HF SC 1000 / 3 HF SC 25 / 3 HF SS HF SS
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- Deirdre Terry
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1 High Feed Indexable Milling Program Tool Contents HFSC Modular Screw-on Heads 54/55 HFA Shell Milling Cutters 54/55 HFSS End Milling Cutters 54/55 Insert Data 56/57 Cutting Conditions Data 58/65 Inch Section Contents Milling Cutters Identification System Modular Measurement System Shank Measurement System Denotes High Feed Cutter Denotes High Feed Cutter SC = Screw-on Cutter A = Shell Cutter Denotes Shank Cutter Denotes Diameter Size Denotes Diameter Size Denotes of Flutes Imperial HF SC 1000 / 3 HF SC 25 / 3 Denotes Tool Cutter Length Denotes Tool Diameter Shank Imperial HF SS HF SS Page 52
2 High Feed Indexable Milling Program Tools With new five- and six-axis CNC grinding technology, Millstar has been able to create some of the most sophisticated and complex geometries in use today. With this increase in grinding technology, high-feed tooling has been reborn. The definition of high-feed geometry is producing a positive cutting edge out of a series of continuous radii with no tangent point to induce wear. The geometry must allow the chip to flow up and out of the cut quickly and smoothly. This cutting motion allows the use of heavy chip loads to achieve very high feed rates. High Feed Indexable Milling Program Tools Page 53 53
3 High Feed Indexable Milling Program Tools HFSC - Modular Screw-On Heads ØD L1 L2 D2 Z Thread G1 Screw Clamp Key Use with Inserts HFSC-1000/ M10 HFIS-1 - T8 HFCI-09T HFSC-1250/ M12 HFIS-1 - T8 HFCI-09T HFSC-1500/ M16 HFIS-2 HFIC-1 T15 HFCI CAM R D1 S2 C1 S2 HFA - Shell Milling Cutters ØD ØD1 L1 L2 Z Screw S1 Screw S2 Clamp C1 Key Use with Inserts HFA-1500/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI HFA-2000/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI HFA-2500/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI HFA-3000/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI HFA-4000/ HFIS-2 HFIS-2 HFIC-1 T15 HFCI CAM R HFSC HFA HFSS Inch HFSS - End Milling Cutters ØD ØD1 L1 L2 Z Screw Clamp C1 Key Use with Inserts HFSS HFIS-1 - T8 HFCI-09T HFSS HFIS-1 - T8 HFCI-09T HFSS HFIS-1 - T8 HFCI-09T HFSS HFIS-1 - T8 HFCI-09T HFSS HFIS-2 HFIC-1 T15 HFCI HFSS HFIS-2 HFIC-1 T15 HFCI CAM R 54 Page 54
