MTG - D Milling PDF

MILLING
Introduction D2
APPLICATIONS
Getting started D3
Milling different materials D 32
Shoulder milling D 42
Face milling D 54
Profile and turn milling D 66
Slot and thread milling D 84
Dedicated methods D 100
Trouble shooting D 128
PRODUCTS
90° shoulder milling cutters D 134
CoroMill® 490, CoroMill® 390, CoroMill® 290, CoroMill® 690,
Coromant Finishing Long Edge Cutter, CoroMill® 790, CoroMill® Century
10° – 75° face and plunge milling cutters D 146

CoroMill® 345, CoroMill® 245, CoroMill® 365, AUTO, CoroMill® 360,
T-Max 45, CoroMill® 210, Cormant Plunge cutter
Round insert cutters D 161

CoroMill® 200, CoroMill®300
Ball nose cutters D 164

CoroMill® 216, CoroMill® 216F Finishing
Slot, groove, side/face and

thread milling cutters
CoroMill® 327, CoroMill® 328, CoroMill® 329, T-Max Q-Cutter, CoroMill® 331 D 166
Solid carbide and exchangeable head cutters

CoroMill® Plura, CoroMill® 316 D 178
Extended offer D 186
Grade information D 188
Feed recommendations D 192
D1
MTG09 Milling D1-D21.indd 2 2009-08-12 08:12:01 MTG09 Milling D1-D21.indd 1 2009-11-24 13:06:51
A
General turning Milling – introduction
B
Parting and grooving
C
Threading
D
Milling
Introduction
Drilling
F When the first CoroMill cutters were introduced in the early

90s, a new standard was set on the market when it comes to Trends
productivity, accuracy and realiability. Since then, the CoroMill
Machines and machining methods
family has grown and developed in a remarkable way. Today’s
comprehensive range of milling solutions meets every need and • Increased flexibility with 5-axes machining centres and
machining trend. multi-task machines
Boring
• Smaller, less stable machines - light and fast milling

Unique and innovative technologies have always been the basis techniques – lower depths of cut
for all CoroMill concepts and the latest developments are no • Fewer machines/set-ups to complete a component
G exception, for example, the smart insert and tip seat designs
• Longer tool lengths
which are the prerequisites for the unmatched performance of
cutters, such as the CoroMill 345, CoroMill 490, CoroMill 690, Components and material
etc. The new exchangable head (EH) coupling system, which • Stronger, lighter and more corrosion-resistant materials
Tool holding/
enables the versatility of the CoroMill 316 end mill range, is • Thin-walled components
Machines
another example of an innovation, developed by Sandvik • Near net shape castings and forgings
Coromant.
Together with a wide assortment of insert geometries and grades,
H a suitable CoroMill solution is always available, irrespective of
workpiece material and machining conditions.
Materials
I
Information/
D2
Index
MTG09 Milling D1-D21.indd 2 2009-11-24 13:06:53

Milling – getting started A
Getting started
General turning
Milling methods
Milling is the most flexible machining method available and can machine almost
any shape. The downside of this flexibility is that many variables are built into the
B
process, making it more challengng to optimize. This chapter identifies these

variables and helps you choose the best method and tools, depending on the
application.
Getting started provides an overview of the milling products, machine types,
definitions of variables and general recommendations, see pages D 3 – D 31.
Milling recommendations from a workpiece material perspective are given in Milling
in different materials, see pages D 32 – D 41. It answers questions like: Should C
cutting fluid be used when milling titanium? What cutter type is best suited for
aluminium? Can ceramic inserts be used in cast iron? etc.
Milling used to be divided into face, shoulder, slot and profile milling, but with the
development of machines and softwares, the number of methods has grown and
Threading
turn-milling, thread milling, circular ramping, trochoidal milling, etc. are very common
in today's operations. In this chapter, milling has been divided into the following
areas:
• F ace milling, see page D 54.
D
• Shoulder milling, see page D 42.
• Profile and turn milling, see page D 66.
• Slot and thread milling, see page D 84.
• Dedicated methods, see page D 100.
Milling
The last section explains methods like ramping, plunging, trochoidal, etc.
Drilling
F
Boring
G
Tool holding/
Machines
Choice of method
Three different areas should be considered to determine the best method and tooling solution.
H
Materials
P M K
N S H
1. Milling component feature 2. Component material, shape and quantity 3. Machine parameters
I
Information/
D3
Index

A
General turning Milling – getting started
Initial considerations
1. The milled configuration

B Milling has been evolved into a method that machines a very
broad range of operations.
In addition to all the conventional applications, milling is a

strong alternative for producing holes, threads, cavities and
surfaces that used to be turned, drilled or tapped.
The configurations to be milled have to to be carefully
considered. These can be located deep, requiring extended
tooling, or contain interruptions and inclusions.
C
Threading
2. The component
Workpiece surfaces can be demanding, with cast skin or
Milling
forging scale.
In cases of bad rigidity, caused by thin sections or weak
E clamping, dedicated tooling and strategies have to be used.
The workpiece material and its machinability must also be
analyzed to establish optimal cutting data.
Drilling
P M K
F N S H
3. The machine
Boring
The machine is of great importance for the choice of milling

method. Face/shoulder or slot milling can be performed in
G 3-axes machines, while milling 3D profiles require alternatively
4- or 5-axes machines.
Turning centres today often have milling capability due to
Tool holding/
driven tools, and machining centres often have turning

Machines
capability. CAM developments mean that 5-axis machines are

increasingly common. They offer increased flexibility, but
stability can be a limitation.
H For more information about machines for milling, see page
D 10.
Materials
I
Information/
D4
Index

General turning
Choice of method – example
Face milling

45° entering angle 90° entering angle 10° entering angle
C
CoroMill® 345 CoroMill® 490 CoroMill® 210
Advantages Advantages Advantages

+ High productivity + Versatile cutter that can be used for many + High productivity
Threading
+ Optimized for face milling other operations + Extremely high feed
+ Low axial forces – favourable for thin walled + Axial cutting force direction – favourable for
Disadvantages components spindle stability
– Moderate depth of cut + Relatively large depth of cut in relation to
the insert size Disadvantages
– Low depth of cut D
Disadvantages
– Lower productivity
Milling
High productivity Versatile High productivity
The basic choice Mixed production Problem solver E
Opening up a cavity/pocket
Drilling
F
Drilling + circular milling Drilling + plunge milling Circular ramping
Boring
G
Advantages Advantages Advantages
+ High material removal for non-round holes + Problem solver in long overhang applica- + Reduced tools – no drill needed
Tool holding/
+ First choice in aerospace frame titanium tions + Flexible – produces wide range of sizes
structural parts + Simple programming suitable for older/ + No cutting fluid required – good for open
Machines
multi-spindle machines machines

Disadvantages + Suitable for all machine concepts and
– Requires a stable machine Disadvantages configurations
– Chip evacuation – horizontal machine – Low material removal
– Careful programming required Disadvantages
– Less productive for large cavities
H
Materials
Problem solver
The basic choice for pockets The basic choice for 3D cavities
Long overhangs
I
Information/
D5
Index

A
Application overview – milling
Shoulder milling
see page D 42
B
C
Face milling
see page D 54
Threading
High feed
D
Wiper
Profile and turn milling

see page D 66
Milling
Turn milling
Roughing to finishing of concave and convex surfaces
Drilling
F Slot and thread milling

see page D 84
Boring
Radial slot milling Axial slot milling Thread milling

G
Dedicated methods
Tool holding/
see page D 100

Machines
Plunge milling
Circular milling
H
Chamfer milling
Closed angles
Materials
Slicing
Linear and circular ramping

I
Information/
D6
Index

General turning
Product overview – milling
90° shoulder milling cutters

CoroMill® Plura CoroMill® 316 CoroMill® 390 CoroMill® 490
B

Page D 179 D 183 D 136 D 134
CoroMill® 690 CoroMill® 790 CoroMill® Century CoroMill® 290
S N N C
Threading
Page D 140 D 143 D 144 D 139
Cutters with a 90˚ entering angle are very versatile and the most • T he solid carbide cutters, CoroMill Plura and CoroMill 316, with
common type of cutter. Shoulder face mills, end mills and long edge exchangeable heads, cover the smaller diameter range.
cutters are all included in this group. D
• CoroMill 690 is a long edge cutter dedicated for titanium milling.
•C
oroMill 490 is the first choice cutter for general shoulder face
milling. •C
oroMill 790 is the cutter, mainly used for aluminium, with the
best ramping capability.
• T he CoroMill 390 is a concept of end mills, shoulder face mills
and long edge cutters with good ramping capabilities. Vibration •O
ther cutters in this group are the Coromant finishing long edge
cutter and the Sandvik Auto-FS finishing face mill.
Milling
dampened tools and a wide range of radius inserts are available
for dedicated operations.
Drilling
10° - 75° face and plunge milling cutters
High feed High feed F
Boring
Page D 179 D 183 D 158 D 148
CoroMill® 345 CoroMill® 360 CoroMill® 365 Auto D 152

T-Max 45 D 156
G
Tool holding/
Machines
Page D 146 D 155 D 150
This wide range of cutters are used mainly for face milling • CoroMill 360 is the real heavy duty milling cutter.
operations, but cutters with very small entering angles that are H
suitable for plunge milling also belong to this group. •C
oroMill 210 and the corresponding versions of CoroMill 316 and
CoroMill Plura are well adapted for use with high feed face milling
•C
oroMill 345 is the basic concept for for general face milling and techniques. These cutters are excellent for ramping operations
CoroMill 245 the complementary choice. and CoroMill 210 can also be used for plunge milling.
• CoroMill 365 is mainly used for cast iron. •O
ther cutters in this group are the Sandvik Auto for cast iron
Materials
milling and the T-Max 45 for heavy machining.
➤ I
Information/
D7
Index

A
➤
Round insert and large radius cutters
B Large radius Large radius
Page D 178 D 182 D 164 D 162
Round insert cutters are very versatile, and are used for both demanding face milling as well as profiling operations, and have excellent
C ramping capabilities.
• T he light cutting CoroMill 300 is the first choice. Also available in toroid end mill design as an alternative to ball nose cutters.
• CoroMill 200 is the tough choice for more demanding applications.
• CoroMill Plura and CoroMill 316 with large radius can be regarded as round insert cutters.
Threading
D
Ball nose cutters
CoroMill® Plura CoroMill® 316 CoroMill® Ball nose
Milling
E
Page D 178 D 182 D 164 D 165
Ball nose cutters are primarily used for profile milling of 3D shapes (sculptured surfaces).
•B all nose designs of the CoroMill Plura and CoroMill 316 are suitable for roughing or finishing operations.
Drilling
• The indexible insert cutter CoroMill 216 is a roughing and semi-roughing cutter, while CoroMill 216F is dedicated for finishing operations.
F
Boring
Slot, groove, side/face and thread milling cutters

G CoroMill® Plura CoroMill® 327 CoroMill® CoroMill®
CoroMill® 328 329 331
Tool holding/
Machines
Page D 95 D 166 D 168 D 170
H These cutters were primarily developed for milling deep or shallow grooves. When the groove is produced in a helical path, they can form a
thread.
•C oroMill 327 and 328 have optimized insert designs for threading and circlip grooving, respectively.
• The CoroMill 329 is for general milling of grooves and shallow slots. The Q-cutter is a complementary tool for slots that exceed the reach
of the CoroMill 329.
Materials
• CoroMill 331 is a comprehensive concept for all types of side and face milling operations, including back-facing.
I
Information/
D8
Index

General turning
Tool maintenance
Check the insert seats regularly to ensure that they have not been damaged during
machining or handling. Make sure that the insert seats are free from dirt or metal
chips from machining.
Replace worn or damaged screws and washers. Use a torque wrench to ensure B
correct screw-tightening.

