Please click here to continue

This PDF document is divided into several files
Please click here to continue
MILLING
CoroMill® 200
Round insert facemill and endmill
Cylindrical shank
Diameter 25 – 160 mm
Arbor
Machines: All types
Materials: All types
Insert geometry:
Top rake angle
az
Dc
D3
A
L
M
H
+21° +16° +9°
l1 = programming length
Ordering code
Dimensions, mm
D3 Coarse pitch
mm Differential
Close pitch
Differential/Even1)
Extra close pitch
Even
KG
dmm4) Dc
l1
l2
l3
az
Max.
ap
3)
nmax
5)
Arbor
50 R200-038Q22-12L
52
040Q22-12L
63
051Q22-12L
80
068Q27-12L
100
088Q32-12L
3 R200-038Q22-12M
3
040Q22-12M
3
051Q22-12M
4
068Q27-12M
4
088Q32-12M
4 R200-038Q22-12H 2) 5
4
040Q22-12H 2) 5
4
051Q22-12H 2) 5
6 –
6 –
0,4
0,4
0,5
1,0
1,5
22
22
22
27
32
38
40
51
68
88
50
50
50
50
50
–
–
–
–
–
–
–
–
–
–
3,7
3,7
3,7
3,7
3,7
6
6
6
6
6
18800
18000
16200 12
14000
12300
63 R200-047Q22-16L2)
66
050Q27-16L2)
80
064Q27-16L
100
084Q32-16L
125
109Q32-16L
3 R200-047Q22-16M 2)
3
050Q27-16M 2)
4
064Q27-16M
4
084Q32-16M
5
109Q32-16M
4
4
5
6
6
–
R200-050Q27-16H 2) 5
064Q27-16H 2) 6
–
–
0,5
0,7
1,0
1,5
3,0
22
27
27
32
32
47
50
64
84
109
50
50
50
50
50
–
–
–
–
–
–
–
–
–
–
4,9
4,9
4,9
4,9
4,9
8
8
8
8
8
15300
14500
13100 16
11400
10000
80 R200-060Q27-20L
100
080Q32-20L
125
105Q32-20L
160
140Q40-20L
Cylindrical shank
Even
25 –
32 –
40 R200-028A32-12L2)
50
038A32-12L2)
40 R200-024A32-16L2)
50
034A32-16L2)
50 R200-030A32-20L2)
3 R200-060Q27-20M 2)
4
080Q32-20M 2)
5
105Q32-20M 2)
6
140Q40-20M 2)
4
6
6
8
–
–
–
–
1,0
1,5
3,0
5,0
27
32
32
40
60
80
105
140
50
63
63
63
–
–
–
–
–
–
–
–
6,1
6,1
6,1
6,1
10
10
10
10
10600
9200
8000 20
6900
Even
R200-015A20-10M 2)
R200-020A25-12M 2)
028A32-12M 2)
038A32-12M 2)
R200-024A32-16M 2)
034A32-16M 2)
R200-030A32-20M 2)
2
2
3
4
3
3
3
Even
R200-015A20-10H 2) 3
R200-020A25-12H 2) 3
–
–
–
–
–
0,5
0,7
1,3
1,4
1,4
1,5
1,5
20
25
32
32
32
32
32
15
20
28
38
24
34
30
–
–
–
–
–
–
–
150
190
240
240
240
240
240
30
35
63
63
63
63
63
2,9
3,7
3,7
3,7
4,9
4,9
6,1
5
6
6
6
8
8
10
37500
31100
26300
22500
21800
18300
20900
2
3
2
2
2
1) Only valid for cutters with 20 mm inserts.
2) Without shim.
3) Inserts are ordered separately.
4) Mounting dimensions, see page A 182.
5) n
max (max. rev/min) for holders must also
High
A 62
A 65
Close pitch (–M)
Reduced number of inserts.
Best productivity if stability or
power is limited.
Deep full-slotting operations.
Extended tooling.
Small machines.
Lowest cutting forces.
Dc = Cutting diameter
ae = Working engagement
A 188
20
Operation stability
Low
ae
Dc = ae
16
be considered.
Coarse pitch (–L)
1,2 – 1,5 x ae
12
Ordering example: 2 pieces R200-038Q22-12L
Best size for facemilling
ae
10
A 182
A 228
General purpose milling
and mixed production.
Small to medium
machines.
Extra close pitch (–H)
Maximum number of
inserts for best productivity
under stable conditions.
Short chipping materials.
Heat resistant materials.
Edging operations.
A 241
A 61
MILLING
CoroMill® 200
Even more possibilities thanks to tailored design!
If you do not find what you need in our comprehensive standard
programme, choose the tool shape you require and we will tailor
it for you to your dimensions.
– Quick quotation
– Easy to order
– Competitive delivery
Standard insert:
RCKT 10 T3 ..., max. ap 5 mm
RCKT 12 04 ..., max. ap 6 mm
RCKT 16 06 ..., max. ap 8 mm
RCKT 20 06 ..., max. ap 10 mm
CoroMill® round insert cutter
R200
A
Arbor mounting
Arbor mounting
Arbor mounting
acc. to ISO 6462
acc. to ISO 6462
acc. to ISO 6462
Style
A22
A27
Style
B27
B32
B40
Dc2
50-68
63-100
Dc2
75-100
80-125
86-160
Style
C40
C60
Varilock 50, 63, 80
Dc2
118,7-250
175,3-254
Dc2
25-125
Cylindrical 20, 25, 32
Weldon 20, 25, 32, 40
Dc2 =25-50
Options
Insert size
Dc2
Dc1
Shim
Pitch type
No of inserts
A 62
10, 12, 16, 20
Diameter—25-254 mm
Diameter—15-234 mm
yes or No
Even or Differential
2-16
Morse 02, 03, 04, 05
Dc2 =25-50
Dc2 =25-50
Note For specific details regarding the options, contact your
Coromant sales representative.
