designs target toughest metal removal...

August 2016 | AdvancedManufacturing.org 51

milling cutters

Designs Target Toughest Metal Removal Applications

Jim LorinczSenior Editor

A lot to choose from in single, double-

sided insert cutters and grades Milling cutter development and advances in machine

tool technology are seldom in step. One or the

other is leapfrogging ahead, tempting manufactur-

ers with impressive new metal removal data and

results. Technical advances are often shrouded in the names of

proprietary and often patentable technology that improve carbide

grades, chipbreaker insert geometries, toolpath programming,

toolholding and workholding, and coolant delivery. Any one

development might be just the right fit that a new more rigid and

powerful machine tool needs to maximize machining results. Or

if a lighter duty machine is used, milling cutters are available that

are specifically designed for them.

Making the right selection of milling cutter, indexable or solid

carbide, substrate, coating, geometry, toolpath programming,

and coolant delivery and chip-handling system is critical to opti-

mizing process performance. It has never been more important

to regard milling cutting tool suppliers as partners, ready, willing,

and able to apply their product solutions to the myriad chal-

Seco’s T4-12 line of square shoulder and helical milling cutters allows manufacturers to achieve increased depths of cut and higher

metal removal rates when roughing and semi-finishing steel, cast iron, among others.

52 AdvancedManufacturing.org | August 2016

lenges manufacturers in every industry face daily. Here’s a

selection of those developments which can be seen at IMTS

2016, along with a bevy of other milling cutter solutions.

Positive Cutting CoroMill 745 Aims at Light-Duty Market

Sandvik Coromant (Fair Lawn, NJ) has introduced Cor-

oMill 745, a double-sided multiedge insert with a positive

cutting action. “Most of our customers are going for lighter

duty machines,” said Dan Tucker, product manager/milling

specialist, US West. “The CoroMill 745 gives them the ability

to produce components much faster with hard data without

giving up economy. Secret to it is the patented insert posi-

tioning system. By tilting the insert, the cutting edge position

and angle are the same as in a light-cutting positive orienta-

tion and, of course, you get 14 edges per insert.”

The CoroMill 745 has a low cost per edge and is suitable

for large batches. “A really key feature of this cutter is the 42°

lead angle face mill allows a little bit more chip thinning than a

traditional 45° lead angle,” said Tucker. “The CoroMill 745 is

being released in a 2.5–10" [51–254-mm] diameter range for

machining steel and cast iron. It’s a very robust insert, 10-mm

IC, easy to change, easy to index, not a lot that can go wrong.

Initially released in CVD grades 4230, K20D and K20W. Cor-

oMill 745 has exceeded our expectations,” said Tucker.

According to Tucker, Sandvik Coromant’s customers are

asking for a better, longer lasting all-purpose grade. “The

days of optimizing grades for one particular material group

seem to be trending in the other direction. Our customers

want one grade that will cross over to many material groups.

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CoroMill 745 is available in medium and close pitch and as a

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For that reason, we introduced GC1130 grade last year,

GC1130 works well in steel, stainless, cast iron, and we’re

seeing very positive results in HRSA materials,” said Tucker.

Sandvik Coromant’s patented Zertivo processing technology

is said to enhance each grade’s benefit, whether it’s PVD or CVD

coated. GC1130 is PVD coated. “It’s all in the processing. Post-

processing and coating adhesion have all been revolutionized,

and with the first release of Zertivo with the 1130 grade we’re

seeing a 40% increase in tool life if you just change nothing else

but the new 1130 grade insert,” said Tucker.

“We’re seeing the biggest benefit in the square shoulder

applications of the 1130, which is currently available in all 90°

square shoulder cutters like 390, 490, and in the future it will

be applied to profile milling like the 745 and button cutters

and slotting cutters. In addition, it might be a slightly different

derivative of 1130 that you will see come out in other geom-

etries and other lead angle type cutters,” said Tucker.

Seco Focuses on Engineered Tooling Solutions

At IMTS, Seco Tools Inc. (Troy, MI) will focus on its compet-

itively priced fully engineered tooling solutions. Featured tool-

ing solutions include its new Square T4-12 milling cutter now

with larger size inserts, the new Highfeed 6 cutter for tough

materials, and the next generation of the high-performance

Niagara Stabilizer solid-carbide end mill. Insert developments

include new grades within its PCBN product range and its

Duratomic-technology based TK and TP ranges for turning

that incorporate Chrome Used Edge Detection.

The T4-12 line of square shoulder and helical milling cutters

allows manufacturers to achieve increased depths of cut and

higher metal removal rates when roughing and semifinishing

steel, cast iron, among others. The larger inserts all come with

four curved cutting edges that lower tooling cost per part and

ensure smooth machining. They tangentially mount in the cutter

bodies for increased performance stability and easier access

to their mounting screws. Cutter diameters for the larger T4-12

range from 1 to 5" (25.4–125 mm). Diameters for the larger T4-

12 helical inserts range from 2 to 4" (50–100 mm).