To get the best performance, we recommend cleaning all male and female parts
and lubricating them with oil at least once a year. Lubricant should be applied, when
needed, to the screw thread as well as the screw head face.
Torque wrench
To get the best performance out of the milling tools, a torque wrench should be used to obtain the correct
Threading
tightening of the assembled boring tool and insert.
Torque that is set too high will affect the performance of the tool negatively and cause insert, washer and
screw breakage.
D
Torque that is set too low will cause slide or insert movement, vibrations and degrade the cutting result.
See Main catalogue to find the correct tightening torque.
Milling
E
Safety precautions – danger points

•C hips are very hot with sharp edges and should not be moved with bare hands. Chips can cause burns to the skin or
Drilling
damage to the eyes.
• Be sure that the insert and component are tight and secured in their holders to prevent them from coming loose during use.
Too much overhang can result in vibration and tool breakage.
• Use appropriate safety guards or machine encapsulations to securely collect particles such as chips or cutting elements,
F
which may spin off.
• Make sure that the machine has the required torque and power needed for rough milling operations, large depths of cut or
large diameters.
Boring
G
Warning! Max spindle revolution

Tool holding/
At high RPM's, the weight of the insert and clamping Correct insert clamping is achieved by tightening the 16 mm
Machines
elements increase, which can effect the clamping screw, using a torque of 2 Nm, and the 22 mm insert with
arrangement. It is recommended that all high speed 5 Nm.
manufacturing takes place only in a well-protected machine
Note: A 19 gram insert weighs 350 kg at 37,500 rpm.
set-up. H
Before mounting the insert, make sure that the insert
and its seat are in perfect condition and free from burrs or
any particles, which may seriously affect the clamping
arrangement.
Materials
I
Information/
D9
Index

A
Machines for milling

Machine tool configuration – number of axes
Previously, machines could be split into four categories – horizontal or vertical,
and turning or milling.
B Today, machines are developing in all directions. Turning centres now have
milling capability due to driven tools, and machining centres have turning
capability – turn mill or mill turn machines. CAM developments mean that
five-axis machines are increasingly common. The results of these trends
create new demands and opportunities for tooling:
• Increased flexibility
• Fewer machines/set-ups to complete a component Vertical machining centre with a fifth A-axis.
C • Reduced stability
• Longer tool lengths
• Lower depth of cuts.
Threading
Vertical machining centre with a fifth B-axis.

Spindle orientation – horizontal or vertical?
Milling
Horizontal:
• Favourable for milling larger components.
E • Facilitates chip evacuation in cavity milling, and prevents re-cutting.
• Less mass to accelerate/decelerate.
• Often, four axes provide access to three sides.
• Ergonomic and economic pallet technology.
• Most common machine type for use of side and face milling cutters.
Drilling
Small vertical machining centers:

• Small total envelope, requires little space in the workshop.
• Well suited to high speed/feed – light and fast. Horizontal machining centre with 5 axes.
F
Large vertical machining centers:
• Provide better stability while the workpiece is resting on the table.
• Suitable for larger and heavier workpieces.
• Column types for huge components.
Boring
• Can work with longer and heavier tool set-ups.
G
Tool holding/
Multi-task machine with 5 axes.

Machines
Stability
The condition and stability of the machine have an effect on the quality of the
H surface, and can also impair tool life. Excessive wear on the spindle bearings
or feed mechanism can result in a poor surface structure.
The stability of the entire tool set-up is of outmost importance. Factors such
as tool overhang, Coromant Capto coupling, tuned adaptors, etc. should be
Materials
considered. Namnlöst-1 1 2009-08-31 09:29:34
I Vertical and horizontal 3-axis machines.

Information/
D 10
Index

General turning
Power and torque
Torque
Basically, the power requirements in milling vary along with the:
• amount of metal to be removed
• average chip thickness
• cutter geometry B
• cutting speed.

Power
The greater the metal removal rate (Q cm³/min), the higher the power requirement.
Low spindle speeds for roughing of exotic materials place great importance on the Spindle speed
availability of sufficient power and torque.
A machine with insufficient torque and power will produce fluctuating chip thickness,
which in turn causes unstable performance.
The majority of modern machining centres have direct driven spindles. Ever C
increasing spindle speed capacity and/or capability results in:
• L ower torque at higher rpm
• Lower power at lower rpm
Threading
Therefore, machines with high rpm capabilities have limitations for roughing wíth
larger diameter cutters, which require low rpm and high power.
Machining strategies need to be adapted. This explains the trend in light and fast
machining – which uses a smaller cutter diameter, small depth of cut, ap/ae, and D
high feed per tooth, fz.
Machines for components requiring high power at low rpm can be geared to produce
an optimum performance for both roughing and finishing.
Milling
E
Spindle sizes
Drilling
ISO 30, 40, 50 and 60 spindles have natural built-in
advantages and limitations.
F
Heavy roughing requires a larger spindle, whereas high speed
milling requires lower torque, making a smaller spindle more
suitable.
The size of the spindle will define the maximum milling cutter
diameter and the depth of cut that the machine is capable of
Boring
handling.
Although there are exceptions, due to varying machine tool
conditions, a general rule for selecting the cutter size is: G
ISO 60 – “larger cutters”.
ISO 50/Coromat Capto size C8 – Dc 160 mm.
Tool holding/

Machines

Components requiring long edge cutters require, at a
minimum, an ISO 50 or Coromant Capto size C8 spindle.
H
Tool coupling integrated in the spindle provides the best
stability.
On gantry machines and other larger machine tools, cutters
may be direct mounted on the spindle nose, which provides
Materials
extreme stability and the smallest possible protrusion.

Large gantry heavy duty milling machine.
I
Information/
D 11
Index

A Milling – getting started
Milling definitions
General turning
The milling cutter

B
Entering angle – kr (degrees)
The major cutting edge angle (kr) of the cutter is the dominant factor affecting the
cutting force direction and the chip thickness, see page D 18.
Cutter diameter – Dc (mm)

C The cutter diameter (Dc) is measured over the point PK, where the main cutting edge
meets the parallel land.
Dc is the diameter that in most cases appears in the ordering code, with the
exception of the CoroMill 300, for which D3 is used.
The most important diameter to consider is (Dcap) – the effective cutting diameter
Threading
at the actual depth of cut (ap) – used for calculation of the true cutting speed,
see page D 76.
D3 is the largest diameter of the insert, for some cutters it is equal to Dc.
D
Milling
Cutting depth – ap (mm)

The cutting depth (ap) is the difference between the uncut
E and the cut surface in axial direction. Maximum ap is primarily
limited by the insert size and machine power.
Another critical factor in roughing operations is torque, and in
finishing operations, it is vibration.
Drilling
Cutting width – ae (mm)

The radial width of the cutter (ae) engaged in cut. Especially critical in plunging step
Boring
over, and for vibration in corner milling, where maximum ae is especially critical.
G
Radial immersion – ae / Dc
Radial immersion (ae / Dc) is the width of the cut in relation to the diameter of the
Tool holding/
cutter.
Machines
H Number of effective cutting edges on the tool – zc

For determining the table feed (vf) and the productivity. This often has a critical
influence on chip evacuation and operational stability.
zc < zn
Materials
The total number of cutting edges on the tool – zn
I zc = zn / 2
Information/
D 12
Index

General turning
Pitch – u (mm)
Distance between the effective cutting edges (u).
For a specific Sandvik Coromant cutter diameter, you can choose between different
pitches: coarse (-L), close (-M), extra close (- H). An X added to the code, denotes a
cutter version whose pitch is slightly closer than its basic design. B

Differential pitch
Indicates an unequal space between the teeth on a cutter. This is a very effective way to
minimize vibration tendencies. For more information about pitch, see page D 17.
C
The milling insert
Threading
Insert geometry
L M H
γ γ γ D
β β β
Milling
Geometry
Parameter L M H
Edge strength E
Cutting forces
Power consumption Low Medium High
Max. chip thickness

Heat generated
Drilling
A closer study of the cutting edge geometry reveals two important angles on the insert:
• rake angle (γ)
• cutting edge angle (β) F
The macro geometry is developed for work under light, medium or heavy conditions.
• L (Light) geometry has a more positive, but weaker edge (large γ, small β)
• H (Heavy) geometry has a stronger, but less positive edge (small γ, large β)
Boring
The macro geometry affects many parameters in the cutting process. An insert with a strong cutting edge
can work at higher loads, but also generates higher cutting forces, consumes more power and generates
more heat.
G
Material optimized geometries are designated with the ISO classification letter. For example, geometries for
cast iron: KL, KM, KH.
Tool holding/
Machines
Radius (Rbo)
Insert corner design Corner radius (r) Parallel land (bs1) Wiper land (bs2)
Materials
The most important part of the cutting edge for producing the bs1
surface is the parallel land bs1 or, when applicable, a convex r
wiper land bs2, or corner radius rε.
I
Information/
D 13
Index

A
The milling process

Cutting speed – vc (m/min)
This indicates the surface speed at diameter and forms a basic value for
calculating cutting data.
B
Recommended cutting speeds for all materials and for different hex values
are available in the Main catalogue.
Effective or true cutting speed

Indicates the surface speed at the effective diameter (Dcap).
C This value is necessary for determining the true cutting data at the actual depth of vc =
Dcap × π × n
1000
cut (ap). This is a particularly important value when using round insert cutters, ball
nose end mills and all cutters with larger corner radii, as well as cutters with an
entering angle smaller than 90 degrees.
Threading
D
Spindle speed – n (rpm)
The number of revolutions the milling tool makes per minute on the spindle. This is
a machine oriented value, which is calculated from the recommended cutting speed
value for an operation.
Milling
E
Feed per tooth – fz (mm/tooth)
A basic value for calculating cutting data, such as table
feed. It is also calculated with consideration of maximum chip
thickness (hex) and entering angle.
Drilling
Recommended (fz) starting values for most CoroMill cutters

are available on page D 192 and in the Main catalogue. For
the CoroMill Plura, the type of machined material is also taken
F into account.
Boring
vf
fz =
G n × zc
Feed per revolution – fn (mm/rev)

Auxiliary value indicating how far the tool moves during one complete rotation.
Tool holding/
Machines
It is used specifically for feed calculations and often to determine the finishing
capability of a cutter.
Feed per minute – vƒ (mm/min)

The table feed, machine feed or feed speed in mm/min It represents the movement
Materials
of the tool in relation to the workpiece, dependent on feed per tooth (fz) and number
of teeth in the cutter (zn).
I
Namnlöst-1 1
Information/
D 14
Index

General turning
Maximum chip thickness – hex (mm)
This value is a result of the cutter engagement as it is related to (fz), (ae) and (kr).
The chip thickness is an important consideration when deciding the feed per tooth,
to ensure that the most productive table feed is employed. See page D 20.
B

Average chip thickness – hm (mm)
A useful value in determining the specific cutting force, used for net power
calculations.
Metal removal rate – Q (cm³/min)
Threading
The volume of metal removed in cubic mm per minute. It is established using the
values for cutting depth, width and feed.
D
Specific cutting force – kct (N/mm²)
A factor used for power calculations. The specific cutting force relates to
the material resistance when cut at a specific chip thickness value. For more
Milling
information, see Materials, Chapter H.
E
Power Pc and efficiency ηmt ap × ae × vf × kc
Pc =
Machine tool oriented values, which assist in calculating the net power to ensure ηmt × 60 × 106
that the machine can handle the cutter and operation.
Drilling
For more formulas and
Machining time – Tc (min)
calculations, see Information/
Machining length (lm) divided by the table feed (vf). index, Chapter I.
F
Boring
Expressions used in the guide
The definitions used are the most common on the market. When multiple expressions exists to describe
the same function, the Sandvik Coromant nomenclature is used. G
High Speed Machining Waterline milling

Tool holding/
The designation HSM is not used in this guide. HSM refers to Milling on a constant z-level.
Machines
topics dealt with separately in different sections.

