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The Milling process ............................................... D5Basic milling definitions ......................................... D6

Application of milling cutters .................................. D9

Milling direction ..................................................... D9

Cutter diameter position ...................................... D10

Entry and exit considerations ............................... D11

Entering angle ..................................................... D12

Methods for machining a cavity ............................ D14

Milling method recommendations ......................... D15

Application hints for milling ................................. D17

Achieving good surface finish in milling ................. D18

Countering vibrations in milling ............................. D19

When results are affected by vibration .................. D21

Selecting cutting data ......................................... D22

Terminology and units for milling ........................... D23

General milling formulas ...................................... D23

Formulas for specific milling cutters ...................... D24

Calculation of power consumption ........................ D25

Constant K for power calculations ........................ D26

Cuttting data calculations for milling ..................... D27

Circular interpolation ........................................... D31

Mounting dimensions for cutters .......................... D33

Insert mounting with Torx Plus .............................. D34

Tool wear ............................................................ D35

If problems should occur ..................................... D36

Selection and application process ........................ D38

Operations tool recommendations ..................... D40

Tool guide and selection ...................................... D42

CoroMill 245 ....................................................... D46Insert geometries and grades .............................. D48

Tailor Made ......................................................... D51

CoroMill 290 ....................................................... D52

Insert geometries and grades .............................. D54

Tailor Made ......................................................... D56

CoroMill 390 ....................................................... D57


Shoulder, plunge milling and peck drilling .............. D64

Tailor Made ......................................................... D65

Turn-milling with CoroMill 390 ............................... D68

CoroMill 200 and 300 round insert cutters ........... D69

Contents

CoroMill 200 ....................................................... D70Inserts and grades .............................................. D72

Ramping and helical interpolation ......................... D74

Tailor Made ......................................................... D75

CoroMill 300 ....................................................... D76

Inserts and grades .............................................. D79

Ramping and helical interpolation ......................... D80

CoroMill 216 ....................................................... D81

CoroMill ball nose cutter ...................................... D82

Machining recommendations ................................ D84

CoroMill 216F ..................................................... D85

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

Machining recommendations ................................ D88

CoroMill 210 ....................................................... D89

CoroMills high feed facemill and plunging cutter .... D90

Tailor Made ......................................................... D92

High feed milling ................................................. D93

Plunge milling ..................................................... D94

CoroMill Century ................................................. D96


Cutter setting ...................................................... D99

Tailor Made ....................................................... D100

CoroMill 790 ..................................................... D101

Interpolation and ramping .................................. D104

Tailor Made ....................................................... D105

CoroMill 331 ..................................................... D106

Applications ...................................................... D108

Insert and grades .............................................. D110

CoroMill 331 with cassettes .............................. D114Gang milling staggered ...................................... D115

Mounting and setting instructions ....................... D117

Tailor Made ....................................................... D119

T-Max Q-cutter ................................................... D126

Tailor Made ....................................................... D127

Heavy duty T-Max 45 .......................................... D129

Sandvik Auto and T-line cutters ........................... D131

Auto inserts ...................................................... D132

Sandvik AUTO-AF ............................................... D133

Mounting and setting ......................................... D134

Square shoulder Auto-FS .................................... D136

Milling

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Auto CAP system ............................................... D137T-Line milling cutters .......................................... D138

Sandvik Auto cylinder boring cutter ..................... D139

Tailor Made ....................................................... D140

Tailor Made Auto-AF ........................................... D143

CoroMill Plura solid carbide cutters ..................... D144

Selecting CoroMill Plura cutters .......................... D145

Endmill types and applications ........................... D146

Cutting data ...................................................... D154

Tailor Made ....................................................... D158

If probles occur CoroMill Plura ......................... D159

Regrinding ........................................................ D160

Application technique ........................................ D161

CoroMill Plura thread milling cutters ................... D162

Cutting data ...................................................... D164

Feed recommendations milling ........................ D165

Productivity parameters, HSM and 3D milling ...... D169

Cutting speed recommendations ........................ D170

Milling grades ................................................... D178

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Milling

The milling process

Modern milling is a very universal machining method. During the past few years, hand-in-

hand with machine tool developments, milling has evolved into a method that machines

a very broad range of configurations. The choice of methods today in multi-axis machinery

is no longer straightforward in addition to all the conventional applications, milling is a

strong contender for producing holes, cavities, surfaces that used to be turned, threads,

etc. Tooling developments have also contributed to the new possibilities along with the

gains in producitivity, reliablity and quality consistency that have been made in indexable

insert and solid carbide technology.

Milling is principally metal cutting performed with a rotating, multi-edge cutting tool

which performs programmed feed movements against a workpiece in almost any direc-

tion. It is this cutting action that makes milling such an efficient and versatile machining

method. Each of the cutting edges remove a certain amount of metal, with a limited

in-cut engagement, making chip formation and evacuation a secondary concern. Most

frequently still, milling is applied to generate flat faces as in facemilling - but other

forms and surfaces are increasing steadily as the number of five-axis machining centres

and multi-task machines grow.

The main types of milling operations as seen from the effect on the component or from

a tool path point of view include:

1 facemilling

2 square-shoulder milling

3 profile milling

4 cavity milling

5 slot milling

6 turn milling

7 thread milling

8 cutting off

9 high-feed milling

10 plunge milling

11 ramping

12 helical interpolation

13 circular interpolation

14 trocidal milling

1 2 3 4 5 6 7

8 9 10 11 12 13 14

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Basic Milling definitionsA milling cutter will basically employ one

or a combination of the following basic

cutting actions: (A) radial, (B) peripheral

and (C) axial. Throughout the variations

in milling methods, one can trace back

the cutting action to these feed direc-

tions in relation to the axis of tool rota-

tion. For example:

Facemilling is a combined cutting action

by the cutting edges, mainly the ones on

the periphery and to some extent by theones on the face of the tool. The milling

cutter rotates at a right angle to the direc-

tion of radial feed against the workpiece.

Side and face milling uses mainly the

cutting edges on the periphery of the

tool. The milling cutter rotates round an

axis parallel to the tangential feed.

Plunge milling mainly uses the cutting edg-

es on the face or end of the tool as it is fed

axially, performing a partial drilling action.

To set-up the milling operation, a number

of definitions should be established.

These define the dynamics of the rotat-

ing milling tool, with a specified diameter

(Dc), having largest diameters (Dc2 orD3), moving against the workpiece, with

an effective cutting diameter (De), the

basis for the cutting speed.

Cutting speed (vc) in m/min indicates

the surface speed at which the cutting

edge machines the workpiece. This is a

tool oriented value and part of the cutting

data which ensures that the operation is

carried out efficiently and within the rec-

ommended scope of the tool material.

Spindle speed (n)in rpm is the number

of revolutions the milling tool on the

spindle makes per minute. This is a ma-

chine oriented value which is calculated

from the recommended cutting speedvalue for an operation.

Dc

Dc2

De

Dc

ap

Dc

D3

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Feed per minutealso known as the table

feed, machine feed or feed speed (v)

in mm/min is the feed of the tool in re-

lation to the workpiece in distance per

time-unit related to feed per tooth and

number of teeth in the cutter.

Maximum chip thickness (hex) in mm

is the most important limitation indica-

tor for a tool, for an actual operation. A

cutting edge on a milling cutter has been

designed and tested to have a recom-

mended starting value and a minimum

and maximum value.

Feed per tooth (fz) in mm/tooth is a

value in milling for calculating the table

feed. As the milling cutter is a multi-edge

tool, a value is needed to ensure that

each edge machines under satisfac-

tory conditions. It is the linear distance

moved by the tool while one particular

tooth is engaged in cut. The feed per

tooth value is calculated from the recom-

mended maximum chip thickness value.

The number of available cutter teethin

the tool (zn) varies considerably and is

used to determine the table feed while

the effective number of teeth (zc) is the

number of effective teeth. The material,

width of component, stability, power, sur-

face finish influence how many teeth are

suitable.

Feed per revolution (fn)in mm/rev is a

value used specifically for feed calcula-

tions and often to determine the finish-

ing capability of a cutter. It is an auxiliary

value indicating how far the tool moves

during the rotation.

Depth of cut (ap) in mm (axial) is what

the tool removes in metal on the face

from the workpiece. This is the distance

the tool is set below the un-machined

surface.

Cutting width (ae)in mm (radial) is the

width of the component engaged in cut by

the diameter of the cutter. It is distance

across the surface being machined or, if

the tool diameter is smaller, that covered

by the tool.

The average chip thickness (hm) is auseful value in determining specific cut-

ting force and subsequently power calcu-

lations. It is calculated in relation to the

type of cutter engagement involved.

fz

hm

hex

ae

ae

ar

ap

ae

asp

EL

ae

ae

apfz

fn

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The removal rate (Q)is volume of metal

removed per time in cubic-mm and can

be established using values for cutting

depth, width and feed.

The machining time (Tc)or period of cut-

ter engagement is the machining length

(lm) divided by the table feed.

