The “Ultimate” Milling Cutter Cartridges, Inserts & Sheet ...sp3cuttingtools.com/wp-content/uploads/2011/04/SP3_2015_PCD... · The “Ultimate” Milling Cutter Cartridges, Inserts

2015

Sheet Diamond that lasts 2x to 3x longer than PCD

Cartridges & Inserts

The “Ultimate” Milling Cutter

Cartridges, Inserts & Round Tools

Page 1/1

The world’s first cutting tool was likely a sharp stone wielded by a cave dweller to sharpen a piece of wood for use as a spear. How far we have come since then! Cutting materials have evolved from stone to carbon steel, to Fredrick Winslow Taylor’s High Speed Cutting steels, to Krupp’s first carbides and now to hundreds of grades of carbide and coating iterations. One of the greatest advancements in cutting technology for abrasive materials was the use of natural and later, synthetic diamond to take advantage of diamond’s miraculous properties of hardness, abrasion resistance, and chemical inertness.

Synthetic diamond was first created much in the same way as diamonds found in nature: with a combination of heat and pressure. The founders of sp3, Jim Herlinger and Jerry Zimmer developed the first commercial process using heat and vacuum to grow diamond as a part of their work as Silicon Valley innovators. The process they perfected uses carbon-rich gases introduced into a heated vacuum chamber (a reactor); to grow diamond crystals on carbide.

This process was first used to coat carbide inserts, then carbide round tools, and later we developed the ability to grow free-standing sheets of diamond using a similar, but larger scale CVD process (TFd, a pure polycrystalline diamond with 3x the wear resistance of PCD). As sp3 evolved as a cutting tool manufacturer, we broadened our offering to include fabricated diamond tools using both conventional PCD and CVD sheet diamond. We developed an innovative line of milling tools and consolidated sp3’s Cutting Tool engineering, marketing, sales, customer service, and manufacturing functions in Indiana in order to be more centrally located to better support our customer base.

In 2013, we purchased the assets of Winco Industries, Inc., a pioneer in the design and manufacture of ultra high precision PCD round tools. This adds additional products such as reamers, step drills, valve seat and guide tools, and transmission spool bore tools to sp3’s capabilities, as well as adding engineering talent, and manufacturing facilities and skills to our portfolio.

Over the past 20 years, sp3 has been an innovator in diamond technology, manufacturing processes, and in the design and application of diamond tooling for a variety of industries. We are not a “fabricator” or a “make to print (somebody else’s design)” company; we are a designer, developer, and application specialist for diamond tools that improve our customers’ manufacturing operations.

Our philosophy is simple: make better tools than our competitors, deliver them when we promise to deliver them, always strive for perfect quality, and continuously engineer and develop better designs that benefit our customers. Our philosophy is not perfectly realized (yet), but we ask you for the chance to work together to improve your company’s performance.

No other diamond cutting tool company provides such broad and deep technical understanding of diamond for use in cutting tools and no one has more field-proven experience in applying diamond tools to real world machining problems.

Definitions of Diamond Technologies..................................2Ultra-Mill Features..............................................................3Ultra-Mill Cutter Body Offerings.......................................4-5Ultra-Mill Coolant Attachments............................................6Ultra-Mill Cartridges............................................................7Ultra-Mill Intermediate Cutter Body Offerings....................8-9Ultra-Mill Intermediate Coolant Attachments........................10Ultra-Mill Intermediate Cartridges.........................................11Ultra-Mill Mini Endmills and Cartridges.........................12-13Ultra Endmill Cutters and Cartridges Inch....................14-15Ultra-Mill Spare Parts.........................................................16Setup Procedure for Ultra-Mill Milling Cutters...................17PCD Tipped ISO Inserts..................................................18-19 Milling Theory and Calculations.........................................20Cutting Data.....................................................................21Ultra-Mill Special Tools................................................22-23sp3-Round Special Tools..............................................24-25Tool Quote Request Form...........................................26-29

sp3 Cutting Tools, Inc3531 West U.S. Highway 224

Decatur, IN 46733Customer Service: (888) 547-4156Email: [email protected]

Website: www.sp3cuttingtools.com

1

2

WWW.SP3CUTTINGTOOLS.COM

sp3 Cutting Tools Inc., located in Decatur, IN, manufactures and services a broad range of super-hard inserts, end mills, drills, cartridges, and cutter bodies for machining applications that demand the use of diamond. sp3 tools are used to machine:

•Abrasive non-metallic materials such as graphite, green ceramics, ceramic matrix composites, filled plastics, and carbon fiber composites.•Non-ferrous metals such as cast aluminums, metal matrix composites, copper, brass, and bronze.•Ferrous metals such as nodular iron, CGI, and steel.

sp3 Cutting Tools is the the only manufacturer of diamond cutting tools to offer the following three major types of diamond materials and cBN:

or TFd – sp3 has extended CVD diamond technology to develop TFd, a free standing thick sheet pure diamond material. By manufacturing the thicker material and then segmenting the sheet, sp3 has essentially created a pure diamond material that can be applied in much the same manner as PCD, offering a cutting surface of pure diamond with no binder. TFd indexable inserts provide a wear life 2 to 3 times that of PCD, and maintain edge sharpness longer. Absence of binder avoids chemical interaction with coolant or workpiece material and allows for a sharper edge.

The world’s leading supplier of diamond tooling

Soft, free-cutting non-ferrous metals. e.g. 6061 aluminum, brass, copper

Graphite, carbon, green ceramics, fiber-enforced plastics, fiberboard

Low-silicon aluminum. e.g. 380

High-silicon aluminum.e.g. 390

Metal Matrix Composites.e.g. Duraclan

or PCD tools are an alternative to tungsten carbide (uncoated and coated) tools and are designed to meet the needs of more demanding non-ferrous machining applications. PCD contains diamond particles and non-diamond metallic synthesis materials. sp3 offers PCD inserts, PCD brazed cartridges, and round tools. We also design and manufacture custom tools and we have a comprehensive tool refurbishing service.

or DIAbide – The Chemical Vapor Deposition or CVD coating of tungsten carbide enables sp3 to provide diamond-coated carbide tools using our patented DIAbide process. The sp3 DIAbide material has gained worldwide acceptance as the proven diamond tool solution for high-speed CNC machining applications using graphite and other non-ferrous materials. We offer a wide array of DIAbide tools, including endmills, profiling endmills, premium mold mills, drills, indexable inserts, profiling inserts, and grooving, cut-off and threading inserts.

Thin-film diamond, Thick-film diamond,

Polycrystaline diamond,

Cubic Boron Nitride,

or cBN, is used for machining a wide variety of ferrous materials. cBN provides increased productivity and cost savings over conventional carbide and ceramic tools. In many cases cBN tools make it possible to machine materials where conventional tools have failed.

cBN tools are typically most effective for alloy steels hardened to a minimum of 45 HRC, cast iron, and powder metals. Although there are exceptions to this rule, it is important to note that if the material being machined does not meet the required hardness, the cBN tool life may be affected.

sp3 offers cBN cartridges that fit our Ultra-Mill line of milling cutters.

Ask your sp3 representative how you can apply the best diamond alternative for your application.

Complete Diamond Tool Solutions

sp3 DIABide™

sp3 PCDsp3 TFd™

Bare Carbidesp3 DIABide™

Coated Carbide

easy Performance Difficulty—Abrasive Index hard

3

CALL TOLL FREE! 1-888-547-4156

The beauty of the Ultra-Mill V-style milling cutter is that it is designed to

accommodate a wide range of coarse, medium and fine pitch cutting

applications. This common body style allows the user to adapt to

different applications simply by changing cartridge styles. For machining

ferrous metals, brazed cBN cartridges are available. For non-ferrous

materials brazed PCD and TFd cartridges are available.

