf n Vf n Vf n Vf n Vf n VfZ=2 Z=3 z = 4 z = 5 z = 4 z = 5 Z=5 Z=6 z = 5 z = 6 Z=5 Z=8

2,970 180 270 2,520 300 380 2,240 270 340 2,020 300 360 1,680 250 300 1,260 190 300

Vc = 660 sfm, fz = 0.040 ipt

2,970 180 270 2,520 400 500 2,240 360 450 2,020 400 480 1,680 340 400 1,260 250 400

Vc = 660 sfm, fz = 0.040 ipt

2,250 140 200 1,910 230 290 1,700 200 260 1,530 230 280 1,270 190 230 960 140 230Vc = 500 sfm, fz = 0.040 ipt

2,250 140 200 1,910 310 380 1,700 270 340 1,530 310 370 1,270 250 300 960 190 310Vc = 500 sfm, fz = 0.040 ipt

2,250 140 200 1,910 230 290 1,700 200 260 1,530 230 280 1,270 190 230 960 140 230Vc = 500 sfm, fz = 0.030 ipt

1,840 70 110 1,570 130 160 1,390 110 140 1,250 130 150 1,040 100 120 780 80 120

Vc = 410 sfm, fz = 0.020 ipt

2,970 180 270 2,520 300 380 2,240 270 340 2,020 300 360 1,680 250 300 1,260 190 300Vc = 660 sfm, fz = 0.040 ipt

2,890 5,200 6,940 2,550 6,110 7,640 2,270 5,460 6,820 2,120 6,780 8,480 1,990 7,960 9,550 1,820 7,280 8,740Vc = 660 sfm, fz = 0.040 ipt

2,650 160 240 2,250 360 450 2,000 320 400 1,800 360 430 1,500 300 360 1,130 230 360

Vc = 590 sfm, fz = 0.030 ipt

670 27 40 570 46 57 510 41 51 460 46 55 380 38 46 290 29 46

Vc = 150 sfm, fz = 0.020 ipt

540 9 13 460 15 18 410 13 16 370 15 18 310 12 15 230 9 15

Vc = 120 sfm, fz = 0.008 ipt

1,710 41 62 1,450 70 87 1,290 62 77 1,160 70 84 970 58 70 730 44 70

Vc = 380 sfm, fz = 0.012 ipt

1,120 18 27 960 31 38 850 27 34 760 30 36 640 26 31 480 19 31

Vc = 250 sfm, fz = 0.008 ipt

900 9 14 760 15 19 680 14 17 610 15 18 510 13 15 380 10 15Vc = 200 sfm, fz = 0.005 ipt

900 5 8 760 6 8 680 5 7 610 6 7 510 5 6 380 4 6Vc = 200 sfm, fz = 0.002 ipt

Tool dia.: øDc (in), Number of revolutions: n (rpm-1), Feed speed: Vf (ipm), Max. depth of cut: ap = 0.039", No. of teeth: z

14 DOFEED

max ap (in) rε

W (in)

t1 (in) t2 (in)

0.059 0.079 0.236 0.079 0.039 -

0.118 0.030 -0.157 0.021 0.010

w

rε15°

R R

t2

t1 t1

max.

ap

max ap (in) rε

W (in)

t1 (in) t2 (in)

0.059 0.079 0.236 0.079 0.035 -

0.118 0.026 -0.157 0.026 0.010

STANDARD CUTTING CONDITIONS TXN06 / EXN06

0.020 0.040 0.060 0.080

0.060

0.040

0.020

0

Vc = 260 - 650 sfm

Vc = 330 - 980 sfm

Tool geometry for programming

When programming for CAM, the tool should be considered

as a radius cutter. Usually, the corner radius should be set

as R = 0.118". If a larger radius is used, overcutting will

occur. The following table shows the amount left as uncut

(t1) and overcut (t2).

The usage of a standard & long shank

When using a long shank, please lower the cutting

conditions (Vc, fz, ap) to 70% of the maximum conditions

for the standard shank.

Tool dia.: øDc = ø1.250" - 1.500"

Workpiece material: 1055

(200HB)

L/D ratio of overhang

Standard shank: L/D ≤ 3

Long shank: L/D = 4

Standard shank

Long shank

Dep

th o

f cu

t: a

p (in

)


When chips stay in the cutting zone during slotting or pocketing, use air blast to

remove chips from the work area.

Tool overhang length must be as short as possible to avoid chatter. When the

tool overhang length is long, decrease the number of revolutions and feed.