The specific cutting force (kct)is a power

calculating factor taking into account the

material in question and for a chip thick-

ness value. It relates to machinability as

well as feed rate and cutting speed.

Power (Pc) and efficiency () are ma-

chine tool oriented values where the netpower can be calculated to ensure that

the machine in question can cope with

the cutter and operation.

As regards cutting geometry in milling,

the entering angle (r), or the major cut-

ting edge angle, of the cutter is the domi-

nant factor affecting the cutting force di-

rection and chip thickness. The choice of

insert geometry has been simplified into

three practical areas of varying cutting

action effects : Light (L), general purpose

(M) and tough (H) geometries.

Pitch (u) is the distance between teeth

on the cutter. It is the distance between

one point on one cutting edge to the same

point on the next edge. Milling cutters are

mainly classified into coarse (L), close

(M) and extra close (H) pitches, as well

as extra, extra close pitch. The different

pitches affect operational stability, power

consumption and suitable workpiece ma-

terial. A differential pitch means an un-

equal spacing of teeth on the cutter andis a very effective means with which to

counter vibration tendencies.

L HM

L HM

Entering angle variation of milling cutter.

Light cutting geometry -L

Sharp, positive cutting edge.

Smooth cutting performance.

Low feed rates.

Low machine power.

Lower cutting force requirements.

Coarse pitch (-L)

Reduced number of inserts, with

differential pitch, for best

productivity when stability andpower are limited.

Extended tooling.

Small machines, i.e. taper 40.

General purpose geometry -M

Positive geometry for mixed

production.

Medium feed rates.

Tough geometry -H

For highest security requirements.

High feed rates.

Close pitch (-M)

General purpose milling and

mixed production.

Extra close pitch (-H)

Maximum number of inserts for

best productivity under stable

conditions.Short chipping materials.

Heat resistant materials.

r90 45 10

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Application of milling cutters

Milling directionDuring the milling operation, the work-

piece is fed either with or against the

direction of rotation and this affects the

nature of the start and finish of the cut.

In Down milling (1) (also called climb

milling), the workpiece feed direction is

the same as that of the cutter rotation at

the area of cut. The chip thickness will

decrease from the start of the cut until it

is zero at the end of the cut in peripheral

milling.

In Up milling (2) (also called conven-

tional milling), the feed direction of the

workpiece is opposite to that of the cut-

ter rotation at the area of cut. The chip

thickness starts at zero and increases to

the end of the cut.

In Up milling, with the insert starting

its cut at zero chip thickness, there are

high cutting forces which tend to push

the cutter and workpiece away from each

other. The insert has to be forced into

the cut, creating a rubbing or burnishing

effect with friction, high temperatures

and often contact with a work-hardened

surface caused by the preceeding insert.Forces will also tend to lift the workpiece

from the table.

In Down milling, the insert start its cut

with a large chip thickness. This avoids

the burnishing effect with less heat and

minimal work-hardening tendencies. The

large chip thickness is advantageous

and the cutting forces tend to pull the

workpiece into the cutter, holding the in-

sert in the cut.

During milling, chips will sometimes

stick or weld to the cutting edge and be

carried around to the start of the next

cut. In Up milling, the chip can easily be

trapped or wedged between the insert

and workpiece, which can then result

in insert breakage. In Down milling, the

same chip would be cut in half and not

damage the cutting edge.

Down milling is preferred wherever the

machine tool, fixturing and workpiece will

allow.

Down milling, however, makes certain

demands on the process in that forces

tend to pull the cutter along while they

hold the workpiece down. This needs

the machine to cope with table-feed

play through back-lash elimination. If the

tool pulls into the workpiece, feed is in-

creased unintentionally which can lead

to excessive chip thickness and edge

breakage. Up milling should be selectedin such cases. Also when large varia-

tions in working allowance occur, up mill-

ing may be advantageous. Fixturing has

to be adapted to hold the workpiece cor-

rectly as well as having the right cutter

size for the job. The direction of cutting

forces are, however, more advantageous

as regards vibration tendencies.

Down-milling and up-milling.

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The selection of milling cutter diameter

is usually made on the basis of the work-

piece width with the power availability

of the machine also being taken into ac-

count. The position of the cutter in rela-

tion to the workpiece engagement andcontact the cutter teeth have are vital

factors for successful operation.

There are three principal types of milling

cutter/workpiece relationship situations:

Firstly, when the workpiece width is larger

than or the same as the cutter diam-

eter, leading to thin chips at entry/exit

or when several passes are required.

(Typical of when the workpiece surfaces

are very large or the cutter diameter too

small for the application).

Secondly, (2) where the cutter-diameter

is somewhat larger than the workpiece

width, as is often case in facemilling.

(20 to 50% - often representing the ideal

situation especially in facemilling.)

Thirdly, (3) where the diameter is consid-

erably larger than the width of cut, with

cutter axis well outside the workpiece

width. (This is often the case with side

and facemilling, long edge milling and

endmilling.)

In facemilling especially, the workpiece

width should influence the milling cutter

diameter. The cutter diameter should

not be the same as the workpiece

width a diameter 20 to 50% larger

than the workpiece width is normally

recommended.

If several passes need to be taken,

these should be taken in a way that cre-ates the diameter/width relationship

of approximately 4/3 and not the full

diameter at each pass as this helps to

ensure good chip formation and suit-

able cutting edge load.

In the ideal situation, with the cutter be-

ing sufficiently larger than the workpiece

width, the milling cutter should always

be positioned slightly off-centre. Being

close to the centre is advantageous in

that the cut which each insert takes is

at its shortest and that entry and exit of

cuts are good from a chip formation and

shock-load point of view. However, when

the tool is positioned dead on centre, a

disadvantageous situation arises. Radial

forces of even magnitude will fluctuate in

direction as the cutting edges go in and

out of cut. The machine spindle can vi-

brate and become damaged, inserts may

chip resulting in poor surface finish.

Moving the cutter slightly off-centre will

mean a more constant force direction - a

type of pre-loading is achieved when the

cutter is against the workpiece.

Cutter diameter and position

Avoid positioning cutters on-centre.

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Also linked to chip thickness in milling is

the entering angle of a facemill. This is

the angle between the main, leading cut-

ting edge of the insert and the workpiece

surface. Chip thickness, cutting forces

and tool-life are affected especially bythe entering angle. Decreasing the en-

tering angle reduces chip thickness for

a given feed rate and this chip thinning

effect spreads the amount of material

over a larger part of the cutting edge. A

smaller entering angle also provides a

more gradual entry into cut, reducing ra-

dial pressure and protecting the cutting

edge. The higher axial forces, however, in-

creases the pressure on the workpiece.

The most common entering angles today

are 45 degrees, 90 degrees, 10 degrees

and those of the round insert.

The 90 degree cutter will generate

mostly radial forces, in direction of the

feed. This means that the surface being

machined will not be subjected to very

much axial pressure, which is positive

for milling workpieces with a weak struc-

ture or thin walls. The main application

area however is for square shoulder mill-

ing, achieving a right-angled edge as a

result of the cut.

The 45 degree cutterhas radial and axial

cutting forces which are about the same

in value, giving rise to more balanced

pressure and being less demanding as

regards machine power. This is the gen-

eral purpose facemilling entering angle.

It is also especially suitable for milling

workpieces in short-chipping materials

that will fritter, because of excessive radi-

al forces acting on the dwindling amount

of material left at the end of a cut. It also

presents the cutting edge more gently at

the start of cut and gives rise to a lower

tendency for vibrations when milling with

long overhangs or smaller toolholding

facilities. The thinnner chip allows for

high productivity in many applications

because of the scope for higher table

feed while maintaining a moderate cut-

ting edge load. This often makes up for

the smaller depth of cut capability which

the smaller angle provides.

The 10 degree entering angle is used

on high-feed and plunge milling cutters.

This allows them to perfom at very high

cutting data, where the chip thickness is

small but the table feed is very high. Low

cutting forces are advantageous because

the dominant direction is axial, both as

regards radial and axial milling, limiting

vibration tendencies and providing a poten-

tial for very high metal removal rates.

The round insert cutterhas a continu-

ously variable entering angle, from zero

upwards to 90 degrees, depending upon

the cutting depth. The insert radius pro-

vides a very strong cutting edge, suit-

able for high table feed rates because

of the thinner chip generated along the

Entering angle

Common milling cutter entering angles and their effect on cutting forces and chip thickness.

90 45 10

fz fzfzfz

apapapap

hex hex

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long cutting edge. The chip-thining ef-

fect is suitable for machining titanium

and heat resistant alloys. The change in

cutting force direction along the insert

radius and the resulting pressure during

the operation will depend upon the depthof cut. Modern insert geometry develop-

ments have made the round insert mill-

ing cutters more widely suitable because

of the smoother cutting action, requiring

less power and stability from the ma-

chine tool. Today, it is not a specialized

cutter anymore and should be regarded

as an efficient roughing cutter, capable

of high material removal rates.

