Dapra Corporationwww.dapra.com

NEWModular Headsand ExtensionsSee page 5

RAMPINGSLOTTING

PROFILINGPOCKETING

STEP MILLINGFACE MILLING

SHOULDER MILLINGHELICAL INTERPOLATING

Cutter bodies machinedfrom hardened steel tominimize runout andcreate excellent surfacefinishes at high feed rates

Long-reach tools available withCarbide Core for enhancedrigidity and reduced deflection

Precision cutter andinsert combinationprovides longer tool life

Deep gulletsprovide efficientchip evacuation,even on theheaviest cuts

Inserts offered in bothpressed and lappedversions for a combinationof economy andperformance

• Square Shoulder milling tools cut to a true 90°, generating smoother finishes

• Positive axial and radial insert geometry, providing maximum metalremoval capabilities with minimum horsepower consumption

• Broad selection of insert radii for varying corner requirements

• Cutters available with thru-coolant capabilities for optimum chip evacuation and cutting zone temperature control

EXTREMESQUARE SHOULDERMetal Removal from

Table of Contents

2

Application & Troubleshooting Information 10

Spare Parts 11

APKT/ADKT Inserts & Cutter Bodies 11

Recommended Cutting Speeds 12

Cutter Bodies 3-5

Insert Geometries, Sizes & Grades 6-7

Hole Diameter Calculation 8

Optimization & Reference Information 8-9

End Millsd2 = shank diameter; I1 = overall length; I2 = effective length

("C" denotes coolant thru tool)

Holder

SSER0500-2000-R35-1SSER0625-2500-R35-2CSSER0750-2500-R35-2CSSER0750-4000-R35-2CSSER1000-4000-R55-2CSSER1000-6000-R55-2CSSER1250-4000-R55-3CSSER1500-4000-R55-3CSSER1500-6000-R55-3C

Holder

CC-SSER0750-2500-R35-2CC-SSER0750-4000-R35-2CC-SSER1000-4000-R55-2CC-SSER1000-6000-R55-2CC-SSER1250-3200-R55-3CC-SSER1250-4000-R55-3CC-SSER1250-6000-R55-3CC-SSER1500-4000-R55-3CC-SSER1500-6000-R55-3

CuttingDia. (D)

.500"

.625"

.750"

.750"1.000"1.000"1.250"1.500"1.500"

CuttingDia. (D)

.750"

.750"1.000"1.000"1.250"1.250"1.250"1.500"1.500"

Depth of Cut

.350"

.350"

.350"

.350"

.550"

.550"

.550"

.550"

.550"

Depth of Cut

.350"

.350"

.550"

.550"

.550"

.550"

.550"

.550"

.550"

Flutes

122222333

Flutes

222233333

d2

.625"

.750"1.000"1.000"1.250"1.250"1.250"1.500"1.500"

d2

1.000"1.000"1.250"1.250"1.250"1.250"1.500"1.500"1.500"

l1

3.907"4.410"4.782"6.282"6.282"8.282"6.282"6.690"8.690"

l1

4.782"6.282"6.282"8.282"5.500"6.282"9.250"6.690"8.690"

l2

2.000"2.500"2.500"4.000"4.000"6.000"4.000"4.000"6.000"

l2

2.500"4.000"4.000"6.000"2.620"4.000"6.000"4.000"6.000"

Inserts

APET1003.. / XPET1003..

APET1604.. / XPET1604..

Inserts

APET1003.. / XPET1003..

APET1604.. / XPET1604..

Extended Reach End Mills with Carbide Core

Extended Reach End Mills

D

l1

l2

d2

3

Extended Reach End Millsd2 = shank diameter; I1 = overall length; I2 = effective length

("C" denotes coolant thru tool)

Extended Reach End Mills with Carbide Cored2 = shank diameter; I1 = overall length; I2 = effective length

D

l1

l2

d2

NEW

SQUARE SHOULDEROrdering Information

NEW1.25" cutters and smaller are available without weldon flats inlimited supplies. Add WOF to end of part number when ordering.