Ultra-Mill Features, Benefits, and Advantages Include:Features Benefits Advantages

Higher density than most

competitive milling cutters

Higher machining speeds Faster throughput (increased

production) or longer tool life

(reduction in tool costs)

2 stage design capacity Rough and Finish in one

pass,aids in reducing

vibration on difficult to clamp

or thin section parts

Faster throughput (increased

production) or better asset

utilization (increased capacity)

Symmetrical cutter body Left hand and right hand

mounting with the same body

Reduced cutter body inventory

and increased flexibility

(reduced tooling costs)

Open design Improved chip evacuation—

less chip damage

Increased cutter body life

(lower tooling costs)

Geometry in the cartridge, not

the body

Fewer application limitations —

PCD, TFd, and cBN brazed cutting

tips, positive or negative rake and

lead angles are available

Faster throughput (increased

production) or longer tool life

(reduction in tool costs)

– Patented Milling Cutter System

4


A= Aluminum Body S= Steel Body

UM-2.50-3-1A/SUM-2.50-6-1A/SUM-3.00-4-1A/SUM-3.00-8-1A/SUM-3.00-10-1A/SUM-4.00-6-1A/SUM-4.00-12-1A/SUM-5.00-8-1A/SUM-5.00-16-1A/SUM-6.00-8-1A/SUM-6.00-12-1A/SUM-6.00-20-1A/SUM-8.00-10-1A/SUM-8.00-12-1A/SUM-8.00-24-1A/SUM-10.00-12-1A/S UM-10.00-28-1A/SUM-12.00-18-1A/SUM-12.00-36-1A/SUM-14.00-16-1A/SUM-14.00-32-1A/SUM-14.00-42-1A/S

3648

106

128

168

122010122412281836163242

2.5002.5003.0003.0003.0004.0004.0005.0005.0006.0006.0006.0008.0008.0008.00010.00010.00012.00012.00014.00014.00014.000

0.7500.7501.0001.0001.0001.2501.2501.5001.5001.5001.5001.5002.5002.5002.5002.5002.5002.5002.5002.5002.5002.500

2.0002.0002.0002.0002.0002.0002.0002.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.375

0.3120.3120.3750.3750.3750.5000.5000.6250.6250.6250.6250.6251.0001.0001.0001.0001.0001.0001.0001.0001.0001.000

15,50015,50014,20014,20014,20012,25012,25011,00011,00010,00010,00010,0008,6008,6008,6007,7507,7507,2507,2506,7506,7506,750

Cutter Bodies

UM 20 1 A6.00

Ultra-MillTM

Cutting Diameter

Number of Pockets

A = Aluminum Body

S = Steel Body

1-Series = Single Stage2-Series = Double Stage

– – –

Standard Cutter Body Offerings

CutterOrder Number

Number of Pockets

Effective Cutting Dia. A (in.)

B Dim.Bore Dia.

C Dim.Set Hgt. Keyway

MAXRPM

RH/LH

B

C

A

5


UM-63MM-3-1A/SUM-63MM-6-1A/S UM-80MM-8-1A/SUM-80MM-10-1A/SUM-100MM-6-1A/SUM-100MM-8-1A/SUM-100MM-12-1A/SUM-125MM-12-1A/SUM-125MM-16-1A/SUM-160MM-10-1A/SUM-160MM-20-1A/SUM-200MM-12-1A/SUM-200MM-24-1A/SUM-250MM-32-1A/S

36 8

1068

1212161020122432

6363 8080100100100125125160160200200250

2222 222232323240404040606060

6363 505050505063636363636363

15,00015,00014,00014,00012,25012,25012,25011,00011,00010,00010,0008,6008,6007,750

1010 101014141416161616252525

Cutter Bodies —Metric

UM 20 1 A160MM

Ultra-MillTM

Cutting Diameter

Number of Pockets

A = Aluminum Body

S = Steel Body


– – –

Metric Cutter Body OfferingsCutterOrder Number

Number of Pockets

Effective Cutting Dia. A (mm)

B Dim.Bore Dia.

C Dim.Set Hgt.

MAXRPMKeyway

RH/LH

B

C

A


sp3 will design special cutter bodies to your specifications:

• Special mounts

• Application specific diameters

• Required number of pockets, etc.

Please call to inquire on further details or request a quote.

6


For operations that require light weight tooling, sp3 Cutting Tools offers our LW-series Coolant Cap Assemblies.

Screw

Cap Assembly

Plate

UM-SS-2.50UM-SS-3.00UM-SS-4.00UM-SS-5.00UM-SS-6.00UM-SS-8.00UM-SS-10.00UM-SS-12.00UM-SS-14.00

UM-SS-5.00-LWUM-SS-6.00-LW

UM-SS-63MMUM-SS-80MM-22UM-SS-80MM-27UM-SS-100MMUM-SS-125MMUM-SS-160MMUM-SS-200MMUM-SS-250MM

UM-SS-125MM-LWUM-SS-160MM-LW

2.50”3.00”4.00”5.00”6.00”8.00”

10.00”12.00”14.00”

5.006.00

63mm80mm80mm

100mm125mm160mm200mm250mm

125mm160mm

3/8 – 241/2 – 205/8 – 183/4 – 163/4 – 16

————

3/4-163/4-16

M10x1.5M10x1.5M12x1.75M16x2.0M20x2.5M20x2.5

——

M20 X 2.5M20 X 2.5

3/165/163/83/85/8————

8mm8mm8mm

10mm14mm14mm

——

35 ft/lbs40 ft/lbs45 ft/lbs55 ft/lbs55 ft/lbs

————

45Nm45Nm60Nm68Nm80Nm80Nm

——

Coolant Attachment Order Number




Metric

Metric

Inch

Inch

Cutter Diameter

Cutter Diameter

Cutter Diameter

Cutter Diameter

Thread

Arbor Screw Thread

Arbor Screw Thread

ThreadHex Size

Hex Size

Hex Size

Hex Size

Torque

Torque

Torque

Torque

Thru Spindle Coolant Attachments for Standard Cutters

7


Cartridge Identification

UC 2 0D R 2 0

UC - Ultra-MillTM

C= CarbideD= PCDT= TFdB=cBN

0= .200” (5,0mm) Standard1= .250” (6,3mm)2= .375” (9,5mm)3= .500” (12,7mm)4= .625” (15,8mm)5= .750” (19,0mm)

0= No Wiper1= .060” (1,52mm)2= .080” (2,03mm)3= .100” (2,54mm)4= .120” (3,05mm)

Maximum Depth of Cut (DOC)Wiper FlatR= Right HandL= Left Hand

– ––

Nose Radius

1= .010” (0,25mm)2= .030” (0,76mm)3= .060” (1,52mm)4= .090” (2,28mm)5= .016” (0,40mm)6= .100” (2,54mm)7= 1,0mm (.039”)8= 1,5mm (.059”)9= 2,0mm (.078”)0= 2,5mm (.098”)C= Chamfer

0= 0/P1= 0/N2= 0/03= P/P4= P/N5= P/06= N/P7= N/N8= N/0

Axial/Radial Rake*

For recomendation on selecting the proper cartridge for your application please visit

www.sp3cuttingtools.com or call sp3 at the number on top of this page.

DOC

NOSE RADIUS

WIPER FLAT DOC

NOSE RADIUS

WIPER FLAT

For information on chip control, contact sp3.

* 0= Neutral P= Positive N= Negative

Wiper Cartridge Identification

UC W1D R N

UC - Ultra-MillTM

D= PCDT= TFdB= cBN

R= Right HandL= Left Hand

–

Wiper Type

Axial Rake

W1= Crowned W2= Flat

P= PositiveN= Negative0= Neutral

Crowned Wiper

1 : 1 1 OF 1

-

-

UT'S/UT-203

ULTRAMILL RH FLAT TOP WIPER

UT-203

AXIAL RAKE AND .0002/.0005 DROPCARTRIDGE WITH 5° NEGATIVE

A

SBD 13JAN07

11JAN07

.005 .XXXX±.0005

NOT OTHERWISE SPECIFIED: ANGLE ±

.XX ±

DO NOT SCALE DRAWING

DEC.: .X ±.03

FINISH

.XXX ±.01FIN.