90 hex

= fz

75 hex

= 0.96 fz

60 hex

= 0.86 fz

45 hex

= 0.707 fz

10 hex

= 0.18 fz

r

hex

O iC2(iC2ap)2 f

z

iCh

ex=

The values for hexare given for

operations with the cutter

centered on the workpiece. For

sidemilling the hexvalue varies

depending on cutter diameter

and working engagement.

Thin walled components

Weak fixtured components

Where 90 form is required

90 entering angle cutters

General purpose first choice

Reduces vibration on long overhang

Chip thinning effect allows increased

productivity

45 entering angle cutters

Strongest cutting edge with multiple

indexes

General purpose cutter

Increased chip thinning effect for

heat resistant alloys

Round insert cutters

100%

chip load75%

50%

25%

Entering angle and max. chip thickness.

45

30

fz

hex

fz

On round inserts the chip load and entering

angle vary with the depth of cut.

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Ramping and circular interpolation in helix

Ramping is an efficient way to approach the workpiece when

machining pockets. For larger holes, however, circular interpo-

lation in helix is much more power efficient and flexible than

using a large boring tool.

1

2

3

4

5

Required

depth of

cut for

machining

the first

layer.

Methods for machining a cavity

Conventional method

Two axis ramping

One of the best methods to reach a

full axial depth of cut, is linear ramp-

ing in the X/Y and Z axis. Note that

if choosing the right starting point,

there will be no need for milling away

stock from the ramping section.

Ramping can start from in to out or

from out to in, depending on the ge-

ometry of the die or mould. The main

criterion is how to get rid of the chips

in the best way e.g. down milling

should be performed in a continuous

cut. When taking a new radial depth

of cut it is important to approach it

with a ramping movement or, prefer-

ably using smooth circular interpo-

lation. In HSM applications this is

crucial.The ramping angle is dependent

upon the diameter of the cutter used,

clearance to the cutter body, insert

size and depth of cut. The clearance

also depends upon the diameter of

the cutter.

Pre-drilling/peck-milling

Pre-drilling of a starting hole is not

recommended as one extra tool is

needed. Unproductive time for posi-

tioning and tool changing are nega-

tive factors, and also tool magazine

positions are unnecessarily filled.

Axial feed capability is an advantage

in many operations. Holes, cavities

as well as contours can be more ef-

ficiently machined.

A number of Coromant tools with this

capability are available in this cata-

logue. These tools are also favour-

able for weak machine spindles and

when using long overhangs, since

the cutting forces are mainly directed

axially.

If using a ball nose endmill it is

pretty common to use a peck-drilling

cycle to reach a full axial depth of

cut and then mill away a layer of the

cavity. This is then repeated until the

cavity is finished. The drawback with

this approach is that chip evacuation

problems rise at the centre of the

end mill.

A better method is to reach the full

axial depth of cut using circular inter-

polation in helix. It is also important

then to facilitate chip evacuation.

Three axis ramping

Feeding the tool in a helical shaped

path in the axial direction of the

spindle is mainly used in die and

mould making. This has several ad-

vantages when machining holes with

large diameters. Machining can be

performed with only one tool, usually

with no chip breaking and evacuation

or vibration problems, as the diam-

eter of the tool is smaller compared

to the diameter of the hole to be

machined.

It is recommended that the diameter

of the hole is twice the diameter of

the cutter.

The maximum ramping angle for the

cutter should also be checked when

using circular interpolation in helix.

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ae= max

0.4 x Dc

- Ramping circular interpolation

Suitable tool is CoroMill 300 round insert cutterHelical interpolation to depth of cut : ap = 0.4 x iC (insert size) with a maximum ramping

angle depending upon cutter diameter

For maximum material removal rate select insert size (iC) 12 or 16 mm and fine-pitch

cutter. Ensure all programmed radii are 15% larger than cutter radius.

FacemillingAvoid milling over holes or slots whenever possible as these

interrrupted cuts are demanding on the cutting edges with mul -

tiple entries and exits. If possible make the holes in a subse -

quent operation. Alternatively, reduce the recommended feed

rate by 50% over the workpiece area containing the holes.

When machining large workpiece surface areas, select tool

path to keep the milling cutter in full contact rather than per -

form several parallel passes. When changing direction, include

a small radial tool path to keep cutter moving, avoiding dwell

and chatter tendencies.

Consider round insert cutters as first choice for facemilling

CoroMill 200 or CoroMill 300 with 45-degree cutter as alter -

native CoroMill 245. For milling against shoulders, select the

90 degree cutter CoroMill 390 as first choice.

Pocket milling- Rough machining of rectangular pockets through circular

interpolation.

Suitable tools are CoroDrill 880 or Coromant U-drill for drilling

and the CoroMill 390 long-edge cutter for milling.

The application is suitable for this method with drilling first and

then opening up through long-edge milling.

The drill diameter (Dc) should be 5 to 10 mm larger than that

of the long-edge cutter.

Apply a maximum depth of cut of 2 x Dc for the long-edge cutterand programme radial step-overs (ae) of 30 to 40%.

A large-diameter cutter will be capable of a high metal removal

rate but leaves more material in the corners to be machined in

a subsequent operation.

All programmed radii should be 15% larger than the cutter ra -

dius.

- Drilling followed by plunge milling , when pockets are deeper than twice the cutter

diameter

Suitable tools are CoroDrill 880 or Coromant U drill and CoroMill 2 10

The largets possible cutter diameter should be used and ensure that two teeth are

constantly engaged in cut.

Milling method recommendations

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Dc= 2 x R 1(D

c= 11 mm)

R = 6 mm

Max. cutter

Milling of a closed slot- drilling and full-slot milling

Suitable tools are CoroDrill 880 or Coromant U-drill and CoroMill

390 long edge cutter.

When a slot is long and narrow, circular interpolation is not pos -

sible so the three options available require full-width machin -

ing. If the machine power allows it the cutter diameter selected

should be as close to the finished slot size, leaving just thefinishing allowance.

retemaidahtiwllirdaesugnillimtols-llufybdewollofgnillirD

5 to 10 mm larger than the long-edge cutter. A maximum depth

of cut of 1 x Dc should be applied and a reduced feed at the

start to produce room for chip evacuation.

- drilling and plunge milling

Suitable tools are CoroDrill 880 or Coromant U drill and CoroMill 2 10.

Use a drill with a diameter (Dc) 1 mm larger than the milling cutte r.A maximum radial cutting depth of 12 mm (Dc : 50 mm) should be applied and two

teeth should constantly be engaged in cut.

- two-axis ramping

Suitable tool is CoroMill 300.

Two-axis ramping to depth of cut ap = 0.3 x iC

The maximum ramping angle is dependant upon cutter diameter. (5 degrees for 50mm). For maximum metal removal rate select insert size 12 or 16 mm and a fine-pitch

cutter.

Semi-roughing of cornersBefore actual finishing operations in a cavity, there are often

requirements to remove material in the form of a large radius

left by a roughing tool. Because of the normally small radius

requirement and relatively deep cavities involved, tools areslender enough to get into corners. This operation can be time

consuming, however, and is worth optimizing, even when two

different cutter diameters are needed to arrive at the finish.

- Rest-milling of 90-degree corners (pocket-depth up to 4 x Dc

of finished radius)

Suitable tools are CoroMill 390 and CoroMill Plura depending

upon diameter.

The cutter radius should be smaller than the corner radius to

avoid vibrations.

- Plunge milling (pocket depths larger than 3 x Dc or finished

corner)

Suitable tools are CoroMill 390, CoroMill 300 and CoroMill

Plura, depending upon diameter.

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2

14

3 5

Dc= 2 x R

Machining sequence 1 to 5.

- Rest-millingof 90-degree corner (pock-

et depth up to 4 x Dc of finished radius)

If there is a lot of material left after the

roughing operation a different machining

strategy should be approached. Above

all the cutter needs stability and good

reach so as to be able to make the larger

radial cuts.The Coromant U plunging drill is suitable

here as it allows cuts of up to 75% of the

cutter diameter which can then be fol-

lowed by semi-finishing using previously

described rest milling strategy.

- closed anglesare a common feature in

cavities and, depending upon the angle in-

volved between the two walls, two different

approches can be used. A pocket with a

5-axis-land can be finished with a square

endmill in a 4-axis machine. When a radius

is specified, a ball nose endmill is needed

to machine the radius. This, however, is

much longer machining process and re-

quires a 5-axis machine capability.

2

1

3

5

4

12

Dc = 12.7 mm

End radius= 6 mm

Start radius =16 mm

Dc = 20 mm

Dc = 12.7 mm

End radius= 6 mm

Start radius =16 mm

Application hints for milling:

check power capability and machine rigidity, making sure that the machine can handle the cutter diameter required

machine with the shortest possible tool overhang on the spindle

use the correct cutter pitch for the operation to ensure that there are not too many inserts engaged in cut causing vibration

while on the other hand, ensure there is sufficient insert engagement with narrow workpieces or when milling over voids

ensure that the right feed per insert is used to achieve the right cutting action through the recommended maximum chip

thickness

use down milling whenever possible

use positive-geometry indexable inserts whenever possible for smooth cutting action and lowest power consumption

select the right diameter in relation to the the workpiece width

select the most suitable entering angle

position the milling cutter correctly

only use coolant if considered necessary, milling is generally performed better without

follow tool maintenance recommendations and monitor tool wear

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The wiper protrudes below the other inserts by approximately

0.05 mm. The wiper facet is crowned (large radius) to give a

step-free surface allowing for different spindle inclinations.