CAUTIONARY POINTS IN USE

Amount left overcut

Max. d

ep

th o

f cut

Corner R when programming

Amount leftuncut

Max. depth of cut

Corner radiusAmount left

uncutCorner R whenprogramming

Each value in table is calculated theoretically at the maximum condition.

Amount left overcut

Max. depth of cut

Corner radiusAmount left

uncutCorner R whenprogramming

Amount left overcut

LNGU06-MH

LNMU06-MJ/ML

ISO Work material Hardness Priority GradesChip-

breaker

Cutting speed

Feed per tooth fz (ipt)

Vc (sfm)

Tool dia: øDc (in)

Feed when plunging

fz(ipt)

ø1.250", z = 2 ø1.500", z = 2 ø2.000"

n Vf n Vf nVf

ø32 ~ ø200 z = 4 z = 5

Carbon steels

1045, 1055, etc.- 300HB

First choice AH3035 MJ330 - 990 0.020 - 0.059 0.006

2,020 162 1,680 134 1,261 202 252


Alloy steels

4140, SCr415, etc.- 300HB

First choice AH3035 ML330 - 990 0.020 - 0.059 0.006

2,018 161 1,682 135 1,261 202 252


Prehardened steels

NAK80, PX5, etc.

30 -

40HRCFirst choice AH8015 ML 330 - 660 0.020 - 0.039 0.006

1,529 92 1,274 76 955 115 143

Vc = 500 sfm, fz = 0.030 ipt

30 -

40HRCfor impact resistance AH3035 MJ 330 - 660 0.020 - 0.059 0.006

1,529 122 1,274 102 955 153 191

Vc = 500 sfm, fz = 0.040 ipt

30 -

40HRCfor wear resistance AH8015 ML 330 - 660 0.020 - 0.039 0.006

1,529 92 1,274 76 955 115 143

Vc = 500 sfm, fz = 0.030 ipt

Stainless steels

304, 316, etc.- 200HB


1,254 50 1,045 42 783 63 78


Gray cast irons

No.250B, etc.

150 -

250HB


2,018 161 1,682 135 1,261 202 252


Ductile cast irons

65-45-12, etc.

150 -

250HB


1,406 113 1,172 94 879 141 176


Titanium alloys

Ti-6AI-4V, etc.- 40HRC


459 18 382 15 287 23 29


Heat-resistant alloys

Inconel, Hastelloy, etc.- 40HRC


367 6 306 5 229 7 9


Hot mold steel

HB, etc.

40 -

55HRC

First choice AH8015 MH260 - 490 0.004 - 0.020 0.002

1,162 28 968 23 726 35 44


Hot mold steel of D.T.C materials(DAC**, DH**, DIEVER, etc)

40 -

55HRC


764 12 637 10 478 15 19


Cold mold steel

D2, etc.

50 -

60HRCFirst choice AH8005 MH 160 - 230 0.002 - 0.008 0.001

611 6 510 5 382 8 10

Vc = 200 sfm, fz = 0.005 ipt

50 -

60HRCfor impact resistance AH8015 MH 160 - 230 0.001 - 0.004 0.001

611 4 510 3 382 5 6

Vc = 200 sfm, fz = 0.030 ipt


The above table shows the conditions for standard shank type cutters.

When using long shank type cutters, the number of teeth may be diff erent.

In this case, the cutting conditions should be changed by referring to: “The

usage of standard and long shanks” shown on previous page.

Cutting conditions are generally limited by the rigidity and power of the

machine and the rigidity of the workpiece. When setting the conditions, start

from half of the values of the standard cutting conditions and then increase

the value gradually while making sure the machine is running normally.

Tool dia. Max. depthof cut

Max. rampingangle

Max. plungingdepth

Min.machinablehole dia.

Max.machinablehole dia.

Inch øDc Max . ap θ° A W øD1 øD2 ae

EXN06R125U... ø1.250 0.059 2.0º 0.020 0.236 1.830 2.300 0.970

EXN06R150U... ø1.500 0.059 1.5º 0.020 0.236 2.330 2.800 1.220

TXN06R200U... ø2.000 0.059 0.9º 0.020 0.236 3.330 3.800 1.720

TXN06R250U... ø2.500 0.059 0.6º 0.020 0.236 4.330 4.800 2.220

TXN06R300U... ø3.000 0.059 0.5º 0.020 0.236 5.330 5.800 2.720

· For øDc above 4.000", slot milling, ramping or contouring is not recommended as chips may be re-cut.