.25°SCALE

FILE NO.

SHEET

INFORMATION RIGHTS ARE RETAINED BY SP3.BE IN WRITING. ALL COMMON LAW COPYRIGHT & CONFIDENTIALFABRICATE THIS ARTICLE. ALL AUTHORIZATION TO DO SO MUSTAND POSSESSION OF IT DOES NOT CONVEY PERMISSION TORIGHT OF USE. THIS DRAWING IS ISSUED IN STRICT CONFIDENCEA PROPRIETARY ARTICLE TO WHICH SP3 RETAINS EXCLUSIVETHIS DRAWING IS THE PROPERTY OF SP3 AND REPRESENTS

MATERIAL

REV

ASIZE DRAWING NO

DATE

DATE

UT-154B

58028-07

DRAWING NO

Fax (260) 547-4214Phone (888) 547-4156DECATUR, IN 467333531 WEST US HIGHWAY 224

CUTTING TOOLSDIAMOND

Flat Wiper

8


A 10AUG10INITIAL RELEASE KAB KAB

DREV DESCRIPTION APPROVEDDATEBY


MATERIAL

FINISH

TREATMENT

DEC.: .X ±.03



.005 .XXXX±.0005.XX ± .XXX ±.01FIN.

.25°SCALE

1:1

FILE NO.

DRAWN

CHECKED

REV1 of 1SHEET

DSIZE DRAWING NO

A

DATE

DATE

APPROVED DATE

DATE

CUST/UT3957ASSM

4140 STEEL

UT3957ASSM

-

UT3957ASSM

BLACK-OXIDE


DESIGN APPROVAL

PLEASE CONFIRM OVERALL DIMENSION, ANGLES, MOUNTING, MARKING AND HAND OF ROTATION.

APPROVED

APPROVED AS MARKED RESUBMIT

BY DATE

REVISION OF KEY FEATURES QUOTED, ARE SUBJECT TO PRICE ADJUSTMENT.


KAB 10AUG10

DESCRIPTIONITEM QTY DRAWING NO

LOCK SCREW, 8-32 X 1/2 T.B.H.

ADJUSTMENT NUT, 10-32 X .25

SET SCREW, 10-32 X 1/2 S.H.S.S.

WASHER

ULTRA-MILL CUTTER

63

1

2

1

6

4

5

6

6 97416A113

63506

63500

-

UT3957

DECATUR, IN 46733Phone (888) 547-4156Fax (260) 547-4214

3531 WEST US HIGHWAY 224

CARTRIDGE 6 6 UT-223

ENGRAVE:ULTRA-MILL ®UT3957S.H. 128.0MMPAT. #5,788,426

Ø1.500 6 STATION ULTRA-MILL ® ASSEMBLY

CARTRIDGE SET-UP PROCEDURE:1 CLEAN POCKETS AND CARTRIDGES THOROUGHLY.2 TURN HEX NUTS DOWN ONE TURN.3 INSTALL CARTRIDGES AND WITH TORX LOCK SCREWS TORQUED TO 10-15 IN/LBS.4 SET INDICATOR TO DESIRED SET HEIGHT.5 MOVE CARTRIDGES TO .001" BELOW SET HEIGHT WITH HEX NUTS.6 TIGHTEN LOCK SCREWS TO 23 IN/LBS. (TORQUE WRENCH REQUIRED)7 MOVE CARTRIDGES TO "SET HEIGHT" USING HEX NUT. (FOR BEST RESULTS ALL EDGES SHOULD BE +/-.0001")8 CHECK ALL SCREWS ARE SET TO PROPER TORQUE.

UMI 28 1 A6.00Cutting Diameter

Number of Pockets

A = Aluminum Body

S = Steel Body

– – –


Endmill Style Cutter Body Offerings


UMI-2.00-8-1A/SUMI-2.50-10-1A/SUMI-3.00-12-1A/SUMI-4.00-18-1A/SUMI-5.00-22-1A/SUMI-6.00-28-1A/SUMI-8.00-38-1A/SUMI-10.00-48-1A/S

2.002.503.004.005.006.008.00

10.00

0.7500.7501.0001.2501.5001.5002.5002.500

2.3752.3752.3752.3752.3752.3752.3752.375

810121822283848

CutterOrder Number

Number of Pockets

B Dim.Bore Dia.


MAXRPM

0.3120.3120.3750.5000.6250.6251.0001.000

17,00015,50014,20012,25011,00010,0008,6007,750

UMI-1.50-4-SS-1.00UMI-1.50-4-SS-1.50UMI-2.00-8-SS-1.00UMI-2.00-8-SS-1.50

4488

1.501.502.002.00

5.005.755.005.75

3.0003.7503.0003.750

20,00020,00015,50015,500

1.0001.5001.0001.500

CutterOrder Number

Number of Pockets

Overall Length L

Shank Length C

MAXRPM

Shank Dia. D

Note: These endmills are manufactured to H6 tolerance in order to maximize tool life, thus we discourage the use of standard endmill holders. We recommend hydraulic chucks or Shrink-fit adapters for these tools. Alternately, these tools can also be made with integral shank holders such as HSK, CAT, ANSI, etc. Upon request, we can supply these endmills with a Weldon flat but tool life will suffer due to excessive runout.

RH/LH

B

C

A

A

C

D

L

UMI - Ultra-MillTM Intermediate


Intermediate Cutter Bodies—Inch

Intermediate Endmill Bodies—Inch




UMI 8 SS 1.002.00Cutting Diameter

Number of Pockets Shank Diameter

– – –Shank Style

SS= Straight ShankWD= Weldon ShankCAT= Cat ShankBT= BT ShankHSK= HSK Shank

9


UMI 18 1 A

Number of Pockets

A = Aluminum Body

S = Steel Body

– – –


Endmill Style Cutter Body Offerings


UMI-50MM-8-1A/SUMI-63MM-10-1A/SUMI-75MM-12-1A/SUMI-100MM-18-1A/SUMI-125MM-22-1A/SUMI-150MM-26-1A/SUMI-200MM-36-1A/SUMI-250MM-46-1A/S

506375100125150200250

1622223240406060

6060606060606060

810121822263646

CutterOrder Number

Number of Pockets

B Dim.Bore Dia.


MAXRPM

810141416162525

17,00015,50014,20012,25011,00010,0008,6007,750

UMI-38MM-4-SS-25MMUMI-38MM-4-SS-32MMUMI-50MM-8-SS-25MMUMI-50MM-8-SS-32MM

4488

38385050

126130126130

76807680

20,00020,00015,50015,500

25322532

CutterOrder Number

Number of Pockets

Overall Length L

ShankLength C

MAXRPM

Shank Dia. D


RH/LH

B

C

A



Intermediate Cutter Bodies—Metric

Intermediate Endmill Bodies—Metric




UMI 8 SS 25MM50MMCutting Diameter



SS= Straight ShankWD= Weldon ShankHSK= HSK Shank

A 10AUG10INITIAL RELEASE KAB KAB

DREV DESCRIPTION APPROVEDDATEBY


MATERIAL

FINISH

TREATMENT

DEC.: .X ±.03



.005 .XXXX±.0005.XX ± .XXX ±.01FIN.

.25°SCALE

1:1

FILE NO.

DRAWN

CHECKED

REV1 of 1SHEET

DSIZE DRAWING NO

A

DATE

DATE

APPROVED DATE

DATE

CUST/UT3957ASSM

4140 STEEL

UT3957ASSM

-

UT3957ASSM

BLACK-OXIDE


DESIGN APPROVAL

PLEASE CONFIRM OVERALL DIMENSION, ANGLES, MOUNTING, MARKING AND HAND OF ROTATION.

APPROVED

APPROVED AS MARKED RESUBMIT

BY DATE

REVISION OF KEY FEATURES QUOTED, ARE SUBJECT TO PRICE ADJUSTMENT.


