workhorse for rough machining operations · pdf fileworkhorse for rough machining operations !...

NEWShoulder milling cutter

Workhorse for rough machining operations !

Tungaloy Report No. 415-US

2

1

3

4

2

ø.750" ~ ø1.000"

ø1.000" ~ ø2.000"

ø2.000" ~ ø2.500"

6

5

4

3

2

1

0

.7502 3

490.004

.8 .4.3

ELD05R075U0075W021

Light machining

High

Low

Machine and work

rigidity

Heavy machining

Suitable for roughing operations on BT40 spindle taper machines

Optimum edge position prevents chatterHigh helix angle distributes and reduces the load for smoother cuttingBest solution for preventing chip recutting• Small inserts create small chips• Through tool air blast blows chips from the

cutting area

Proven insert from standard range• 4 cornered insert offers

higher operating profi t• Positive rake chipbreakers

MJ: for general purposeincluding exotic materialAJ: for machining of aluminum

Application range of roughing series

Comparison of metal removal rate

Met

al r

emov

al r

ate

Q (i

n3 /min

)

Competitor A

Improved by 33%!

Optimum cutter design allows high productivity with large depth of cut

Work material Tool diameter øDc (in)Effective number of cutting edge lineCutting speed Vc (sfm)Feed per edge line fz (ipt)Depth of cut ap (in)Width of cut ae (in)Machine

CompetitorCondition

Vertical M/C CAT40

1055

3

1

3

4

2

50

40

30

20

10

0

15

12

9

6

3

0

1.250

3 2330.0061.25.55

ELS11R125U0125W03

TLM11R200U0075A03

23 4

330.008

2 1.6

1.2 .8



Versatile cutters for various work materials

New solution for roughing operations on large machines

• Large core thickness increases body rigidity

Optimized angular positioning prevents chatter

Tangential insert with tough edge allows high feed machiningHighly rigid body, suitable for heavy machining

Air blast through tool to blow off chips

Cutters with high insert density delivers higher productivity

Air blast through tool blows off chips

Proven insert from standard range

Proven insert from standard range

• Suitable for roughing operation of various materials

• Tough cutting edge and low cutting force chipbreakersMJ: for general purposeMS: for stainless steel and exotic material machiningAJ: for machining of aluminum

• 4 cornered insert offers higher operating profi t

Met

al r

emov

al r

ate

Q (i

n3 /min

)M

etal

rem

oval

rat

eQ

(in3 /m

in)

Competitor A

Competitor A

Higher number of fl utes guarantees high productivity

Tough cutting edges provide stable machining even in heavy roughing operations



Competitor

Competitor

Condition

Condition

Vertical M/C CAT50

Vertical M/C CAT50

Improved by 40%!

Improved by 50%!

1055

1055

4

HB Vc (sfm)

< 200

AH725

330 - 820

.0015 - .004200 - 300330 - 660

150 - 300

< 300 330 - 430 .0012 - .0035

− AH140 300 - 490 .0012 - .0035

150 - 250 AH725330 - 820 .002 - .005

260 - 660 .002 - .005

−TH10

660 - 1650.002 - .006

− 330 - 660

øDc øDs rs Lf L Max.ap

ELD05R075U0075W02 � 2 .750 .750 2.031 1.219 3.250 .800 .33 10 SDMT050204PN-MJSDHT050204FN-AJELD05R100U0100W03 � 3 1.000 1.000 2.250 1.500 3.750 .969 .69 18

L

Lf Rs

øDc

øDs

ap90°

rε

TA

AH725 AH140 TH10 A T rεSDMT050204PN-MJ M � � .200 .094 .016

ELD05…SDHT050204FN-AJ H � .200 .094 .016

CSPB-2L043IP-6DB

� : Stocked items

Inserts

Cutters

Low carbon steels (1015 etc.)

High carbon steels (1045 etc.)

Alloyed steels (4140 etc.)

Tool steels (W1-8 etc.)

Stainless steels (304 etc.)

Gray cast irons (No35B etc.)

Ductile cast irons (60-40-18 etc.)

Aluminum alloys (Si < 13%)

Aluminum alloys (Si ≥ 13%)

Standard cutting conditions

Description Cat. No.

Shank typeWeight

(Ib)Air

holeNo. ofinserts

Clamping screwWrench

withwithout

withwith

Cat. No.

Cat. No.

GradesCoated Carbide

Dimensions (in)

Dimensions (in)Cutters

InsertsStock

Accuracy Honing

Brinell hardness Cutting Speed Feed per tooth Work material Grades

fz (ipt)

No. of eff. edge lines

Replacement parts

5

Corner radius rε (in) The dimension of modifying (in)

øDc øDb ød r Lf b a Max. ap

TLS11R200U0075A04 � 4 2.000 1.875 .750 .750 2.356 .197 .315 1.921 1.22 20 ASMT11T3..., ASGT11T3...

