New Profile Milling Cutters Carrying Round Ceramic Inserts

Highlights

Cutters
The new cutters are intended mostly for rough and semi-finish milling of planes and 3D surfaces at extremely high cutting speeds. The more common applications include machining faces, cavities, pockets, and shoulders. The cutters are available in shell mill configurations in 2.00 and 3.00” diameters.

Cutter Body Features

• More teeth increase productivity and higher feed rate capability
• Low-wearing design due to superior toughness and high resistance to abrasive and chemical wear
• Coating of the cutter body facilitates chip flow and protects against corrosion and wear
• Wedge design can supply airflow directed to each cutting edge

Inserts
The economical double-sided round inserts are made from the following cutting ceramic grades:

• IS25 and IS35 - SiAlON
• IN22 and IN23 - “black” ceramics
• IW7 - whisker reinforced ceramics

The inserts feature superior cutting-edge integrity while ensuring impressive wear-resisting properties when machining at high cutting speeds and high feed rates.

Insert Features

• Durable structure
• Double-sided design for high ceramics utilization
• Excellent wear resistance and thermal shock resistance
• High fracture toughness
• Available in 3 design options according to cutting edge preparation:
  honed, chamfered (T-land), and combined (chamfered and honed)

Application Notes

• Main ISO groups of application: S (high temperature Ni- and Co-based superalloys), K (cast iron) and H (hard materials). Cutters carrying inserts from the grade IN23 can be also successfully applied to productive milling steel parts (ISO P group)
• Industries: the main fields of application relate to aerospace, power generation, and marine engineering
• Examples of the machined parts: blades, airfoils, discs, shafts, casings, high-strength wear-resistant components
• Dry coolant only. Using a wet coolant is prohibited due to its negative impact on performance and insert tool life!
• Insert tightening torque: the insert should be secured by applying tightening torque 42.5 lbf x in

Due to the advanced design, the new cutters feature more teeth in comparison with the same diameter tools that are provided by main competitors. This is an important advantage that represents an additional source for increasing productivity in milling difficult-to-cut materials

Machining data
The attached tables provide recommendations regarding selecting a more suitable ceramic grade, cutting-edge-preparation type and machining data. For milling in unstable conditions, the limit values of cutting speeds and feeds in the table data should be reduced by 20-30%.




FRN
Face Mill for Wedge-Clamped Double-Sided Round Insert • Radius for programing: .25"
(1) Cutting diameter maximum   (2) Number of inserts   (3) For interpolation   (4) For interpolation   (5) Maximum ramping angle

(a) Recommended tightening torque:4.8 Nm



RNGN-Ceramic
Round Double-Sided Ceramic Inserts (1) Insert with a dimple


Recommended ceramic grade and machining data for milling
*According to VDI 3323 standard.
Recommended range of depth of cut is .002-.118”.
The attached table provides recommended machining data. For milling in unstable conditions the limit values in the table data should be reduced by 20-30%.


Edge preparation types



TEST REPORT [ISO K]

	Competitor	ISCAR
Tool	Ø50 (≈2.00”)	FRN D038A050-05-22-12 (≈2.00”)
Number of teeth	4	5
Insert	RNGN 1207	RNG 45T
Grade	SiAION	IN22
Vc (sfm)	2296	2956
Fz (inch/t)	0.004	.004
Vf (ipm)	62.1	111
n (rpm)	4458	5732
Ae (inch)	1.378	1.378
Ap (inch)	.039	.039
Q (cipm)	3.81	6.12
Tool life (min/corner)	15	35
Workpiece	ASTM 65-45-12
Application	Shoulder milling

TEST REPORT [ISO S]

	Competitor	ISCAR
Tool	Ø63 (≈2.50”)	FRN D051A063-06-22-12 (≈2.50”)
Number of teeth	5	6
Insert	RNGN 1207	RNG 45T
Grade	SiAION	IN35
Vc (sfm)	2952	3936
Fz (inch/t)	.006	.006
Vf (ipm)	105.7	214
n (rpm)	4549	6066
Ae (inch)	1.378	1.378
Ap (inch)	.079	.098
Q (cipm)	11.4	29.15
Tool life (min/corner)	10	10
Workpiece	Inconel 718
Application	Face milling

TEST REPORT [ISO P]

	ISCAR
Tool	FRN D038A050-05-22-12 (≈2.00”)
Number of teeth	5
Insert	RNGN 45T
Grade	IN23
Vc (sfm)	1312
Fz (inch/t)	.004
Vf (ipm)	49.363
n (rpm)	2507
Ae (inch)	1.378
Ap (inch)	.039
Q (cipm)	2.678
Tool life (min/corner)	50
Workpiece	AISI 4340 HRC 24-29
Application	Shoulder milling

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