Holder

SSEM0500-0625-R35-1SSEM0625-0625-R35-2SSEM0750-0750-R35-2SSEM0750-0750-R35-2CSSEM0750-0750-R35-3SSEM0625-0750-R55-1SSEM0750-0750-R55-1SSEM1000-0750-R35-4SSEM1000-1000-R35-3CSSEM1000-1000-R55-2SSEM1000-1000-R55-2CSSEM1000-1000-R55-2LCSSEM1250-1250-R35-5CSSEM1250-1250-R55-3SSEM1250-1250-R55-3CSSEM1500-1250-R35-5CSSEM1500-1250-R55-3SSEM1500-1250-R55-4SSEM1500-1250-R55-4C

CuttingDia. (D)

.500"

.625"

.750"

.750"

.750"

.625"

.750"1.000"1.000"1.000"1.000"1.000"1.250"1.250"1.250"1.500"1.500"1.500"1.500"

Depth of Cut

.350"

.350"

.350"

.350"

.350"

.550"

.550"

.350"

.350"

.550"

.550"

.550"

.350"

.550"

.550"

.350"

.550"

.550"

.550"

Flutes

1222311432225335344

d2

.625"

.625"

.750"

.750"

.750"

.750"

.750"

.750"1.000"1.000"1.000"1.000"1.250"1.250"1.250"1.250"1.250"1.250"1.250"

l1

2.750"3.000"3.500"3.500"3.500"3.350"3.490"3.500"4.000"4.000"4.000"5.280"4.000"4.000"4.000"4.400"4.400"4.400"4.400"

l2

.968"1.093"1.468"1.468"1.468"1.150"1.400"1.468"1.718"2.000"2.000"3.000"1.718"1.718"1.718"2.000"2.118"2.118"2.118"

D

l1

l2

d2

Inserts

APET1003.. / XPET1003..

APET1606.. / XPET1606..

APET1003.. / XPET1003..

APET1606.. / XPET1606..

APET1003.. / XPET1003..

APET1606.. / XPET1606..

APET1003.. / XPET1003..

APET1606.. / XPET1606..

End Mills

NEW

Holder

HREM1000-1000-R2-120HREM1250-1250-R2-165HREM1500-1250-R3-215

CuttingDia. (D)

1.000"1.250"1.500"

Depth of Cut

1.200"1.650"2.150"

Flutes

223

d2

1.000"1.250"1.250"

l1

4.500"4.875"4.875"

l2

2.040"2.440"2.440"

No. ofInserts

8612

Inserts

APET1003.. / XPET1003..APET1604.. / XPET1604..APET1604.. / XPET1604..

Helical Roughing End Mills

SQUARE SHOULDEROrdering Information

Inserts

APET1604.. / XPET1604..

APET1604.. / XPET1604..

l

.650"

.750"

.750"

.750"

.750"1.000"1.000"1.000"

.750"

.750"

Holder

SSSM1500-0500-R55-4SSSM2000-0750-R55-4SSSM2000-0750-R55-5SSSM2500-1000-R55-5SSSM3000-1000-R55-6SSSM4000-1500-R55-8SSSM5000-1500-R55-8SSSM6000-1500-R55-10

SSSM2000-0750-R55-3SSSM3000-1000-R55-3

CuttingDia. (D)

1.500"2.000"2.000"2.500"3.000"4.000"5.000"6.000"

2.000"3.000"

Depth of Cut

.550"

.550"

.550"

.550"

.550"

.550"

.550"

.550"

.550"

.550"

Flutes

445568810

33

d2

.500"

.750"

.750"1.000"1.000"1.500"1.500"1.500"

.750"1.000"

h

1.500"1.500"1.500"1.500"2.000"2.000"2.000"2.000"

1.500"2.000"

Standard Pitch Shell Mills

Coarse Pitch Shell Mills

l

D

h

d2

Standard Pitch Shell Mills / Coarse Pitch Shell Millsd2 = arbor diameter; h = overall height; l = arbor depth

Helical Roughing End Millsd2 = shank diameter; I1 = overall length; I2 = effective length

Holder

SSEM16-16-R35-2SSEM20-20-R35-2SSEM25-20-R35-4SSEM25-25-R55-2SSEM32-32-R35-5SSEM32-32-R55-3SSEM40-32-R55-4

CuttingDia. (D)

16mm20mm25mm25mm32mm32mm40mm

InsertLength

10mm10mm10mm16mm10mm16mm16mm

Flutes

2242534

d2

16mm20mm20mm25mm32mm32mm32mm

l1

80mm90mm90mm100mm100mm100mm115mm

l2

31mm39mm39mm44mm44mm44mm55mm

D

l1

l2

d2 Inserts

APET1003.. / XPET1003..

APET1604.. / XPET1604..APET1003.. / XPET1003..

APET1604.. / XPET1604..

Metric End Millsd2 = shank diameter; I1 = overall length; I2 = effective length

Inserts

APET1604.. / XPET1604..