øD1, øD2

θ°a p A

aeW

Shoulder milling

Traversing

Small depth plunging Ramping Plunging

Drilling(Helical feed)

Enlarged hole

APPLICATION RANGE

Max. cutting width in plunging

Max. cutting width in enlarged

hole

Tool dia:øDc (in), Number of revolution: n (rpm), Feed speed: Vf (ipm), Max. depth of cut:ap = 0.059", Number of teeth:z

ø2.500" ø3.000" ø4.000" ø5.000" ø6.000"

nVf

nVf

nVf

nVf

nVf

z = 4 z = 5 z = 4 z = 6 z = 5 z = 8 z=8 z=12 z=10 z=15

1,009 161 202 841 168 235 631 151 252 504 161 242 420 168 252

Vc = 660 sfm, fz = 0.040 ipt

1,009 161 202 841 168 235 631 151 252 504 161 242 420 168 252

Vc = 660 sfm, fz = 0.040 ipt

764 92 115 637 96 134 478 86 143 382 92 138 318 96 143

Vc = 500 sfm, fz = 0.030 ipt

764 122 153 637 127 178 478 115 191 382 122 183 318 127 191

Vc = 500 sfm, fz = 0.040 ipt

764 92 115 637 96 134 478 86 143 382 92 138 318 96 143

Vc = 500 sfm, fz = 0.030 ipt

627 50 63 522 52 73 392 47 78 313 50 75 261 52 78

Vc = 410 sfm, fz = 0.020 ipt

1,009 161 202 841 168 235 631 151 252 504 161 242 420 168 252

Vc = 660 sfm, fz = 0.040 ipt

703 113 141 586 117 164 439 105 176 352 113 169 293 117 176

Vc = 460 sfm, fz = 0.040 ipt

229 18 23 191 19 27 143 17 29 115 18 28 96 19 29

Vc = 150 sfm, fz = 0.020 ipt

183 6 7 153 6 9 115 6 9 92 6 9 76 6 9

Vc = 120 sfm, fz = 0.008 ipt

581 28 35 484 29 41 363 26 44 290 28 42 242 29 44

Vc = 380 sfm, fz = 0.012 ipt

382 12 15 318 13 18 239 11 19 191 12 18 159 13 19

Vc = 250 sfm, fz = 0.008 ipt

306 6 8 255 6 9 191 6 10 153 6 9 127 6 10

Vc = 200 sfm, fz = 0.005 ipt

306 4 5 255 4 5 191 3 6 153 4 6 127 4 6

Vc = 200 sfm, fz = 0.030 ipt

16 DOFEED

TXN06R300U0100A07 (ø3.000", z = 7) EXN03R125U0125-06 (ø1.250", z = 6)

LNMU06X5ZER-ML x 6 / LNGU06X5ZER-W x 1 LNMU0303ZER-ML

AH130 / AH725 AH130

333 233

0.016 0.006

0.020 0.040

2.362 1.575

2.5

2.0

1.5

1.0

0.5

0

0.7

87"

3.54"

1.575"

Cu

ttin

g c

on

dit

ion

s

Workpiece type Cutter

Insert

Grade

Workpiece material

Cutting speed: Vc (sfm)


Depth of cut: ap (in)

Width of cut: ae (in)

Process

Coolant

Machine

Results

17-4

Automotive / Rod end

Face milling

Internal supply

Turning center / 7.5 kW

DoFeed is a versatile cutter and was used against a shoulder milling cutter, achieving double tool life.

Part

s /

cutt

ing

ed

ge

(pcs)

Tool life Tool life improved byimproved by

100100%!%!

Competitor

3.9

37"

59"

78.75"

360

300

240

180

120

60

0

S30400

Cutt

ing

tim

e (m

in/p

cs) 55

timestimesproductivity!productivity!

CompetitorCompetitor's tool took 300 minutes for roughing and fi nishing. DoFeed with wiper insert reduces time for fi nishing and improves total productivity by 5 times that of the competitor.

Face milling

Wet

Vertical M/C, CAT50

Machine frame


LNMU06X5ZER-MJ LNMU0303ZER-MJ

AH3035 AH725

384 330

0.028 0.031

0.043 0.020

1.654 0.709

11.82

7.88

3.94

0

1009080706050403020100

20"

40"

80"

3.1

50"

5.9"

5.9"


Insert

Grade

Workpiece material





Process

Coolant

Machine

Results

Prehardened steel HPM7 (30HRC)

Die & Mold / Back block

Contour milling

Air blow

Vertical M/C, CAT50Cu

ttin

g c

on

dit

ion

s

1.51.5

timestimes tool life!tool life!