Mounting
type
dmm/D5m
l3
l2
l1
Coolant
hole
Cylindrical,Weldon,Morse taper,Arbor mounting,
Varilock
Mounting size—see above
Reach length—30-150 mm
Total length—81-240 mm
Programming length—40-183 mm,
For Varilock—l1 max 80 mm
A 62
MILLING
CoroMill® 200
Improve your productivty
M
The CoroMill inserts are optimized for a material group and
type of operation. Correctly applied and with optimized cutting data the productivity improvement is far beyond what
any general type of insert can offer.
Medium
H
L
Light
Heavy
General use in most
materials.
Light machining.
Low cutting forces.
Low feed rates.
Example:
RCHT -10 T3 M0-PL
Heavy machining.
Highest edge security.
High feed rates.
A
L = Light cutting geometry (L)
P = Workpiece material steel
(ISO P)
Four insert sizes available in three geometries covering depths of cut up to 10 mm, with a feed range of 0,05 – 0,6
mm/insert.
Facets on the base of the insert prevent insert movement
during the cutting action.
fz 0,05 - 0,6
Inserts are centre screw located for easy chip evacution and
mounted on carbide shims for good cutter body protection.
Feed range, mm/tooth
The torque wrench for Torx Plus screws offers a possibility
to always ensure correct torque value, in the workshop as
well as in the tool-room environments.
Correct torque values are vitally important when clamping
ceramic inserts.
Always wear protection goggles when using ceramic inserts.
Basic grades for CoroMill® 200
Wear resistance
Difficult
Toughness
SM
30
GC
4040
GC
2030 GC
2040
CC
6090
CT
530
GC
3020
GC
3040
H13
A
S
H
CB50
H13A
GC1025
GC
1025
GC
2030
H10F
Hardened materials
GC
4030
GC
1025
N
Heat resistant and
titanium alloys
30
40
50
Steel
20
Average
conditions
GC
1025
GC
4020
CB50
Aluminium / Non-ferrous
10
K
Cast iron
Good
M
CT530
Stainless steel
01 P
CT GC
530 1025
GC
4020
For grade description, see pages E 12 - E 17.
A 63
CoroMill® 300
MILLING
Benchmarks – CoroMill® 300
Productivity
Versatility
Designed for small depths of cut.
General contouring and profiling
Feed per tooth up to 0,5 mm.
Pocketing by ramping or helical interpolation.
Secure insert geometries and grades, optimized by
application, make high removal rates a reality.
Designed for high speed machining.
Ideal for HSM, high speed machining.
A
Built-in precision
Safe and easy to use
Long, consistent and predictable insert life
Permanent marking of insert and cutter body with
important product information
Excellent surface finish achieved at high feeds.
Precision ground inserts for even greater accuracy.
Torx Plus screw and key for safer grip and insert clamping (optional part).
Use torque wrench for correct torque values.
Available as optional part
Applications with CoroMill 200 and CoroMill
300 round insert cutters
Operations:
Facemilling
Helical interpolation
More information on the next page
Shoulder milling
Ramping
Full slot milling
Contouring
Rest milling
Plunge milling
Profiling
Turn-milling
A 67
MILLING
CoroMill® 300
Contouring tool paths
When machining cavities using contouring tool paths, down milling is recommended as the best method.
If the machine spindle speed is limited, contouring will help to retain the
cutting speed and also reduce changes in work load and direction. This is
of specific importance in HSM applications and hardened materials.
Contouring with the periphery of the milling cutter results in high
productivity.
A
Contouring with the periphery of the
milling cutter often results in higher
productivity, as more teeth are
effectively in cut on a larger tool
diameter.
Safe cutting process
The toroid endmill operates with two round inserts, positioned so that each insert is overlapping or almost overlapping the centre line of the cutter.
This design eliminates the unfavourable cutting action that
takes place at the tool centre of a conventional full radius
endmill, where the cutting speed goes down to zero.
The operating part of a toroid cutting edge is at no point
subjected to zero cutting speed.
ve
ve
Two round inserts are positioned so that each insert
either overlaps or almost overlaps the centre line of
the cutter depending on insert diameter.
Cutting speed/feed relationship
The true or effective diameter in cut varies depending on
the actual ap value.
De = D3 – iC +
This variation might be considerable – particularly for small
cutters using large diameter inserts.
If this is not taken into account, there will be severe
miscalculations of the feed rate as this is dependent on
the spindle speed (rpm) and the diameter in cut for a
specific cutting speed.
√iC
2
2
– (iC – 2 × ap)
Effective cutting speed (ve)
ve =
π x n x De
1000
m/min
It is also particulary important at small depths of cut to
base calculations of cutting speed on the effective diameter in cut (De).
Dc = 6 mm
vc = 250 m/min
n = 13262 rpm
Dc = 6 mm
ve = 250 m/min
n = 36942 rpm
ap = 0,2 mm
To compensate for a smaller diameter the rpm must be
increased to keep the cutting speed constant — also
resulting in a higher feed.