The feed per rev. (fn) should be limited to 60% of parallel land

to ensure a stepfree surface.

The most common reason for a bad result with a wiper insert is

incorrect mounting. To mount correctly, push the wiper radially and

slide axially against the third support point, before clamping.

Endmills

The surface finish will depend on the radial run-out of the end-

mill and both the cutter and its clamping have to be consid-

ered. The worst situation is where only one tooth generates the

surface finish, see sketch.

A change from down to up-milling can for some materials im-

prove the surface finish, and the same applies to the use of

coolants, especially when finishing sticky materials.

For finishing operations the radial depth of cut should be kept

low. This has an important effect on the deflection of cutter.

With an indexable endmill, tolerances and cutter deflection will

contribute to a deviation from a true 90 shoulder.

A surface finish is best described by its roughness and wavi-

ness values. The key to obtaining a good surface finish is to

use inserts with wiper flats.

Length of the wiper edge

If the feed per rev. is smaller than the length of the parallel land

the surface will be generated by the highest insert.

Achieving good surface finish in milling

Surface finish with wiper inserts

bs

2.0 2.3 R2451.46 2.12 R2900.4 1.6 N331.1A / R/L331.1A0.4 1.5 R3901.6 2.0 SEKR / SEMN / SEER /SEHN / SEKN

1.5 SNKN / SNAN1.4 2.7 SPKR / SPAN / SPKN1.2 1.4 TPKR / TPKN2.0 2.2 LNCX

Parallel land Inserts

bs

8.2 R24510.0 SPEX10.0 SNEX

Parallel land

Wiper inserts

mm

mm

Wiper insert set below other inserts.

fz

Dc

H =f

z2

4xDc

8.2

r

bs

H

0.05

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Countering vibrations in milling

Due to a number of factors tuned adapters are being used more

and more when machining with long overhangs. Workpieces are

becoming increasingly more complicated while machining opera-

tions need to be done ever faster. This means that there is no

time to re-position the workpiece, instead long tools are used to

reach all the surfaces to be machined in one mounting. This inturn means that in many cases the workpiece does not have suf-

ficient support in the fixture at every machining point.

To maintain maximum productivity when machining e.g a cavity its

important to choose the right extentions. To start with the long-

est will in many cases decrease the productivity due to vibration

problems. Therefore its better to choose a series of extensions

and start with the shortest one and use a tuned adapter in the

deepest sections.

On those occasions when cutting data has to be reduced be-

cause of problems with vibration, a tuned adapter provides an in-

crease in productivity.

Tapered tool adapters can be used in order to achieve as advan-

tageous a mounting as possible and in relation to machine and

tool. This optimizes the rigidity throughout the whole tool.

Workpiece support: In order to achieve the best results, the

workpiece should have correct support in relation to the cutting

forces which arise during the machining process. Machining in a

workpiece with an overhang should be avoided where there is no

support.

The condition and stability of the machine has an effect on the

quality of the surface which is generated. Excessive wear of the

spindle bearings or feed mechanism can result in a poor surface

structure. If the machine is not properly set and maintained, vibra-

tion can cause impaired tool-life and poor surface quality.

Tool: Choose the right milling cutter for the job in hand. Use the

correct ratio between the milling cutter diameter and the width of

the workpiece. Choose the correct tooth pitch, since too many

teeth in the milling cutter can cause excessive loading. Where

possible, use a positive geometry to reduce the cutting forces.

The positioning of the cutter is also extremely important in this

connection.

A basic rule/recommendation: When the total tool length, from

the gauge line to the lowest point on the cutting edge, exceeds

4-5 times the diameter at the gauge line, tuned, tapered bars

should be used.

Tuned toolsTuned tools used for milling, function in the same way as previ-

ously described for turning tools. That is to say that inside the tool

there is a heavy tuning body suspended on rubber bushes. If the

tool begins to vibrate, the heavy tuning body tries to counteract the

vibration so that it disappears entirely.

Sandvik Coromant offers tuned adapters in different versions, such

as Coromant Capto and HSK mountings, for both arbor mounting

face and shoulder milling cutters and smaller shank cutters with

threaded coupling. These tuned adapters for milling are preset as

for turning tools, which means that they can be used without any

additional measures.

Handling, storage and maintenance oftuned products

A tuned bar should be handled with care and should

never be exposed to blows or shaking to free a tuning

system which has stuck. A tuned bar is often stored hori-

zontally for practical reasons without causing any harm.

Under normal conditions a tuned bar will operate with-

out maintenance. However, rubber bushes which are

vital for the functioning of the damping system will age

with time and lose their spring characteristic and their

capacity to act as a complement to the oil in the damp-

ing system. When the critical point for service life of

the rubber bushes has been reached, the damping sys-

tem will cease to function.

The service life of the damping system is shortened if it

is exposed to intense heat. Therefore coolant should be

used to extend the service life of the damping system.

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FlywheelVibration occurs frequently during side and face milling but this

problem can be remedied in an effective and simple way. In

addition to up milling, a flywheel can be fitted to the arbor on

which the milling cutter is set up. In order to improve stability

further when side and face milling, it is a basic rule to use the

largest possible flywheel to which the application permits.

The best way to make a flywheel is to use a number of round

carbon steel discs, each with a centre hole and key groove to fit

the arbor. For a particular flywheel weight the effect increases

as the diameter of the flywheel increases. This means that if

circumstances permit a large diameter, the weight of the fly-

wheel can be reduced. The flywheel weight can, if necessary, be

distributed over several flywheels where space permits.

Higher spindle speeds and a larger cut reduces the need for a

flywheel. The smallest possible milling cutter diameter should

be used for this so that the spindle speed can be increased for

a particular cutting speed.

Some rules of thumb for use of a flywheel

In a small machine with low power the need for

a flywheel is greater than in a large powerful ma-

chine.

Position the flywheel as close to the tool as pos-

sible.

Strengthening the workpiece mounting is always a

good investment.

The smoother machining, which results from using

a flywheel, leads to a reduction in noise and vibra-

tion, and a longer tool-life.

When mounting a tool on a tuned adapter it is important to

remember that there is a tuning body inside the adapter.

Since the adapter is not solid it can easily be deformed

and therefore must not be clamped in a screw clamp when

mounting is taking place. Deformation means that the tun-

ing system will be impaired or cease to function entirely.

The best way to mount a tool and adapter is to use fixtures

designed for the purpose.

27 32 40 50

15 20-

25

25-

35

35-

50

mm

d

m

kg

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When the machining results are affected by vibration

Unstable/weak tool holding Establish the direction of the cutting forces and position the material support

accordingly.

Try to improve the clamping generally.

Reduce the cutting forces by reducing the radial and axial cutting depth.

Choose a milling cutter with a coarse tooth pitch and positive design.

Choose positive inserts with a small corner radius and small parallel flats.

Where possible, choose an insert grade with a thin coating and a sharp cutting

edge. If necessary, choose an uncoated insert grade.

Avoid machining where the work-piece has poor support against cutting forces.

Unstable/weak workpiece

clamping

The first choice is a square shoulder facemill with positive inserts.

Choose an L-geometry with a sharp cutting edge and a large clearance angle

which produces low cutting forces.

Try to reduce the axial cutting forces by reducing the axial cutting depth, as well

as using positive inserts with a small corner radius, small parallel flats and

sharp cutting edges.

Large overhang either on the

spindle or the tool

Square shoulder milling with a

radially pliable spindle

Uneven table feed

Always use a coarse tooth pitch and a differentially pitched milling cutter.

Balance the cutting forces axially and radially. Use a 45 degree entering angle,

large corner radius or round inserts.

Use inserts with a light cutting geometry.

Try to reduce the overhang, every millimetre counts.

Choose the smallest possible milling cutter diameter in order to obtain the most

favourable entering angle. The smaller the milling cutter diameter the smaller theradial cutting forces will be.

Choose positive and light cutting geometries.

Try up milling.

Try up milling.

Look at the possibility of adjusting the feed screw on CNC machines. Adjust the

locking screw or replace the ball screw on conventional machines.

Cause Action

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Example of how to find the values when calculating spindle

speed (n) and table feed (vf):

vc In order to get v

c, the max chip thickness (h

ex) for an

operation and the Coromant Material Classification

(CMC) code is needed.

See feed recommendations.

The cutter selected has a 45 entering angle (r) and

PM insert geometry will be used.

Max chip thickness (hex) for the operation is 0.17 mm

The material is SS1672-08 and corresponding CMC code is

01.2.

The cutting speed vcis approx. 283 m/min for CMC 01.2 (be-

tween 325 and 270 m/min for hex= 0.10 and 0.20 mm respec-

tively).

This cutting speed is valid for hardness HB150. If your hard-

ness is HB180 a compensation factor of 0.92 for the deviationof +30 units.