Point milling
Linear ramping A shallow radial cut with round insert or ball nose cutters in which
A simultaneous straight movement in axial and radial feed the cutting zone is moved away from the tool centre.
directions.
Scallop H
Circular milling A configuration with cusps that occurs when producing sculptured
A circular tool path on a constant z-level (circular interpolation). surfaces.
Circular ramping
A circular ramping tool path (helical interpolation).
Materials
I
Information/
D 15
Index

A
Definition - Productivity in milling

Productivity in milling, when defined as metal removal rate, Q cm³/min, can be
optimized in many different ways. Choosing the right tool for the application is
important, but the choice of cutting parameters is equally critical.
B The seven examples below show how cutting data can be increased above normal
recommendations and contribute to a higher productivity:
1 2 3 4 5 6 7
Peripheral
Face milling Profile milling Face milling Face milling Face milling Face milling
C Application
milling
Aluminium Small ae/Dc Finishing Small ent.angle Heavy duty Wiper Cast iron
vc High High High
n High High
fz High High High High
Threading
Cutting pa- z High

rameters
vf High High High High High High High
ap Small Small Small
D ae Small Small High
Q = vf x ap x ae/1000 (cm³/min), where vf = fz x n x zn (mm/min)
1. Face milling – High cutting speed, vc 4. Face milling with small entering angle and high feed, fz
Milling
In machining aluminium, and sometimes in machining cast Cutters with very small entering angles enabla a dramatic
iron with CBN or ceramic inserts, cutting speeds of more increase in the feed, fz, due to the chip thinning effect when
than 1000 m/min can be used, which results in a very high ap is small. For more information, see page D 20.
E table feed, vf. Also, this type of machining can be called
5. Heavy duty milling – large depth of cut – heavy duty
High Speed Machining (HSM).
In heavy duty applications, large insert cutters with large
2. Peripheral milling – High cutting speed, vc, and feed, fz diameters are used. Cutting speed is normal, but high ap
When the cutter has a small radial depth of cut, ae, the and fz, combined with a large ae, make it very productive.
time in cut per rev. is short, consequently the cutting edge For more information, see page D 62.
Drilling
temperature will be low. This means that the cutting speed

6. Finishing with wiper inserts
can be raised above normal recommendations. Also, the
In a finishing operation with a large face milling cutter, the
feed, fz, can be increased, because the maximum chip
F feed, fz, normally has to be kept low. However, by using
thickness, hex, will be low. The feed will be limited by the
wiper inserts in the cutter, the feed can be raised 2–3 times
surface finish requirement. For more information, see
without sacrificing the surface quality. For more information,
page D 50
see page D 64.
3. Profile milling – High spindle speed, n
7. Face milling – extra close pitch cutter
This milling technique is often called High Speed Machining
In milling short-chipping materials, like grey cast iron, a
Boring
(HSM) and is typical in finishing or super-finishing profiling

face milling cutter with an extra close pitch can be used,
operations with a ball nose end mill. For more information,
resulting in high table feed. Also, in HRSA material where
see page D 76.
G cutting speed is normally low, an extra close pitch results
in a high table feed.
Tool holding/
Machines
H
Materials
"Light and fast" technique: Methods 2, 3 and 4 are based upon small depth of cut, ae, and/or ap, which generate low cutting
forces and heat, making it possible to increase speed and/or feed.
I
Information/
D 16
Index

General guidelines
General turning
Pitch and the number of cutting edges
When choosing the most suitable number of effective cutting However, increasing the number of edges changes the design
edges, zc, for the operation, it is also essential to consider the of the tool. Shorter distances between tool edges mean that B
pitch (distance between the cutting edges). All CoroMill cutters there is less space left for chip evacuation and, in most cases,

are available in evenly pitched versions. the cutter must be evenly pitched.
Depending on size and the number of cutting edges, some Power requirement is often a factor that limits the possible
cutters are also available in a differentially pitched version number of cutting edges that are engaged in cut.
(unequal spacing of the teeth around the cutter).
Sandvik Coromant offers three pitches for cutters to optimize
Differentially pitched cutters are advantageous because they the particular application:
break up harmonic vibrations and therefore increase stability,
especially useful with a high ae and a long overhang.
Coarse –L C
Close –M
The pitch mainly affects: Extra close –H
• roductivity
P The closer pitched cutters, -M and -H, are used when stability
Threading
• Stability is good and for low ae applications. This ensures that more
• Power consumption than one tooth is always engaged in cut.
• Suitable workpiece material.
By increasing the number of cutting edges, the table feed can D
be increased, while retaining the same cutting speed and feed
per tooth, without generating any more heat at the cutting
edge.
Milling
E
Drilling
Coarse pitch –L Close pitch –M Extra close pitch –H F
Differentially pitched cutters with re- Evenly or differentially pitched cutters, Evenly pitched cutters with maximum
duced number of edges. depending on concept, with medium number of inserts.
• First choice for unstable operations number of edges. • First choice for high productivity with
due to lowest cutting forces • First choice for roughing in stable low ae (more than one edge in contact)
conditions
Boring
• Limited power • Roughing and finishing in ISO K ma-
• Extended tooling • Good productivity terials
• Full slotting operations • Good chip space for roughing in ISO P, • Roughing in ISO S materials in
• Long-chipping materials ISO N (large M and S materials. combination with round inserts. G
chip pocket).
Tool holding/
Machines
H
Materials
Note: An X added to the code, describes a

cutter version that has a slightly closer pitch
than its basic design.
I
Information/
D 17
Index

A
Entering angle
This is the angle between the main, leading cutting edge of the insert and the workpiece surface.
Chip thickness, cutting forces and tool life are all especially affected by the entering angle.
The most common entering angles are 90°, 45°, 10° and those eliminated by round inserts, such as
B cutters using ball nose inserts at smaller depths of cut.
•D ecreasing the entering angle, kr, on straight edges reduces chip thickness, hex, for a given feed rate, fz.
This chip thinning effect spreads the amount of material over a larger part of the cutting edge.
• Smaller entering angles provide a more gradual entry into the cut, reducing radial pressure and protecting
the cutting edge.
• Higher axial forces at decreasing entering angles will increase the pressure on the workpiece.
C
Threading
90° cutters
•M ain application area is square shoulder milling.
D • Generates mostly radial forces, in direction of the feed.
• The surface being machined will not be exposed to high axial pressure, which is
advantageous for milling workpieces with a weak structure or thin walls, and in cases
of unstable fixture.
Cutter assortment: CoroMill 290, CoroMill 390, CoroMill 490, CoroMill 590, CoroMill 690,
Milling
CoroMill 790, CoroMill Plura and Auto-FS – and for special purposes, the side and face
milling and grooving cutters: CoroMill 331, CoroMill 327/328 and the T-Max Q-cutter.
E
Drilling
45° cutters
Boring
• eneral choice for face milling.

G
• Generates well balanced radial and axial cutting forces.
G • Smooth entry into cut.
• Low tendency for vibrations when milling with long overhangs or smaller/weaker tool
holders and couplings.
Tool holding/
• Especially suitable for milling workpieces in short-chipping materials that easily fritter if
Machines
excessive radial forces act on the gradually reduced amount of material left at the end of a
cut.
• Formation of a thinner chip allows for high productivity in many applications, because of the
opportunity for higher table feed while maintaining a moderate cutting edge load.
H
Cutter assortment: CoroMill 245, CoroMill 345, T-Max 45 and Sandvik Auto programme.
Materials
I
Information/
D 18
Index

General turning
60° to 75° cutters
•S pecial purpose face mills offering larger depth of cut, compared to the general
choice face mills.
• Lower axial forces, compared to 45° face mills.
• Better edge strength, compared to 90° cutters.
B
Cutter assortment: CoroMill 360, CoroMill 365, Auto AF.

C
Threading
10° cutters
•H igh-feed and plunge milling cutters.
• The thin chip generated, allows for very high feeds per tooth, fz, at small depths of cut and, D
consequently, for extreme table feeds, vf.
• The dominating axial cutting force is directed towards the spindle and stabilizes it. This is
favorable for long and weak set-ups, as it limits vibration tendencies.
• For plunge milling of cavities, or whenever use of an extended cutter is required.
Milling
• Effective in hole making using three axes.
Cutter assortment: CoroMill 210, CoroMill 316 and CoroMill Plura high feed cutters.
E
Drilling
F
Round inserts or cutters with a large corner radius
Boring
• fficient roughing and general purpose cutters.
E
• Corner radius provides very strong cutting edge.
• High table feed rate capability due to thinner chips generated along the long cutting edge.
G
• The chip-thining effect makes these cutters suitable for machining titanium and heat resistant
alloys.
Tool holding/
• Depending on cutting depth variations, ap, the entering angle changes from zero up to 90°,
Machines
altering the cutting force direction along the edge radius, and consequently the resulting
pressure during the operation.
Cutter assortment: CoroMill 200, CoroMill 300 and – at smaller depths of cut – CoroMill 390
radius insert cutters; the ball nose cutters CoroMill 216 and CoroMill 216F. Also, the solid carbide H
end mills, CoroMill Plura and CoroMill 316, are available in ball nose versions with a large corner
radius.
Materials
I
Information/
D 19
Index

A
Maximum chip thickness

Maximum chip thickness is the most important parameter for achieving a productive
and reliable milling process.
Effective cutting will only take place when this is maintained at a value correctly
B matched to the milling cutter in use.
•A thin chip with a hex value that is too low, is the most common cause of poor
performance resulting in low productivity. This can negatively affect tool life and
chip formation.
• A value that is too high will overload the cutting edge, which can lead to breakage.
Chip thinning allows for increased feed

Threading
Feed per tooth can be increased in the three following situations due to the chip
thinning effect when:
D 1. Using straight edge cutters with entering angles lower than 90°.
2. Using round inserts or large radius inserts, at smaller depths of cut, ap.
3. Peripheral milling at a small radial engagement, ae/De.
Milling
E 1. Straight edge insert

For straight edge inserts, chip thickness, hex, is equal to fz when entering angle is 90
degrees. As entering angle, kr, decreases, fz can be increased.
Example:
If the maximum chip thickness, hex, is 0.1 and the entering angle, kr, is 45°, the
Drilling
feed recommendation, fz, is 1.4 x 0.1 = 0.14 mm/tooth.
Entering angle Modification factor fz (mm/tooth):

Boring
kr hex (mm)
min. start max.
G 0.1 0.15 0.2
90° 1.0 0.10 0.15 0.20
75° 1.0 0.10 0.16 0.21
65° 1.1 0.11 0.17 0.22
Tool holding/
45° 1.4 0.14 0.21 0.28

Machines
10° 5.8 0.58 0.86 1.15
H
k=90° kr 45° kr 10°
hex = fz x sin kr
Materials
I
Information/
D 20
Index

General turning
2. Round and radius insert cutters
est performance is achieved when the entering angle, kr, remains under 60°,
•B
<60°
when using round insert cutters or ball nose end mills at limited depths of cut.
This means that the depth of cut should not exceed 25% x insert diameter, iC. <25% iC
• F or larger depths of cut, it is better to use square inserts with a constant kr of B

45°.