A 68
De = 2,15 mm
MILLING
CoroMill® 300
CoroMill® 300
Cylindrical
Weldon
Morse taper
Threaded
coupling
Diameter 10—42 mm
dth
Machines:
Materials:
Inclination angle:
Diameter tolerance:
Shank
type
Weldon
Morse taper
A
D3 + 0,0/-0,12 mm
l1 = programming length
Ordering code
D3
Cylindrical
All types
All types
0°
10
12
15
16
20
25
12
15
16
20
25
12
15
20
Dimensions, mm
Coarse pitch (L)
R300- 010A16L-05L
012A16L-07L
015A20L-07L
016A20L-08L
020A25L-10L
025A32L-12L
R300- 012B16L-07L
015B20L-07L
016B20L-08L
020B25L-10L
025B32L-12L
R300- 012E02L-07L
015E02L-07L
020E03L-10L
Close pitch
(M)
Extra close
pitch (H)
KG
2
2
2
2
2
2
2
2
2
2
2
2
2
2
0,2
0,2
0,4
0,4
0,8
1,6
0,1
0,2
0,2
0,4
0,7
0,1
0,2
0,4
l1
l2
–
–
–
–
–
–
160
200
200
200
250
250
85 109
106 131
106,5 131
105 137
105,5 141
60 124
60 124
80 161
l3
l4
l5
dmm Max1)
D5m ap
dth
60
60
80
80
80
80
60
80
80
80
80
–
–
–
24
34
43
43
43
41
34
43
43
43
41
34
39
43
18
20
25
25
30
30
20
25
25
30
30
20
25
30
16
16
20
20
25
32
16
20
20
25
32
2
2
3
0,7
1
1,5
1,2
2
5
1
1,5
1,2
2
5
1
1,5
2
–
–
–
–
–
–
–
–
–
–
–
–
–
–
3)
2)
nmax
15900
8200
11200
12700
8100
15800
34000
25000
24700
34000
20200
34000
25000
34000
5
7
7
8
10
12
7
7
8
10
12
7
7
10
20
24
20
24
20
24
Threaded coupling
10 R300-10T08-05L
2 –
0,1
25 –
–
15,7 14,1 12,8 0,7 M8 4)
5
12 –
R300-12T08-05M 3
0,1
25 –
–
17,8 15,1 12,8 0,7 M8
5
12 R300- 12T08-07L
2 –
0,1
25 –
–
16,8 14,1 12,8 1,0 M8 4)
7 20
15
15T08-07L
2 R300-15T08-07M 3
0,1
25 –
–
–
–
12,8 1,2 M8
7 24
16 –
R300-16T08-07M 3
0,1
25 –
–
–
–
12,8 1,2 M8
7 24
16 R300-16T08-08L
2 –
0,1
25 –
–
–
–
12,8 1,5 M8 4)
8
20 –
R300-20T10-08M 3
0,1
30 –
–
–
–
17,8 1,5 M10
8
20 R300- 20T10-10L
2 –
0,1
30 –
–
–
–
17,8 2,0 M10 4)
10
25 –
25T12-10L
2 R300-25T12-10M 3
0,2
35 –
–
–
–
20,8 2,0 M12
32
R300- 32T16-10H 4 0,2
45 –
–
–
–
28,8 2,0 M16
35
35T16-10H 4 0,2
45 –
–
–
–
28,8 2,0 M16
40
40T16-10H 5 0,3
45 –
–
–
–
28,8 2,0 M16
42
42T16-10H 5 0,3
45 –
–
–
–
28,8 2,0 M16
32
R300- 32T16-12M 3
0,2
45 –
–
–
–
28,8 2,0 M16 4)
12
35
35T16-12M 3
0,2
45 –
–
–
–
28,8 2,0 M16
40
40T16-12M 4
0,3
45 –
–
–
–
28,8 2,0 M16
42
42T16-12M 4
0,3
45 –
–
–
–
28,8 2,0 M16
The theoretical maximum ap for CoroMill 300 is half the diameter of
Ordering example: 2 pieces R300-010A16L-05L
the insert. This should be used only at very
small ae
Max. rpm (nmax) in relation to the protrusion
The max. rpm values (nmax) are theoretical values for the cutter. Also
of the tool on cylindrical shanks
the overhang and the holding system have to be considered when
running at high rpm.
Inserts are ordered separately.
nmax
D3 = 12
Max. rpm values, nmax, are not given for modular design as they
35 000
D3 = 10
are always used with long extensions.
D3 = 15
30 000
Threaded
1)
2)
3)
4)
ll
D3 = 16
25 000
The max. rpm depends on the outstick of the tool.
The values for cylindrical shanks are given for full length of their
shank.
If the shank is shortened the max. rpm can be
increased as shown in the diagram.
D3 = 20
D3 = 25
20 000
15 000
10 000
l mm
5 000
50
A 71
A 188
A81, A183
A 228
100
150
200
A 241
A 69
MILLING
CoroMill® 300
M-xM
Improve your productivity
E-xM
Medium
The CoroMill inserts are optimized for a material group and
type of operation. Correctly applied and with optimized cutting data the productivity improvement is far beyond what
any general type of insert can offer.
Medium
The CoroMill 300 inserts are available in four grades covering
machining in most workpiece materials.