4 HFSC - Modular Screw-On Heads ØD L1 L2 D2 Z Thread G1 Screw Clamp Key Use with Inserts HFSC-20/ ,5 2 M10 HFIS 1 - T8 HFCI-09T3 2,27 HFSC-25/ ,5 3 M12 HFIS 1 - T8 HFCI-09T3 2,27 HFSC-30/ ,5 4 M16 HFIS 1 - T8 HFCI-09T3 2,27 HFSC-32/ ,5 4 M16 HFIS 1 - T8 HFCI-09T3 2,27 HFSC-32/ ,5 3 M16 HFIS 2 HFIC-1 T15 HFCI ,52 HFSC-42/ ,5 4 M16 HFIS 2 HFIC-1 T15 HFCI ,52 D1 S2 C1 S2 CAM R HFA - Shell Milling Cutters ØD ØD1 L1 L2 Z Screw S1 Screw S2 Clamp C1 Key Use with Inserts HFA-42/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-50/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-52/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-63/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-66/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-80/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 HFA-100/ , HFIS-2 HFIS-2 HFIC-1 T15 HFCI ,52 CAM R HFSS - End Milling Cutters ØD ØD1 L1 L2 Z Page 55 HFSS HFIS-2 HFIC-1 T15 HFCI ,52 Screw Clamp C1 Key Use with Inserts HFSS HFIS-1 - T8 HFCI-09T3 2,27 HFSS HFIS-1 - T8 HFCI-09T3 2,27 HFSS HFIS-1 - T8 HFCI-09T3 2,27 HFSS HFIS-1 - T8 HFCI-09T3 2,27 HFSS HFIS-1 - T8 HFCI-09T3 2,27 HFSS HFIS-1 - T8 HFCI-09T3 2,27 HFSS HFIS-2 HFIC-1 T15 HFCI ,52 CAM R HFSC HFA HFSS 55
5 High Feed Indexable Milling Program Tools Helical Interpolation Insert Data Grade CAM D S D1 XRN HSN R HFCI-09T HFCI HFCI HFSC Machining Application Data Helical Interpolation ØD ØDh Ap F ØDh min ØDh max HFSC-1000/ mm HFSC-1250/ mm HFSC-1500/ mm HFSS mm HFSS mm HFSS mm HFSS mm HFSS mm HFSS mm HFA-1500/ mm HFA-2000/ mm HFA-2500/ mm HFA-3000/ mm HFA-4000/ mm Slant Milling For Slant Milling or Helical Interpolation decrease the recommended feed by 30%. In case of Helical Interpolation do not exceed the max Ap/revolution. For Plunging use 50% of recommended feed only. For insert HFCI 09T3 the max Ae is: For insert HFCI 1204 the max Ae is: Inch 56 The values of n and Vf in the tables on the following pages are computed. In the application, use the closest (up side) speed from the range of the machine tool. The cutting parameters have to be adjusted accordingly to the rigidity of the machine-tool and working piece. In case of hard steel alloy of HRC decrease by 30% the Ap, Vc and feed. Page 56