øDc øDs rs Lf L Max. ap

ELS11R100U0100W02 � 2 1.000 1.000 2.250 1.500 3.750 1.197 .67 6ASMT11T3…ASGT11T3…

ELS11R125U0125W03 � 3 1.250 1.250 2.250 2.250 4.500 1.535 1.24 12ELS11R150U0125W03 � 3 1.500 1.250 2.329 2.171 4.500 1.551 1.47 12

L

øDs

øDc

˚ Lf Rs

ap

TLS11R... ELS11R...CSPB-2.5

IP-8DCM10X40H -

AH725 AH120 AH130 AH140 T3130 T1115 DS1100 NS740 KS05F A B T rε

ASMT11T304PDPR-MJ

M

� � � � �

.457 .264 .146

.016

ELS11RTLS11R

ASMT11T308PDPR-MJ � � � � � .031ASMT11T312PDPR-MJ � � � .047ASMT11T316PDPR-MJ � � � � .063ASMT11T320PDPR-MJ � .079ASMT11T330PDPR-MJ � .118ASMT11T304PDPR-MS � � .016ASGT11T304PDFR-AJ

G� � .016

ASGT11T308PDFR-AJ � � .031

B

TAA

B

T

r r

A

B

T

r

.016 ~ .063

.079 ~ .118 .080

R

øDc

øDb

b

R

øda

apL f

90º

� : Stocked items

Inserts

Cutters


withwithwithwithwithwithwithwithwith

No modifi cation required

When using inserts with corner radius rε ≥ .079", standard cutter bodies have to be modifi ed “R”.

• From 2nd row onwards, please use insert with rε = .016" or .031".

Cautionary point in modifying cutter bodies

Shank typeBore type

Bore type

Shank type

Fig.4Fig.4Fig.4Fig.4Fig.4Fig.4Fig.5Fig.6Fig.6

Weight(Ib)

Weight(Ib)

Airhole

Airhole

No. ofinserts

No. ofinserts

Cutter

Clamping screwWrench

Center bolt

Fig. 5 MSFig. 4 MJ Fig. 6 AJ

withwith

with

with

Cat. No.

Cat. No.

Cat. No.

GradesCoated CarbideCermet

Dimensions (in)

Dimensions (in)

Dimensions (in)Shape Cutters

Inserts

Inserts

Stock

Stock

Acc

urac

y

Ho

ning



Replacement parts

6

HB Vc (sfm) fz (ipt)

MJ MS AJ

< 200AH725

330 - 820.004 - .007 - -

T3130 .004 - .007 - -

200 - 300AH725

330 - 660.003 - .006 - -

T3130 .003 - .006 - -

150 - 300AH725

330 - 490.003 - .006 - -

T3130 .003 - .006 - -

- - AH130 330 - 490 - .003 - .006 -

150 - 250AH120

330 - 820.004 - .007 - -

T1115 .004 - .007 - -

150 - 250AH120

260 - 660.004 - .007 - -

T1115 .004 - .007 - -

- - DS1100 660 - 1650 - - .002 - .007

- - DS1100 330 - 660 - - .002 - .007

- - AH130 60 - 200 - .003 - .006 -

- - AH725 60 - 130 .003 - .005 - -

TLM11R200… TLM11R250…

CSTB-3.5L110

BT15S

H-TB

T-15T

SD06-A2 SD08-52øDc

øda

øDb

ap

L f

R

b

90º

AH725 T3130 AH140 AH120 T1115 A B T rε

LMMU110708PNER-MJ M � � � � � .413 .280 .461 .031

TLM11…LMMU110716PNER-MJ M � � � � � .413 .280 .453 .063LMMU110724PNER-MJ M � � � � � .413 .280 .445 .094LMMU110732PNER-MJ M � � � � � .413 .280 .437 .125

A

rε

BT

øDc øDb ød r Lf b a Max. ap

TLM11R200U0075A03 � 3 2.000 1.850 .750 .750 2.750 0.157 .315 2.323 1.85 21LMMU1107**

TLM11R250U0100A04 � 4 2.500 2.323 1.000 .750 3.250 0.197 .374 2.654 3.33 32


Replacement parts


Cutters

Inserts

� : Stocked items

Bore type

Work materialBrinell

hardness Priority GradeCutting speed Feed per tooth:

First choiceFor wear resistance





Wre

nch

Applicable cutter Clamping screw

Torx bit

Grip Mono block type substitution wrench

Center bolt

Cat. No.Dimensions (in)

InsertsNo. of eff.

edge lines

Stock Air holeWeight(lb)

No. ofinserts

withwith

Stock Cat. No. Accuracy Honing Coated grades

Dimensions (in) Cutters

withwithwithwith

Low carbon steels (1010, 1015 etc.)High carbon steels and alloy steels (1045, 4140 etc.)

Tool steels (H13 etc.)

Stainless steels (304,316 etc.)