General use in most
materials
A
For highest edge sharpness
and precision in combination
with security
Example:
R300 -05 17E-PM
Insert sizes 10 and 12 mm
M = Geometry for medium
machining (M)
Insert sizes 5, 7 and 8 mm
P = Workpiece material steel
(ISO P)
Shallow cuts
The small cutter diameters and long overhangs combined
with the small insert sizes and thicknesses limit the possibilities for deep axial depths of cut.
The tools work best at small axial depths where the round insert shape can be used to increase the feed per tooth 4 – 5
times, due to the thin chip.
A small axial and radial depth of cut gives a short cutting
edge engagement. Low cutting forces (F) and very little heat
is generated allowing the cutting speed to be increased 50 –
100 %. Together with the high feed per tooth this will allow
the table feed to be increased 5 – 10 times compared to general milling.
Low cutting forces ( F) and little heat allow the table
feed ( Vf ) to be increased 5 – 10 times compared to
General milling.
The common working area for HSM in semi-finishing operations is a radial and axial d.o.c. less than 1 mm.
Basic grades for CoroMill® 300
Average
conditions
Difficult
30
40
50
Toughness
A 70
Steel
20
GC
4040
GC
1025
GC
2040
CT
530
N
GC
4040
S
CT
530
H
GC
1025
Hardened materials
CT
530
K
Heat resistant and
titanium alloys
GC
1025
10
Stainless steel
Good
M
Aluminium / Non-ferrous
01 P
Cast iron
Wear resistance
GC
1025
For grade description, see pages E 12 - E 17.
MILLING
CoroMill® 300
Inserts for CoroMill® 300
E-xM
Coromant grades
1)
7
R300- 0720E-PM
0720E-MM
0724E-PM
0724E-MM
✩ ✩ ✩
8
R300-0828E-PM
0828E-MM
✩ ✩ ✩
10
R300- 1032E-PM
1032E-MM
✩ ✩ ✩
12
R300-1240E-PM
1240E-MM
1240M-PM
1240M-MM
✩ ✩
✩ ✩
CT
S
GC
H
GC = Coated carbide/Cermet (ISO = HC)
CT = Cermet (ISO = HT)
A
GC
Dimensions, mm
1025
✩ ✩ ✩
GC
N
1025
R300- 0517E-PM
0517E-MM
CT GC GC
2040
4040
1025
5
K
530
MEDIUM
530
CT GC GC
M
4040
P
1025
M = Highest edge security
E = Highest edge sharpness and precision
530
M-xM
s
For cutter 1)
diameter
✩
✩
✩
✩
5
1,70
10
✩
✩
✩
✩
7
1,99
12
✩
✩
✩
✩
7
2,38
15
✩
✩
✩
✩
8
2,78
16
✩
✩
✩
✩
10
3,18
20
✩
✩
✩
12
3,97
25
iC
✩
✩ ✩
✩
✩ ✩ ✩
✩ ✩
✩
✩ ✩
✩
✩ ✩
✩
✩ ✩
✩
✩
✩
✩
Ordering example: 10 pieces R300-0517E-PM 530
For cutters with threaded coupling, see page A 69.
Feed recommendations
fz
hex
0,5
0,4
0,3
R300-0517E-PM
R300-1240E-PM
5
7
8
10
12
0,2
0,1
0
Geometry
Insert
size
Feed/tooth, mm
0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
E-xM
(maximum chip thickness, mm)
M-xM
Starting
value
(min. – max.)
Starting
value
(min. – max.)
0,08
0,10
0,13
0,18
0,18
(0,05
(0,05
(0,05
(0,05
(0,05
0,15
(0,07 – 0,25)
–
–
–
–
–
0,12)
0,15)
0,20)
0,25)
0,25)
ae, ap
Radial and/or axial depth of cut, mm
Cutting speed recommendations, see
page A 228 – A 235.
Formulas for cutters with round inserts
fz
Max cutting diameter at a
specific depth (mm)
De = Dc +√iC – (iC − 2ap) 2
Feed per tooth
(mm/tooth), cutter
centered
fz =
Feed per tooth (mm/tooth),
side milling
fz =
2
hex
iC × hex
De – Dc
De × iC × hex
(De – Dc) × √De2 – (De – 2 × ae) 2
Value for hex is given on pages A 224.
A 71
CoroMill® Ball Nose
MILLING
Recommendations
Edge tolerance
-M
-E
R
A
B
R
A
B
5
6
8
10
12,5
15
16
20
25
–
1,4
1,7
2,2
3,0
3,9
3,5
3,6
3,8
–
0,07
0,09
0,12
0,1
0,20
0,22
0,24
0,26
5
6
8
10
12,5
15
16
20
25
0,15
0,15
0,15
0,15
0,15
0,15
0,15
0,15
0,15
<0,01
<0,01
<0,01
<0,01
<0,01
<0,01
<0,01
<0,01
<0,01
D3
M
D3 +0,07
–0,23
E
D3 +0,0
–0,20
A
Insert tolerances for highest precision
or highest security
Machined form
The form error occuring at the centre point according
to the table is minimized by using the -E type inserts.
The M-inserts are designed for a high security
level and effective transportation of the heat
generated by heavy cuts.
The new E-inserts are designed for highest
edge sharpness and precision.
Contouring
The preferred method is to use contouring.
This allows the effective cutting speed to be
controlled more easily, utilise higher feed
rates and machine in the preferred climb
mode. The overall result being higher
productivity, increased security and longer
insert life.