Holder

SSSM50-22-R55-4SSSM50-22-R55-5SSSM63-27-R55-5SSSM80-27-R55-6

CuttingDia. (D)

50mm50mm63mm80mm

InsertLength

16mm16mm16mm16mm

Flutes

4556

d2

22mm22mm27mm27mm

l1

38mm38mm38mm50mm

MountingScrew

M10M10M12M12D

l1

d2

Standard Pitch Metric Shell Mills d2 = arbor diameter; I1 = overall height

4

Metric End Mills

Standard Pitch Metric Shell Mills

D

I1

I2

DOC

d2

SQUARE SHOULDEROrdering Information

5

S

OAL

MOUNTING THREAD(BOTH ENDS)

Inserts

APET1003.. / XPET1003..APET1604.. / XPET1604..

l

.780"

.800"

Inserts

APET1003.. / XPET1003..APET1003.. / XPET1003..APET1604.. / XPET1604..APET1604.. / XPET1604..

l2

1.45"1.45"1.72"1.72"

A

30˚45˚30˚45˚

Holder

BCSM2000-0750-R35-4BCSM3000-1000-R55-5

Holder

CMEM0750-30-R35-3CMEM0750-45-R35-3CMEM1000-30-R55-3CMEM1000-45-R55-3

CuttingDia. (D)

2.000"3.000"

CuttingDia. (D)

0.750"0.750"1.000"1.000"

Depth of Cut

.250"

.375"

Depth of Cut

.300"

.245"

.475"

.390"

Flutes

45

Flutes

3333

OD

2.11"3.16"

OD

1.05"1.18"1.53"1.76"

d2

.750"1.000"

d2

.750"

.750"1.000"1.000"

h

1.500"2.000"

l1

3.50"3.50"4.00"4.00"

15˚ Back Corner Shell Mills

Chamfering End Mills

d2

h

l

DOD

l1

l2

d2

DOD

d2 = arbor diameter; h = overall height; l = arbor depth

d2 = shank diameter; I1 = overall length; I2 = effective length

• BCSM shell mills allow the unused corner of the APET/XPET inserts to be usedfor general face milling – this means you get 4 usable edges per insert instead of 2!

• CMEM end mills are perfect for chamfer milling, providing a free-cuttingpositive geometry for both 30˚ and 45˚ chamfering.

BCSM Shell Mill

CMEM End Mill

Screw-On Modular Heads and Extensions

Utility CuttersMake the most of your APET and XPET Inserts!NEW

Dia.

.750"1.000"1.250"1.500"

Holder

SSEM0750-MOD-R35-2SSEM1000-MOD-R55-2SSEM1250-MOD-R55-3SSEM1500-MOD-R55-3

M

M10M12M16M16

DOC

.350"

.550"

.550"

.550"

E

1.50"1.50"1.75"1.75"

Flutes

2233

Inserts

APET1003.. / XPET1003..APET1604.. / XPET1604..APET1604.. / XPET1604..APET1604.. / XPET1604..

Open-endWrench

9/16"11/16"15/16"15/16"

Square Shoulder Screw-On Heads

Dapra's Line of Screw-On Heads Fits Industry Standard Cutting Systems

• Compatible with ISO standard modularcutting systems

• Close-tolerance mounting of headsminimizes runout and maximizes rigidity

• Provide significantly more effective reachthan solid end mills

• Use standard inch wrench flats, no specialmetric wrenches needed

Dapra's NEW Modular Extensions Provide Even More Cutting Options

• Made of high-density tungsten, providingextra resistance to deflection and chatter

• Machined on both ends; can be cut in halfand used with two different modular heads

• Metric shank diameter provides clearancefor each inch size modular head

E

M (MOUNTING THREAD)

DOC

DIA

ForHeadDia.

.750"1.000"1.250"1.500"

ModularExtensions

ME-0750-18MM-900ME-1000-25MM-1100

ME-125/150-25MM-1200ME-125/150-25MM-1200

OAL

9"11"12"12"

ShankDiameter

(S)

18mm25mm25mm25mm

Modular Extensions

NEW

NEW

6

The most economical, high-performance inserts available!• APET and XPET inserts carry a .001" tolerance, providing good accuracy

and repeatability.

• Feature a high positive pressed cutting geometry for aggressivematerial removal rates and low horsepower consumption.

• Have a strong edge preparation for heavy chiploads.

• Are available in a large variety of corner radii with a true tangential blend.

• Provide excellent surface finishes due to computer-designed wiper geometry.

• Are economical and offer high-performance cutting capabilities.