Gray cast irons (No.250B, No.300B etc.)Ductile cast irons (65-45-12, 80-55-06 etc.)

Aluminum alloys (Si < 13%)

Aluminum alloys (Si ≥ 13%)

Titanium alloys (Ti-6AI-4V etc)Nickel-based alloys(Inconel718 etc.)

7

HB Vc (sfm) fz (ipt)

< 200

AH725 330 - 820

.004 - .009AH140 260 - 590

T3130 330 - 820

200 - 300

AH725 330 - 660

.003 - .008AH140 260 - 490

T3130 330 - 660

150 - 300

AH725 330 - 660

.003 - .008AH140 260 - 490

T3130 330 - 660

< 300

AH725 330 - 490

.003 - .008AH140 260 - 390

T3130 330 - 490

- AH140 300 - 490 .003 - .008

150 - 250

AH120330 - 820 .004 - .010

T1115

AH120260 - 660 .004 - .010

T1115

- AH725 70 - 160 .002 - .006

ELD05R075U0075W02 (ø.75", z = 2) TLS11R200U0075A04 (ø.2", z = 4)ASMT11T308PDPR-MJ

AH725 AH725

330 490.003 .00710 26.2.4 1.575

.2

2.5

2.0

1.5

1.0

0.5

0

5

4

3

2

1

0


• From 2nd row onwards, please use insert with rε = .031"

Work materialBrinell

hardness Priority Grade Cutting speed Feed per tooth

First choice

Priority for impact resistance

Priority for wear resistance

First choice



First choice



First choice



First choice

First choice


First choice


First choice

Practical examplesCover of machine

Competitor Competitor

Machine part

Shoulder millingDry

Vertical M/C CAT50

Shoulder millingWet

Flexible machine BT40

Met

al r

emov

al r

ate

Q (i

n3 /m

in)

Mac

hini

ng t

ime

(min

)

TungRec can machine at a 30% higher table speed with no chatter, even when machining on machine tools and components with low rigidity levels.

Higher productivity achieved than with competitor solid end mills. Reduction of inventory with the reduction of regrinding costs.

Productivity 1.3 times!

Machining time

reduced 20%!

Low carbon steel4140

Cut

ting

co

nditi

ons

Work piece typeCutterInsertGrade

Work material

Cutting speed: Vc (sfm) Feed per tooth: fz (ipt) Feed speed: Vf (in/min) Depth of cut: ap (in) Width of cut: ae (in) Method of machining

Coolant

Machine

Results

.24 × 3 passes

SDMT050204PN-MJ

Low carbon steels (1010, 1015 etc.)

High carbon steels (1045, 1055 etc.)

Alloy steels (4140, 5120 etc.)

Tool steels (D-2, M3-1 etc.)

Stainless steels(304, 316 etc.)

Gray cast irons(No.250B etc.)

Ductile cast irons(65-45-12 etc.)

Super alloys (Inconel718, Ti-6AL-4V etc.)

1.57

5"

.4"

TLS11R200U0075A04 (ø2", z = 4) TLM11R200U0075A03 (ø2", z = 3)ASMT11T308PDPR-MJ LMMU110708PNER-MJ

AH725 AH120

100 490.003 .0082.3 22

1.65 1.6.080 .8

160140120100806040200

302520151050

1.6"

1.65

"

Power generator part Base of machine

Shoulder millingDry

Vertical M/C CAT50

Shoulder millingWet

Horizontal M/C CAT50

Met

al r

emov

al r

ate

Q (c

m3 /

min)

Mac

hini

ng t

ime

(min

)

Machining with large depth of cut with TungRec can drastically reduce machining time. Achieves stable tool life due to no chipping on cutting edges.

TecMill allows more stable machiningwithout chipping on the cutting edges, this improves productivity by 60%.

Inconel 718 No.250B

Cu

ttin

g c

on

dit

ion

sWork piece type

CutterInsertGrade

Work material

Cutting speed: Vc (sfm) Feed per tooth: fz (ipt) Feed speed: Vf (in/min) Depth of cut: ap (in) Width of cut: ae (in) Method of machining

Coolant

Machine

Results

Productivity 1.6 times!

CompetitorCompetitor

Machining time

reduced 60%!

Distributed by:

Jan. 2013 (TJ)

3726 N Ventura Drive, Arlington Heights, IL 60004, U.S.A.Phone: +1-888-554-8394 Fax: +1-888-554-8392

Tungaloy Canada432 Elgin St. Unit 3, Brantford, Ontario N3S 7P7, CanadaPhone: +1-519-758-5779 Fax: +1-519-758-5791

Tungaloy de Mexico S.A.C Los Arellano 113, Parque Industrial Siglo XXIAguascalientes, AGS, Mexico 20290Phone:+52-449-929-5410 Fax:+52-449-929-5411

www.tungaloyamerica.comScan for instant

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workhorse for rough machining operations · pdf fileworkhorse for rough machining operations !...

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