6 Plunge Milling Insert Data Grade CAM D S D1 XRN HSN R HFCI-09T3 9,525 3,97 4,4 2,27 HFCI ,700 4,76 3,4 3,52 Facing - Max Flat Machining Application Data Helical Interpolation ØD ØDh Ap F ØDh min ØDh max HFSC-20/ ,8 26,3 38,1 HFSC-25/ ,8 36,3 48,1 HFSC-30/ ,8 46,3 58,1 HFSC-32/ ,8 50,3 62,1 HFSC-32/ ,7 15,4 44,6 61,8 HFSC-42/ ,7 25,4 64,6 81,8 HFSS ,8 26,3 38,1 HFSS ,8 36,3 48,1 HFSS ,8 36,3 48,1 HFSS ,8 36,3 48,1 HFSS ,8 50,3 62,1 HFSS ,8 50,3 62,1 HFSS ,8 66,3 78,1 HFSS ,7 23,4 60,6 77,8 HFSS ,7 8,8 26,3 38,1 HFA-42/ ,7 25,4 64,6 81,8 HFA-50/ ,7 33,4 80,5 97,8 HFA-52/ ,7 35,4 84,5 101,8 HFA-63/ ,7 46,4 106,5 123,8 HFA-66/ ,7 49,4 112,5 129,8 HFA-80/ ,7 63,4 140,5 157,8 HFCI HFSC Page 57 The values of n and Vf in the tables on the following pages are computed. In the application, use the closest (up side) speed from the range of the machine tool. The cutting parameters have to be adjusted accordingly to the rigidity of the machine-tool and working piece. In case of hard steel alloy of HRC decrease by 30% the Ap, Vc and feed. 57
7 High Feed Indexable Milling Program Tools HF Cutting Conditions Inch Cutting Conditions Data HFSC-1000/3 HFCI-09T3 HSN-XRN HFSC-1250/4 HFCI-09T3 HSN-XRN HFSC-1500/4 HFCI-1204 HSN-XRN Work Piece RPM sfm Max RPM inch/tooth inch inch <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <1 3D-5D <1 5D-7D <1 >7D <1 <3D <1 3D-5D <1 5D-7D <1 >7D <1 <3D <1 3D-5D <1 5D-7D <1 >7D <1 <3D <1 3D-5D <1 5D-7D <1 >7D <1 58 Page 58
8 Cutting Conditions Data Work Piece RPM mm/min mm/min mm/tooth mm mm <3D ,4 0,6 <15 HFSC-20/2 HFCI-09T3 HSN-XRN HFSC 25/3 HFCI-09T3 HSN-XRN HFSC-30/4 HFCI-09T3 HSN-XRN 3D-5D ,8 0,6 <15 5D-7D ,8 0,5 <15 >7D ,8 0,4 <15 <3D ,4 0,4 <15 3D-5D ,8 0,5 <15 5D-7D ,8 0,4 <15 >7D ,8 0,3 <15 <3D ,2 0,4 <15 3D-5D ,8 0,4 <15 5D-7D ,8 0,3 <15 >7D ,6 0,2 <15 <3D ,6 0,8 <15 3D-5D ,2 0,8 <15 5D-7D ,2 0,6 <15 >7D ,2 0,5 <15 <3D ,6 0,6 <20 3D-5D ,6 <20 5D-7D ,5 <20 >7D ,4 <20 <3D ,6 0,4 <20 3D-5D ,5 <20 5D-7D ,4 <20 >7D ,3 <20 <3D ,4 0,4 <20 3D-5D ,8 0,4 <20 5D-7D ,8 0,3 <20 >7D ,6 0,2 <20 <3D ,6 0,8 <20 3D-5D ,2 0,8 <20 5D-7D ,2 0,6 <20 >7D ,2 0,5 <20 <3D ,5 0,6 <21 3D-5D ,9 0,6 <21 5D-7D ,9 0,5 <21 >7D ,9 0,4 <21 <3D ,4 <21 3D-5D ,9 0,5 <21 5D-7D ,9 0,4 <21 >7D ,9 0,3 <21 <3D ,2 0,4 <21 3D-5D ,8 0,4 <21 5D-7D ,6 0,3 <21 >7D ,6 0,2 <21 <3D ,6 0,8 <21 3D-5D ,2 0,8 <21 5D-7D ,2 0,6 <21 >7D ,2 0,4 <21 HF Cutting Conditions Page 59 59