Competitor

Pocket milling

Dry (air)

Vertical M/C, CAT40

Prehardened steel (40HRC)

Actual machining time: 29 min

Actual machining time: 69 min

VBmax = 0.012"

VBmax = 0.012"

Cutt

ing

leng

th (ft

)

Machining Machining time time

improved by improved by

240240%!%!Competitor

AH3035 grade showed better chipping resistance than competitor improving tool life by 50%.

Too

l lif

e (m

in)

Machine parts

PRACTICAL EX AMPLES


TXN06R250U0075A06 (ø2.500" , z = 6) EXN03R125U0125-06 (ø1.250", z = 6)

LNGU06X5ZER-MH LNMU0303ZER-MJ

AH8015 AH8015

387 560

0.031 0.031

0.031 0.036

1.496 0.93

10

9

8

7

6

5

4

3

2

1

0

5

4

3

2

1

0


LNMU06X5ZER-MJ LNMU0303ZER-MJ

AH120 AH725

500 634

0.040 0.016

0.020 0.012

4.700 0.354

160140120100806040200

2.0

"

5.9"

7.8"

15.25

12.20

9.15

6.10

3.05

0

196.8"

59"

27.6

"

Cu

ttin

g c

on

dit

ion

sWorkpiece type

Cutter

Insert

Grade

Workpiece material





Process

Coolant

Machine

Results

CompetitorCompetitor

Die & moldLarge machine parts

Pocket milling

Dry (air)

Vertical M/C, CAT40

Face milling

Dry

Horizontal M/C, CAT50

Cutt

ing

tim

e (min)

Meta

l re

mo

val ra

te:

MR

R (in

3/m

in)

Due to the lower cutting forces, DoFeed can increase productivity 3 times higher than competitor. AH725 grade can effectively reduce sudden fracture, achieving double tool life.

DoFeed, with high density insert, can effectively increase productivity. Lower cutting forces reduce chattering, achieving 1.5 times tool life.

80-55-0680-55-06

DoubledDoubledtool life!tool life!

MRR MRR improvedimproved byby

1.41.4 times!times!

AH8015 exhibited superior wear resistance producing seven times the number of pieces compared to the competitor.

Cu

ttin

g c

on

dit

ion

s

Workpiece type

Cutter

Insert

Grade

Workpiece material





Process

Coolant

Machine

Results

Press-cutter blade

4140(44HRC)4140(44HRC)

Machine part

Pocketing

Air blast

Vertical M/C

Face milling

Dry (air)

Vertical M/C

Competitor


77 timestimes!!

Num

. o

f p

ieces

(pcs/c

orn

er)

A combination of the MH chipbreaker and AH8015 reduced chipping and wear. Tool life has increased to 130%.

Num

. o

f p

ieces

(pcs/c

orn

er)

Competitor


1.31.3 timestimes!!

18 DOFEED

EXN03R112U0100-05 (ø1.125", z = 5) EXN03R100U0100-05 (ø1.000", z = 5)

LNMU0303ZER-ML LNMU0303ZER-ML

AH725 AH725

230 160

0.020 0.028

0.020 0.020

1.181 1.000

1.83

1.53

1.22

0.92

0.61

0.30

0

1.53

1.22

0.92

0.61

0.30

0

9.8"5.9"

19

.7"

7.9

"

1.2

"

Turbine blade

Shoulder milling

Wet

Vertical M/C, CAT50

Tripled cutting speed and super high feed milling offer 16 times higher productivity.

Aerospace component

Pocket milling

Wet

Vertical M/C, CAT40

7.3 times higher feed machining that drastically improves productivity.

Ti-6Al-4V (36HRC)

Cu

ttin

g c

on

dit

ion

s


Insert

Grade

Workpiece material





Process

Coolant

Machine

Results

Competitor Competitor

Heat resistant cast steel

Meta

l re

mo

val ra

te:

MR

R (in

3/m

in)

Meta

l re

mo

val ra

te:

MR

R (in

3/m

in)


1616 times!times!


3.33.3 times!times!


Check our site and our App to get more info!

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Jan. 2018 (TA)

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MillLine - Tungaloy Corporation · MillLine ... special insert geometry that reduces cutting force....

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Transcript of MillLine - Tungaloy Corporation · MillLine ... special insert geometry that reduces cutting force....