• T he chip thickness, hex, varies with round inserts, and depends on the entering
(0.5 iC - ap)
angle. With low ap/iC ratios, the feed can be increased considerably in order to coskr =
0.5 iC
raise the chip thickness to a desired level.
•R
ound inserts have a higher maximum chip thickness capability than straight edge
solutions, due to the stronger insert shape and longer cutting length.
Threading
hex × iC
fz =
2 × √ ap × iC − ap²
D
Example: CoroMill 300 insert geometry E-PL
Max. chip thickness, hex (mm)

Feed per tooth, fz (mm)
Milling
ap (mm)
iC Min. Start Max. 0.5 1 1.5 2 2.5 3 3.5 4

8 0.1 0.15 0.2 0.31 0.23 0.19 0.17 E
10 0.1 0.2 0.25 0.46 0.33 0.28 0.25 0.23
12 0.1 0.2 0.25 0.50 0.36 0.30 0.27 0.25 0.23
16 0.1 0.2 0.25 0.57 0.41 0.34 0.30 0.28 0.26 0.24 0.23
Drilling
3. Peripheral milling
The hex value varies depending on the cutter diameter and working engagement, the F
radial immersion of a cutter, ae/Dc.
When this is smaller than 50%, maximum chip thickness is reduced relative to fz.
Feed can be increased by the modification value in the table below depending on the
ratio, ae/Dc.
Boring
Example:
Dc 20 mm – ae = 2 mm, ae/Dc = 10%
hex = 0.1 mm, fz = 0.17 mm/tooth. G
Tool holding/
Machines
Width of cut diameter ratio Modification factor fz (mm/tooth):

ae/Dc hex (mm)
H
min. start max.
0.1 0.15 0.2
Namnlöst-1 1 2009-08-31 09:29:34
50-100% 1.0 0.10 0.15 0.20
Materials
25% 1.16 0.12 0.17 0.23

20% 1.25 0.13 0.19 0.25
15% 1.4 0.14 0.21 0.28
10% 1.66 0.17 0.25 0.33
5% 2.3 0.23 0.34 0.46
I
Information/
D 21
Index

A
Chip formation through cutter position

The load on the cutting edge
Each time a milling edge enters a cut, it is subjected to a shock load. The right type of contact between edge
and material at the entry and also at the exit of a cut must be considered for successful milling.
B
Down-milling
In down-milling (climb milling), the cutting tool is fed with the direction of rotation.
•D own-milling is always preferred wherever the machine tool, fixture and workpiece will
allow.
• In peripheral down-milling, the chip thickness will decrease from the start of cut,
C gradually reaching zero at the end of cut. This prevents the edge from rubbing and
burnishing against the surface before engaging in the cut.
• The large chip thickness is advantageous, and the cutting forces tend to pull the
workpiece into the cutter, holding the cutting edge in the cut.
Threading
Exceptions, when up-milling is preferred:

• However, as the cutter tends to be pulled into the workpiece, the machine needs to
handle the table-feed play using back-lash elimination.
D • If the tool pulls into the workpiece, feed is unintentionally increased which can lead to
excessive chip thickness and edge breaking.
• Up-milling may be advantageous when large variations in working allowance occur.
Note: When using ceramic inserts in heat resistant alloys, up-milling is recommended,
because ceramics are sensitive to impact at workpiece entry.
Milling
Up-milling
Drilling
In up-milling (conventional milling), the feed direction of the cutting tool is opposite to its
rotation.
F
• T he chip thickness starts at zero and increases toward the end of the cut. Cutting
forces tend to push the cutter and workpiece away from each other.
• High tensile stresses, caused when the edge is leaving the workpiece, will often result
in rapid edge failure.
• The cutting edge has to be forced into the cut, creating a rubbing or burnishing effect
Boring
due to friction, high temperatures and, often times, contact with a work-hardened
surface caused by the preceding edge. All this reduces the tool life.
• Forces, mainly radial, will tend to lift the workpiece from the table.
G
• Thick chips at the exit from the cut will reduce tool life.
• The large thickness and higher temperature at the exit will sometimes cause chips to
stick or weld to the cutting edge, which will then carry them around to the start of the
Tool holding/
next cut, or cause momentary edge frittering.

Machines
Work piece fixturs

Feed direction of the tool places different demands on the workpiece fixture. During
up-milling, it should resist lifting forces. During down-milling, it should resist pulling
H forces.
Materials
I
Information/
D 22
Index
Namnlöst-1 1
Kopia av MTG09 Milling D22-D41.indd 22 2010-01-14 13:05:28

General turning
Chip formation through cutter position
The cutting edge in a radial direction engages with the workpiece in three different phases:
1. Entrance into cut
2. Arc of engagement in cut
3. Exit from cut B

C
Threading
ϕ = +30°
ϕ = –30° ϕ = 0°
Milling
1. Entrance into cut
• T he least sensitive of the three cutting zones, when using carbide inserts.
• Carbide handles the compressive stresses at the impact of entering well. E
Drilling
F
Boring
ϕ = 0°
ϕ = –30° Namnlöst-1 1 ϕ = +30° 2009-08-31 09:29:34
G
Tool holding/
Machines
2. Exit from cut

H
•E xiting from the workpiece is the most sensitive of the three cutting zones.
• A thick chip will often cause a drastic reduction in tool life when using carbide inserts. The chip lacks
support at the final point of cut and tries to bend, which generates a tensile force on the carbide that can
create a fracture on the edge.
Materials
I
Information/
D 23
Index

A
3. Arc of engagement in cut

• T he maximum possible arc of engagement is 180°
(ae = 100% Dc) when slotting.
• For finish milling, the arc can be very small.
• The grade requirements are quite different, depending on the
B percentage of radial immersion, ae/Dc.
• The larger the arc of engagement, the greater the heat trans-
ferred into the cutting edge.

• With a large arc of engagement, CVD coated grades provide
the best heat barrier.
• With a small arc of engagement, the chip thickness is nor-
mally smaller, and the sharper edge on PVD coated grades
generates less heat and reduced cutting forces. Large (max.) arc of engage- Small arc of engagement
C ment
• Short time in cut and less
• L ong time in cut heat => higher vc
• High radial forces • Thinner chip => higher fz
• More heat generated • Higher vc and fz can be
Threading
• CVD coated grades applied

• Sharp edges
• PVD coated grades
D
Milling
E
Drilling
F
Summary of cutter positions
•A void thick chip thickness on exit - always use down
milling.
Boring
• Do not position the cutter symetrically on the centre line.

• By moving the milling cutter off the centre (to the left) a
more constant and favorable direction of the cutting forces
G will be obtained, minimizing vibration tendencies.
• The cutter diameter, Dc, should be 20-50% larger than the
width of cut, ae.
Tool holding/
• Available spindle power must also be considered, because

Machines
it also influences the choice of pitch.
H
•C
utter Dc should be +20–50% •C
utter on centre line can
large than ae generate vibrations
•P
osition the cutter off-centre
(to the left) to achive a thicher
chip at entry.
Materials
I
Information/
D 24
Index

General turning
Entering the component
When the cutter is programmed to enter straight into the workpiece,
thick chips will be produced at the exit until the cutter is fully engaged.
This can dramatically reduce tool life, especially in harder steels, tita-
nium and heat resistant alloys.
B
Also, from a vibration point of view, it is essential to enter the

workpiece smoothly.
There are two ways to solve this problem:
1. Lower feed
Reduce feed to 50% until the cutter is fully engaged.
2. Roll into cut
Program a roll into cut in a clockwise motion (counter-clockwise will C
not solve the thick chip thickness problem). By rolling into cut, the chip Thick chip on exit of cut until cutter is fully
thickness on exit is always zero, allowing for higher feed and longer tool engaged.
life.
Threading
D
Milling
E
Keep cutter constantly engaged

Sharp changes of direction in a cut will cause the same
problem as occurs when entering straight into the workpiece.
Drilling
•R olling around all corners should always be applied as a key
step to provide a robust, optimized process.
• Width of cut, ae, should be 70% of Dc to ensure maximum F
coverage of the corner.
• Keep cutter constantly engaged.
In face milling, sharp changes of cutter direction generate thick chips
• Program around interruptions and holes when possible. on exit.
Boring
G
Tool holding/
Machines
In peripheral milling, roll around external corners.
H
Materials
Namnlöst-1 1
Keep cutter constantly engaged. Programme around holes and interruptions.

I
Information/
D 25
Index

A
Milling in corners
Considerations
The problem
Machining into corners requires careful considerations of the suitable arc of
cutter engagement, and also of the appropriate feed rate.
B •W hen feeding the cutter into internal corners, the radial arc of engagement
will increase and place extra demands on the cutting edge.
• Often, the process becomes unstable, creating vibration and an insecure ae 90% Dc
ae 20% Dc
process.
• Wobbling cutting forces often create undercutting of the corner.
• There is also a risk for frittering the tool edges, or total tool break down.
Corner radius = 50% x Dc
C Solution – limit the arc of engagement Taditional corner milling
Using a programmed radius (circular milling) to reduce the arc of engagement

and a radial cut will reduce the vibration tendencies, which will allow higher
Solution No 1
depths of cut and feed rates.
Threading
•M ill a bigger corner radius than stated in the drawing. This can sometimes
be favorable, as it allows the use of a bigger cutter diameter in roughing,
which maintains high productivity.
D • Alternately use a smaller Dc cutter to mill the desired corner radius.
ae 20% Dc
ae 55% Dc
Roughing
A programmed radius of 50% Dc is optimal.
Milling
Finishing
For finishing, it is not always possible to have such a large radius; however, the Mill a bigger component radius
cutter diameter should be no larger than 1.5 x component radius (e.g. corner
E radius 10 mm = max 15 mm).
Solution No 2
Drilling
ae 20% Dc
ae 40% Dc
F
Use a smaller cutter

Boring
G
Programming
Centre line or periphery feed
Tool holding/
Machines
A machine is designed for either centre line feed, vf, (without

radius compensation) or periphery feed, vfm (with radius
compensation).
H If the machine requires a centre line feed, and periphery

feed is programmed instead (on machines without radius
compensation), the fz value will become too high, with the
subsequent risk of insert breakdown.
Materials
I Centre line, vf, or periphery feed, vfm.

Information/
D 26
Index

General turning
Centre line feed programming
The NC codes generated will program the centre of the cutter
rather than the periphery.
For straight line cutting (G1), the feed at the wall of the
component, vfm, is the same as the programmed feed, vf, while
the periphery feed around a radius (G2) will be higher than
B

the tool centre feed. Therefore the table feed, vf, needs to be
reduced to maintain the feed per tooth, fz.
A reduction factor is found in the table, and is dependent on:
• Cutting diameter to component radius – Dc/radm Without centre line feed reduction, fz will increase in corners.
• Radial immersion – ae/Dc
Threading
D
With centre line feed reduction.