The compensated cutting speed becomes 0.925 x 283 m/min

262-m/min.

n =v

c 1000

Dc

fz=

hex

sin r

R245-125Q40-12M

R245-12 T3 M-PM GC4030

SS1672-08 HB =180

vf= z

n n f

zFormulas to be used:

Conditions:

Dc

zn

r

fz

n

vf

Selecting cutting data

Difference in hardness

CMC No. Hardness Brinell (HB)

Reduced hardness

80 60 40 20 0 +20 +40 +60 +80

01 - - - 1.07 1.0 0.95 0.90 - -02 1.26 1.18 1.12 1.05 1.0 0.94 0.91 0.86 0.8303 - - 1.21 1.10 1.0 0.91 0.84 0.79 -05 - - 1.21 1.10 1.0 0.91 0.85 0.79 0.7506 - - 1.31 1.13 1.0 0.87 0.80 0.73 -

07 - 1.14 1.08 1.03 1.0 0.96 0.92 - -08 - - 1.25 1.10 1.0 0.92 0.86 0.80 -09 - - 1.07 1.03 1.0 0.97 0.95 0.93 0.9120 1.26 - 1.11 - 1.0 - 0.90 - 0.82

6 3 0 +3 +6 +9

04 1.10 1.02 1.0 0.96 0.93 0.90

Increased hardness

CMC No. Hardness Rockwell (HRC)

Hardness of workpieceThe cutting speeds given on the following pages are valid for a

specific material hardness. If the material being machined differs

in hardness from those values, the recommended cutting speed

must be multiplied by a factor obtained from the table below.

Cutter-

Insert-

Workpiece material:

The cutter selected has a diameter, Dc, of 125 mm.

Number of teeth is found on the same page and zn is

in this case 8.

The selected cutter has a 45 entering angle.

Feed per tooth for the cutter and selected insertgeometry.

Feed per tooth

Revolutions per minute

Table feed per minute vf = 8 667 0.24 = 1281

mm/min

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Dc

lm

De

ap

ae

vc

Q

Tc

zn

fz

fn

vf

hex

hm

Terminology and units for milling

General milling formulas

Feed per revolution(mm/rev)

Feed per tooth(mm)

vf= f

z n z

nTable feed (feed speed)(mm/min)

fz= vf n zn

Spindle speed(rev/min)

n = vc 1000

Dc

Cutting speed(m/min)

vc= D

c n

1000

Average chip thickness (mm)when a

e/D

c 0.1

hm=

sin r 180 a

ef

z

Dc arcsin (ae) D

c

Machining time(min)

Tc=

lm

vf

fn= v

f

n

Removal rate(cm3)

Q = a

pa

ev

f

1000

Specific cutting force(N/mm2)

kc= k

c1 h

m-mc

Average chip thickness (mm)(Side and facemilling) when a

e/D

c 0.1

hm fz ae

Dc

Net power

(kW)

Pc=

apa

ev

fk

c

60 106

zn=8

fz

fn

fz

hex

hm

Dc

ae

r= 90

= Cutting diameter

= Machined length

= Effective cutting diameter

= Cutting depth

= Working engagement

= Cutting speed

= Metal removal rate

= Period of engagement

= Total number of edges in the tool

= Feed per tooth

= Feed per revolution

= Table feed (feed speed)

= Max chip thickness

= Average chip thickness

mm

mm

mm

mm

mm

m/min

cm3/min

min

piece

mm

mm

mm/min

mm

mm

zc

kc1

n

Pc

r

vc0

cvc

mc

iC

= Effective number of teeth

= Specific cutting force

(for hex

=1 mm)

= Spindle speed

= Cutting power net= Efficiency

= Major cutting edge angle

= Constant for cutting speed

= Correction factor for cutting speed

= Rise in specific cutting force (kc)

as a function of chip thickness

= inscribed circle

piece

N/mm2

rev/min

kW

degrees

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Feed per tooth (mm/tooth), cutter centered

Feed per tooth (mm/tooth),side milling

Feed per tooth (mm/tooth),

side milling

Feed per tooth (mm/tooth),cutter centered

Feed per tooth (mm/tooth),cutter centered

fz=

hex

sin

r

fz= iC h

ex

D

e D

c

Formulas for specific milling cutters

Facemilling cutters, side and facemilling cutters and endmills

Cutters with round inserts

These tools are characterized by having straight cutting edges.

Feed per tooth (mm/tooth),side milling

fz=

D3 h

ex

De2 (D

e 2 a

e)2

fz=

D3 h

ex

De

Ballnose endmills

fz

=D

e h

ex

De2 (De2 ae)2sin r

Max cutting diameter at aspecific depth (mm)

De= D

c+ 2 ap

tan r

Max cutting diameter at aspecific depth (mm)

De= D

c+iC2 (iC 2a

p)2

Max cutting diameter at aspecific depth (mm) De= D3

2

(D3 2 ap)2

fz=

De iC h

ex

(De D

c) D

e2 (D

e 2 a

e)2

ap

De

ap

De

Dc

ap

De

Dc

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Calculation of power consumption

Optimized power consumption calculation

The example is valid for 0 top rake angle. The power consump-

tion changes 1% per degree of change in top rake. A positive

top rake angle decreases the power consumption and a nega-

tive top rake increases the power consumption. A positive cut-

ter with +15 top rake angle requires 15% less power than a

cutter with 0 top rake angle.

Use multiplying factor from top rake angle to adjust Pc

values.

Example

For an engagement of 80% the K value is 5.4. For a top rake angle of +21 the Mvalue is 0.79.

For different insert geometries the power consumption

must be adjusted.

For each degree more positive top rake angle the power consump-

tion will decrease with 1%.

For a CoroMill 245 facemill with M-geometry. The M-geometry has

+21 top rake angle.

Pc=

apa

ev

fK

100 000 Pc()= PcM

Pc()

= 27.0 0.79 = 21.3 kWP

c=

5 100 1000 5.4= 27.0 kW

100 000

45 facemilling of steel, CMC 01.3

Cutter diameter, Dc=125 mm

Depth of cut, ap=5 mm

Width of cut, ae=100 mm

Feed per insert, fz

=0.2 mm

Table feed, vf=1000 mm

Milling in general

When machine power is a problem Go from close to coarse pitch, i.e. less number

of teeth.

A positive cutter is more power efficient than a

negative.

Reduce the cutting speed before the table feed.

Warning:

Be aware of the power curve for machining centres.

The machine may lose efficiency if the rpm is too

low.

Use a smaller cutter and take several passes.

Reduce the depth of cut.

True rakeangle,

Multiplyingfactor, M

True rakeangle,

Multiplyingfactor, M

7 1.07

6 1.06

5 1.05

4 1.043 1.03

2 1.02

1 1.01

0 1

1 0.99

2 0.98

3 0.97

4 0.96

5 0.95

6 0.94

7 0.93

8 0.92

9 0.91

10 0.9011 0.89

12 0.88

13 0.87

14 0.86

15 0.8516 0.84

17 0.83

18 0.82

19 0.81

20 0.80

21 0.79

22 0.78

23 0.77

24 0.76

25 0.75

26 0.74

27 0.73

28 0.72

29 0.7130 0.70

Pc=

A x vfx K

60 x 106x

A aex D3

A aex S

Plunge milling

(slot)

(stepover S)

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ISO DescriptionCMC

No.

ae/D

c=0.8

fz=0.1 f

z=0.2 f

z=0.4

ae/D

c=0.4

fz=0.1 f

z=0.2 f

z=0.4

ae/D

c=0.2

fz=0.1 f

z=0.2 f

z=0.4

01.1 5.7 4.8 4.0 6.2 5.2 4.4 6.8 5.7 4.801.2 6.1 5.1 4.3 6.6 5.6 4.7 7.2 6.1 5.1

01.3 6.5 5.4 4.6 7.1 5.9 5.0 7.7 6.5 5.401.4 6.9 5.8 4.8 7.5 6.3 5.3 8.2 6.9 5.801.5 7.6 6.4 5.4 8.3 7.0 5.9 9.1 7.6 6.4

02.1 6.5 5.4 4.6 7.1 5.9 5.0 7.7 6.5 5.402.2 7.6 6.4 5.4 8.3 7.0 5.9 9.1 7.6 6.4

03.11 7.4 6.2 5.3 8.1 6.8 5.7 8.8 7.4 6.203.13 8.2 6.9 5.8 8.9 7.5 6.3 9.7 8.2 6.903.21 11.0 9.3 7.8 12.0 10.1 8.5 13.1 11.0 9.303.22 11.8 9.9 8.4 12.9 10.8 9.1 14.0 11.8 9.9

06.1 5.3 4.5 3.8 5.8 4.9 4.1 6.3 5.3 4.506.2 6.1 5.1 4.3 6.6 5.6 4.7 7.2 6.1 5.106.3 7.4 6.2 5.3 8.1 6.8 5.7 8.8 7.4 6.2

