CoroMill ball nose finsihing endmill ....................... D86

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 produced by a solid carbide tool, is with the CoroMill Ball Nose
Finishing endmill – equipped with Coromant P10A inserts.
A
B
C
D
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
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 finishing is possible using either smaller CoroMill Plura solid carbide
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.
By applying accurate programming techniques, the finishing cutters may, in many operations, replace conventional ball nose
endmills and greatly improve the surface quality, very often, at
ten times higher feed.
E
F
G
Dimensions, mm
Cutter Dc mm
H
8
10
12
16
20
25
30
32
D 86
R216F-08 24 E-L
R216F-10 26 E-L
R216F-12 30 E-L
R216F-16 40 E-L
R216F-20 50 E-L
R216F-25 60 E-L
R216F-30 70 E-L
R216F-32 70 E-L
s
iC
ap max
2.4
2.6
3.0
4.0
5.0
6.0
7.0
7.0
8
10
12
16
20
25
30
32
1.2
1.5
1.8
2.4
3.0
3.7
4.5
4.5
Milling
A
P10A is first choice for:
P20A is first choice for:
- high effective cutting speed (HSM) applications.
- contouring applications (not cutting with centre point of insert)
- hardened steels and cast iron.
- copy milling applications or all applications where the centre of the
insert is cutting (zero vc).
- machines with limited rpm (non HSM).
- non hardened materials.
- semi-finishing applications.
B
C
Cutting data recommendations
Cutting speed ve
m/min
Material
Cutting
depth
Feed per tooth, fz (mm/z)
Insert diameter
CMC
No
P
ap or ae
8
10
12
16
20
25
30
32
150–375
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
200–400
180–330
100–300
80–200
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
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
200
200
150–200
120–170
100–200
80–120
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
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
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
160
250
400–500
200–350
150–350
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
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
HB
P10A
125
150
300–500
250–450
175
330
P20A
Unalloyed steel
01.1
01.2
D
Low alloy steel
02.1
02.2
High alloy steel
03.11
M
K
05.11
05.21
Malleable cast iron
07.1
07.2
Grey cast iron
08.2
Nodular cast iron
09.1
09.2
N
S
Aluminium
30.22
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
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
150–250
90–150
75–190
40–110
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
Titanium alloys
23.22
H
E
Stainless steel
F
G
Hardened steel
04
04
55 HRC
63 HRC
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 performance milling
A
The capability of the ball nose finishing cutter can be demonstrated 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
CoroMill 200 cutters.
Down milling is preferred method for best performance of the tool.
Cutter body selection
B
Steel shank cutter bodies are generally first selection.
Carbide shank cutter bodies are recommended for applications
with the highest demands on precision. Carbide shank cutters
are also recommended for finishing of bi-metal surfaces.
Shallow cut allows higher table feed
C
D
E
F
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
increased by up to 5 times compared with general milling, resulting in very high table feeds and metal removal rates without
any reduction of security or tool life.
For both security and tool life an effective evacuation of the
chips is essential – preferably executed by compressed air.
Calculate the cutting speed
Particularly when using round insert cutters at small depths of
cut, it is always important to calculate the true cutting speed
(ve) based on the effective – or true diameter in cut (De).
The De value deviates considerably from the Dc value for shallow depths of cut.
If these factors are not taken into consideration, there will be
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.
Compensated cutting speed, vc,
due to low ae or ap
vc
1 400
m/min 1 200
1 000
800
600
400
200
0
0
1
2
3
4
5
6
7
8
G
H
Effective cutting speed ( ve )
ve = π × n × De
1000
D 88
9
10
ae , ap mm
m/min
Milling
CoroMill 210
Versatile cutter for both high feed milling and plunging
Highly productive roughing cutter
A
B
C
D
Plunge milling
High feed helical
interpolation
High feed facemilling
E
ap
F
F
ae
10° entering angle results in favourable
cutting forces directed towards the
spindle.
l
l
ap ae
09
14
1.2
2.0
G
8
13
H
ISO application areas:
Tool options designed to individual customer
requirements are available.
D 89
Milling
CoroMill high feed facemill and plunge
milling cutter
A
B
C
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
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 cutter body, insert seat and the inserts themselves. A ten degree
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.
The inserts are avalible in two sizes, and have four cutting edges. The CoroMill 210 programme includes modular tools with
Coromant Capto or screw mounted couplings, as well as arbor
mounted cutters and cylindrical shank cutters.