Centre line feed reduction
Milling
Reduction factor value for feed in corners (k)
ae/Dc E
Dc/radm 0.05 0.15 0.25 0.35 0.45 0.55 0.65 0.75 0.85 0.95
2.00 0.22 0.34 0.40 0.45 0.48 0.53 0.60 0.67 0.75 0.86
1.80 0.30 0.34 0.42 0.46 0.50 0.53 0.60 0.67 0.75 0.86
1.60 0.44 0.42 0.44 0.49 0.53 0.56 0.60 0.67 0.75 0.86
Drilling
1.40 0.55 0.54 0.54 0.52 0.56 0.59 0.62 0.67 0.75 0.86
vf reduced = k × vf
1.20 0.63 0.64 0.64 0.64 0.62 0.65 0.63 0.71 0.75 0.86
1.00 0.71 0.72 0.72 0.73 0.74 0.62 0.77 0.79 0.83 0.86
F
0.80 0.78 0.79 0.79 0.80 0.82 0.83 0.85 0.87 0.89 0.94
0.60 0.84 0.85 0.86 0.86 0.87 0.88 0.90 0.91 0.93 0.96
0.40 0.90 0.90 0.91 0.92 0.92 0.93 0.94 0.95 0.96 0.98
0.20 0.95 0.96 0.96 0.96 0.96 0.97 0.97 0.98 0.98 0.99
Boring
G
Feed reduction prior to corner
Reducing the feed before reaching the corner is especially essential when milling at
Tool holding/
high speeds.
Machines
As the cutter is still feeding straight towards the end of the G1 line, the arc of
engagement starts to increase. Therefore, the feed has to be reduced before the
corner is reached, i.e. within the ln range that is 50% x Dc.
H
A machine control with an advanced look ahead function will manage the changes in
feed rate automatically.
Materials
Reduce the feed at a distance: ln = 50% Dc

I
Information/
D 27
Index

A
Milling dry or with cutting fluid

The milling operation is an inherently intermittent process. This causes the
temperatures generated at the cutting edge to constantly fluctuate between
various levels of hot (~1000°C) and cold.
B The effect of cutting fluid
• T he temperature variations are exacerbated when the cutting edge goes into and
out of cut.
• The cutting edge is thus subjected to thermal shocks and cyclic stresses that can
result in cracking and, in the worst case, can lead to a premature end to the tools
effective life.
• The hotter the cutting zone is, the more unsuitable the use of cutting fluid
becomes. In finishing operations, the application of cutting fluid will not reduce
C the tool life as much as in roughing, due to the reduced level of heat generation.
Threading
Thermal cracks on the cutting edge
D
Dry milling extends the life of the cutting edge
• In dry milling, temperature variations do take place, but remain within the design
scope of the carbide grade.
• Rough milling operations should allways be run dry.
Milling
Exceptions, when cutting fluid can be justified

• F inishing of stainless steel and aluminium: •M
illing of thin walled components:
– to prevent smearing of metal particles into the surface – to prevent geometrical distortion.
Drilling
texture.
•M
icro-lubrication systems, i.e. compressed air with small
• Milling of heat resistant alloys at low cutting speeds: amount of special oil, can be applied to assist chip
F – to lubricate and to cool down the component. evacuation in deep cavities.
•M
illing in cast iron:
– to dampen and flush away dust for environmental, health
and component quality reasons.
Boring
Compressed air Oil mist Cutting fluid

Tool holding/
+++ ++ + (-)
Machines
In micro-lubrication systems the Copious flow through External flow

amount of “oil mist” is only
Materials
a few ml of oil per hour and is

If milling has to be performed wet, cutting fluid should be applied
evacuated via the normal, filtered
copiously.
ventilating system.
I
Information/
D 28
Index

General turning
Surface generation
Axially generated surface Corner radius (r) Parallel land (bs1)
The face milled surface is generated by the parallel facet, bs.

Depending on the axial tolerance and run-out of the cutter, the
insert with the lowest position will create the surface finish. B
To generate a good surface, it is important to ensure that the

feed per revolution (fn = fz x zn) is less than 80% of bs.
Extra close pitch cutters increase the feed per revolution, The
larger the diameter cutter, the greater the fn, requiring a larger
bs.
Radius (Rbo)
Parallel land (bs1)
As soon as the feed per rev. exceeds the width of this land, Wiper land (bs2)
the axial run-out of the cutter will affect the surface profile. C
For the best surface finish use:
• Wiper inserts or milling inserts with bs at least 25% larger
than fn
Threading
• Cermet inserts for mirror finish
• Cutting fluid to avoid smearing.
Round inserts, or inserts with a large corner radius, although
extremely productive, will not generate a high quality surface. D
The larger the cutter's diameter, the worse the surface finish.
For more information about finish milling using wiper inserts,
see Face milling, page D 64.
Milling
E
Drilling
Radially generated surface
When using an end mill, shoulder mill or a side and face mill
cutter, a radial surface is generated. For more information, see
Shoulder milling, edging, page D 51.
F
Boring
G
Sculptured surface generation

Tool holding/
Machines
When using a ball nose end mill, a sculptured surface

is generated. For more information, see Profile milling,
page D 78.
H
Materials
I
Information/
D 29
Index

A
How to reduce vibrations

Vibrations can arise due to limitations in the cutting tool, the
holding tool, the machine, the workpiece or the fixture.
Longer overhang
Decreased tool stability
The cutting tool
B • For face milling, the direction of the cutting forces must be
considered:
– With a kr 90° cutter, the dominant forces focus in the

radial direction. This creates deflection of the cutter at
long overhangs; however, the small axial force is ad-
vantageous when millng thin walled/vibration sensitive
components.
– Cutters with kr 45° generate evenly distributed axial and
C radial forces.
– Round insert cutters direct most of the forces up the
spindle, particularly at small depths of cut. Also, the
CoroMill 210 with kr 10° transmits the forces primarily
into the spindle, which reduces vibrations generated due
Threading
to long tool overhangs.

• Choose the smallest diameter possible for the operation
• Dc should be 20-50% larger than ae
D • Choose a coarse pitch and/or differential pitch cutter. Decreased workpiece stability
• A cutter with a low weight is advantageous e.g, CoroMill

Century with aluminium body.
At long tool overhangs, use a small entering angle=high axial cutting
force. With thin walled, unstable workpieces use a large entering angle
Milling
= small axial cutting force.
E
Drilling
The holding tool

The Coromant Capto® modular holding tool system enables tools to be
F assembled to the required length, while maintaining high stability and
smallest run-out.
•K eep the tooling assembly as rigid and short as possible.
• Choose the largest possible adaptor diameter/size.
• Use Coromant Capto adaptors with oversize cutters to avoid reduction
Boring
adaptors, see picture.

• For small milling cutters, use a tapered adaptor if possible.
G • In operations where the final pass is located deep in the component, Oversized cutters
allow the largest
Always use the shortest
possible tool length. Extend
change to extended tools at pre-determined positions, see picture.
possible coupling length succesively.
Adapt cutting data for each tool length. size.
• For spindle speeds over 20 000 rpm, use balanced cutting and holding
Tool holding/
tools.
Machines
Silent Tools dampened milling cutters

Materials
For overhangs greater than 4 times the tool diameter, vibration tendencies can
become more apparent, and Silent Tools damped cutters can dramatically improve
the productivity. For more information, see Tool holding, Chapter G.
I
Information/
D 30
Index

General turning
The cutting edge
To minimize the cutting force:
• Choose a light cutting geometry, -L, with a sharp edge, and a grade with a thin
coating.
• Reduce cutting forces by using inserts with small corner radii and small parallel
lands. B

Sometimes adding more damping to a system can decrease the vibration
tendencies:
• Use a more negative cutting edge geometry and a slightly worn cutting edge.
C
Cutting data and tool path programming
•A lways position the cutter off-centre in relation to the milled surface.
• With kr 90° long edge cutters or end mills use low radial immersion – max ae = 25% Dc and
Threading
high axial cut – max ap = 100% De.
• In face milling, use a small depth of cut, ap, and high feed, fz, with round inserts or high feed
cutters with small entering angles.
• Avoid vibrations in corners by programming a large path radius, see milling of corners, page D
D 26.
• If the chip thickness becomes too low, the cutting edge will rub rather than cut, causing
vibration. In such instances, the feed per tooth should be increased.
Milling
E
The machine tool

The machine condition can have a large influence on vibration tendencies. Excessive
wear on the spindle bearing or feed mechanism will result in poor machining
Drilling
properties.
• Choose machining strategies and cutting force directions to take full advantage of
the machine stability. F
Each machine spindle has natural areas which are prone to vibration. The areas of
stable cutting are described as stability lobes, and increase as the rpm increases.
• Even small increases as low as 50 rpm, can move a cutting process from
unstable, with vibration, to stable.
For weak fixturs, feed di-
Boring
rection into machine table
G
Tool holding/
Workpiece and its fixture

Machines
Pass 2 Pass 1
Milling components with thin wall/base and/or when the fixture is weak. Pass 3 Pass 4
• The fixture should be close to the machine table. Pass 6 Pass 5
• Optimize the tool path and feed direction towards the machine's/fixture’s Pass 7 Pass 8 H
strongest node to obtain the most stable cutting conditions.
• Avoid machining in directions where the workpiece is poorly supported.
• Up-milling can reduce vibration tendencies when fixture and/or workpiece are
finish allowance
weak in a specific direction.
Materials
Note that the first step should be made at

half the depth of the second, third, etc. For
more detailed information, see Shoulder
milling, page D 52.
I
Information/
D 31
Index

A Milling different materials – Steel milling
Steel milling
General turning
The machinability of steel differs, depending on alloying

B elements, heat treatment and manufacturing process (forged,
cast, etc.)
For more detailed information about materials and

classifications, see Materials, Chapter H.
Cutting data recommendations, see Main catalogue.
Main issues
• In soft, low carbon steels, built-up edge and burr formation
C on the workpiece are the main issues.
• In harder steels, the positioning of the cutter becomes more
important to avoid edge chipping.
Suitable cutters and inserts
Threading
• Most CoroMill cutters are well suited for steel machining

with a comprehensive assortment of insert grades and
geometries.
• Note, that CoroMill Century (with steel body) and CoroMill Cutting speed vc
D 790, originally developed for aluminium, also perform very m/min
well in finishing steel. 400
• The only tools not suitable for steel are the AUTO-cutters
dedicated for grey cast iron. 350
• PL, PM, PH and WL, WM, WH geometries
Milling
• The GC4200-series of MT-CVD coated grades are the 300

basic choice. However, for smaller diameter cutters, below GC4220
Dc 32mm, and for shoulder milling cutters, k=90°, grade 250 GC1030
E GC1030 is the first choice. GC4220
• In harder steels, use GC1030 and GC1010. 200 GC4230
GC4230
GC4220
GC4240
150 GC1030
GC4230
GC4240
Drilling
100 GC1030
50
F
0
60 – 240 241 – 330 > 330
Cutting speed and grade recommendations
related to material hardness.
Boring
G
Tool holding/
Machines
Application hints
All recommendations provided on the previous pages in Getting started are
H valid for steel milling.
Recommendations, such as positioning of the cutter to avoid a large chip
thickness on the exit, and to always run dry without cutting fluid, should always
be considered, especially in roughing operations.
Materials
I
Information/
D 32
Index

Milling different materials – Steel milling A
General turning
Grade guideline – face milling
Wear resistance/hardness
Dry conditions
Maximum productivity conditions.
Improved wear resistance.
PD performance.
High vc and fz. B