05.11 6.2 5.4 4.7 6.7 5.8 5.0 7.2 6.2 5.405.12 9.7 8.4 7.2 10.4 9.0 7.8 11.2 9.7 8.405.13 8.0 6.9 5.9 8.6 7.4 6.4 9.2 8.0 6.9

05.21 6.9 6.0 5.2 7.4 6.4 5.6 8.0 6.9 6.005.22 9.7 8.4 7.2 10.4 9.0 7.8 11.2 9.7 8.4

05.51 6.9 6.0 5.2 7.4 6.4 5.6 8.0 6.9 6.005.52 8.3 7.2 6.2 8.9 7.7 6.7 9.6 8.3 7.2

15.11 6.5 5.4 4.6 7.1 5.9 5.0 7.7 6.5 5.415.12 9.5 8.0 6.7 10.4 8.7 7.3 11.3 9.5 8.015.13 8.0 6.7 5.7 8.7 7.3 6.2 9.5 8.0 6.7

15.21 6.9 5.8 4.8 7.5 6.3 5.3 8.2 6.9 5.815.22 9.5 8.0 6.7 10.4 8.7 7.3 11.3 9.5 8.0

15.51 6.9 5.8 4.8 7.5 6.3 5.3 8.2 6.9 5.815.52 8.4 7.0 9.1 7.7 10.0 8.4

20.11 9.1 7.7 10.0 8.4 10.9 9.120.12 9.5 8.0 10.4 8.7 11.3 9.5

20.21 10.1 8.5 11.0 9.3 12.0 10.120.22 11.0 9.3 12.0 10.1 13.1 11.020.24 11.4 9.6 12.5 10.5 13.6 11.4

20.31 10.3 8.6 11.2 9.4 12.2 10.320.32 11.4 9.6 12.5 10.5 13.6 11.420.33 11.8 9.9 12.9 10.8 14.0 11.8

23.1 4.7 4.0 5.1 4.4 5.5 4.723.21 5.1 4.3 5.5 4.7 6.0 5.123.22 5.1 4.3 5.5 4.7 6.0 5.1

04.1 16.0 13.5 17.4 14.7 19.0 16.0

10.1 9.0 7.4 9.9 8.2 10.9 9.0

07.1 3.3 2.7 2.2 3.6 3.0 2.4 4.0 3.3 2.707.2 3.7 3.0 2.5 4.1 3.3 2.8 4.5 3.7 3.0

08.1 3.7 3.0 2.5 4.1 3.3 2.8 4.5 3.7 3.008.2 4.5 3.7 3.1 5.0 4.1 3.4 5.5 4.5 3.7

09.1 3.7 3.0 2.5 4.1 3.3 2.8 4.5 3.7 3.009.2 5.5 4.6 6.1 5.0 6.7 5.5

30.11 1.5 1.3 1.7 1.4 1.8 1.5

30.12 2.5 2.1 2.7 2.3 2.9 2.5

30.21 2.3 1.9 2.5 2.1 2.7 2.330.22 2.7 2.2 2.9 2.4 3.2 2.7

30.3 1.3 1.1 1.5 1.2 1.6 1.3

30.41 2.7 2.2 2.9 2.4 3.2 2.730.42 2.7 2.2 2.9 2.4 3.2 2.7

33.1 2.1 1.8 2.3 1.9 2.5 2.133.2 2.1 1.8 2.3 1.9 2.5 2.133.3 5.1 4.3 5.6 4.7 6.1 5.1

P

M

S

H

K

N

Unalloyed

Low-alloyed(alloying elements 5%)

High-alloyed(alloying elements 5%)

AnnealedHardened tool steel

Non-hardenedHardened and tempered

Castings UnalloyedLow-alloy, alloying elements 5%High-alloy, alloying elements >5%

Non-hardenedPH-hardenedHardened

Non-hardenedPH-hardenedHardened

Annealed or solution treatedAged or solution treated and aged

Hardened and tempered

Non-hardenedPH-hardened

Non-weldable 0.05%CWeldable

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n = vc 1000 D

e

vf= n f

z z

n

Calculate spindle speed (n)

Calculate table feed (vf)

fz= 0.17

0.24sin

r

fz= hex

rpm

4

85

Facemilling with round inserts

= 732283 1000 123

vf= z

n n f

z

fz=

0.17

= 0.34

vf= 8 721 0.24 1384 mm/min



125n = 721

283 1000

sin 45

85

Facemilling

ae:

ap:

r

R245-125Q40-12M zn= 8

R245-12 T3 M-PM GC4030

45

rpm

mm/tooth

4

To get vc, first find h

exvalue for -PM

geometry.The cutting speed v

cfor h

ex= 0.17 mm is

283-m/min (between 325 and 270-m/min).

De= D

c+ iC2 (iC - 2a

p)2 D

e= 109 + 162 (16 - 2 4)2 123

mm/toothsin 30

= 732 0.34 6 1493 mm/minMax a

p

100% of max ap r= 45 75% of max ap r = 38

50% of max ap r= 30 25% of max ap r= 21


exvalue for -PM

geometry.

The cutting speed vcfor h

ex= 0.17 mm is

283-m/min (between 325 and 270-m/min).

SS 1672-08 HB =150 CMC 01.2

Cutter:

4 mm

45

30

mm

Example

Example

Cutting data calculations for milling operations

ae:

ap:

R200-109Q32-16M zn= 6

RCKT 16 06 M0-PM GC4030SS 1672-08 HB =150 CMC 01.285 mm4 mm

n =v

c 1000

Dc

sin r

fz= hex

85 mm

Insert:

Workpiece material:

Cutter:Insert:

Workpiece material:

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R390-063Q22-17M zn= 5

R390-17 04 08M-PM GC1025

mm/min

rpm

5

50

vf= n f

z z

n = 1263 0.15 5 = 947



= 1263250 1000

63

Slotting/facemilling with 90 entering angle

rpm

5

5

Shoulder milling with 90 entering angle

vf= k1 z

n n f

z

= 1607318 1000

63


Dc= 12.6

ae


vf= 1.82 5 1607 0.15 2193 mm/min

Find the compensation factor, k1, in the table below by calculating Dc/a

e

For sidemilling the feed can be increased with acompensation factor.

Factor k1

Dc

ae

1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.8 2.0 2.2 2.5 2.8 3.2 3.6 5.0

2 3 4 5 6 8 10 12 15 20 25 30 40 50 100

k1 = 1.82


exvalue for -PM

geometry.


ex0.15 is 250-m/

min (between 280 and 230-m/min).


exvalue for -PM

geometry.


ex0.15 is 318-m/

min (between 325 and 310-m/min).

Example

Example

n =v

c 1000

Dc

n =v

c 1000

Dc

ae:

ap:

R390-063Q22-17M zn= 5

R390-17 04 08M-PM GC1025SS 1672-08 HB =150 CMC 01.250 mm5 mm

ae:ap:

R390-063Q22-17M zn= 5

R390-17 04 08M-PM GC1025SS 1672-08 HB =150 CMC 01.2

5 mm5 mm

Cutter:Insert:

Workpiece material:

Cutter:Insert:

Workpiece material:

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vf= n z

c f

z

vf= 720 5 0.22 792 mm/min



This gives:

This gives:

125283 1000

n = 720

zn= 10 z

c= 5

fz = 1.3 0.17 0.22 mm/tooth

1.0 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.8 2.0 2.2 2.5 2.8 3.2 3.6 5.0

1 2 3 4 5 6 8 10 12 15 20 25 30 40 50 100

Dc

=

ae

125

23 = 5.43

23 (ae)

14 (ap)

k1 = 1.3

rpm

Side and facemilling


exvalue for -PM geometry.


ex0.17 is 283-m/min

(between 325 and 270-m/min).

Example

ae:

ap:

SS 1672-08 HB =150 CMC 01.22 mm

4 mm

R245-125Q40-12M zn= 8

R245-12 T3 M-PM GC4030

Factor k1

Dc

ae

n =v

c 1000

Dc

Cutter:Insert:

Workpiece material:

zc= Number of effective edges = z

n/2

For N331.32-125S40FM

fz= factor k1 h

ex

The factor k1 can be found in table below.

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16n = 6130

308 1000

Find effective diameter, De

Select axial depth of cut in this diagram.

Go horizontally across the diagram to the curve represent-

ing the tool diameter. Move down vertically to the axis andread the effective diameter.

4

2

Axial depth of cut (mm)

De

Effective tooldia.(mm)

1716

151413121110 9 8 7 6 5 4 3 2 1 0

252422201816141210 8 6 4 2 0

ap

4 8 12 16 20 24 28-32-36-40-44-4850

D332 mm

D325 mm D

350 mm

D320 mm D

340 mm

D316 mm

D312 mm

D310 mm

2 4 6 8 10 12 14 16 18 20-22-24-26-28-30-32

D3= 10 32 mm

D3= 40 50 mm

rpm

Profile milling

vf= z

n n f

z

vf= 2 6130 0.1 1226 mm/min


fzaccording to table below. In stable conditions the feed can

be increased. When working with long tools and difficult con-

ditions the feed can be lowered.