KAB 10AUG10

DESCRIPTIONITEM QTY DRAWING NO

LOCK SCREW, 8-32 X 1/2 T.B.H.

ADJUSTMENT NUT, 10-32 X .25

SET SCREW, 10-32 X 1/2 S.H.S.S.

WASHER

ULTRA-MILL CUTTER

63

1

2

1

6

4

5

6

6 97416A113

63506

63500

-

UT3957

DECATUR, IN 46733Phone (888) 547-4156Fax (260) 547-4214

3531 WEST US HIGHWAY 224

CARTRIDGE 6 6 UT-223

ENGRAVE:ULTRA-MILL ®UT3957S.H. 128.0MMPAT. #5,788,426

Ø1.500 6 STATION ULTRA-MILL ® ASSEMBLY

CARTRIDGE SET-UP PROCEDURE:1 CLEAN POCKETS AND CARTRIDGES THOROUGHLY.2 TURN HEX NUTS DOWN ONE TURN.3 INSTALL CARTRIDGES AND WITH TORX LOCK SCREWS TORQUED TO 10-15 IN/LBS.4 SET INDICATOR TO DESIRED SET HEIGHT.5 MOVE CARTRIDGES TO .001" BELOW SET HEIGHT WITH HEX NUTS.6 TIGHTEN LOCK SCREWS TO 23 IN/LBS. (TORQUE WRENCH REQUIRED)7 MOVE CARTRIDGES TO "SET HEIGHT" USING HEX NUT. (FOR BEST RESULTS ALL EDGES SHOULD BE +/-.0001")8 CHECK ALL SCREWS ARE SET TO PROPER TORQUE.

100MMCutting Diameter

10


Screw

Cap Assembly

Plate

UI-SS-2.00UI-SS-2.50UI-SS-3.00UI-SS-4.00UI-SS-5.00UI-SS-6.00UI-SS-8.00UI-SS-10.00UI-SS-12.00UI-SS-14.00

UI-SS-5.00-LWUI-SS-6.00-LW

UI-SS-50MMUI-SS-63MMUI-SS-75MMUI-SS-80MMUI-SS-80MMUI-SS-100MMUI-SS-125MMUI-SS-150MMUI-SS-200MMUI-SS-250MM

UI-SS-125MM-LWUI-SS-160MM-LW

2.002.503.004.005.006.008.00

10.0012.0014.00

5.006.00



125mm160mm

3/8-243/8-241/2-205/8-183/4-163/4-16

————

3/4-163/4-16

M8 x1.25M10x1.5M10x1.5M10x1.5M12x1.75M16x2.0M20x2.5M20x2.5

——

3/163/165/163/83/85/8————

5mm8mm8mm8mm8mm

10mm14mm14mm

——

35 ft/lbs35 ft/lbs40ft/lbs45 ft/lbs55ft/lbs55ft/lbs

————

50 Nm45Nm45Nm45Nm60 Nm68Nm80Nm80Nm

——





Metric

Metric

Inch

Inch

Cutter Diameter

Cutter Diameter

Cutter Diameter

Cutter Diameter

Thread

Arbor Screw Thread

Arbor Screw Thread

ThreadHex Size

Hex Size

Hex Size

Hex Size

Torque

Torque

Torque

Torque

For operations that require light weight tooling, sp3 Cutting Tools offers our LW-series Coolant Cap Assemblies.

Thru Spindle Coolant Attachments for Intermediate Cutters

11


UI 2 0D R 2 0

UI - Ultra-MillTM Intermediate

C= CarbideD= PCDT= TFdB= cBN

0= .200” (5,0mm) Standard1= .250” (6,3mm)2= .375” (9,5mm)

0= No Wiper1= .060” (1,52mm)2= .080” (2,03mm)3= .100” (2.54mm)


– ––

Nose Radius1= .010” (0,25mm)2= .030” (0,76mm)3= .060” (1,52mm)7= 1,0mm (.039”)8= 1,5mm (.059”)C= Chamfer

0= 0/P1= 0/N2= 0/03= P/P4= P/N5= P/06= N/P7= N/N8= N/0

Axial/Radial Rake*

For recomendation on selecting the proper cartridge for your application please visit

www.sp3cuttingtools.com or call sp3 at the number on top of this page.

DOC

NOSE RADIUS

WIPER FLAT DOC

NOSE RADIUS

WIPER FLAT

For information on chip control, contact sp3.


Intermediate Cartridge Identification

Intermediate Wiper Cartridge Identification

UI W1D R ND= PCDT= TFdB= cBN

R= Right HandL= Left Hand

–

UI - Ultra-MillTM Intermediate

Wiper Type

Axial Rake

W1= Crowned W2= Flat

P= PositiveN= Negative0= Neutral

Crowned Wiper

1 : 1 1 OF 1

-

-

UT'S/UT-203

ULTRAMILL RH FLAT TOP WIPER

UT-203

AXIAL RAKE AND .0002/.0005 DROPCARTRIDGE WITH 5° NEGATIVE

A

SBD 13JAN07

11JAN07

.005 .XXXX±.0005


.XX ±


DEC.: .X ±.03

FINISH

.XXX ±.01FIN.

.25°SCALE

FILE NO.

SHEET


MATERIAL

REV

ASIZE DRAWING NO

DATE

DATE

UT-154B

58028-07

DRAWING NO

Fax (260) 547-4214Phone (888) 547-4156DECATUR, IN 467333531 WEST US HIGHWAY 224


Flat Wiper

12


Mini Endmill Identification—Inch

sp3 offers the Ultra-Mill Mini Endmill when machining small areas as well. What separates the Mini Endmill from its Ultra Endmill counterpart is that it has more cartridges per cutting diameter, which allows the user to increase the feed rate and hence increase throughput and production.

MUE 10 SS 1.002.00

MUE - Mini Endmill

Cutting Diameter



SS= Straight ShankWD= Weldon ShankCAT= Cat ShankBT= BT ShankHSK= HSK Shank

MUE-1.00-6-SS-.75MUE-1.00-6-SS-1.00MUE-1.25-6-SS-.625MUE-1.25-6-SS-.75MUE-1.25-6-SS-1.00MUE-1.50-6-SS-.625MUE-1.50-6-SS-.75MUE-1.75-8-SS-1.00MUE-1.75-8-SS-1.25MUE-2.00-10-SS-1.25

1.001.001.251.251.251.501.501.751.752.00

3.754.003.503.754.003.503.754.004.254.25

666666688

10

2.7503.0002.5002.7503.0002.500 2.750 3.000 3.250 3.250

0.7501.0000.6250.7501.0000.6250.7501.0001.2501.250

.150

.150

.150

.150

.150

.150

.150

.150

.150

.150

Standard Mini Endmill BodiesEffective Cutting Dia.A (in.)

Cutter Order Number

Overall Length L

No.Inserts

Shank Length C

Shank Dia. D

D.O.C. Max

C

A D

L


Mini Endmill Cartridge Identification—Inch

WIPER FLAT

NOSE RADIUSDOC


2= 0/05= P/08= N/0

Axial/Radial Rake* Nose Radius

2 5

1= .006” (0,15mm)2= .015” (0,38mm)3= .030” (0,76mm)C= Chamfer

0= .150” (3,8mm) Standard0= No Wiper1= .015” (0,38mm)2= .030” (0,76mm)3= .060” (1,52mm)

Maximum Depth of Cut (DOC)Wiper Flat

C

A D

L

13


Mini Endmill Identification—Metric

sp3 offers the Ultra-Mill Mini Endmill when machining small areas as well. What separates the Mini Endmill from its Ultra Endmill counterpart is that it has more cartridges per cutting diameter, which allows the user to increase the feed rate and hence increase throughput and production.