Dry and wet
conditions
First choice in average conditions
Dry and wet

Edge line C
security
conditions Insert bulk toughness
Low vc and fz.
Threading
Toughness
Edge line security with low cutting data. Predictable choice in difficult conditions. Larger Dc.
Smearing materials. Low carbon steels.
Adhesive wear. Built-up edge. Small Dc.
D
Wear resistance/
Grade guideline – end milling CoroMill® 490, CoroMill® 390, CoroMill® 316 hardness
Milling
Maximum productivity when crater wear and
PD-resistance are crucial wear mechanisms.
E
Productive choice, large engagements
and high cutting data.
Drilling
First choice in good to average
conditions.
F
First choice in good to dif-
ficult conditions.
Toughness
Boring
CoroMill® Plura
G
Finishing in hardened steels, e.g. D&M applications
Tool holding/
Machines
General end milling, finishing, semi-finishing and roughing in all ISO groups H
Materials
Roughing in difficult conditions, tough edge behaviour
Toughness I
Information/
D 33
Index

A Milling different materials – Stainless steel milling
Stainless steel milling

General turning
The machinability of stainless steels differs, depending on

B alloying elements, heat treatment and manufacturing process
(forged, cast, etc.)

classifications, see Materials, Chapter H. For cutting data
recommendations, see Main catalogue.
C
Ferritic/martensitic
Material Classification: P5.x
Threading
Ferritic and annealed martensitic stainless steels have a

machinability that is comparable to low alloyed steels, and
therefore, the recommendations for steel milling can be used.
D
Austenitic and duplex stainless

Milling
Material Classification: M1.x, M2.x and M3.x Edge chipping on the insert. Burr formation and bad surface
finish.
Main issues
E • The dominant wear criteria when milling austenitic and
duplex stainless steels are: chipping on the edges due to
thermal cracks, notch wear and built-up edge/smearing.
• On the component, burr formation and surface finish
problems are the main issues.
Drilling

• Most CoroMill cutters can be used in austenitic and duplex
F stainless steel simply by choosing a dedicated insert
geometry and grade.
Thermal cracks due to cutting fluid
• In face milling, CoroMill 245 and CoroMill 300 are more
suitable than CoroMill 345 and CoroMill 200, due to the
more positive cutter geometry.
Cutting speed vc
• Use cutters with round inserts or small entering angles to m/min
Boring
minimize notch wear. 300

• Use positive insert geometries (-ML, -WL).
G • GC2030 (PVD) is the first choice. 250
GC1030
• GC2040 (MT-CVD) is the complementary grade for tough
conditions and cast stainless steel, where abrasive wear 200 GC2030
dominates. GC1030
Tool holding/
• GC1030 (PVD) is the universal choice for mixed production 150 GC2040
GC2030
Machines
(ISO P, M and S)
• If thermal cracks appear, change to a harder/more wear 100 GC2040
resistant grade, i.e. from GC2040 to GC2030.
H • For CoroMill Plura, grade GC1630 is the basic choice and 50
GC1640 is a complementary choice at an increased demand
for toughness and an internal cutting fluid supply is needed. 0
Austenitic Duplex
Materials
I
Information/
D 34
Index

Milling different materials – Stainless steel milling A
General turning
Application hints
Roughing
• Use high cutting speeds (vc = 150-250 m/min) to avoid built-up edge.
• In roughing, always run dry, without cutting fluid, to minimize problems with
thermal cracks. B

Finishing
• In finishing, cutting fluid, or preferably mist coolant/minimal lubrication, is
sometimes necessary to improve the surface finish. There are fewer problems
with thermal cracks in finish milling, because the heat generated in the cutting
zone is lower.
• With a cermet grade, CT530, sufficient surface finish can be obtained without
cutting fluid. C
• A feed, fz, that is too low can cause higher insert wear because the edge is
cutting in the deformation hardened zone.
Threading
D
CoroMill® indexable insert cutters
Milling
Drilling
First choice
Tough choice
Boring
Toughness
CoroMill® Plura G
Tool holding/
For finishing
Machines
H
First choice
Materials
Tough choice
Toughness I
Information/
D 35
Index
A Milling different materials – Cast iron milling
Cast iron milling

General turning
Cast iron can be divided into malleable, grey, nodular, compact

B graphite iron (CGI), and austempered ductile iron (ADI).

classifications, see Materials, Chapter H. For cutting data
recommendations, see Main catalogue.
Grey cast iron

C Material Classification: K2.x
Main issues
• The dominant wear criteria when milling grey cast iron are
abrasive flank wear and thermal cracks.
Threading
• On the component, frittering at the cutter exit side of the

workpiece, and surface finish problems are the main issues.
D There are several cutter concepts that have been developed
primarily for milling grey cast iron:
• oroMill 365 allround cutter.
C
• AUTO R roughing cutter.
• AUTO-AF adjustable finishing cutter.
Milling
• AUTO-FS non-adjustable finishing cutter. CoroMill 245 Typical insert wear Frittering on the component
cassettes are available for AUTO-AF cutter bodies as an
E alternative.
• Wiper inserts, see page D 64, are available for all of the
above cutter concepts.
• Most other CoroMill cutters can also be used in grey cast
iron simply by choosing a dedicated insert geometry and
grade.
Drilling
• CoroMill 345 is a good choice for mixed production of steel

and cast iron.
F • Use K-geometries -KL, -KM, -KH and -KW (wiper).
• Grade recommendations for indexable insert cutters, see
Application hints below.
• For CoroMill Plura solid carbide endmills, grade GC1620, and
for CoroMill 316 grade GC1030 are the basic choices.
Boring
G
Tool holding/
Machines
Application hints
Roughing
H • Preferably run dry, without cutting fluid, to minimize problems with thermal cracks. Use carbide inserts with thick
coatings. GC3040 is the first choice and GC3220 an optimizer for higher speeds.
• If workpiece frittering is a problem

Materials
– check flank wear

– lower the feed, fz, in order to reduce chip thickness.
– use a more positive geometry, -KL
I ➤
Information/
D 36
Index

Milling different materials – Cast iron milling A
General turning
➤
• If cutting fluid must be used to avoid dust, etc. choose the wet milling grades. K20W is the basic choice and K15W and
GC3040 are complementary grades.
•C
oated carbide is always the first choice, but ceramics (CC6190) can also be used. Note that the cutting speed, vc, should B
be very high, above 800 m/min. Burr formation on the workpiece limits the cutting speed. No cutting fluid should be used.

Finishing
• Use carbide inserts with thin coatings, or, alternately, an uncoated carbide, e.g. GC3220 in dry and K15 W in wet
conditions.
• Cubic boron nitride (CB50) can be used for finishing at high speeds in grey cast iron. No cutting fluid should be used.
C
Nodular cast iron
Threading
Material Classification: K3.x
Ferritic and ferritic/perlitic nodular cast iron
The machinability of ferritic nodular cast iron is very similar to that of low alloyed steel. Therefore, the milling recommendations
provided for ISO P materials should be used regarding selection of tools, insert geometries and grades. The first choice grade is D
GC1020.
Perlitic nodular cast iron
Is more abrasive, therefore ISO K grades are recommended.
Milling
Compact graphite iron (CGI) Cutting speed vc
m/min E
900
GC6190
Perlitic content less than 90%
CB50
This type of CGI, which often has a perlitic structure of around 80%, is the most 600
common being milled. Typical components are engine blocks, cylinder heads and
Drilling
exhaust manifolds.
250
Cutter recommendations are the same as for grey cast iron; however, sharper, GC3220
more positive insert geometries should be selected, for example –KX and –KL 200 K20W GC1020 F
for AUTO-R cutters, to minimize burr formation on the component. GC1020
GC3040 K20D
150 K20W
The first choice grade is GC1020. K20W
GC3040
GC1020 is the basic choice for both dry and wet conditions. An alternative for 100 GC1020
dry conditions is K20D, and for wet conditions K20W.
Boring
0
Cirular milling can be a very good alternative method to conventional cylinder GCI NCI CGI ADI
boring in CGI.
G
Tool holding/
Machines
Austempered ductile iron (ADI)

Roughing is normally carried out in the non-hardened condition and can be compared with milling of a high alloyed steel. H
The finishing operation, however, is performed in the hardened material, which is very abrasive. This can be compared with milling
of hard steels, ISO H. Grades with high resistance against abrasive wear are prefered. GC1020 is the first choice for both dry
and wet conditions, the complementary grade for harder ADI-materials is GC1010.
Materials
In comparison with NCI, the tool life in ADI is reduced to approx. 40%, and the cutting forces are approx. 40% higher.
I
Information/
D 37
Index

A Milling different materials – Aluminium milling
Aluminium milling
General turning
The machinability of aluminium differs primarily depending on

B the Si-content. Hypo-euthectic is the most common type, with
a Si-content below 13%.
The ISO N material group includes not only aluminium, but also
magnesium, copper and zinc based alloys. For more detailed
information about materials and classifications, see Materials,
Chapter H. For cutting data recommendations, see Main
catalogue.
C
Threading
Aluminium with Si-content below 13%

CoroMill 790 dedicated for aluminium.
Material Classification: N1.1-3
D Main issues
• The dominant wear criteria are built-up edge/smearing on
the edges, leading to burr formation and surface finish
problems.
• In cast aluminium sand inclusion can sometimes be a
problem.
Milling
• Good chip formation and evacuation are crucial for avoiding

scratch marks on the component surface.
E Suitable cutter concepts CoroMill Century for face milling of alumini- PCD-tipped insert,
um. CoroMill Century
Cutters developed primarily for milling of aluminium are:
• CoroMill Century
• CoroMill 790
• CoroMill Plura R216.32, R216.33 and R216.42
Drilling
Most other CoroMill cutters can be used in aluminium simply

by choosing a dedicated insert geometry and grade.
F Choose positive insert geometries with sharp edges

• Use uncoated carbide grades (H13A, H10) when Si-content
is below approx. 8%
• When the Si-content is above approx. 8%, PCD-inserts
(CD10) normally provide better machining cost efficiencies.
Boring
G Application hints Cutting speed vc m/min

•U nlike most other milling applications, cutting fluid should always be used in aluminium to
4000
avoid smearing on the insert edges and to improve surface finish.
• A higher cutting speed generally improves the performance and does not negatively effect tool
Tool holding/
3000 CD10
life.
Machines
• A hex value of 0.10-0.20 mm is recommended. Values that are too low can lead to burr
2000
formation. H10
Warning: Make sure that the maximum rpm for the cutter is not exceeded! 1000
H13A
H • Due to the high table feeds, a machine with ”look-ahead” function should be used to avoid
dimensional errors. 0
• Tool life is always limited by the burr formation or surface finish on the component. Wear on SiC < 8% SiC > 8%
the insert is difficult to use as a tool life criteria.
Materials
I
Information/
D 38
Index

Milling different materials – HRSA and titanium milling A
HRSA and titanium milling
General turning
S
Heat resistant super alloys (HRSA) fall into three material

groups; nickel-based, iron-based and cobalt-based alloys.
B
Titanium can be pure or alloyed. The machinability of both