Recommended radial steps and depth of cutfor ball nose endmills

Large cutsIt is not recommended to exceed the val-

ues below for radial step and axial depthof cut.

Small cutsWith the same axial depth of cut as for

large cuts, surface can be improved bydecreasing the radial step.

D3

Cutterdia.

Radialstep

Radialstep

Radialstep

12 1.0 0.02 1.5 0.05 2.0 0.0816 1.0 0.02 2.0 0.06 3.0 0.1420 2.0 0.05 3.0 0.11 4.0 0.2025 3.0 0.09 4.0 0.16 5.0 0.2530 3.0 0.08 4.0 0.13 5.0 0.2132 3.0 0.07 4.0 0.13 5.0 0.20

40 4.0 0.10 6.0 0.23 8.0 0.4050 4.0 0.08 6.0 0.18 8.0 0.32

Cutterdia.

D3 Radial step Depth of cut

Max. recommended

12 5 616 6 820 10 1025 12 1230 15 1232 16 12

40 20 1550 20


exvalue for -M geometry.


ex0.15 is 308-m/min (between 310

and 295-m/min).

Start value

Diameter, D3

Recommended feed, fzmm

Range

12 16 20 25 30 32 40 50

0.05 0.08 0.10 0.12 0.15 0.15 0.20 0.25

0.05 0.10 0.08 0.15 0.10 0.20 0.12 0.25 0.15 0.35 0.15 0.35 0.20 0.40 0.25 0.40

Example

n =v

c 1000

De

ae:

ap:

R216-20A25-055 zn= 2

R2160-20 T3 M-M GC4040SS 1672-08 HB =150 CMC 01.22 mm4 mm

Cutter:Insert:

Workpiece material:

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Simplified version

Method for internal circular interpolation

Calculated version

1

De

ae

Dm

2 Dw

2

4 (Dm D

e)

Feed per insert, mm

Radial depth of cut, mm

Tool centre feed, mm/minvf= n z

c f

z

fz

De h

ex

sin rD

e2 (D

e 2 a

e)2

vf1 = v

f K

Dm+ DcD

m

Tool centre feed, mm/min

The values can be taken from the table below

Straight line feed, mm/minvf= n z

c f

z

K =

Cutter

diameter

Hole diameter = Dm

15 20 25 30 40 50 60 75 100 125 150 200 250 300

10 0.58 0.71 0.77 0.82 0.87 0.89 0.91 0.93 0.95 0.96 0.97 0.97 0.98 0.98

16 0.45 0.60 0.68 0.77 0.82 0.86 0.89 0.92 0.93 0.95 0.96 0.97 0.97

20 0.45 0.58 0.71 0.77 0.82 0.86 0.89 0.92 0.93 0.95 0.96 0.97

25 0.41 0.61 0.71 0.76 0.82 0.87 0.89 0.91 0.94 0.95 0.96

32 0.45 0.60 0.68 0.76 0.82 0.86 0.89 0.92 0.93 0.95

40 0.45 0.58 0.68 0.77 0.82 0.86 0.89 0.92 0.93

50 0.41 0.58 0.71 0.77 0.82 0.87 0.89 0.91

63 0.40 0.61 0.70 0.76 0.83 0.86 0.89

80 0.45 0.60 0.68 0.77 0.82 0.86

100 0.45 0.58 0.71 0.77 0.82

125 0.41 0.61 0.71 0.76

160 0.45 0.60 0.68200 0.45 0.58

Dcmm Factor K

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Calculated version

Method for external circular interpolation

Simplified version

ae

Dw

2 Dm

2

4 (Dm D

e)

Feed per insert, mm

Radial depth of cut, mm

Tool centre feed, mm/minvf= n z

c f

z

vf1 = v

f K

Dm+ DcDm

Tool centre feed, mm/min

The values can be taken from the table below

Straight line feed, mm/minvf= n z

c f

z

K =

De

vf1

fz

De h

ex

sin rD

e2 (D

e 2 a

e)2

Cutter

diameter

Hole diameter = Dm

15 20 25 30 40 50 60 75 100 125 150 200 250 300

10 1.29 1.22 1.18 1.15 1.12 1.10 1.08 1.06 1.05 1.04 1.03 1.02 1.02 1.02

16 1.44 1.34 1.28 1.24 1.18 1.15 1.13 1.10 1.08 1.06 1.05 1.04 1.03 1.03

20 1.53 1.41 1.34 1.29 1.22 1.18 1.15 1.13 1.10 1.08 1.06 1.05 1.04 1.03

25 1.63 1.50 1.41 1.35 1.27 1.22 1.19 1.15 1.12 1.10 1.08 1.06 1.05 1.04

32 1.77 1.61 1.51 1.44 1.34 1.28 1.24 1.19 1.15 1.12 1.10 1.08 1.06 1.05

40 1.91 1.73 1.61 1.53 1.41 1.34 1.29 1.24 1.18 1.15 1.13 1.10 1.08 1.06

50 2.08 1.87 1.73 1.63 1.50 1.41 1.35 1.29 1.22 1.18 1.15 1.12 1.10 1.08

63 2.28 2.04 1.88 1.76 1.60 1.50 1.43 1.36 1.28 1.23 1.19 1.15 1.12 1.10

80 2.52 2.24 2.05 1.91 1.73 1.61 1.53 1.44 1.34 1.28 1.24 1.18 1.15 1.13

100 2.77 2.45 2.24 2.08 1.87 1.73 1.63 1.53 1.41 1.34 1.29 1.22 1.18 1.15

125 3.06 2.69 2.45 2.27 2.03 1.87 1.76 1.63 1.50 1.41 1.35 1.27 1.22 1.19

160 3.42 3.00 2.72 2.52 2.24 2.05 1.91 1.77 1.61 1.51 1.44 1.34 1.28 1.24200 3.79 3.32 3.00 2.77 2.45 2.24 2.08 1.91 1.73 1.61 1.53 1.41 1.34 1.29

Dcmm Factor K

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Mounting dimensions for milling cutters

Style A Dia. 50 63 Dia. 80 Dia. 100

Centre bolts

Style C

Dia. 160

Dia. 315 500

Dia. 200 250

Design with single pcd ( 4 bolts)

Design with double pcd ( 8 bolts)

Mounting diameter (dmm)

Style BDia. 125

Centre bolts + washer




1)For all Modulmill cutters and for R/L262.2AL the dimensions are 22.0 and 10.4 mm respectively.

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Torque wrench for Torx Plus screws Note!Torx Plus is a registered trademark of Camcar-Textron (USA).

Wrench benefits:

ergonomic handle consisting of two materials, one of which

has a rubber base for best grip

a "click" function when tightening the screws- is impossible to over tighten.

a fixed stop in counter clockwise direction, making it easier

to loosening screws

design of blade tip has been optimised for best screw fitting

blade material consists of a higher class of material grade

Sandvik Coromant has introduced the Torx Plus system on all

insert screws to ensure an improved and secure clamping. The

new Torx Plus screws will keep their previous codes, while the

keys will change the code. All keys for insert clamping are con-

cerned: screwdrivers, T-style keys, L-style keys, flag-style keys

and combination keys (Torx Plus/hex).

The torque wrench for Torx Plus screws offers a possibility to

always ensure correct torque value, in the machine shop as

well as in the tool-room environments.

Correct torque values are imperative especially when clamping

ceramic and CBN inserts.

Always use protective goggles when using ceramic inserts.

Note!

The new Torx Plus keys and screw-drivers do NOT fit into the

standard Torx screws.

However, the standard Torx keys and screw-drivers will fit the

new Torx Plus screws.

Torx Plus Torx

Cross section

Insert mounting with Torx Plus

Milling cutter mountings

Coromant Capto:provides the best stability and thus basis

for high productivity, reliablity and quality. Cutters are avail-

able as over-size in relation the the coupling for extended

tooling. Best choice, especially for long edge milling.Cylindrical shanks:Recommended for use with precision

chucks like CoroGrip for best stability and precision. Extra

long tools available.

Weldon:established tool mounting but not recommended

as first choice if productivity and precision are issues.

Arbor:established tool mounting and the only solution for

large-diameter cutters. Gives good stability for high produc-

tivity.

Threaded:modular system with exchangeable cutting heads.

Silent tool solution and carbide shank adapters for extended

tooling.

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Tool wear Cause: Remedy:

a. Rapid flank wearcausing poor surfacefinish or out of toler-ance.

b/c. Notch wear causingpoor surface finishand risk of edgebreakage.

Built-up edge causingpoor surface finish andcutting edge fritteringwhen the B.U.E. is tornaway.

a. Cutting speed too highor insufficient wearresistance.

a. Too low feed.

b/c. Work hardeningmaterials.

b/c. Skin and scale.

Reduce cutting speed.Select a more wear resistantgrade.

Increase feed.

Reduce cutting speed.Select tougher grade.

Increase cutting speed.

Workpiece material iswelded to the insertdue to:

Negative cuttinggeometry.

Low feed.

Low cuttingspeed.

Flank and notch wear

Select a positive geometry.