MUE 10 SS 32MM50MM

MUE - Mini Endmill

Cutting Diameter



SS= Straight ShankWD= Weldon ShankHSK= HSK Shank

MUE-25MM-6-SS-20MMMUE-25MM-6-SS-25MMMUE-32MM-6-SS-20MMMUE-32MM-6-SS-25MMMUE-38MM-6-SS-20MMMUE-38MM-6-SS-25MMMUE-45MM-8-SS-20MMMUE-45MM-8-SS-32MMMUE-50MM-10-SS-32MM

252532323838454550

104121104121104121104133133

66666688

10

74917491749174103103

202520252025203232

3,53,53,53,53,53,53,53,53,5

Standard Mini Endmill BodiesEffective Cutting Dia.A (mm)

Cutter Order Number

Overall Length L

No.Inserts

Shank Length C

Shank Dia. D

D.O.C. Max


WIPER FLAT

NOSE RADIUSDOC

2= 0/05= P/08= N/0

Axial/Radial Rake*

Mini Endmill Cartridge Identification—Metric

Nose Radius

MU 2 5D R 2 0

MU - Mini Endmill

C= CarbideD= PCDT= TFd

1= .006” (0,15mm)2= .015” (0,38mm)3= .030” (0,76mm)C= Chamfer

0= .150” (3,8mm) Standard0= No Wiper1= .015” (0,38mm)2= .030” (0,76mm)3= .060” (1,52mm)


– ––


14


UE 4 SS 1.00D1.25

UE - Ultra Endmill

Cutting Diameter


– – –

Shank StyleSS= Straight ShankWD= Weldon ShankCAT= Cat ShankBT= BT ShankHSK= HSK Shank

Endmill Identification —Inch

Endmill Cartridge Identification —Inch

Wiper Flat

Nose RadiusDOC

UE-D0.75-3-SS-0.75UE-D1.00-3-SS-1.00UE-D1.25-4-SS-1.00UE-D1.50-4-SS-1.00UE-D1.75-4-SS-1.25UE-D2.00-4-SS-1.25

0.751.001.251.501.752.00

4.254.504.504.504.754.75

334444

2.7503.0003.0003.0003.2503.250

0.751.001.001.001.251.25

1.001.001.001.001.001.00

25,00025,00025,00025,00025,00019,000

Effective Cutting Dia.A (in.)

Cutter Order Number

Overall Length L

Number of Pockets

DimensionsShank

Length CShank Dia. D

D.O.C. Max

Maxrpm

Nose Radius

EI 2 2D R 2 0

Endmill Inch


1= .0102= .0303= .0604= .090**5= .0166= .100**C= Chamfer

0= 0/P1= 0/N2= 0/0

0= .2001= .3752= .5003= .6254= 1.0005= .750

0= No Wiper1= .0302= .0603= .1004= .120

Axial/Radial Rake*

Maximum Depth of CutWiper FlatR= Right HandL= Left Hand

– ––



** Use of .090 nose radius or larger requires use of modified tool body.

A

C

D

L

UE 3 SS 25mmD25mm

UE - Ultra Endmill

Cutting Diameter


– – –

Shank StyleSS= Straight ShankWD= Weldon ShankCAT= Cat ShankBT= BT ShankHSK= HSK Shank

Endmill Identification—Metric


15


Endmill Cartridge Identification—Metric

Wiper Flat

Nose RadiusDOC

Nose Radius

EM 2 2D R 2 0

Endmill Metric


1= 0.252= 0.753= 1.504= 2.25**5= 0.406= 2.50**C= Chamfer

0= 0/P1= 0/N2= 0/0

0= 5.001= 9.502= 12.003= 16.004= 25.005= 19.00

0= No Wiper1= 0.752= 1.503= 2.504= 3.00

Axial/Radial Rake*

Maximum Depth of CutWiper FlatR= Right HandL= Left Hand

– ––


** Use of 2.25mm nose radius or larger requires use of modified tool body.

A

C

D

L

UE-D20MM-3-SS-20MMUE-D25MM-3-SS-25MMUE-D32MM-3-SS-32MMUE-D40MM-4-SS-32MMUE-D50MM-4-SS-32MM

2025324050

106116120120120

33344

6676808080

2025323232

25.025.025.025.025.0

25,00025,00025,00025,00019,000

Effective Cutting Dia.A (mm)

Cutter Order Number

DimensionsShank

Length CShank Dia. D

D.O.C. Max

Maxrpm

Overall Length L

Number of Pockets

16


Miscellaneous Adjustment Tools

sp3 is not responsible for any defects caused by improper use or setting of its milling cutters. Care should be taken and exercised when handling aluminum cutter bodies. Although the outside surface is hard, aluminum will dent or nick from improper handling. Extreme caution should be taken when handling and setting to ensure maximum cutter performance.

Hardware

Hardware and Adjustment Tools

Part # Description Cutter Family

63600 3/16" & 1/4" Cartridge Adjustment Wrench Ultra-Mills Standard and Intermediate - INCH

63601 Pre-set 45 in-lbs Torque Wrench Ultra-Mills Standard and Intermediate - INCH

63616 Replacement T-25+ 1/4" Drive Socket Ultra-Mills Standard and Intermediate - INCH

63602 Torx T-25+ T-handle Wrench Ultra-Mills Standard and Intermediate - INCH

63605 6mm & 7mm Cartridge Adjustment Wrench Ultra-Mills Standard and Intermediate - METRIC

63606 Pre-set 50 in-lbs Torque Wrench Ultra-Mills Standard and Intermediate - METRIC

63615 Replacement T-25 1/4" Drive Socket Ultra-Mills Standard and Intermediate - METRIC

63611 Torx T-25 T-handle Wrench Ultra-Mills Standard and Intermediate - METRIC

63603 Pre-set 14.5 in-lbs Torque Wrench Mini Ultra-Mills - INCH and METRIC

63604 Torx T-9 T-handle Wrench Mini Ultra-Mills - INCH and METRIC

63600 3/16” & 1/4” Cartridge Adjustment Wrench Mini Ultra-Mills - INCH

63624 5mm Cartridge Adjustment Wrench Mini Ultra-Mills - METRIC

63607 Torx T-15 Wing Style Handle Wrench Ultra-Endmills - INCH and METRIC

63609 Pre-set 19 in/lbs Torque Wrench Ultra-Endmills - INCH and METRIC

63627 1/16” Allen Cartridge Adjustment Wrench Ultra-Endmills - INCH

63626 1.5mm Allen Cartridge Adjustment Wrench Ultra-Endmills - METRIC

63350 UMPP - Pocket Protector Ultra-Mills - INCH and METRIC

63351 UMIPP - Pocket Protector Ultra-Mill Intermediate - INCH and METRIC

Description Cartridge Mount Screw

Cartridge Adjustment

Nut

Stud for Adjustment

Nut

Cartridge Adjustment

Screw

Ultra-Mill 2-1/2” Diameter thru 4.0” using UCxx style cartridges 63501 63500 63502

Ultra-Mill 4-1/2” Diameter or larger using UCxx style cartridges 63503 63500 63504

Ultra-Mill 63.5mm Diameter thru 76.2mm using UCxx style cartridges 63521 63520 63522

Ultra-Mill 76.3mm Diameter or larger using UCxx style cartridges 63523 63520 63524

Ultra-Mill Intermediate 2” Diameter thru 4.0” using UIxx cartridges 63501 63500 63502

Ultra-Mill Intermediate 4-1/2” Diameter or larger using UIxx cartridges 63503 63500 63504

Ultra-Mill Intermediate 75.0mm using UIxx cartridges 63521 63520 63522

Ultra-Mill Intermediate 80.0mm Diameter or larger using UIxx cartridges 63523 63520 63524

Mini Ultra Endmill 1.0” Diameter Only using MUxx cartridges 63540 63541

Mini Ultra Endmill 1.25” Diameter and Larger using MUxx cartridges 63542 63541

Mini Ultra Endmill 25mm Diameter Only using MUxx cartridges 63540 63568

Mini Ultra Endmill 32mm Diameter and Larger using MUxx cartridges 63542 63568

Ultra Endmill .75” Diameter thru 1.25” using EIxx cartridges 63300 63547

Ultra Endmill 1.50” and larger using EIxx cartridges 63302 63547

Ultra Endmill 20mm Diameter thru 32mm using EMxx cartridges 63527 63528

Ultra Endmill 40mm Diameter and larger using EMxx cartridges 63549 63528

1.) When installing new cartridges, ensure pockets are clean and free of burrs.