HRSA and titanium is poor, especially in the aged condition,
which imposes particular demands on the cutting tools. For
more detailed information, see Materials, Chapter H, and
application guide ”Heat resistant super alloys”, order No.
C-2920:24, or ”Titanium machining”, order No. C-2920:22.
Threading
General recommendations
valid both for HRSA and titanium alloys D
Main issues
• Milling HRSA and titanium often requires machines with high
rigidity, and high power and torque at low rpm.
• Notch wear and edge chipping are the most common wear
Milling
types. Use round insert cutters to minimize notch wear
• High heat generation limits the cutting speed.
Suitable cutter concepts and inserts E
• Use round insert cutters (CoroMill 300, CoroMill 200)
whenever possible to increase the chip thinning effect.
• The CoroMill 690 long edge cutter is optimized for titanium
machining. For cutting depths below 5 mm, the entering
angle should be less than 45°. In practice, a round,
Drilling
positive-rake insert is recommended.
• Cutter accuracy in both radial and axial directions is
essential to maintain a constant tooth load and a smooth F
operation, and to prevent premature failure of individual
cutter teeth.
• The cutting edge geometry should always be positive with an
optimized edge-rounding, to prevent chip adherence at the
Stay in cut ae 30% of Dc
point where the edge exits the cut.
Boring
• The number of cutting teeth actually in cut during the milling
cycle should be as high as possible. This will provide good
productivity if there is stability. Use extra close pitch cutters. G
vc
ae
Tool holding/
fz
Machines
ap
z
H
= Tool life
= Reduction in tool life as cutting parameter is increased

Materials
Changes have varying impacts on tool life; the cutting speed, vc, has
the greatest impact, followed by ae, etc.
I
Information/
D 39
Index
Namnlöst-1 1 2009-08-31 09:29:34

A
General turning Milling different materials – HRSA and titanium milling
Cutting fluid
Unlike milling in most other materials, coolant is always recommended to assist in
chip removal, to control heat at the cutting edge, and to prevent the re-cutting of
chips. High pressure coolant (70 bars) applied through the spindle/tools is always to CoroMill 690
be preferred instead of an external supply and low pressure.
B Exception: Cutting fluid should not be applied when milling with ceramic inserts due
to the thermal shock.
Cutting fluid supplied through the cutter is

advantageous when using carbide inserts
C Insert/tool wear
The two most common causes of tool failure and poor surface finishing are:
• Excessive flank wear and edge line frittering.
• Notch wear.
Threading
• The best practice is to index the cutting edges at frequent intervals, to ensure a
reliable process. Typical insert wear
• Flank wear around the cutting edge should not exceed 0.2 mm for a cutter with
D a 90 degree entering angle, like the CoroMill 490, or a maximum of 0.3 mm for
round inserts. Cutting speed vc
m/min
100
Grade and geometry recommendations
• C2040 for roughing and difficult conditions
G 50 GC1030
Milling
• GC1030 for semi-roughing and finishing GC2040 GC1030

GC2040
• Use positive geometries, like -ML and -PL 0
ISO S ISO S
E • GC1620 is the basic choice for CoroMill Plura solid carbide end mills Titanium HRSA
Drilling
F
Ceramic inserts cutter for roughing HRSA
•C eramic milling typically runs at 20 to 30 times the speed of carbide, although at
lower feed rates (~0.1 mm/tooth), which results in high productivity gains. Due
to intermittent cutting, it is a much cooler operation than turning. For this reason,
Boring
speeds of 700-1000 m/min when milling are adapted, compared with 200–300
m/min for turning.
• Ceramics have a high tendency for notching, which is why round inserts are prima-
G rily used to ensure a low entering angle.
• Never use coolant.
• Ceramics have a negative effect on the surface integrity and topography, and are
Tool holding/
therefore not used when machining close to the finished component shape. Ceramic insert cutter for HRSA.
Machines
• The primary application for grade CC6060 (sialon) is milling Inconel 718 engine
Note:
castings and oil drilling equipment, in both cases due to the high metal removal
rates. •C
eramic inserts are NOT recommended in
titanium
• Maximum flank wear when using ceramic inserts in HRSA is 0.6 mm.
H • Cutter assortment – please contact your local Sandvik Coromant representative for •C
utting fluid should NOT be used with
ceramic inserts.
ordering.
Materials
I
Information/
D 40
Index

Milling different materials – milling hard steel A
Milling hard steel
General turning
H
This group contains hardened and tempered steels with

hardness >45 – 65 HRC. For more detailed information
B
about materials and classifications, see Materials, Chapter H.

For cutting data recommendations, see Main catalogue.
Typical components being milled are:
• T ool steel inserts for stamping dies
• Plastic moulds
• Forging dies
• Die casting dies C
• Fuel supply pumps
Main issues
• Abrasive flank wear on the insert.
Threading
• Workpiece frittering.
Suitable cutter concepts
Milling
•M ost CoroMill cutters can be used in hardened steel simply
by choosing a dedicated insert geometry and grade.
• Use positive insert geometries with sharp edges. This will E
reduce the cutting forces and produce a softer cutting
action. Stamping dies
• Grade GC1010 is optimized for hard steels.
• GC1030 is a complementary choice for unstable conditions,
Gear housing
Drilling
i.e. roughing in welded-on materials.
• For finishing with CoroMill Plura, choose grade GC1610.
The CBN grade, CB50, can be used in finishing operations.
F
Grade GC1010 is optimized for hard
Boring
steels
G
Application hints
•R un dry, avoid cutting fluid.
Tool holding/
• Trochoidal milling (see page D 121) is a suitable method, which

Machines
enables high table feeds in combination with low cutting forces,

generating low cutting edge and workpiece temperatures which
are beneficial for productivity, tool life and component
tolerances.
• The machining strategy to run "light but fast" should also be
H
applied in face milling, i.e. small depths of cut, both ae and
ap. Use an extra close pitch cutter and relatively high cutting
speeds.
Materials
Trochoidal milling
I
Information/
D 41
Index

A Shoulder milling – application overview
Shoulder milling
General turning
Application overview
B
Shoulder/face milling
Choice of tools D 44
C
How to apply D 46
Threading
D
Milling
E
Drilling
F
Boring
Edging
G
Tool holding/
How to apply D 50
Machines
H
Materials
I
Information/
D 42
Index

Shoulder milling – application overview A
General turning
Shoulder milling
B
How to apply D48

C
Threading
D
Milling
E
Drilling
F
Deep located
Boring
G
Tool holding/
Machines
H
Materials
Milling
I
Information/
D 43
Index

A Shoulder face milling – choice of tools
Shoulder face milling

General turning
Shoulder milling generates two faces simultaneously, which

B requires peripheral milling in combination with face milling.
Achieving a true, ninety degree shoulder, is one of the most

important requirements.
Shoulder milling can be performed by traditional square
shoulder cutters, and also by using end milling cutters, long
edge cutters and side and face milling cutters. Due to these
numerous options, it is essential to consider the operational
C requirements carefully to make an optimal choice.
Threading
Choice of tools
Milling
Shoulder face milling

CoroMill® 490 CoroMill® 390 CoroMill® 290 CoroMill® Century CoroMill® 331
E
Drilling
Cutter dia. (Dc), mm 20 – 80 40 – 200 40 – 250 40 – 200 80 – 315
F Max. cutting depth (ap), mm 5.5 15.7 10.7 10 10.6
True 90° shoulder +++ ++ + + ++
Material
P M K P M K P K P M K
Boring
N S H N S H N N S H
G Shoulder milling cutters

Shoulder face mills of conventional designs are often capable ·C
oroMill Century is the first choice cutter for high speed
of milling “true”, 90 degree shallow shoulders. finishing of aluminium, but is also suitable for milling other
materials.
Tool holding/
· F irst choice cutter is the accurate and light cutting

Machines
CoroMill 490. This cutter provides the precision for milling ·M

any shoulder face mills are universal cutters, and can be
deeper shoulders by using repeated passes with very used advantageously for making holes. They offer a good
limited cusps. alternative to face milling cutters when milling axially
deflecting surfaces or for milling close to vertical faces.
H ·C
oroMill 390 cutter product range offers a wide range of
inserts, in particular a complete series of inserts with corner · T he side and face milling cutter, CoroMill 331, is a slot milling
radii, which contribute to its success as a general purpose cutter than can also be used advantageously for milling wide,
cutter. It is also the first choice cutter for shallow, heavy duty shallow shoulders. It can also be employed for some special
shoulder milling. purpose milling operations, such as back-face milling.
Materials
I
Information/
D 44
Index

Shoulder face milling – choice of tools A
General turning
Shoulder milling – end milling cutters
CoroMill® Plura CoroMill® 316 CoroMill® 490 CoroMill® 390 CoroMill® 390 CoroMill® 790
Dampened

Cutter dia. (Dc), mm 10 – 20 10 – 25 20 – 80 12 – 40 20 – 40 25 – 100
Max. cutting depth (ap), mm 38 11 5.5 15.7 10 12 / 18

C
True 90° shoulder +++ +++ +++ ++ ++ ++
Material
P M K P M K P M K P M K P M K
N S H N S N S H N S H N S H N
Threading
End milling cutters
The indexable insert and solid carbide end mills offer good
solutions for shoulders requiring accessibility.
·C
oroMill 790 is the first choice cutter for milling non-ferrous
materials.
D
· F irst choice for universal milling is the CoroMill 390. ·C
oroMill Plura solid carbide end mills are available in a huge
A vibration dampening version allows for effective machining number of versions for most milling conditions.
of deep located surfaces.
Milling
E
Shoulder milling – long edge cutters
CoroMill® 390 CoroMill® 690 Coromant Finishing

Long edge cutter Long edge cutter Long edge cutter
Drilling
F
Cutter dia. (Dc), mm 32 – 200 50 – 100 50 – 80
Boring
Max. cutting depth (ap), mm 85 112 150
True 90° shoulder +++

G
P M K P M K
Material
N S H S N S H
Tool holding/
Machines
Long edge milling cutters

Long edge cutters are generally used for milling deeper ·A
mong cutters of this type, the light cutting Sandvik Coromant
shoulders. finishing long edge cutter produces a superior surface finish. H
· F irst choice for general roughing is CoroMill 390; under
stable conditions, it is capable of heavy metal removal.
Note: All the above cutters can perform edging operations and
· CoroMill 690 is the first choice cutter for milling of titanium. milling of ledge type shoulders.
Materials
I
Information/
D 45
Index

A Shoulder face milling – how to apply
How to apply
General turning
Application checklist and hints

B
•D
own-milling is always the first choice, and is especially important for shoulder
milling due to the 90° entering angle.

•M
achining should be performed in a manner that directs the cutting forces
towards the support points of the fixture insofar as this is possible. Up-milling
can, therefore, be a favorable alternative in some cases.
•S
election of cutter pitch is dependant on the stability of the entire system,
C including: the machine tool, workpiece and its clamping, as well as the
workpiece material.
• In ISO 40 machines and smaller, coarse-pitch cutters are recommended, due to
limited stability.
Threading
•C
oarse-pitch cutters are also recommended for machining components mounted
high up on a cube fixture. For more information about workpiece rigidity and
mounting stability, see Getting started, page D 31.
D • T he positioning of the cutter on the workpiece is extremely important and should

receive extra attention.
•W
hen Dc/ae >10, the feed, fz, should be adjusted in accordance with the hex
value to achieve a good result and avoid edge breakdown.
• If the shoulder depth is smaller than 75% of the cutting edge length, the quality
Milling
of the vertical surface does not normally require extra finishing.

• Choose a tougher carbide insert grade than for face milling.
E • If CoroMill long edge cutters are used, the conditions are demanding, therefore,
an even tougher grade may be required.
• T he deeper the cut, the more important it is to choose a lower cutting speed in
order to avoid vibrations.
Drilling
•W
hen vibrations occur, decrease vc and increase fz, check against the recom-
mended hex value!
•E
nsure that enough machine power is available for the chosen cutting data.
F See chapter I, for information about how to calculate this.
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 46
Index

Shoulder face milling – how to apply A
General turning
Tool holding
•P
ay special attention to power requirements when taking large cuts, particularly B
with long edge cutters.