D
E
Diameter 25 — 100 mm
Threaded
coupling
Cylindrical
Coromant Capto
Arbor
F
κr 10°
G
Machines: All types
Materials: All types
l1 = programming length
Operations:
H
High-feed
milling
D 90
Plunge
milling
Shoulder
milling
Profiling
Ramping
Helical
interpolation
Slot milling
Milling
High feed machining
Speed and feed values
Cutting speed,
vc (m/min)
Material
CMC
No
HB
Unalloyed steel
01.1
01.2
125
150
180 – 280
180 – 280
Low alloy steel
02.1
02.2
175
330
High alloy steel
03.11
03.21
M
Stainless steel
05.11
05.21
K
Grey cast iron
P
Grade
recommendations
Feed per tooth, fz (mm/z)
Insert size 9
Insert size 14
fz rec
fz min — fz max
fz rec
2030
3040
1.5
1.5
(0.4 – 2.0)
(0.4 – 2.0)
2.0
2.0
(0.4 – 3.0)
(0.4 – 3.0)
150 – 250
120 – 200
3040
3040
1.5
1.0
(0.4 – 2.0)
(0.4 – 1.5)
2.0
1.5
(0.4 – 3.0)
(0.4 – 2.0)
200
300
130 – 220
100 – 180
3040
3040
1.5
1.0
(0.4 – 1.7)
(0.4 – 1.3)
2.0
1.5
(0.4 – 2.5)
(0.4 – 2.0)
200
200
150 – 250
140 – 210
2040
2040
1.5
1.0
(0.4 – 1.7)
(0.4 – 1.5)
2.0
1.5
(0.4 – 2.5)
(0.4 – 2.0)
245
130 – 220
4020
1.5
(0.4 – 2.0)
2.0
(0.4 – 3.0)
250
120 – 200
4020
1.5
(0.4 – 2.0)
2.0
(0.4 – 3.0)
350
25 – 35
2030
0.8
(0.6 – 1.2)
1.0
(0.6 – 1.5)
23.22
350
30 – 50
2030
0.8
(0.6 – 1.2)
1.0
(0.6 – 1.5)
Hardened steel
04
04
45 HRC
55 HRC
70 – 140
50 – 90
3040
3040
0.8
0.8
(0.4 – 1.2)
(0.4 – 1.2)
1.0
1.0
(0.4 – 1.5)
(0.4 – 1.5)
08.2
fz min — fz max
A
B
Nodular cast iron
09.2
S
Heat resistant alloys
20.22
C
Titanium alloys
H
D
Grades
Wear resistance
Difficult
GC
2040
GC
2040
GC
4020
GC
3040
GC
2030
GC
2040
Hardened materials
40
GC
2030
H
Heat resistant and
titanium alloys
30
GC
2030
Cast iron
GC
4020
GC
3040
20
Average
S
K
M
10
Steel
Conditions
Good
P
Stainless steel
01
E
GC
4020
GC
2030
GC
3040
F
50
Toughness
Grade recommendation
High feed milling
Grade
ISO
1)
Good
conditions1)
P
3040
M
2040
K
4020
S
2030
H
3040
G
Plunge milling
Grade
Difficult
conditions
2030
3040
2030
ISO
P
2040
M
2040
K
3040
S
2030
H
2030
H
Good conditions = recommended machining strategies are used, tool overhang = ≤3 × Dc
D 91
Milling
Standard inserts:
R210-09 ..., max. ap 1.2 mm
R210-14 ..., max. ap 2.0 mm
CoroMill 210
A
Arbor mounting
Style
A22
A27
A32
B
D3
50- 72
63-102
72-127
Coromant Capto
l1
48.4-85
48.4-85
48.4-85
Size
C3
C4
C5
C6
C8
D3
25- 40
32- 50
32- 72
40- 82
50-127
l1
50-133
45-163
46-163
55-163
60-200
C
Cylindrical
shank
Weldon
Cylindrical shank for
power chuck
D
E
Size
20
25
32
F
D3
25-32
25-40
32-50
l2
84.4-254
90.4-254
90.4-254
Size
32
42
D3
32-50
42-63
l2
112.4-254
132.5-254
Size
20
25
32
D3
25-32
25-40
32-50
l1
85.4-229.5
94.4-218.5
90.4-222.5
Coolant holes on all cutters up to diameter 102 mm
G
Options
Insert size
D3
H
No of inserts
D 92
9, 14
– 9, Diameter 25-82 mm
–14, Diameter 50-127 mm
2–8
depending on cutter diameter
and size of inserts
Mounting type
dmm/D5m
l3
l2
l1
Arbor mounting, Coromant Capto,
Cylindrical, Cylindrical power chuck
Weldon
Mounting size—see above
Reach length—34-192 mm
Total length—see above
Programming length—see above
Milling
High feed milling
High feed face milling with CoroMill 210 is the most productive roughing method.
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
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.
Hole
A
Ramping
In penetrating operations ramping is preferred. The maximum ramping angle is dependent on insert size and cutter diameter. The angle α (alpha) for each cutter is
presented in table below.
B
Widening cavity
- Smooth entry and exit
- Correct strategy for machining corners
Helical interpolation
C
By using helical interpolation it is possible to produce a hole in a solid workpiece. This
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 productivity of a Coromant U-drill.
D
Open up a cavity
iC
9
14
- Helical interpolation to reach a new
z-level
- Use correct strategy for machining
corners.
max
ap, mm
1.2
2.0
E
ap
F
Do not exceed max ap during high feed rate!