2.) Clean bottom of cutter to ensure it is free of burrs and dirt. Cutter must sit flat on surface or setting fixture.

3.) Turn axial adjusting nuts or screws down one turn.

4.) Install cartridges in body and tighten mounting screw to:

a.) Ultra-Mill and Ultra-Mill Intermediate - 15-20 in/lbs or 1.7-2.3 Nm

b.) Ultra-Mill Mini Endmill – 8-10 in/lbs or .9-1.2 Nm

c.) Ultra Endmill – 10-12 in/lbs or 1-1.5 Nm

5.) Set indicator to desired height.

6.) Using the proper wrench, adjust cartridges to within .001” or .03mm from setting height.

7.) Tighten mounting screws to:

a.) Ultra-Mill and Ultra-Mill Intermediate - INCH - 45 in/lbs or 5.1 Nm

b.) Ultra-Mill and Ultra-Mill Intermediate - METRIC - 50 in/lbs or 5.7 Nm

c.) Ultra-Mill Mini Endmill – 15.5 in/lbs or 1.8 Nm

d.) Ultra Endmill – 19 in/lbs or 2.1 Nm

i.) Make sure screws are securely tightened

8.) Using the proper wrench, adjust cartridges to finished setting height. To achieve the best surface finishes, all cartridges need to be within +/- .0001” or .0025mm.

Setup Procedure for Milling Cutters

Page 1/1

Scan this code with your smart phone to view sp3’s online setup video.

Note: sp3 recommends that any tool running at 10,000 rpm or greater be balanced as an assembly to G2.5 or better.

17


18


sp3 offers a standard family of Positive Rake PCD tipped ANSI/ISO inserts for your turning and boring needs. Utilizing a premium grade of PCD, sp3 inserts offer excellent tool life and performance to suit your application. Please contact your local sp3 sales representative for assistance in selecting the proper insert for your requirements.

55°80°60°

5°5°5°

Part # ANSI Description ISO Description Tip Size Top Rake

41990-01 TCGX-21.51 4mm PCD TCGX-110204 4mm PCD 4.0MM 5°

41990-02 TCGX-21.52 4mm PCD TCGX-110208 4mm PCD 4.0MM 5°

41990-03 TCGX-32.51 4mm PCD TCGX-16T304 4mm PCD 4.0MM 5°

41990-04 TCGX-32.52 4mm PCD TCGX-16T308 4mm PCD 4.0MM 5°

41991-01 TPGX-21.51 4mm PCD TPGX-110204 4mm PCD 4.0MM 5°

41991-02 TPGX-21.52 4mm PCD TPGX-110208 4mm PCD 4.0MM 5°

41991-03 TPGX-32.51 4mm PCD TPGX-16T304 4mm PCD 4.0MM 5°

41991-04 TPGX-32.52 4mm PCD TPGX-16T308 4mm PCD 4.0MM 5°

41992-01 CCGX-21.51 4mm PCD CCGX-060204 4mm PCD 4.0MM 5°

41992-02 CCGX-21.52 4mm PCD CCGX-060208 4mm PCD 4.0MM 5°

41992-03 CCGX-32.51 4mm PCD CCGX-09T304 4mm PCD 4.0MM 5°

41992-04 CCGX-32.52 4mm PCD CCGX-09T308 4mm PCD 4.0MM 5°

41993-01 CPGX-21.51 4mm PCD CPGX-060204 4mm PCD 4.0MM 5°

41993-02 CPGX-21.52 4mm PCD CPGX-060208 4mm PCD 4.0MM 5°

41993-03 CPGX-32.51 4mm PCD CPGX-09T304 4mm PCD 4.0MM 5°

41993-04 CPGX-32.52 4mm PCD CPGX-09T308 4mm PCD 4.0MM 5°

41994-01 DCGX-21.51 4mm PCD DCGX-070204 4mm PCD 4.0MM 5°

41994-02 DCGX-21.52 4mm PCD DCGX-070208 4mm PCD 4.0MM 5°

41994-03 DCGX-32.51 4mm PCD DCGX-11T304 4mm PCD 4.0MM 5°

41994-04 DCGX-32.52 4mm PCD DCGX-11T308 4mm PCD 4.0MM 5°

41995-01 DPGX-21.51 4mm PCD DPGX-070204 4mm PCD 4.0MM 5°

41995-02 DPGX-21.52 4mm PCD DPGX-070208 4mm PCD 4.0MM 5°

41995-03 DPGX-32.51 4mm PCD DPGX-11T304 4mm PCD 4.0MM 5°

41995-04 DPGX-32.52 4mm PCD DPGX-11T308 4mm PCD 4.0MM 5°

PCD Tipped ANSI/ISO Screwdown Inserts - 5° Positive Rake

sp3 offers a standard family of Flat Top PCD tipped ANSI/ISO inserts for your turning and boring needs. Utilizing a premium grade of PCD, sp3 inserts offer excellent tool life and performance to suit your application. Please contact your local sp3 sales representative for assistance in selecting the proper insert for your requirements.

19


PCD Tipped ANSI/ISO Screwdown Inserts - Flat Top

Part # ANSI Description ISO Description Tip Size Top Rake

41984-01 TCGW-21.51 4mm PCD TCGW-110204 4mm PCD 4.0MM 0°

41984-02 TCGW-21.52 4mm PCD TCGW-110208 4mm PCD 4.0MM 0°

41984-03 TCGW-32.51 4mm PCD TCGW-16T304 4mm PCD 4.0MM 0°

41984-04 TCGW-32.52 4mm PCD TCGW-16T308 4mm PCD 4.0MM 0°

41985-01 TPGW-21.51 4mm PCD TPGW-110204 4mm PCD 4.0MM 0°

41985-02 TPGW-21.52 4mm PCD TPGW-110208 4mm PCD 4.0MM 0°

41985-03 TPGW-32.51 4mm PCD TPGW-16T304 4mm PCD 4.0MM 0°

41985-04 TPGW-32.52 4mm PCD TPGW-16T308 4mm PCD 4.0MM 0°

41986-01 CCGW-21.51 4mm PCD CCGW-060204 4mm PCD 4.0MM 0°

41986-02 CCGW-21.52 4mm PCD CCGW-060208 4mm PCD 4.0MM 0°

41986-03 CCGW-32.51 4mm PCD CCGW-09T304 4mm PCD 4.0MM 0°

41986-04 CCGW-32.52 4mm PCD CCGW-09T308 4mm PCD 4.0MM 0°

41987-01 CPGW-21.51 4mm PCD CPGW-060204 4mm PCD 4.0MM 0°

41987-02 CPGW-21.52 4mm PCD CPGW-060208 4mm PCD 4.0MM 0°

41987-03 CPGW-32.51 4mm PCD CPGW-09T304 4mm PCD 4.0MM 0°

41987-04 CPGW-32.52 4mm PCD CPGW-09T308 4mm PCD 4.0MM 0°

41988-01 DCGW-21.51 4mm PCD DCGW-070204 4mm PCD 4.0MM 0°

41988-02 DCGW-21.52 4mm PCD DCGW-070208 4mm PCD 4.0MM 0°

41988-03 DCGW-32.51 4mm PCD DCGW-11T304 4mm PCD 4.0MM 0°

41988-04 DCGW-32.52 4mm PCD DCGW-11T308 4mm PCD 4.0MM 0°

41989-01 DPGW-21.51 4mm PCD DPGW-070204 4mm PCD 4.0MM 0°

41989-02 DPGW-21.52 4mm PCD DPGW-070208 4mm PCD 4.0MM 0°

41989-03 DPGW-32.51 4mm PCD DPGW-11T304 4mm PCD 4.0MM 0°

41989-04 DPGW-32.52 4mm PCD DPGW-11T308 4mm PCD 4.0MM 0°

55°80°60°

Quick Reference:ae=

35%25%10%

5%

1.201.452.053.00

increase feed by:

Feed Rates:vf= n · z · fz

f= z · fz

vf= n · zc · fz

f= zc · fz

or

or

Metal Removal Rates:Q= ae · ap · vf

Average Chip Thickness:

hm= fz · ae

Dfz= hm · D

ae

Note: If using a two- or three-stage Ultramill, use the effective (zc) number of teeth to calculate feed rate.