Seco’s new high-performance Highfeed 6 milling cutter

easily handles a variety of difficult-to-machine materials from

stainless to heat-resistant superalloys. The large-diameter

cutter bodies are capable of 0.070" (1.8-mm) axial DOC and

feature double-sided insert with six cutting edges, performing

equally well in all types of high-feed applications, including

face milling and plunging operations.

The Niagara Stabilizer 2.0 next generation STR-430 and

STR-440 series solid-carbide end mills offer metal removal

rates double those of their predecessors. With twice the chip

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load capacity, the new versions shorten part machining cycle

times, boosting productivity. The end mills come in diameters

from 0.125 to 1.0" (3–25.4 mm) with square corner and

corner radii, based on series and diameter, of 0.010, 0.020,

0.030, 0.060 and 0.120" (0.25, 0.51, 0.76, 1.52 and 3 mm).

Lengths are 1×D, 2×D, and 3×D and shanks available are

either cylindrical or Weldon flats.

MAPAL Expands Cutters

with ISO Indexable Inserts

MAPAL Inc. (Port Huron, MI) is ex-

panding its range of milling cutters with

ISO indexable inserts to include new

tools, increasing feed, DOC, and cost

effectiveness in machining cast iron and

steel. As with the whole portfolio of mill-

ing cutters with ISO indexable inserts,

the new milling cutters have high-preci-

sion insert seats. Cutting edge geom-

etries and high performance coatings

are basic features of the various forms

of indexable inserts used.

For machining of steel and cast iron,

the close pitch of the new 75° face and

90o tangential shoulder milling cutters is

responsible for the high feed rates. The

45o face and 88o tangential shoulder

milling cutters for machining steel,

stainless steel and cast iron are capable

of large cutting depths. They are both

available with the same construction,

i.e., four useful cutting edges per LTHU

tangential indexable insert. With LTHU

tangential indexable inserts installed on

alternate sides, they are cost-effective

with eight useful cutting edges.

The properties of the tangential

technology optimize tool life of all the

milling cutters. The indexable inserts

are tangentially embedded so that the

machining forces are first absorbed

over the whole cross-section of the

cutting edge. Only very small loads are

transmitted to the tool body, resulting

in an improved quality of the machining

results. The reduced cutting forces due

to the positive cutting edge geometries

also lower the drive power required

from the machine, and as a result

increase the energy efficiency.

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In addition, the soft cutting action results in longer tool

lives. Compared with the use of radial ISO indexable inserts,

more inserts can be constructively fitted in the tool with the

same or even higher stability. The ground ISO indexable

inserts are recommended for high-precision results, the

sprayed inserts for maximum cost-effectiveness.

Cutting depths of up to 10 mm are offered by the new

45° face milling cutters with eight-sided OFMT radial index-

able inserts. Up to a cutting depth of 4 mm, all eight cutting

edges can be used for machining steel and stainless steel.

For cutting depths >4 mm, four cutting edges can be used

per indexable insert. This new milling cutter is available with

medium and close pitch delivering very low costs per cut-

ting edge and very high cost-effectiveness.

High-Performance Milling Cutters in Inch Sizes

Komet of America Inc. (Schaumburg, IL) offers its new

line of milling tools, comprised of over 280 articles in 63

new imperial (inch) sizes, joining its 63 new metric bodies.

Well-known for its high-precision drilling, reaming, and

threading products, Komet’s high-performance milling cut-

ters include six more indexable insert milling cutter systems

(four single-sided and two doubled-sided indexable inserts)

alongside its well-established Komet Quatron hi.feed,

Komet hi.aeQ, and Komet hi.apQ milling cutter lines.

Komet’s more than 70 indexable inserts feature different

topographies, substrates, and coatings that can be combined

with 60 different basic body designs. The cutting inserts can

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milling cutters

MAPAL is expanding its range of milling cutters with ISO index-

able inserts to include new tools, increasing feed, DOC, and cost

effectiveness in machining cast iron and steel.

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handle all milling tasks, from face, shoulder, and chamfer

milling to straight, 45° and T-slot milling, circular and plunge

milling, angled plunge milling, and free-form milling.

The Komet Q55-KCM copy mill is particularly suitable for

machining turbine blades, but can also

be used universally. The 45° Komet

Q63-KFM face milling cutter, also part

of the product range, is designed for

face milling operations with the cutting

depth of up to 6.5 mm and a tooth feed

of up to 0.5 mm. The Komet Q56-KHF

face-milling cutter is particularly efficient

in high-feed applications, achieving a

high chip volume with optimum surface

quality. The Komet Q43-KSM shoulder

milling cutter produces shoulders that are

step-free and are exactly 90° as a result

of its soft-cutting geometry.