SQUARE SHOULDERInsert Geometries

APET & XPET CNC Pressed Inserts

w

l

r

APETCutting Edge(T-Land Edge)High Strength

XPETCutting Edge(Honed Edge)High Shear

* This insert is designed for heavy roughing and has a corner radius that actually measurescloser to .115 than .125 (.010 difference) due to distortion by the positive radial insert angle.

• APET inserts feature a high-strength cutting edgeand are ideal for high-performance milling of mostharder steels and cast irons.

• XPET inserts are ideal for high-performance millingof stainless steels and nonferrous materials suchas copper alloys and aluminum. Also good forgummy, softer, free-machining steels.

APET & XPET Insert Sizes and Available Grades

l

.380"

.380"

.625"

.625"

.625"

.625"

.380"

.380"

.625"

.625"

.625"

.625"

.625"

w

.250"

.250"

.375"

.375"

.375"

.375"

.250"

.250"

.375"

.375"

.375"

.375"

.375"

r

.031

.062

.031

.047

.062

.120

.031

.062

.015

.031

.047

.062

.120

Uncoated CoatedDMP35-GLH

DMP30-GLH

DMK25-GLHPressed to Size

DMP35

DMP30

DMK25

DMP353

DMP303

DMK253

DMP35-HP

DMP30-HP

DMK25-HP

DMP357

DMP307

DMK257

Stocked standard

NEW

Insert

APET100308

APET100316

APET160408

APET160412

APET160416

APET160431*

XPET100308

XPET100316

XPET160404

XPET160408

XPET160412

XPET160416

XPET160431*

APET – feature a high-strength cutting edge and are ideal for high-performance milling of most harder steelsand cast irons.

XPET – ideal for high-performance milling of stainless steels and nonferrous materials such as copper alloysand aluminum. Also good for gummy, softer, free-machining steels.

SQUARE SHOULDERInsert Grade Selection

w

l

r

XPET..

7

XPET Lapped, Aluminum-Cutting Inserts

** This insert is designed for heavy roughing andhas a corner radius that actually measurescloser to .115 than .125 (.010 difference) dueto distortion by the positive radial insert angle.

• feature precision-ground and lapped rakeface, ideally suited for machining aluminumand copper alloys, bronze, brass, etc.Built-up edge is virtually eliminated.

• have higher positive rake angle than standard inserts, providing highest shear possible.

• offer sharp cutting edge configured specifically for cutting nonferrous materials, yielding the ultimate in low-torque material removal.

• feature a variety of corner radii with a true tangential blend.

• available standard in uncoated grade DMK25 only.

NEW PCD-tipped inserts provide the ultimate in wearresistance for high-volume aluminum or graphite milling.Available in 1/32" corner radius only.Note: PCD tipped inserts are capable of up to .125" depth of cut.

APET & XPET Grade DescriptionDescription

Extreme toughness for high-shock applications involving interrupted cuts, long tooloverhang or very heavy cuts.DMP35 substrate with a PVD TiCN coating. Excellent resistance to cratering and flankwear for light roughing when increased feed is possible. Best suited to carbon andalloy steels or low- to medium-speed stainless steel applications.

High-performance medium-temperature grade. Optimum performance and wearresistance in most soft steels, soft stainless steels and cast iron.DMP35 substrate with a PVD AlTiN coating. Excellent resistance to oxidation forhigh-speed cutting when increased surface speed is possible. Good coating for toolsteels, heat-treated materials and higher-speed stainless steel applications.Premium high-temperature grade. Unbeatable performance and wear resistance inhigh-heat applications such as harder steels, tough stainless steels and high-temperature alloys.Tough and wear-resistant. Optimum grades for high-speed machining of most steels.

DMP30 substrate with our medium-temperature TiCN PVD coating; excellent forlow-to-medium operating speeds where toughness and good wear resistanceare expected.High-performance medium-temperature grade. Optimum performance and wearresistance in most soft steels, soft stainless steels and cast iron.DMP30 substrate with our high-temperature AlTiN PVD coating; use for high-speedmachining, heavy roughing and semi-finishing applications.

Premium high-temperature grade. Unbeatable performance and wear resistance inhigh-heat applications such as harder steels, tough stainless steels and high-temperature alloys.Highest wear resistance with reduced shock absorption capabilities. Micro-graincarbide provides excellent edge strength for abrasive applications in nonferrousmaterials. Suitable for castings, aluminum and smoother cuts in tough stainlesssteels and high-temperature alloys.DMK25 substrate with PVD TiCN coating. Excellent resistance to built-up edge inaluminum and copper alloys.High-performance medium-temperature grade. Optimum performance and wearresistance in most soft steels, soft stainless steels and cast iron.DMK25 substrate with PVD AlTiN coating. Appropriate for higher-temperatureapplications such as high-velocity cast iron machining, tougher stainless steels, high-temperature alloys and high-speed copper alloy machining. Excellent for hard milling.Premium high-temperature grade. Unbeatable performance and wear resistance inhigh-heat applications such as harder steels, tough stainless steels and high-temperature alloys. Excellent for hard milling.