Copy milling
The traditional technique – mainly linked to older types
of copy milling machines.
100%
100%
Typical problem
area
20º
45º
50%
40%
100%
60%
90º
45º
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.
Operations:
Profiling
Ramping
Helical interpolation
Full slot milling
A 73
MILLING
CoroMill® Ball Nose
CoroMill® Ball Nose
Cylindrical
Diameter 12—50 mm
Weldon
Weldon
Threaded coupling
dth
Morse Taper
A
Machines:
All types
Materials:
All types
Inclination angle: –10°
Shank type
l1 = programming length
Ordering code
Dimensions, mm
D3
mm
Cylindrical
Weldon/
short
Weldon/
long
KG
Inserts1)
l3
l4
50
45
45
55
65
70
70
40
40
50
60
70
70
100
100
125
60
60
70
80
100
100
150
175
20
20
27
33
40
50
50
20
27
33
40
50
50
69
–
95
20
27
33
70
80
82
120
145
16
20
20
25
32
32
32
20
20
25
25
32
32
40
40
50
20
20
25
25
32
32
40
50
Taper
8,6
10,8
14,4
17,9
22,3
26,9
28,6
10,8
14,4
17,9
22,3
26,9
28,6
36,5
44,6
44,6
10,8
14,4
17,9
22,3
26,9
28,6
36,5
44,6
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
15900
21000
20000
24000
24000
19500
18500
21000
20000
24000
24000
19500
18500
8000
7000
7000
21000
20000
24000
24000
19500
18500
8000
7000
R216-10 02
12 02M
16 03M
20 T3M
25 04M
30 06M
32 06M
R216-12 02M
16 03M
20 T3M
25 04M
30 06M
32 06M
40 07M
50 07M
50 07M
R216-12 02M
16 03 M
20 T3M
25 04M
30 06M
32 06M
40 07M
50 07M
–
–
–
–
–
APMT 160408-M
–
–
–
–
–
APMT 160408-M
–
APMT 160408-M
–
APMT 160408-M
–
–
–
–
APMT 160408-M
–
APMT 160408-M
APMT 160408-M
20
27
–
33
70
–
82
2
2
2
3
3
3
4
10,8
14.4
17,9
17,9
22,3
28,6
28,6
–
–
–
–
–
–
–
21000
20000
24000
24000
24000
18500
18500
R216-12 02M
16 03M
20 T3M
20 T3M
25 04M
32 06M
32 06M
–
–
–
–
–
–
APMT 160408-M
8,6
10,8
14,4
17,9
22,3
26,9
28,6
M8
M8
M8
M10
M12
M16
M16
3)
3)
3)
3)
3)
3)
3)
R216-10A16-050
12A20-045
16A20-045
20A25-055
25A32-065
30A32-070
32A32-070
R216-12B20-040
16B20-040
20B25-050
25B25-060
30B32-070
32B32-070
40B40-100
50B40-100
50B50-125
R216-12B20-060
16B20-060
20B25-070
25B25-080
30B32-100
32B32-100
40B40-150
50B50-175
2
2
2
2
2
2+1
2
2
2
2
2
2+1
2
2+2
2
2+2
2
2
2
2
2+1
2
2+2
2+2
0,3
0,4
0,4
0,6
1,3
1,4
1,4
0,2
0,2
0,3
0,4
0,6
0,6
1,3
2,0
2,5
0,2
0,2
0,3
0,4
0,7
0,8
1,7
3,1
–
–
–
–
–
–
–
66
66
75
85
95
95
131
131
161
86
86
95
105
125
125
181
211
160
200
200
200
250
250
250
91
91
107
117
131
131
171
171
207
111
111
127
137
161
161
221
257
12
16
20
20
25
32
32
R216-12E2-040
16E2-060
20E2-070
20E3-070
25E3-080
32E3-100
32E4-100
2
2
2
2
2
2
2+1
0,1
0,1
0,2
0,3
0,4
0,5
0,8
45
65
70
70
80
105
105
104
40
124
60
134
70
151
70
161
80
181 100
202,5 100
R216-10T08
12T08
16T08
20T10
25T12
30T16
32T16
2
2
2
2
2
2
2
0,1
0,1
0,1
0,1
0,2
0,2
0,2
25
25
25
30
35
45
45
–
–
–
–
–
–
–
18
18
–
–
–
–
–
1) Inserts are ordered separately.
2) n
max (max. rev/min) for holders
3) Max. rpm values, n
max, are not
must also be considered.
given for Modular design as they
are always used with long extensions.
A 75
A 74
A81-A183
nmax
D5m
Threaded coupling
10
12
16
20
25
30
32
2)
l2
10
12
16
20
25
30
32
12
16
20
25
30
32
40
50
50
12
16
20
25
30
32
40
50
dth
Shank protection
insert
l1
Morse
Threaded
Max
dmm ap
Main insert
A 188
A 228
A 241
–
–
–
–
–
–
–
12,8
12,8
12,8
17,8
20,8
28,8
28,8
R216-10 02M
12 03M
16 T3M
20 T3M
25 04M
30 06M
32 06M
Ordering example: 2 pieces
–
–
–
–
–
–
–
R216-10A16-050
MILLING
CoroMill® Ball Nose
Inserts for CoroMill® Ball Nose
Main inserts
Shank protection insert
25
M-M
E-M
M
E = Highest edge sharpness and precision
M = Highest edge security
Coromant grades
P
M
S H
Dimensions, mm
4040
✩
✩
H13A
2040
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
4040
1025
CT GC GC GC – GC
530
SM30
4020
4040
➚rε
1025
530
CT GC GC GC –
For
cutter
dia.