Note: Use to calculate when width of cut (ae) is less than 50% of D.

Milling Theory and Calculations:

Formulas and Legend

D =Dw=R =z =zc=n =vc=vf=f =fz=

hm=ae=ap=Q =K =π=

Cutting DiameterWorking DiameterCutter RadiusNumber of TeethEffective Number of TeethRPMSurface Feet/Meters per MinuteCutter Feed—Inches/mm per MinuteFeed per RevolutionFeed per ToothAverage Chip ThicknessWidth of Cut —Radial Depth of CutDepth of Cut—Axial Depth of CutMetal Removal Rate—in3/min or mm3/min Lead AnglePi (3.1415)

100%75%50%25%

Axial chip thinning requires increase in feed rate to maintain proper chip thickness.

If ap≤

If ap=If ap=If ap=

25% of cartridge radius, increase feed by 4x26-50% of cartridge radius, increase feed by 2x51-75% of cartridge radius, increase feed by 25%100% or more of cartridge radius, do not increase feed

Cutting Speed and RPM–Inch:

Cutting Speed and RPM–Metric:

Vc=

Vc=

Vc= n ÷ 3.82 · D

Vc= n · .00314 · D

n=

n=

n= Vc · 3.82 ÷ D

n= Vc · 318.057÷ D

n · π · D

n · π · D

Vc · 12

Vc · 1,000

12

1,000

π · D

π · D

Note:The equations and quick-reference charts below do not take into account the condition of the machine or spindle, fixture design or condition, part configuration, size / condition of taper or any other applicaton specific data. Before relying on data gathered from any calculations, please make an assesment of your specfic machining conditions and adjust feeds, speeds and depths of cut accordingly. Please do not adjust feed-per-tooth to a value greater than your wiper flat.

20


Cutting DataInch

Metric

High Silicon Aluminum

>10% Silicon

Cutting Speed Vc

1000 1500 2000

Feed Rate per Tooth fz

0.001 0.004 0.008

0.001 0.004 0.006

0.001 0.003 0.004

0.001 0.003 0.004

Carbide and Ceramic (Green)

Cutting Speed Vc

500 1000 1500


0.002 0.004 0.008

0.002 0.004 0.006

0.001 0.003 0.004

0.001 0.003 0.004

Manufactured Wood

Cutting Speed Vc

3000 6000 8000


0.004 0.006 0.010

0.004 0.006 0.008

0.003 0.005 0.008

0.003 0.005 0.008

Medium Silicon Aluminums

8-10% Silicon

Cutting Speed Vc

2000 3000 6000


0.001 0.004 0.008

0.001 0.004 0.006

0.001 0.003 0.004

0.001 0.003 0.004

Free Machining Alloys

ie: Gold, Platinum, Lead

Cutting Speed Vc

500 1000 1500


0.003 0.004 0.007

0.003 0.004 0.006

0.002 0.003 0.005

0.002 0.003 0.005

Reinforced Plastics

ie: Carbon Fiber Composites

Cutting Speed Vc

1500 2500 5000


0.002 0.003 0.005

0.002 0.003 0.004

0.001 0.002 0.004

0.001 0.002 0.004

Copper - Bronze - Zinc

Cutting Speed Vc

1000 1500 2500


0.001 0.003 0.006

0.001 0.003 0.005

0.001 0.002 0.005

0.001 0.002 0.005

Unfilled Plastics

Cutting Speed Vc

1500 2500 5000


0.001 0.003 0.006

0.001 0.003 0.005

0.001 0.002 0.005

0.001 0.002 0.005

Low Silicon Aluminums

<8% Silicon

Cutting Speed Vc

2000 4000 10,000


0.001 0.004 0.008

0.001 0.004 0.006

0.001 0.003 0.004

0.001 0.003 0.004

High Silicon Aluminum

>10% Silicon

Cutting Speed Vc

305 460 610


0.025 0.100 0.200

0.025 0.100 0.150

0.025 0.075 0.100

0.025 0.075 0.100

Carbide and Ceramic (Green)

Cutting Speed Vc

150 305 460


0.050 0.100 0.200

0.050 0.100 0.150

0.025 0.075 0.100

0.025 0.075 0.100

Manufactured Wood

Cutting Speed Vc

915 1830 2440


0.100 0.150 0.250

0.100 0.150 0.200

0.075 0.120 0.200

0.075 0.120 0.200

Medium Silicon Aluminums

8-10% Silicon

Cutting Speed Vc

610 915 1830


0.025 0.100 0.200

0.025 0.100 0.150

0.025 0.075 0.100

0.025 0.075 0.100

Free Machining Alloys

ie: Gold, Platinum, Lead

Cutting Speed Vc

150 305 460


0.075 0.100 0.180

0.075 0.100 0.150

0.050 0.080 0.120

0.050 0.080 0.120

Reinforced Plastics

ie: Carbon Fiber Composites

Cutting Speed Vc

460 760 1525


0.050 0.075 0.120

0.050 0.075 0.100

0.025 0.050 0.100

0.025 0.050 0.100

Copper - Bronze - Zinc

Cutting Speed Vc

305 460 760


0.025 0.075 0.150

0.025 0.075 0.120

0.025 0.050 0.120

0.025 0.050 0.120

Unfilled Plastics

Cutting Speed Vc

460 760 1525


0.025 0.075 0.150

0.025 0.075 0.150

0.025 0.050 0.150

0.025 0.050 0.120

Low Silicon Aluminums

<8% Silicon

Cutting Speed Vc

610 1220 3050


0.025 0.100 0.200

0.025 0.100 0.150

0.025 0.075 0.100

0.025 0.075 0.100

Cutter Family

Ultramill

Ultramill Intermediate

Ultramill Mini

Ultra Endmill

Cutter Family

Ultramill


Ultramill Mini

Ultra Endmill

Cutter Family

Ultramill


Ultramill Mini

Ultra Endmill

Sample

Cutting Speed Vc

Low Starting High


Low Starting High

Lowest

recommended

cutting data

Recommended

starting cutting data

Not recommended to

exceed without calling sp3

Cutter Family

Ultramill


Ultramill Mini

Ultra Endmill

Cutter Family

Ultramill


Ultramill Mini

Ultra Endmill

Cutter Family

Ultramill


Ultramill Mini

Ultra Endmill

Note: Do not exceed maximum RPM listed on product pages.21


22


Tool Function: Drills thru from a blind hole, creates 3 diameters, a chamfer and 2 shoulders for a differential carrier housing.

Benefits: The Ultra-Mill Boring Bar features replaceable and axially adjustable cartridges. The adjustable cartridges vs. a fixed pocket insert provide a more uniform cut and load sharing which provides more even wear. Their replaceable trait reduces cost compared to a fixed pocket PCD

Tool Function: Drills through for a pipe thread, chamfers and faces the holes and faces the outer seal surface for an oil filter housing.

Benefits: The replaceable core drill that threads into the tool body allows for easy maintenance and replacement. Axially and radially adjustable cartridges

Tool Function: Boring and chamfering 2 diameters and facing one surface.

Benefits: The full form is in each cartridge and each cartridge is radially adjustable for ease of setting.

tool. This boring bar also features coolant thru which removes the chips from the cutting edge.