Specifications

ANSI C1,ISO P40,M30-M40

ANSI C5-C6,ISO P25-P35,

M25-M35

ANSI C2-C3,ISO K10-K25

Uncoated(Base Grade)

DMP35

DMP30

DMK25

Shock & WearResistance

TOUGHESTShock

Resistance

MEDIUMShock

and Wear

HARDESTWear

Resistance

withCoating

DMP353

DMP35-HP

DMP357

DMP35-GLH

DMP303

DMP30-HP

DMP307

DMP30-GLH

DMK253

DMK25-HP

DMK257

DMK25-GLH

Insert

XPET100308-ALU

XPET100316-ALU

XPET160404-ALU

XPET160408-ALU

XPET160412-ALU

XPET160416-ALU

XPET160431-ALU**

XPET160408-PCD

l

.380"

.380"

.625"

.625"

.625"

.625"

.625"

.625"

w

.250"

.250"

.375"

.375"

.375"

.375"

.375"

.375"

r

.031

.062

.015

.031

.047

.062

.120

.031

Al, Ti, SS DMK25

Uncoated

NEW

NEW

PCD-Tipped DMK25

Dapra's high-performance cutters work best when allowed to work within their designedoperating parameters. Adhering to the following steps will ensure that you are getting themost from your investment.

1. Refer to the Feed and Speed Chart (see page 12) to find the recommended Surface Feet per Minute(SFM) and Feed per Tooth (FPT) at which to run your cutter, based on the material to be machined.

2. Use the following formula to determine the Revolutions per Minute (RPM) for your cutting tool:

(SFM x 3.82) / Tool Dia. = RPMExample: A 2" diameter tool operating at 900 SFM (900 x 3.82) / 2 = 1720 RPM

3. Use the following formula to determine the feed in Inches per Minute (IPM) to beprogrammed into the machine tool:

FPT x RPM x N (number of teeth in cutter) = FeedExample: A 5-flute cutter at .008" FPT (.008 x 1720) x 5 = 69 IPM

4. If the Width of Cut (WOC) < 1/2 the cutter diameter, use the feed rate compensationchart (below) to compensate for chip thinning.

After determining the percentage of WOC for the tool diameter, multiply the desired feed rate by thecorresponding factor shown in the chart. This will be the Adjusted Feed per Tooth (AFPT) resulting in atrue chip thickness of the desired amount.

Example: If using a 1" dia. end mill @ .100" WOC, the WOC = 10% of the cutter diameter. Using the chart above, the factor for the chip thickness = 1.7.If a chip thickness of .005" is desired, a feed rate of .0085" (.005 x 1.7) should be programmed into the machine tool.

or

Adjusted Feed per Tooth (AFPT) = desired chip thickness x chip thinning factor (from chart).

SQUARE SHOULDERReference Information

PartNumber

SSEM0500-0625-R35-1SSEM0625-0625-R35-2SSEM0750-0750-R35-2SSEM1000-1000-R55-2SSEM1250-1250-R55-3SSEM1500-1250-R55-3SSSM2000-0750-R55-5SSSM2500-1000-R55-5SSSM3000-1000-R55-6SSSM4000-1500-R55-8SSSM5000-1500-R55-8SSSM6000-1500-R55-10

Min. HoleDia.0.56"0.78"1.03"1.28"1.78"2.28"3.28"4.28"5.28"7.28"9.28"11.28"

Max. HoleDia.1.00"1.25"1.50"2.00"2.50"3.00"4.00"5.00"6.00"8.00"10.00"12.00"

Hole Diameter Calculation

Smaller holes may be interpolated by predrilling.Typical recommended ramp angle is 1˚ or less.

Helical Interpolation for Larger Diameter Hole MakingLarger diameter hole making can be quick andeasy when a Square Shoulder Cutter is used incombination with Helical Interpolation. Thistechnique resembles thread milling in that all threeaxes (X, Y and Z) are in motion simultaneously. Itdiffers from thread milling in that the tool isintroduced into the material without a start hole ofany kind. The tool simply is positioned at the insidediameter of the hole to begin its helix from there,achieving complete material removal from the holeby ramping down to the final depth. This smoothoperation tends to avoid the high horsepower

consumption characteristic of large diameter hole making. The quick and easyprocess offers the added advantage of allowing many different hole sizes to begenerated with the same diameter tool. Hole size variation is all in the programming.