N
K
A
GC = Coated carbide/Cermet (ISO = HC)
CT = Cermet (ISO = HT)
– = Uncoated carbide (ISO = HW)
Εr
rε1
rε2
1,7 –
2,38 –
–
–
–
–
–
–
16,0
3,18 –
–
–
–
17,9
20,0
3,97 –
–
–
–
22,3
24,9
4,76 –
–
–
–
26,9
29,9
6,35 –
–
–
–
28,6
31,8
6,35 –
–
–
–
36,5
39,9
7,94 –
–
–
–
44,6
49,7
7,94 –
–
–
–
–
16,4
4,76 9,25
85º
0,8
0,4
la
l
s
8,6
10,8
9,8
12,0
14,4
iW
Central and peripheral
10
12
5
6
R216-10 02 E-M
R216-12 02 E-M
12 02 M-M
16
8
R216-16 03 E-M
16 03 M-M
20
10
R216-20 T3 E-M
20 T3 M-M
25
12,5 R216-25 04 E-M
25 04 M-M
30
15
R216-30 06 E-M
30 06 M-M
32
16
R216-32 06 E-M
32 06 M-M
40
20
R216-40 07 E-M
40 07 M-M
50
25
50 07 E-M
50 07 M-M
Shank protection insert
30 - 50
–
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩ ✩ ✩
✩
✩ ✩ ✩
✩
✩ ✩ ✩
✩
✩ ✩ ✩
✩
✩ ✩ ✩
✩
✩
✩
✩
✩
✩
✩
✩
APMT 160408-M
✩✩ ✩
✩
✩✩ ✩
✩
✩✩ ✩
✩
✩✩ ✩
✩
✩✩ ✩
✩
✩✩ ✩
✩
✩✩ ✩
✩
✩✩ ✩
✩
✩
Ordering example: 10 pieces R216-10 02 E-M 1025
Wear resistance
GC
1025
10
CT
530
30
40
50
Difficult
Steel
20
Average
conditions
GC
4020
SM
30
GC
4040
K
GC
1025
GC
2040
CT
530
GC
4040
Cast iron
M
Stainless steel
01 P
Good
H13
A
GC
4040
Toughness
For grade description, see pages E 12 - E 17.
Recommended feed
fz ( feed in mm/tooth)
Insert size
Starting value
(min – max.)
10
12
16
0,10
0,10
0,10
(0,05 – 0,21)
(0,05 – 0,21)
(0,05 – 0,21)
20
25
30
0,15
0,15
0,17
(0,05 – 0,25)
(0,05 – 0,25)
(0,05 – 0,28
32
40
50
0,17
0,20
0,20
(0,05 – 0,28)
(0,05 – 0,35)
(0,05 – 0,35)
Torque wrench
The wrench for Torx Plus offers a possibility to
always ensure correct torque value.
Cutting speed recommendations, see
page A 228 – A 235.
A 75
MILLING
CoroMill® Ball Nose Finishing
Precision profiling
with CoroMill® Ball Nose Finishing endmill
A
High speed finishing to super finishing of
profiles is now possible with new indexable
insert tools
A surface finish equal to that produced by a solid carbide tool,
is now made a reality with the new CoroMill Ball Nose
Finishing endmill – equipped with Coromant P10A inserts.
The inserts are screw clamped in high security seats allowing
safe milling with high speed machining performance.
Two effective edges provide the opportunity for highest
productivity.
Same insert for a wide range of applications
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 steel hardened up to HRC 60 as well as stainless steel, grey or nodular
cast iron, aluminium, Kirksite and graphite.
A 76
Coromant tool programme for finish
profiling
With the introduction of the new 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.
Precision from spindle nose to cutting edge
Both the CoroMill ball nose high precision cutter and CoroMill
Plura provide their optimum performance when clamped in
Coromant CoroGrip precision chucks.
Improved productivity in finish profiling
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.
MILLING
CoroMill® Ball Nose Finishing
CoroMill® Ball Nose Finishing
A
Machines: All types
Materials: All types
Shank type
Ordering code
Dimensions, mm
Dc
mm
Cylindrical
1)
2)
3)
KG
l2
A 78
l5
dmm
Max
ap
nmax 2)
iC
8
8
8
R216F-08A12S-035
08A12S-053
08A12S-075
0,2
0,2
0,2
92
110
132
35
53
75
19
34
19
12,0
12,0
12,0
1,2
1,2
1,2
40 000
33 600
16 800
8
10
10
10
R216F-10A12S-038
10A12S-053
10A12S-075
0,2
0,2
0,2
95
110
132
38
53
75
22
39
22
12,0
12,0
12,0
1,5
1,5
1,5
40 000
40 000
20 300
10
12
12
12
R216F-12A12S-026
12A12S-053
12A16S-085
0,2
0,2
0,3
83
110
145
26
53
85
–
–
23
12,0
12,0
16,0
1,8
1,8
1,8
40 000
40 000
19 800
12
16
16
16
R216F-16A16S-032
16A16S-063
16A20S-100
0,3
0,3
0,4
92
123
166
32
63
100
–
–
30
16,0
16,0
20,0
2,4
2,4
2,4
36 000
36 000
20 000
16
20
20
20
R216F-20A20S-038
20A20S-075
20A25S-115
0,4
0,4
0,7
104
141
191
38
75
115
–
–
35
20,0
20,0
25,0
3,0
3,0
3,0
40 000
40 000
18 400
20
25
25
25
R216F-25A25S-045
25A25S-090
25A32S-135
0,5
0,7
1,1
121
166
215
45
90
135
–
–
43
25,0
25,0
32,0
3,7
3,7
3,7
40 000
37 100
16 500
25
30/323) R216F-32A32S-054
30/323)
32A32S-107
30/323)
32A32S-160
0,8
1,1
1,6
134
187
240
54
107
160
–
–
54
32,0
32,0
32,0
4,5
4,5
4,5
35 500
32 500
14 500
30, 32
Ordering example: 2 pieces R216F-08A12S-035
Inserts are ordered separately.