9 High Feed Indexable Milling Program Tools Cutting Conditions Data Work Piece RPM sfm Max RPM inch/tooth inch inch <3D <.75 HF Cutting Conditions Inch HFSS HFSS HFSS HFSS HFSS HFSS HFCI-09T3 HFCI-09T3 HFCI-1204 HSN-XRN HSN-XRN HSN-XRN 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <.75 3D-5D <.75 5D-7D <.75 >7D <.75 <3D <1 3D-5D <1 5D-7D <1 >7D <1 <3D <1 3D-5D <1 5D-7D <1 >7D <1 <3D <1 3D-5D <1 5D-7D <1 >7D <1 <3D <1 3D-5D <1 5D-7D <1 >7D <1 60 Page 60
10 Cutting Conditions Data Work Piece RPM mm/min mm/min mm/tooth mm mm <3D ,5 0,6 <22 HFSC-32/4 HFCI-09T3 HSN-XRN HFSC-32/3 HFCI-1204 HSN-XRN HFSC-42/4 HFCI-1204 HSN-XRN 3D-5D ,9 0,6 <22 5D-7D ,9 0,5 <22 >7D ,9 0,4 <22 <3D ,5 0,4 <22 3D-5D ,9 0,5 <22 5D-7D ,9 0,4 <22 >7D ,9 0,3 <22 <3D ,2 0,4 <22 3D-5D ,8 0,4 <22 5D-7D ,6 0,3 <22 >7D ,6 0,2 <22 <3D ,6 0,8 <22 3D-5D ,2 0,8 <22 5D-7D ,2 0,6 <22 >7D ,2 0,4 <22 <3D ,5 1 <22 3D-5D ,9 1,2 <22 5D-7D ,9 1 <22 >7D ,9 0,8 <22 <3D ,5 0,8 <22 3D-5D ,9 1 <22 5D-7D ,9 0,8 <22 >7D ,9 0,6 <22 <3D ,4 0,8 <22 3D-5D ,8 0,6 <22 5D-7D ,8 0,5 <22 >7D ,6 0,4 <22 <3D ,8 1,2 <22 3D-5D ,4 1 <22 5D-7D ,4 0,8 <22 >7D ,4 0,6 <22 <3D ,5 1 <28 3D-5D ,9 1,2 <28 5D-7D ,9 1 <28 >7D ,9 0,8 <28 <3D ,5 0,8 <28 3D-5D ,9 1 <28 5D-7D ,9 0,8 <28 >7D ,9 0,6 <28 <3D ,4 0,8 <28 3D-5D ,8 0,6 <28 5D-7D ,8 0,5 <28 >7D ,6 0,4 <28 <3D ,8 1,2 <28 3D-5D ,4 1 <28 5D-7D ,4 0,8 <28 >7D ,4 0,6 <28 HF Cutting Conditions Page 61 61
11 High Feed Indexable Milling Program Tools Cutting Conditions Data Work Piece RPM sfm Max RPM inch/tooth inch inch <3D <1 HF Cutting Conditions Inch HFA-1500/4 HFCI-1204 HSN-XRN HFA-2000/5 HFCI-1204 HSN-XRN HFA-2500/6 HFCI-1204 HSN-XRN 3D-5D <1 5D-7D <1 >7D <1 <3D <1 3D-5D <1 5D-7D <1 >7D <1 <3D <1 3D-5D <1 5D-7D <1 >7D <1 <3D <1 3D-5D <1 5D-7D <1 >7D <1 <3D < D-5D < D-7D <1.375 >7D <1.375 <3D < D-5D < D-7D <1.375 >7D <1.375 <3D < D-5D < D-7D <1.375 >7D <1.375 <3D < D-5D < D-7D <1.375 >7D <1.375 <3D <1.8 3D-5D <1.8 5D-7D <1.8 >7D <1.8 <3D <1.8 3D-5D <1.8 5D-7D <1.8 >7D <1.8 <3D <1.8 3D-5D <1.8 5D-7D <1.8 >7D <1.8 <3D <1.8 3D-5D <1.8 5D-7D <1.8 >7D < Page 62
12 Cutting Conditions Data Work Piece RPM mm/min mm/min mm/tooth mm mm <3D ,4 0,6 <15 HFSS HFCI-09T3 HSN-XRN HFSS HFSS HFSS HFSS HFSS HFCI-09T3 HFCI-09T3 HSN-XRN HSN-XRN 3D-5D ,8 0,6 <15 5D-7D ,8 0,5 <15 >7D ,8 0,4 <15 <3D ,4 0,4 <15 3D-5D ,8 0,5 <15 5D-7D ,8 0,4 <15 >7D ,8 0,3 <15 <3D ,2 0,4 <15 3D-5D ,8 0,4 <15 5D-7D ,8 0,3 <15 >7D ,6 0,2 <15 <3D ,6 0,8 <15 3D-5D ,2 0,8 <15 5D-7D ,2 0,6 <15 >7D ,2 0,5 <15 <3D ,6 0,6 <20 3D-5D ,6 <20 5D-7D ,5 <20 >7D ,4 <20 <3D ,6 0,4 <20 3D-5D ,5 <20 5D-7D ,4 <20 >7D ,3 <20 <3D ,4 0,4 <20 3D-5D ,8 0,4 <20 5D-7D ,8 0,3 <20 >7D ,6 0,2 <20 <3D ,6 0,8 <20 3D-5D ,2 0,8 <20 5D-7D ,2 0,6 <20 >7D ,2 0,5 <20 <3D ,5 0,6 <21 3D-5D ,9 0,6 <21 5D-7D ,9 0,5 <21 >7D ,9 0,4 <21 <3D ,5 0,4 <21 3D-5D ,9 0,5 <21 5D-7D ,9 0,4 <21 >7D ,9 0,3 <21 <3D ,2 0,4 <21 3D-5D ,8 0,4 <21 5D-7D ,6 0,3 <21 >7D ,6 0,2 <21 <3D ,6 0,8 <21 3D-5D ,2 0,8 <21 5D-7D ,2 0,6 <21 >7D ,2 0,4 <21 HF Cutting Conditions Page 63 63
13 High Feed Indexable Milling Program Tools Cutting Conditions Data Work Piece RPM mm/min mm/min mm/tooth mm mm <3D ,5 1 <28 Inch HF Cutting Conditions HFSS HFSS HFCI-1204 HSN-XRN HFA-42/4 HFCI-1204 HSN-XRN HFA-50/5 HFCI-1204 HSN-XRN 3D-5D ,9 1,2 <28 5D-7D ,9 1 <28 >7D ,9 0,8 <28 <3D ,5 0,8 <28 3D-5D ,9 1 <28 5D-7D ,9 0,8 <28 >7D ,9 0,6 <28 <3D ,4 0,8 <28 3D-5D ,8 0,6 <28 5D-7D ,8 0,5 <28 >7D ,6 0,4 <28 <3D ,8 1,2 <28 3D-5D ,4 1 <28 5D-7D ,4 0,8 <28 >7D ,4 0,6 <28 <3D ,5 1 <28 3D-5D ,9 1,2 <28 5D-7D ,9 1 <28 >7D ,9 0,8 <28 <3D ,5 0,8 <28 3D-5D ,9 1 <28 5D-7D ,9 0,8 <28 >7D ,9 0,6 <28 <3D ,4 0,8 <28 3D-5D ,8 0,6 <28 5D-7D ,8 0,5 <28 >7D ,6 0,4 <28 <3D ,8 1,2 <28 3D-5D ,4 1 <28 5D-7D ,4 0,8 <28 >7D ,4 0,6 <28 <3D ,4 0,7 <35 3D-5D <35 5D-7D ,8 <35 >7D ,8 0,6 <35 <3D ,2 0,6 <35 3D-5D ,6 <35 5D-7D ,6 <35 >7D ,8 0,4 <35 <3D ,2 0,6 <35 3D-5D ,8 0,5 <35 5D-7D ,8 0,4 <35 >7D ,8 0,3 <35 <3D ,6 1 <35 3D-5D ,2 0,8 <35 5D-7D ,2 0,6 <35 >7D ,2 0,4 <35 Page 64
14 Cutting Conditions Data Work Piece RPM mm/min mm/min mm/tooth mm mm <3D ,4 0,7 <36 HFA-52/5 HFCI-1204 HSN-XRN HFA-63/6 HFCI-1204 HSN-XRN HFA-66/6 HFCI-1204 HSN-XRN 3D-5D <36 5D-7D ,8 <36 >7D ,8 0,6 <36 <3D ,2 0,6 <36 3D-5D ,6 <36 5D-7D ,6 <36 >7D ,8 0,4 <36 <3D ,2 0,6 <36 3D-5D ,8 0,5 <36 5D-7D ,8 0,4 <36 >7D ,8 0,3 <36 <3D ,6 1 <36 3D-5D ,2 0,8 <36 5D-7D ,2 0,6 <36 >7D ,2 0,4 <36 <3D ,4 0,7 <45 3D-5D <45 5D-7D <45 >7D ,8 0,6 <45 <3D ,2 0,6 <45 3D-5D ,6 <45 5D-7D ,6 <45 >7D ,8 0,4 <45 <3D ,2 0,6 <45 3D-5D ,8 0,5 <45 5D-7D ,8 0,4 <45 >7D ,8 0,3 <45 <3D ,6 1 <45 3D-5D ,2 0,8 <45 5D-7D ,2 0,6 <45 >7D ,2 0,4 <45 <3D ,4 0,7 <47 3D-5D <47 5D-7D ,8 <47 >7D ,8 0,6 <47 <3D ,2 0,6 <47 3D-5D ,6 <47 5D-7D ,6 <47 >7D ,8 0,4 <47 <3D ,2 0,6 <47 3D-5D ,8 0,5 <47 5D-7D ,8 0,4 <47 >7D ,8 0,3 <47 <3D ,6 1 <47 3D-5D ,2 0,8 <47 5D-7D ,2 0,6 <47 >7D ,2 0,4 <47 HF Cutting Conditions Page 65 65
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