For more information on how Helical Interpolation can improve yourmanufacturing efficiency, contact your Dapra Applications Specialist.

8

Width of Cut (WOC)(% of tool Ø) 50% or > 40% 30% 20% 10%

Feed Rate Multiplier 1 1.02 1.1 1.25 1.7

Optimizing Cutting Performance

9

SQUARE SHOULDERReference Information

* Only one grade (except for aluminum) suggested. Contact Applications Specialist if first choice doesn't work.** Customer preference. Both are acceptable – see cutting edge differences above.

APET Geometry

Positive/negative cutting edge with T-land

Somewhat free-cutting; meant for higher chiploads (>.005" IPT); creates medium burr

Higher force due to negative edge; will deflect more than XPET

Higher heat generation than XPET; creates more heat at higher speeds

Very strong cutting edge; able to withstand more shock and interruptions

Longer edge life due to strong cutting edge; will roll more burr and wear out rather than chip out

XPET GeometryPositive cutting edge with a light hone andno T-land

Free-cutting, small burr; can run at lighterchiploads (>.002" IPT)

Lower force due to sharper edge; less deflection

Less heat generated due to positive edge

Weaker, due to edge sharpness; not able towithstand significant interruptions

Shorter, due to edge sharpness; may chip out if run too long

Grade SelectionTraits

Toughness(Fracture)

Wear Resistance(Edge Life)

Heat Resistance

Resistance toBuilt-Up Edge

Feed Capability

CoolantCapability

DMP35

Very tough, able to withstandshock and interruptionsSofter carbide, will not last aslong as DMK25Lower heat resistance due tolower hardness of carbideFair resistance to built-up edge;some buildup may occur – usecoolant as a preventative

High, due to toughness

Good; toughness gives it moreresistance to thermal shock

DMP30

Tough and hard; not as tough asDMP35, but tougher than DMK25Longer life than DMP35, but shorterthan DMK25Higher heat resistance than DMP35,less than DMK25

Poorer resistance to built-up edge;not typically a stainless steel grade

Strong feed capabilities, approx.20% lower than DMP35

Fairly tough; will allow machiningwith good coolant flow

DMK25

Not as tough; may fracture inabusive applicationsLonger edge life due to highercarbide hardness

Highest heat resistance

Good resistance

Lower, due to brittleness; run athigher speeds and lower feeds

Not as high; may experience thermalshock unless coolant flow is very good.

APET and XPET Insert Grade and Geometry Selection

Traits

Cutting Edge

Cutting Action

Force

Heat

Strength

Edge Life

Geometry Selection

Choose the Best Grade for Your ApplicationOperating Speed

Low to MediumHigher

Low to MediumHigher

AllLow to MediumLow to Medium

Higher

Low to Medium

HigherAll

All

All

Geometry

XPETXPET

APET/XPET**APET/XPET**

APETAPETXPETXPET

XPET

XPETAPET

XPET-ALUXPET-PCD

XPET

1st Choice Grade*

DMP303DMP30-HPDMP303

DMP30-GLHDMP35-HP

DMK25-GLHDMP303

DMP30-GLH

DMP35-GLH

DMP35-GLHDMK25-HP

DMK25/DMK253

DMP35-GLH

Coolant

Air/FloodAir

Air/FloodAirAirAir

Air/FloodAir/Flood

Flood

FloodAir

Flood

Flood

Material

Free machining, low-carbon steelsFree machining, low-carbon steelsMedium-carbon steels, tool steelsMedium-carbon steels, tool steels

All steels – interrupted cuts and heavy roughing cutsHeat-treated steels (48-62 Rc)Soft stainless steels (303, 304)

Soft stainless steelsTough stainless steels

(304L, 316, 400 series and PH series)Tough stainless steels

Cast iron

Aluminum alloys, copper alloys

High-temperature alloys, titanium

Technical Considerations• Always use anti-seize compound on screws.

• Thoroughly clean pocket at each insert change.

• Change insert screw every 10 inserts.

• Use the shortest-length tool holder (end mill holder) formaximum rigidity. The shank of the cutting tool should beup inside the machine spindle taper whenever possible.

• Use tool holders appropriate for roughing operations: endmill holders and power chucks are recommended; colletsare not recommended.