nmax (max.rev/min for holders must also be considered.
Depending on insert size.
A 79
l3
Insert size 1)
A 188
A 183
A 228
A 241
MILLING
CoroMill® Ball Nose
Inserts for CoroMill® Ball Nose Finishing
Insert code
Coromant grades
P
GC
P10A
GC
P10A
E-L
E-L
E-L
E-L
E-L
E-L
E-L1)
E-L
GC
S H
P10A
24
26
30
40
50
60
70
70
GC
N
P10A
R216F-08
R216F-10
R216F-12
R216F-16
R216F-20
R216F-25
R216F-30
R216F-32
GC
K
P10A
8
10
12
16
20
25
30
32
M
P10A
GC
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
Cutter Dc
mm
A
GC = Coated carbide/Cermet (ISO = HC)
Dimensions, mm
s
iC
2,4
2,6
3,0
4,0
5,0
6,0
7,0
7,0
8
10
12
16
20
25
30
32
Ordering example: 10 pieces R216F-08 24 E-L P10A
For grade description, see pages E 12 - E 17.
1) Note: The 30 mm insert fits the diameter 32 mm endmill.
Cutting data recommendations for CoroMill® Ball Nose Finishing
Material
CMC
No
P
Cutting
speed ve
m/min
Cutting
depth
Note: fn = 2 x fz
Feed per tooth, fz (mm/z)
Insert diameter
HB
ap or ae
8
10
12
16
20
25
30
32
Unalloyed steel
01.1
01.2
125
150
300-500
250-450
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
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
200-330
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
150-200
120-170
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
200-450
300-450
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
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
245
200-400
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
90
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
Low alloy steel
02.1
02.0
175
330
High alloy steel
03.11
200
M
Stainless steel
K
Malleable cast iron
05.11
05.21
07.1
07.2
200
200
130
230
Nodular cast iron
09.1
09.2
Grey cast iron
08.2
N
S
Aluminium
30.22
Heat resistant alloys
20.22
350
40-80
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
70-120
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
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
350
Hardened steel
04
04
55 HRC
63 HRC
A 79
MILLING
CoroMill® Ball Nose Finishing
CoroMill® Ball Nose Finishing
MACHINING RECOMMENDATIONS
Shallow cuts for security
in high performance milling
A
The capability of the ball nose finishing cutter can be
successfully 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.
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 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.
Compensated cutting speed, vc,
due to low ae or ap
1 400
1 200
m/min
1 000
800
600
400
200
0
vc
0
1
2
3
4
5
6
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.
Effective cutting speed ( ve )
ve =
A 80
π × n × De
m/min
1000
7
8
9 10
ae , ap mm
CoroMill® modular tools
MILLING
CoroMill® cutters with threaded coupling
A system of small CoroMill® screw type cutters and a variety of shanks
for demanding die and mould making.
Coromant Capto®
ISO/ MAS
HSK
Page D 109
Page D 111
Page D 110
Damped milling adaptor
A
Coromant Capto
Page D 109
®
HSK
Page D 110
Basic holders
Solid carbide
extension
Intermediate
adaptors
Page D 113
Page D 112
CoroMill® cutters
CoroMill® 390
CoroMill® 300
CoroMill® Ball Nose
Page A 32
Page A 69
Page A 74
Tool set-ups with CoroMill® performance
Slim — but rigid — assemblies with accessibility for milling of deep and
narrow cavities.
Opportunities to optimise the total gauge length of the set-up for best
performance in each application.
Many tool solutions with minimum number of modules will reduce
inventory costs.
Damped milling adaptor for high productivity at extremely long
overhangs – with no vibration.
A 81
CoroMill® 331
MILLING
Benchmarks – CoroMill® 331
Productivity
Versatility
Feed per tooth up to 0,4 mm per edge.
Easy chip flow due to wide open pockets.
Secure insert geometries and grades, optimized by
application, make high removal rates a reality.
Long lasting cutter body with precision that resists heavy
loads.
Safe and easy to use
General slotting and parting off.
Boring by helical interpolation.
Back facing capability.
Wide setting range.
Vast programme of corner radii.
Round inserts for high and safe metal removal.
Insert for all materials. New geometry, -NL, for aluminium
machining .
A
Built-in precision
Inserts self locating into their seats.
Cutter bodies machined from hardened steel resulting in
close tolerances and high strength.
Permanent marking of insert and cutter body.
Spring loaded cassettes make setting easy, fast and
accurate.
Recommended start values for speed and feeds on the
insert box.
Spring loaded cassettes give minimal insert runout and therefore equal cutting conditions for all inserts.