Advantages: The Ultra-Mill Multi-Step Boring Bar replaced a core drill and a fixed pocket boring bar. It provides reduced tooling costs. In addition, the cost to refurbish the

diamond components in the bar is much less than retipping a fixed pocket boring bar.

allow for more uniform wear, which enhances tool life and provides improved part finish.

Advantages: This tool configuration replaced 3 tools – therefore reducing cycle time and lowering overall tooling cost.

Advantages: The Ultra-Mill Form Boring Tool replaced 2 tools that interpolated the form. Therefore, this tool has reduced cycle time and has provided a reduction in tool inventory, reducing tool costs.

Ultra-MillTM Multi-Step Boring Bar

Ultra-MillTM Core Drill and Facing Tool

Ultra-MillTM OD Form Trepannng Tool

Ultra-MillTM Fin Mill

Tool Function: Removing casting flash and temporary reinforcements used to equalize cooling rates on die cast cylinder housings.

Benefits: We designed this mill to replace the additional handling and band saw labor used previously to allow the task to be completed within the machining center used to process the part from as-cast to finish machined part.

23


Special Tools

Tool Function: The face milling of a remote deep cavity limited access area.

Benefits: The Ultra-Mill Mini-Mill with integral shank provides improved rigidity. The axially adjustable cartridges allow for more uniform load sharing. The through spindle coolant provides better chip evacuation and reduces heat.

Tool Function: The face milling of a throttle body.

Benefits: The Ultra-Mill with integral shank provides improved rigidity. The axially adjustable cartridges allow for more uniform load sharing. The through spindle coolant provides better chip evacuation and reduces heat.

Advantages: This Ultra-Mill replaced an indexable 5 blade

Tool Function: Quickly and efficiently removing excess casting stock and establishing locating surfaces prior to loading the casting into a machining center for complete processing

Benefits: This special Ultra-Mill Cubing Mill allows for higher metal removal rates, reducing machining time and longer tool life than the previous indexable carbide mill.

Advantages: The versatility of a Mini Ultra-Mill allows for additional cartridges in the same cutting diameter which allows for increased feed rates and therefore faster throughput. The integral shank reduces deflections during the cut, which was critical in this long reach application.

cutter. The versatility of an Ultra-Mill allows for additional cartridges in the same cutting diameter which allows for increased feed rates and therefore faster throughput. In this particular application, the Ultra-Mill is providing a significant annual tool reduction cost (in excess of $150,000) to this particular customer.

Advantages: The UltraMill provides almost unlimited freedom to create special tools for specific applications often replacing multiple tools in the process with one tool.

Ultra-MillTM Cubing Mill

Ultra-MillTM Mini Mill with CAT40 Integral Shank

Ultra-MillTM with HSK63 Integral Shank

Ultra-MillTM Fin Mill

Advantages: A classic example of using the Ultra Mill base to design a special purpose cutter with special form cartridges allows for standardization of spare parts and hardware, as well as reduction of previously required operations.

24


Roundsp3-Round Monoblock Tool

sp3-Round Monoblock Tool

sp3-Round High Precision Reamer

sp3-Round Modular Tooling

Tool Design: PCD tipped monoblock tools with multiple steps and cutting edges. All tool bodies are machined from tool steel and are precision ground from the taper to the PCD blades between centers for the best possible TIR. HSK, CAT, BT and tapers for wet and MQL machining are available. All tools are balanced by design as well as mechanically before shipment.

Tool Design: Built of modular exchangeable components to accommodate exhaust and intake machining of the parent seat and valve guide holes. The body is solid carbide with solid carbide guide pads and PCD blades for precision reaming. Mounted on the reamer is a bushing made from tool steel and PCD tipped. All parts are precision ground between centers for the best possible TIR.

Tool Design: This high precision reaming system is based on using multiple solid carbide guides and PCD inserts to ensure precision hole making with diametric and geometric consistency. For optimal TIR the system is paired with a simple runout adjustment and clamping system designed for this precision reamer system.

Tool Design: PCD tipped monoblock tools with multiple steps and cutting. All tool bodies are machined from tool steel and are precision ground from the taper to the PCD blades between centers for the best possible TIR. HSK, CAT, BT and tapers for wet and MQL machining are available. All tools are balanced by design as well as mechanically before shipment.

Application: This tool is used in a cylinder head for the cup plug bore. Challenges are machining the feature in one step and not allowing chips/swarf to fall into the water passages.

Advantages: No assembly, no runout adjustment, no setup of cutting edges to size.

Application: Components are interchangeable to accommodate different exhaust and intake valve seat parent holes. Similar modular solutions are available for engine, transmission, fluid technology, chassis and brake as well as aircraft parts.


Application: For use in all reaming operations requiring precise diameter consistency, straightness and roundness requirements.

Advantages: Precision holes; the operation doesn’t follow the pre-bored holes. This system is ideal when more open tolerance requirements exist in situations with low component, fixture or machine spindle rigidity.

Application: This tool is used in a cylinder head for the springseat face and diameter. Challenges are machining the hole in one step into the casting and not allowing chips in the head nor ring or half ring inside the part.


*Solutions are available for engine, transmission, fluid technology, chassis and brake as well as aircraft parts.

Round

25


sp3-Round Tool Holders for Runout Adjustment

sp3-Round Special Tools

sp3-Round PCD Contour Milling Cutter

sp3-Round PCD Drills

Tool Design: Multiple contoured, precision PCD tips match your required complex contouring operation. The tools are available as steel body monoblock tools, with solid carbide body, and as combination tools.

Holder Design: We have multiple precision ground holder solutions with adjustment capabilities for HSK, CAT and BT.

Application: All precision machining operations with weak spindle interface conditions, or high length to diameter ratios.

Tool Design: Our drills are based on solid carbide bodies and either PCD wing tipped, across center or sandwich diamond tipped.

Application: If diametric consistency is needed in your drilled hole or longer life is needed, or

Tool Design: If you did not see an obvious solution above, please contact us with your requirements and we will develop one for you.

Application: Solutions are available for engine, transmission, fluid technology, chassis and brake as well as aircraft parts.

Application: All axial, radial, circular milling, grooving, and plunging contour operations.

Advantages: No restrictions due to clamping/location of inserts. No difficult set up of multiple inserts to match your contour.

Advantages: Eliminate runout issues and improve the quality of your machining operation.

you have high silicon content in your material this is the way to go.

Advantages: PCD drills will hold hole size to your specification longer than solid carbide drills can.

Advantages: If you are using multiple tools and cycle time is an issue, let us deal with tooling solutions that work and which will improve your operations, lower your costs, and improve throughput.

*Solutions are available for engine, transmission, fluid technology, chassis and brake as well as aircraft parts.

26


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29


Quote Request

Ship To: Customer: Distributor: Other: Special Instructions (Note Below)

Distributor:

Contact Person:

Phone Number:

Address:

End User:

Contact Person:

Phone Number:

Address:

Customer Data

Special Requirements

Reference Quote #

Sales Person:

Date Entered: Date Required:

Request for Quote

Test

Projected Annual Usage:

New Tool #:

Description:

Cutter Diameter / IC:

# of Stations / Blades: LH: RH:

Cartridge Style / Insert: (Geometry) PDC TFd

Depth of Cut:

Customer Supplied Insert / Tool: Yes No Grade: Manufacturer

Proposed ToolCatalog: Yes No

Quote Quantity:

Current Process Conditions

Material to Cut: Spindle RPM: Feed Rate IPM: DOC:

Current Tool: Carbide: PCD: Other:

Surface Finish Required: Coolant: Thru Spindle: Shower Screw: Flood:

Common Failure Mode: Finish: Wear: Chipping: Burr: Other:

Desired Improvement Over Current Tool: Life: Cost: Finish: Other:

Inch: Metric:

Other:Milling: Turning: Boring: Drilling:

sp3 Cutting Tools, Inc.3531 West US Hwy 224, Decatur, IN 46733

Phone: 888-547-4156 • Phone 260-547-4150 • Fax: 260-547-4214 • E-Mail: [email protected]

Documents

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