Recommendations• Square Shoulder milling allows heavier Depths of Cut

(DOC), but Dapra recommends that no more than 2/3 ofthe insert length should be engaged to reduce the chancefor screw breakage.

• Although the cutter is capable of the heavier cut, take careto allow for the machine tool's capabilities in horsepowerand rigidity.

• Utilize as much of the cutting edge per pass (DOC) as possible, to get the most metal removalwithin the insert's tool life.

• Feed rates should not go significantly below or above the recommended ranges (see page 12),or premature failure can occur.

• Square Shoulder tools can not plunge; instead, use up to a 2° ramp angle for full diameter cut.Greater ramp angles possible with partial width cut.

• Climb milling is recommended whenever possible.

• Use the larger corner radii for the strongest cutting edge during roughing applications.

• Compensate for radial chip thinning (see chart on page 8) when Width of Cut (WOC) is less than50% of the cutter diameter.

• Because our Square Shoulder tools cut a true 90°, they are a good choice for a wide rangeof finishing applications.

• Use Coarse Pitch cutters for slotting cuts or when cutting pressure needs to be reduced; use Fine Pitchcutters for lighter profiling cuts or when feed rates can be maximized.

• Most of Dapra's high-performance grades run best without coolant. Coolant in most milling applicationscreates a high potential for thermal shock, which can produce premature, and sometimes catastrophic,failure. Use air pressure to provide adequate cooling and chip evacuation.

• For long-reach applications, utilize the Carbide Core cutting tools for increased rigidity and reduced chatter.

SQUARE SHOULDERApplication Information

10

Troubleshooting

Concern

Insert wearappears high(flank wear)

Insertchipping

Possible Cause

-Not enough chip load-Surface footage is high-Incorrect grade or coating

-Surface footage is low-Incorrect grade or coating-Using sharp edge insertincorrectly

-Feed too high

Solutions

-Verify correct speed and feed-Increase feed rate-Decrease RPM-Consider different insert

-Verify correct speed and feed-Increase spindle speed-Decrease feed rate-Change insert selection-Decrease DOC

Concern

Built-up edge on insert

Poor finish/chatter

Tool shankbreaks

Possible Cause

-Low surface footage-Light chip load (feed per tooth)-Incorrect coating

-Cutter hung out too far-Excessive run out-Inadequate tool holding

-Tool pressure too great-Fatigued cutter body

Solutions

-Verify correct speed and feed-Increase cutting speed-Increase feed rate-Select different coating

-Use Carbide Core cutter body-Reduce tool gage length-Check tool holder wear-Use high-rigidity tool holder

-Decrease DOC-Reduce tool gage length-Decrease feed rate

11

SQUARE SHOULDERSpare Parts & Tools

APKT and ADKT inserts are the low-cost solution for your high-performance cutting requirements. They are designed to fit Dapra's APKT-compatible (SSIE) tools only (see below),and most third-party cutting tools. APKT and ADKT inserts:

• Provide maximum wear resistance• Have a positive cutting geometry for quiet, efficient cutting action

• Are available in three new grades:

DMP302 – A multi-layer CVD coating for excellent wear resistance at low-to-mediumoperating temperatures for most steel, stainless steel and cast iron applications.

DMP303 – A TiCN PVD coating for excellent wear resistance and toughness at low tomedium operating speeds. An excellent choice for stainless steels, this coating providesgood adhesion resistance.

DMP306 – A single layer PVD TiAIN coating for high-temperature applications in steel,stainless steel, cast iron and many high-temperature alloys.

Improve Cutting Performance Without Replacing Your Cutters!

Stocked standard

w

l

r

APKT.. ADKT..

Holder

SSIE1000-1000-R35-4SSIE1250-1000-R35-5

CuttingDia. (D)

1.000"1.250"

Depth of Cut

.350"

.350"

Flutes

45

d2

1.000"1.000"

l1

3.380"3.750"

l2

1.160"1.450"

Inserts

APKT100304

APKT-Compatible End Mills

D

l1

l2

d2

d2 = shank diameter; l1 = overall length; l2 = effective length

APKT-Compatible End Mills

Insert

APKT100304

ADKT150508

l

.413"

.625"

w

.263"

.375"

r

.015

.015

MoldedDMP302DMP306 DMP303

Coated

for all ..1003.. Inserts

SSTX08-ST8-F

8.85 in-lbs (1.0 Nm)

for all ..1604.. Inserts

SSTX15-ST15-F

31 in-lbs (3.5 Nm)

Clamping ScrewWrench

Tightening Torque for Clamping Screw

Order Number

Part Description

T8-FT15-F

SSTX-08-S

SSTX-15-S

APKT/ADKT Inserts

© Copyright 2006 Dapra Corporation 5-06-6M

Dapra 90˚ SquareShoulder products are made in the USA.