Result – predictable and long cutting edge life.
Precision ground inserts for even greater accuracy.
Delivered to customer specification within 0,01 mm width.
Fixed pocket design
Smaller diameters.
Increased productivity as more inserts
are used on the same diameter.
No cassettes.
Lower costs.
Even more possibilities thanks to tailored design!
If you do not find what you need in our comprehensive
standard programme, choose the tool shape you require
and we will tailor it for you to your dimensions.
Operations:
Slotting
Gang milling
Parting off
Double half side milling
Back facing
Square shoulder
milling
Boring
Facing
More information on
the next page
A 83
MILLING
CoroMill® 331
CoroMill® 331 with cassettes
Side and facemilling with precision and productivity
The design with serrations and wedge locking of the cassette gives high precision
in setting and high productivity with reliability.
The screw mounted insert together with wide open pockets gives good chip flow
even in deep slots. The five insert sizes together with the modular design provide
scope to build many different styles of cutters.
A
There are many as standard, but the Tailor Made option offers a greater variety of
cutters.
Dc = 80–315 mm
Dc = 80 – 315 mm
(Dc = 80 – 550 mm Tailor Made)
(Dc = 80–550 mm Tailor Made)
CM ap = 6,0 – 8,0 mm
DM ap = 8,0 – 10,0 mm
EM ap = 10,0 – 12,0 mm
FM ap = 12,0 – 15,0 mm
KM ap = 15,0 – 17,5 mm
LM ap = 17,5 – 20,5 mm
QM ap = 20,5 – 23,5 mm
RM ap = 23,5 – 26,5 mm
Full slot
rε
A rε
B rε
C rε
D rε
E rε
Full slot with
radius
ap
= 0,20 – 1,54
= 1,55 – 2,60
= 2,61 – 3,50
= 3,51 – 4,50
= 4,51 – 5,50
= 5,51 – 6,50
ap = 6,0–26,5 mm
ap
Dc = 80–315 mm
(Dc = 80–400 mm Tailor Made)
Recommendations for full slot milling with round inserts
Max axial depth of cut (ap) = insert size (iC)
Max radial depth of cut (ae) = ap
Insert size 08
asp = 7,6 mm
Note!
The contact length of the cutting
edge is 180°
zeff =
iC
zn
2
Insert size 11
asp = 10,6 mm
For slots deeper than iC a 0,5 mm
adjustment of each cassette is
recommended. This will widen the
0,02 groove 0,5+0,5 mm and reduce the
contact length for each insert to 90°.
Half side
Dc= 200–315 mm
(Dc = 80–550 mm Tailor Made)
Cutter diameter
Dc 200–250 mm
aBp= 27,2–30,2 mm
Cutter diameter
Dc 315 mm
aBp = 30,8–33,8 mm
Double half
side
Helical interpolation
ap
80%
iW
Recommendations when machining with helical interpolation:
The radial depth of cut ae should not exceed 80% of the iW on the insert.
Recommended start value for axial feed is 0,02 mm/tooth.
ae = 80% of iW
The interpolation feed in axial direction must not exceed the axial width ap of
the cutter.
If a good surface finish is required use half side cutters. Do not exceed asp.
A 84
CoroMill® 331
MILLING
Recommendations for cutting depth and
feed per tooth
As a rule of thumb the CoroMill 331 cutters will machine
to a depth of four times the width. Deeper than four times
the width the cutter has to be optimized.
100%
40%
Smaller ae
Increase fz
ae (40 %)
Larger ae
Recommended fz
mm/tooth
Decrease fz
A
Standard cutters mounted together for wider slots
Cutters mounted with bore having a keyway can be adjusted so
they can be mounted together to machine wider slots. In order to
mount the cutters together the hub on one side of each cutter has to
be ground as shown in the adjoining picture.
ap
0,9
0,9
0,3
Two standard cutters mounted together. Cutter (1) has the hub as
standard on the left side and the hub is ground on the cutter right
side. Cutter (2) is reversed and has the hub as standard on its right
side and the hub is ground on the left side. In the middle (1+2) the
cutters are mounted together with the ground hubs facing each other.
The hubs should be ground until 1,2 mm is left. The inserts should
be set 0,9 mm out from the ground hub, to overlap correctly.
0,3
1
1
2
1,2
2
1,2
Only five insert sizes needed!
For the total programme for full side and face cutters 6,0 – 26,5 mm slot
widths, use only five insert sizes.
CoroMill 331 with cassettes
Security pin control
for safe performance within the
total setting range
Insert size
04
08
11
14
10,0
15,0
20,5
Groove width (ap )
Min. width
6,0
8,0
Cutter widths, mm
-CM
-DM
-EM
-KM
-QM
(ap 6,0 - 8,0)
(ap 8,0 - 10,0)
(ap 10,0 - 12,0)
(ap 15,0 - 17,5)
(ap 20,5 - 23,5)
-CM
-DM
-EM
-KM
-QM
Max. width
8,0
10,0
12,0
17,5
23,5
Min. width
8,0
10,0
12,0
17,5
23,5
Cutter widths, mm
Wide application area
2,0 or 3,0 mm depending on size
of cutter.
05
-FM
-LM
-RM
-FM (ap 12,0 - 15,0)
-LM (ap 17,5 - 20,5)
-RM (ap 23,5 - 26,5)
Max. width
15,0
20,5
26,5
A 85
This PDF document is divided into several files
Please click here to continue