Cutter dia.
D3
25
32
35
36
42
50
52
52
63
63
66
66
80
82
100
iC = 9 mm
ap ≤ 1.2 mm
Insert
size
Max. ramp
angle α°
9
9
9
9
9
9
9
14
9
14
9
14
14
14
14
14.5
8
7.0
7.0
5.0
3.5
3.3
–
2.6
–
2.4
–
–
–
–
iC = 14 mm
ap ≤ 2 mm
Hole dia. (mm)
Min.
Max.
32
46
52
54
66
82
86
–
108
–
114
–
–
–
–
49
63
69
71
83
99
103
–
125
–
131
–
–
–
–
Max. ramp
angle α°
Hole dia. (mm)
Min.
Max.
–
–
–
–
–
–
–
5.8
–
3.8
–
3.2
2.4
2.0
1.6
–
–
–
–
–
–
–
76
–
98
–
104
132
136
172
–
–
–
–
–
–
–
103
–
125
–
131
159
163
199
G
H
When machining a flat surface, maximum width of cut, ae, is determined
by Dc. If a larger width of cut is used
the cutter will produce a surface
with scallops.
D 93
Milling
High feed milling
Caution should be exercised
when high feed milling against
high shoulders. Depending
upon the tool overhang, an excessive feed rate can result in
vibrations which can damage
the periphery of the insert. The
feed rate should be reduced if
any such risk prevails.
A
hex = fz
hex =
fz
5.8
fz
B
Kr : 10º
ap
Dc
De
D3
C
Do not exceed the max. ap value when high feed milling. Any
excess depth of cut above the
main cutting edge will result in
extreme hex-values.
If the max. recommneded value
has to be exceeded, the feed
rate should be reduced by approx. 80%.
max. ap
iC
Dc
ap
9
D3-14.1
0.25
Dc
Dc+2.8
14
D3-24
0.5
Dc+5.7
1.0
Dc+11.3
1.2
Dc+13.6
1.5
Dc+17.0
2.0
Dc+22.7
Machining of corners
D
Programming
CM
210
iC
E
F
G
H
CM
300
Dimensions, mm
Uncut
material
x
R
b
ap
9
2.5
7.05
1.2
0.79
14
3.5
12.0
2.0
1.48
When using CoroMill 210 in high feed applications, program as
a round insert cutter with insert radius R.
Special care needs to be taken when machining corners to
avoid vibration from maximum contact between cutter and material. Best practice is to program a radius by circular interpolation, considerably bigger than the cutter radius (alternatively
a cutter radius considerably smaller than corner radius). If
recommended machining strategy is not followed, reduce feed
rate by approximately 50%.
Plunge milling
Plunge milling with CoroMill 210 is the fastest way to mill away
large volumes of metal in the axial direction.
Repeated plunging of the cutter to a predetermined depth, followed by retraction and repositioning for the next plunge removes metal rapidly through overlapping passes, cutting with
the front face of the tool.
It is a highly productive method for internal milling of deep cavities, 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
The considerable axial forces experienced in rough plunge milling mean that optimum performance is obtained with ISO 50
machine tools, or similar.
Milling
ae
Plunge milling
Programming
For long tool overhangs and
unstable conditions, plunge
milling might be the only possible solution.
Avoid using a drilling cycle.
Programme path to move away from the wall
prior to rapid feed.
Best performance is achieved if a smooth exit
from workpiece is programmed prior to retraction.
s
A
max recommax recommended ae, mm mended s
iC
9
14
8
13
= programme table feed
= rapid traverse
<0.75 × D3
Recommended overhang
When using long tool overhangs, vibration
can occur which will be detrimental to
both the machine tool spindle bearings,
<6 × Dc the tool and the quality of the finished result. CoroMill 210 reduces this risk when
rough milling as the major cutting forces
act in the Z-plane where the machine tool
spindle is generally the strongest, and is a real problem-solver
for operations where extended tooling is required.
Plunging
Feed values
Insert
size
fz mm/ tooth
iC
Starting value
min - max
9
0.10
0.08 - 0.15
14
0.15
0.10 - 0.20
Alternative method for milling with extra
long tools
Recommended method
•
•
•
•
Most effective plunge milling strategy.
Step, s, recommendation approximately 0.75 x D3
Recommended for L<4 x D3
For a longer tool an alternative method is
recommended.
5
6
7
2
C
D
• Plunge millling with tool overhang longer than 4 x D3
• Smaller engagement – less risk of vibration
• Gradually decrease plunge depth to minimize vibration
E
8
iC
L ≥ 4 x D3
1
B
3
4
6
7
8
Max ae
9
7
14
12
F
9
G
1
2
3
4
5
For example, the main part of a deep die can be roughed out using high feed milling
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
H
This catalogue has been split into smaller parts
to enhance downloading speeds.
If you want to view the next page
please click HERE!
(To go back to the last viewed page, use the integrated green arrows
at the bottom of the Acrobat® user interface)