SQUARE SHOULDERRecommended Cutting Speeds

The parameters provided are suggested operating parameters. Actual speeds and feeds will depend on many variables,such as rigidity, workpiece hardness, tool extension, machine accuracy, Depth of Cut, etc. Start at the middle of the SFMrange and the low end of the IPT range. Next, increase IPT to optimize productivity and tool life. Higher SFM will providehigher output but will reduce tool life. Try different combinations to find the parameters that best suit your needs.

66 Granby Street, Bloomfield, CT 06002

800-243-3344 • 860-242-8539 • Fax 860-242-3017

Email info@dapra.com • www.dapra.com

Bringing Better Ideas to the Cutting Edge™

LOW-TO-MEDIUMCARBONSTEELS

1018,12L14,

1041, 1045

TOOL STEELS,HIGH-ALLOY

STEELS (SOFT)

4140, 41504340, H13,P20, A2, D2

TOOL STEELS,HIGH-ALLOY

STEELS(HARDENED)

4140, 41504340, H13,P20, A2, D2

CAST IRONS

GRAY,MALLEABLE,

DUCTILE

TOUGHERSTAINLESS

304L, 316, PH

STAINLESS

FREEMACHININGSTAINLESS

303, 304LOW 400SERIES

PLASTICS,NON-

FERROUS

RECOMMENDED GEOMETRY

RECOMMENDED FPT - 10mm

RECOMMENDED FPT - 16mm

XPET / APET

.003-.010

.006-.015

XPET / APET

.003-.008

.005-.012

APET

.003-.008

.006-.012

APET

.003-.005

.004-.008

XPET

.003-.007

.004-.010

XPET / ALU

.003-.025

.003-.025

APET

.003-.010

.006-.015

Speeds and Feeds for Dapra

Square Shoulder

Cutters

TOUGHESTShock

Resistance

HARDESTWear

Resistance

HIGH-TEMP.ALLOYS/TITANIUM

INCONEL,WASPALOY,

MONEL

COPPERALLOYS

AMPCO,WEARITE

ALUMINUMALLOYS

6061, 7075

XPET / ALU

.003-.020

.003-.025

XPET

.003-.015

.003-.025

XPET

.003-.006

.003-.008

MEDIUMShock &

Wear

LOW

ER T

EMPS

HIGH

ER T

EMPS

LOW

ER T

EMPS

HIGH

ER T

EMPS

LOW

ER T

EMPS

HIGH

ER T

EMPS

XPET

.003-.012

.003-.012

DMP35

DMP353

DMP35-HP

DMP357

DMP35-GLH

DMP30

DMP303

DMP30-HP

DMP307

DMP30-GLH

DMK25

DMK253

DMK25-HP

DMK257

DMK25-GLH

PCD

GRAPHITE

150-300

300-600

500-800

600-900

600-1100

250-400

400-700

500-900

600-1000

600-1200

250-400

400-700

500-900

600-1000

600-1200

1000+

1000+

1000+

1000+

2000+ 700-1500

1000+

1000+

1000+

1000+

1000+

1000+

1000+

1000+

1000+

1000+

1000+

1000+

1000+

1000+

1000+

50-150ROUGHING

75-300ROUGHING

75-450ROUGHING

50-150FINISHING

50-200FINISHING

50-250FINISHING

50-150FINISHING

50-250FINISHING

50-250FINISHING

75-250FINISHING

75-350FINISHING

200-600

400-1200

200-600

400-1200

200-600

400-800

400-900

400-1200

250-500

250-700

250-700

300-800

250-400

300-600

400-700

500-800

500-900

375-700

400-800

500-900

600-1000

600-1200

500-900

600-1000

600-1200

300-450

400-700

500-800

600-900

700-1000

450-800

500-850

600-1000

700-1200

800-1600

600-1000

700-1200

800-1600

125-250

150-400

250-500

300-600

300-800

125-250FINISHING150-400

FINISHING250-500

FINISHING300-600

FINISHING300-800

FINISHING

300-450

500-800

600-900

600-1200

350-550DUCTILE

500-900DUCTILE500-1100DUCTILE500-1300DUCTILE350-600

GRAY

600-900GRAY

700-1100GRAY

800-1300GRAY

• First choice grade shown in bold text.• For heavy WOC and/or DOC, use the lower end of the FPT range.• For light WOC and DOC, the higher end of the FPT range may be possible.