Increase feed.

Increase cuttingspeed.

Built-up edge (B.U.E.)

Poor surface finish

Small cutting edge frac-tures (frittering) causing

poor surface finish andexcessive flank wear.

Select tougher grade.

Select an insert with astronger geometry .

Increase cutting speed orselect a positive geometry.Reduce feed at beginningof cut.

Grade too brittle.

Insert geometry tooweak.

Built-up edge.

Frittering

Small cracks perpendic-ular to the cutting edgecausing frittering andpoor surface finish.

Select a tougher grade withbetter resistance to thermal

shocks.

Coolant should be appliedcopiously or not at all.

Thermal cracks due totemperature variationscaused by:

- Intermittent machining.

- Varying coolant supply.

Reduce feed.

Change position.

Better stability.

Check overhang.

Reduce overhang.Better stability.

Too high feed.

Wrong insertposition.

Bad stability.

Deflection.

Vibrations Reduce cutting speed.Increase feed.Change cutting depth.

Wrong cutting data.

Bad stability.

Thermal cracks

bc

a

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If problems should occur

Excessive vibration

1. Weak fixture

Possible solutions:

Assess the direction of cutting forces and provide adequate support or improve the fixture.

Reduce cutting forces by decreasing cutting depths.

Select a coarse and differentially pitched cutter with a more positive cutting action.

Select an L-geometry with small corner radius and small parallel land.

Seplect a fine-grain, uncoated insert or thinner coating

2. Weak workpiece

Consider a square shoulder cutter (90-degree entering angle) with positive geometry.

Select an insert with L-geoemetry

Decrease axial cutting force lower depth of cut, smaller corner radius and parallel land.Select a coarse-pitch cutter with differential pitch.

3. Long tool overhang

Minimize the overhang.

Use coarse-pitch cutters with differential pitch.

Balance radial and axial cutting forces 45 degree entering angle, large corner radius

or round insert cutter.

Increase the feed per tooth

Use a light-cutting insert geoemtry L/M

4. Milling square shoulder with weak spindle

Select smallest possible cutter diameter.

Select positive cutter and insert.Try up-milling.

Check spindle deflection to see if acceptable for machine.

5. Irregular table feed

Try up-milling

Tighten machine feed mechanism.

Unsatisfactory surface finish

1. Excessive feed per revolution

Set cutter axially or classify inserts. Check height with indicator.

Check the spindle run-out and the cutter mounting surfaces.

Decrease the feed per rev to max. 70% of the width of the parallel land.

Use wiper inserts if possible. (Finishing operations)

2. Vibration

See section on vibration.

3. Built-up edge formation on insert

Increase cutting speed to elevate machining temperature.

Turn off coolant.

Use sharp cutting edge inserts, with smooth rake side.

Use positve insert geometry.

Try a cermet grade with higher cutting data.

Some typical problems in milling and possible solutions

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4. Back-cutting

Check spindle tilt (Tilt spindle approx 0.10mm/1000 mm)

Axial run-out of spindle should not exceed 7 microns during finishing.

Reduce the radial cutting forces (decrease the depth of cut)

Select a smaller cutter diameter.

Check the parallelism on the parallel lands and on wiper insert used. (Should not be

standing on heel or toe)

Make sure the cutter is not wobbling adjust the mounting surfaces.

5. Workpiece frittering

Decrease feed per tooth.

Select a close or extra-close pitch cutter.

Re-position the cutter to give a thinner chip at cutter exit.

Select a more suitable entering angle (45-degrees) and lighter cutting geometry.

Choose a sharp insert.Monitor flank wear to avoid excessive wear.

Insert fracture in general milling

1. Excessive chip thickness at cutter exit

Minimize the chip thickness at exit by changing the cutter position in relation to

workpiece.

Use down-milling

Decrease the feed per tooth.

Select a smaller cutter diameter.Use a stronger insert geometry (H).

Insert fracture in square shoulder milling

1. Swarf follows cutter in up-milling, getting stuck between shoulder and edge.

Change to down-milling.

Use compressed air.

Use a sharper insert to facilitate re-cutting of chips.

Monitor flank wear to avoid excessive wear.

2. Down-milling with several passes.

Consider performing the operation in one pass.

3. Chip jamming between shoulder and edge.

Try up-milling

Select a tougher insert grade.

Select a horisontal milling machine.

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Define the operationIdentify the type of operation:

Facemilling

Shoulder milling

Profile milling

Slot milling

Then select the most suitable tool considering productivity, reliability and quality.

Define the materialDefine workpiece material according to ISO:

Steel (P)

Stainless steel (M)

Cast iron (K)

Aluminium (N)

Heat resistant and titanium alloy (S)

Hardened material (H)

Select cutter conceptAssess which concept is the most productive for the application:

CoroMill 245, CoroMill 210, CoroMill 390, CoroMill 290.

Select the milling cutterChoose cutter pitch and mounting.

Use a close pitch cutter as first choice.

Use a coarse pitch cutter for long overhang and unstable conditions.Use an extra close pitch cutter for short chipping materials and super alloys.

Choose a mounting type.

Select the insertChoose the insert geometry for your operation:

Geometry L = Light

For light cuts when low forces / power are required

Geometry M = Medium

First choice for mixed production

Geometry H = Heavy

For rough operations, forging, cast skin and vibrations

Select insert grade for optimum productivity.

Define the start valuesCutting speeds and feeds for different materials are given on the insert

dispensers and in the tables.

The values should be optimized according to machine and conditions!

Selection and application process

P

M

K

S

N

H

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General facemilling

Material/Application

Finishing

Semi-finishing

Roughing

Heavy roughing

CoroMill 245

CoroMill 245

CoroMill 245

T-MAX 45

CoroMill 245

CoroMill 245

CoroMill 245

-

AUTO-AF*

CoroMill 245

AUTO R

CoroMill 245 (18)

CoroMill Century

CoroMill Century

CoroMill 245

-

CoroMill 245

CoroMill 300

CoroMill 300

T-Max 45

CoroMill 245

CoroMill 245

CoroMill 300

CoroMill 200

P M K N S H

* CoroMill Century

Thin walls

Close to fixture

Long overhang

Back facing

High feed milling

CoroMill 390 CoroMill Century

CoroMill 390 CoroMill Century

CoroMill 390

CoroMill 210 (R)/CoroMill 245 (F)

CoroMill 331

CoroMill 210/CoroMill 300

P M K S H N

P M K S N

P M K S N

P M K S

H

H


Finishing

Semi-finishing

Roughing

CoroMill 390

CoroMill 390

CoroMill 390

CoroMill 390

CoroMill 390

CoroMill 390

AUTO-AF

CoroMill 290

CoroMill 290

CoroMill Century

CoroMill 790

CoroMill 790

CoroMill Plura

CoroMill 390

CoroMill 390

CoroMill Plura

CoroMill 290

CoroMill 290

P M K N S H

Repeatedshoulder milling

Deep shouldermilling

Edging/Contouring

CoroMill 390 CoroMill 790 CoroMill Plura

CoroMill 390 LE-11 CoroMill 390 LE- 18

P M K S HN

CoroMill 390/CoroMill Plura

For diameters smaller than 20 mm, CoroMill Plura solid

carbide endmills are first choice generally for all materials.

General shoulder milling

Operations tool recommendations

Steel Stainless steel Cast-iron Aluminium Super alloys Hardened steel


(Small ae (ae/Dc..)

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Slot milling

Slotting

Deep slotting

CoroMill Plura CoroMill 331

T-Max Q-cutter CoroMill 331

ap: 2 6 a

p> 6


Super finishing

Finishing

Semi-finishing

Roughing

High-feed milling

CoroMill Plura

CoroMill 216F

CoroMill 300

CoroMill 300

CoroMill 210

-

CoroMill Plura

CoroMill 300

CoroMill 300

CoroMill 210

CoroMill Plura

CoroMill 216F

CoroMill 300

CoroMill 200

CoroMill 210

-

CoroMill 790

CoroMill 790

CoroMill 790

-

-

CoroMill Plura

CoroMill 300

CoroMill 300

CoroMill 300

CoroMill Plura

CoroMill Plura

CoroMill 300

CoroMill 200

CoroMill 210

P M K N S H

Profile milling

Axial/plunge milling

CoroMill Plura CoroMill 210

CoroMill 390 CoroMill 210

Dc> 25 D

c 25


Application/Cutter diameter

Semi-finishing

Roughing

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Face-, shoulder-, profile and slot milling

Tool guide and selection

CoroMill 245

6/10 mm

Facemilling

Shouldermilling

Profilemilling

Slotmilling

Others

Cutting depth ap

Dc

CoroMill 290

10.7 mm

Dc32 250 mm D

c40 250 mm

245-12 / 245-18

MaterialP M K S H

N

CoroMill 390

10/15.7 mm

Dc12 200 mm D

c32 200 mm

15.7 mm

P M S

N

P M K S H

N

K H

P

1:stchoice

2:ndchoice

Very good Good Fair

Dc32 200 mm

36 85 mm

P M K N S H

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Documents

D - Milling