The new indexable milling tools

feature single and double-sided inserts,

as well as a variety of geometries and

grades to match the most challenging

milling operations. The portfolio includes

tools specifically designed for face

milling, profile milling, and high-speed

milling processes in a variety of diam-

eters and configurations. These Komet

indexable milling cutters can machine all

common materials, including hardened

steels and high-temperature alloys.

Double-Sided Insert Face Mill

with Low Cutting Forces

The WSX445 double-sided insert-

type face milling cutter from Mitsubishi

Materials Corp. (Fountain Valley, CA) is

designed for general machining applica-

tions, but features low cutting resistance.

According to Mike Pace, director of

marketing and business development,

the WSX445 face milling cutter strikes a

perfect balance between high efficiency

and low cutting forces.

“The WSX445 features a proprietary

double-sided Z- geometry insert that

provides a sharp cutting edge with low

cutting resistance similar to both conventional positive rake

and negative rake inserts,” said Pace. “These lower axial

cutting forces and radial cutting forces increase rigidity, lower

vibration, and optimize performance with reduced horsepower

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consumption. Chips are easily discharged because the axial

rake is positive and the radial rake is negative, which helps

prevent adhesion to the cutting edge.”

The net result, according to Pace, is that the WSX445

double-sided insert-type face milling cutter has a cutting per-

formance unlike a conventional double-sided insert cutter. “In

recent years, the conventional single-sided insert type for the

face milling cutter was replaced by the economically superior

double-sided insert type which has twice as many cutting

edges. This led to the assumption that it would dominate the

cutting tool market. However, for various reasons this did not

happen. The main issue with a double-sided insert design is

the reduction of the rake angle which has a detrimental effect

on the cutting action. This will cause an increased require-

ment in horsepower with less rigidity and reduced tool life,”

said Pace. “We are overcoming a big problem of chip control

with the patented double Z insert geometry and the shape

of the cutting edge as it is related to the work part. The high

positive cutting angles are useful in light powered machines

and with the 5-mm DOC we can go into heavier duty machin-

ing as well, covering a broad range of machine types from low

power to high power. We have grades for all materials such

as steel, stainless, high-temp alloys, nonferrous, as well as all

the combinations of insert breaker geometry for light, medium,

and heavy machining,” said Pace.

Iscar’s High-Feed Cutters Tackle High-Temp Materials

Iscar Metals Inc. (Arlington, TX) has introduced its Fast

Feed Quad 4 (FFQ4) high-feed milling cutters to enhance

rough milling of high-temperature alloy materials. “They

feature a more positive design which incorporates square

single-sided inserts,” said Tom Raun, national milling product

manager. “That goes in a different direction from what we

previously offered, cutting tools with double-sided inserts

with more cutting edges. What’s gained in cutting edges, you

lose in terms of clearance angles which are typically needed

to avoid building up too much heat when machining high-

temperature materials. This is critical,” said Raun.

High-feed milling has become a common milling ap-

proach used to tackle difficult-to-machine materials and

applications. The FFQ4 has been designed with this in

mind and to meet the demand from various industries such

as aerospace, medical and oil & gas. In terms of being ma-

terial specific, the FFQ4 has shown improved results when

machining titanium, stainless steel (especially austenitic

stainless steel), PH stainless and Inconel material grades.

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milling cutters


“Aerospace applications continue to provide opportunities

to apply the FFQ4 family of tools. Applications are not easily

outsourced and the aerospace business seems to remain

strong,” said Raun. Typical machining applications include

heavy-duty machining with cutting

tools 2" (50 mm) in diameter and up on

robust CAT 50, HSK 100, and HSK 125

machining centers.

OSG End Mills Tackle

Difficult-to-Machine Materials

The latest milling cutter develop-

ment from OSG USA Inc. (Glendale

Heights, IL) for machining nickel alloys

like Inconel are the EXOPRO UVX-

Ni end mills. UVX-Ni end mills are

designed for slotting and side cutting

in any high-temperature application,

according to David Aly, OSG’s national

aerospace specialist, “but the UVX-Ni

end mills can also be used in hard-

ened material machining.” With its

variable helix/variable index design,

the UVX-Ni eliminates chatter and

vibration for more stable machining.

Machining performance is further enhanced due to the

proprietary cutting edge geometry that reduces heat while

cutting, and the unique flute form that produces excellent

chip formation and evacuation.

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Iscar Metals Inc.817-258-3200 / www.iscar.com

Komet of America Inc.847-923-8400 / www.komet.com

MAPAL Inc.810-364-8020 / www.MAPAL.com

Mitsubishi Materials Corp.800-523-0800 / www.mmus.com

OSG USA Inc.630-274-3112 / www.osgtool.com

Sandvik Coromant201-794-5000 / www.sandvik.coromant.com/us

Seco Tools LLC248-528-5200 / www.secotools.com/us

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designs target toughest metal removal...

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