• T ool mounting has the greatest influence on the milling result for cutters smaller
than 50 mm.
• T he larger the cutting depth, the more important the size and stability of the
coupling become: since the radial forces are considerable when using shoulder
face mills, particularly long edge milling cutters.
•C
oromant Capto couplings provide optimum stability and the smallest deflection C
for all types of cutters – particularly important with long or extended tooling.
• F or more information about extended and vibration dampened adaptors,
Silent Tools, see Getting started, page D 30 and Profile milling, page D 71.
Threading
D
Milling
Rolling into cut
•S
mooth entrances into the cut are essential for avoiding vibrations and
E
extending tool life, particularly when milling shoulders.
•P
rogram the cutter to roll into cut; always generate a chip thickness on exit
that is zero: together this will ensure both, higher feed and longer tool life.
Drilling
• T his method is most suitable for applications in which you are milling around
external corners, as it avoids sharp changes in the cut. For more information
about rolling into cut, see Getting started, page D 25.
• Keep the cutter engaged in a continuous cut.
F
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 47
Index

A Shoulder face milling– how to apply
How to apply
General turning
Milling of shallow shoulders

This frequently used operation is generally performed by shoulder face mills and end
B mills. A shallow cut allows for a larger radial cut.
Often these cutters can replace face mills, in particular when the axial pressure on
the component is a limitation, and when there is a demand for accessibility close to
vertical faces or fixture sections.
•O
versized shoulder cutter options provide for optimal accessibility when milling
shallow shoulders located deep.
•A
n extra robust version of the CoroMill 390 shoulder cutter is, under stable condi-
C tion, capable of heavy removal rates. It also functions reliably under demanding
conditions, like milling through interruptions.
Threading
D
Milling of deep shoulders
Use repeated passes with shoulder face mills and end mills
To minimize surface errors, such as scallops and transition-edges between the
Milling
passes, a high precision cutter that is able to produce true 90º shoulders is an
absolute requirement.
E If shoulder depth is smaller than 75% of the cutting edge length, the quality of
the vertical surface does not normally require extra finishing.
Drilling
Use a single pass with a long edge milling cutter

F The long edge cutter is a good solution for deeper, larger and
usually heavier shoulder milling applications:
• High metal removal capacity.
• Generally used for rough milling, as the resulting surface
texture is characterized by side milling at high feed rates.
Boring
These cutters make demands on:

G • Stability
• Spindle condition
• Chip evacuation
• Tool holding
Tool holding/
• Power.
Machines
Radial forces are considerable making this a tough side milling Shorter long edge cutters are suitable for:
application. • Radially large but shallow shoulders.
• Full slotting at a depth equal to the diameter, which can
H make up for machine limitations.
Longer versions are intended for:
• Milling of shoulders with moderate radial depth.
• Edging in powerful, stable machines.
Materials
I
Information/
D 48
Index

Shoulder face milling – how to apply A
General turning
Milling of shoulders located deep
•O
versized shoulder cutter options provide for optimal accessibility in milling shallow shoulders
located deep. For those shoulders that are located at even larger depths, use extensions with the
Coromant Capto coupling. B
• L ong edge cutters are also available in oversized versions to be used for deeper shoulders located

deep. However, the radial depths of cut are more limited.
Threading
D
Milling
E
Milling of shoulders using side and face milling cutters
Side and face milling cutters are also used for milling shoulders, particularly if the configuration is narrow
yet radially wide.
Drilling
These cutters are often the only possible solution for back-facing of hidden shoulders and faces.
Right Left
Boring
R331.52 L331.52
G
R331.52 L331.52
Tool holding/
Machines
R331.52 L331.52 H
L331.52 R331.52
Materials
The right choice of a CoroMill 331 cutter for facing and back-facing in right and left-hand spindles.
I
Information/
D 49
Index

A Edging – choice of tools
Edging - peripheral milling

General turning
Machining an edge is really a side milling operation applied in

B contouring tool passes. Side milling and edging are options of
peripheral milling.
Choice of tools
• T hin edges are generally produced by end milling cutters,
while deeper or thicker edges are generated by end mills
C using repeated “shoulder milling” passes, or by long edge
cutters in a single pass.
•S
houlders with depths of twice the diameter are effectively
machined using long edge milling cutters or CoroMill Plura
Threading
solid carbide cutters. For such deep shoulders, or thick

component edges, a radial depth of cut of 0.5 times the
diameter is recommended.
D •S
ide and face milling cutters can also be used for edging or
peripheral milling.
•A
large helix ensures a sufficient number of teeth in cut and
a smooth cutting action for edging at small radial cutting
depths.
Milling
•A
close pitch or extra close pitch type of cutter is especially
suitable for edging. This is also true when milling thinner
edges or shallow ledge type shoulders using 90º end mills.
E
Drilling
F
Boring
How to apply
G
• A critical factor in peripheral milling is achieving a suitable feed per tooth, fz.
Tool holding/
• The feed value, fz, has to compensate for the cutter engagement, which influ-
Machines
ences the chip thickness, see Getting started, page D 20.

• Feed per tooth, fz, should be multiplied by the modification factor.
H • T his will give a higher feed rate with a smaller arc of engagement, and at the
same time ensure that the chip thickness is large enough.
•H
owever, the modification factor may not always be fully applicable: surface
texture and climbing tendencies may limit the feed rate.
Materials
I
Information/
D 50
Index

Edging – how to apply A
General turning
Surface texture – radially generated
As mentioned, surface texture and climbing tendencies may

fz2
limit the feed rate, especially when the radial depth of cut is h=
4×D
small. B
When using the side of an end mill to mill a profile, a series

of ‘cusps’ are generated. The height of the cusp, - h, is
determined by:
• Cutter diameter, Dc
• Feed per tooth, fz
• Tool indicator reading of the run-out, TIR.
C
Indexable insert cutters will always have a higher TIR than
solid carbide cutters. Also, the larger the cutter diameter,
When there is no run-out in the cutter, the height of the cusp, h, will be
the greater the number of teeth, which increases the equally high and can be calculated using the formula:
distance between the high and low spots of the cusp.
Threading
For best surface finish:
• Use a solid carbide CoroMill Plura or CoroMill 316.
• Use a high precision power chuck (CororGrip or HydroGrip)
D
with Coromant Capto coupling.
• Use the shortest possible overhang.
Feed recommendation (disregard hex):
Milling
• Indexable insert cutters, start value fz = 0.15 mm/tooth
• Solid carbide cutters, start value fz = 0.10 mm/tooth
E
Note: The worst surface quality is achieved if only one cutting
edge generates the surface, due to bad run-out of the cutter.
Drilling
When there is a run-out in the cutter, the feed per tooth, fz, and conse-
quently the height of the cusp, h, will vary depending on the TIR.
F
Boring
G
Profile depth/cusp height
Rt = h
Tool holding/
Machines
fz2
Rt =
4×D
H
For more information about cutter size, engagement and
position relative to the workpiece, chip formation and
rolling into cut, see Getting started, page D 22.
Materials
For information about axial edging using face milling fz fz run-out

cutters, see Face milling, page D 59.
I
Surface with and without run-out.
Information/
D 51
Index

A Shoulder milling – how to apply
Shoulder milling of thin and deflecting walls

General turning
•M
achining strategies for thin wall sections will vary,
B depending on height and thickness of the wall.
• T he number of passes will be determined in all cases by

the wall dimensions and the axial depth of cut.
• Consider stability of both the cutter and the wall.
•U
se of high speed techniques, i.e. small ap/ae and high vc,
facilitates milling of thin walls, as they reduce the time of
tool engagement and consequently, the impulse and the
C deflection.
• Down-milling should be applied.
• Equal methods are used for milling aluminium and titanium.
Threading
Small height to thickness ratio <15:1:

Milling
"Thinwalls"
E • Machine one side of the wall in non-overlapping passes.
• Repeat on the opposite side.
• Leave an allowance on both sides for subsequent finishing.
Drilling
Moderate height to thickness ratio <30:1

"Waterline" milling:
F •A
lternate sides, machining to given depths, in non-
overlapping passes.
Alternately
Boring
Step support milling:

•A
similar approach, but overlap between passes on opposite
G sides of the wall: this provides more support at the point
being machined. The first pass should be at a reduced depth
of cut, ap/2.
Tool holding/
• In either case, leave an allowance on both sides for subse-

Machines
quent finishing of 0.2 – 1.0 mm.
The passes should be made in a zig zag path.

Materials
I
Information/
D 52
Index

Shoulder milling – how to apply A
General turning
Very large height to thickness ratio >30:1
In addition to alternating sides of the wall while machining,

approach the desired wall thickness in stages, using a
"christmas tree" routine. B
• T he thinner section is always supported by thicker sections

below them as they are machined. Pass 2 Pass 1
• Move down the wall in this stepwise manner.
Pass 3 Pass 4
Pass 6 Pass 5
>30:1
Threading
Thin walls Waterline Step support
D
Pass 2 Pass 1 Pass 1
Pass 3
Pass 5 Pass 2
Pass 6 Pass 5
Milling
Pass 5 Pass 6
Pass 6 Pass 3
Pass 8
<15:1 Pass 9 E
<30:1
Finishing allowance
Finishing allowance
Finishing allowance
Drilling
Shoulder milling of thin walled base F
Machining thin bases:
• Use circular ramping at the centre of the base area to required depth.
• Mill outwards in a circular ramping path from that point.
Boring
If this involves milling a surface whose opposite side has already been machined:
• Use a tool with a minimum number of cutting edges. G
• Apply as little contact pressure to this side as possible.
Tool holding/
Machines
If the component has a hole at the centre of the base:

• Leave a support leg in place when machining the first side.
• Machine the second side.
H
• Remove the support leg after both sides have been completed.
Materials
I
Information/
D 53
Index

A Face milling – application overview
Face milling
General turning
B
General face milling

C
How to apply D 58
Threading
D
Milling
E
Drilling
Heavy duty milling

F Choice of tools D 62
How to apply D 63
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 54
Index

Face milling – application overview A
General turning
B

High feed milling
How to apply D 61
C
Threading
D
Finishing with wiper inserts
Milling
How to apply D 65
E
Drilling
Material optimized cutters F
K N
Boring
See page D 36 See page D 38
G
Tool holding/
Machines
H
Materials
Milling
I
Information/
D 55
Index

A Face milling – choice of tools
Face milling
General turning
Face milling is the most common milling operation and can be

B performed using a wide range of different tools. Cutters with a
45º entering angle are most frequently used, but round insert
cutters, square shoulder cutters and side and face mills are
also used for certain conditions.
C
Threading
Overview of face milling cutters

D The diagram below shows the main application area for different cutter concepts, in terms depth of cut, ap,
and feed per tooth, fz.
ap
Milling
CoroMill 390 LE
CoroMill 690
CoroMill 245 Heavy duty cutters

CoroMill 345
CoroMill 360
Drilling
CoroMill 390
CoroMill 490
F Round cutters
CoroMill 200
CoroMill 300
CoroMill 210
Boring
45° cutters
90° cutters
G
fz
Tool holding/
Machines
H
Materials
I Direction of cutting forces generated by different entering angles.

Information/
D 56
Index

General face milling – choice of tools A
General face milling
General turning
Choice of tools
B

45°cutters CoroMill® 245 CoroMill® 345 Sandvik AUTO
• F irst choice for general purpose

• Reduce vibrations on long overhangs
• Chip thinning effect allows increased
productivity C
Max. cutting depth (ap), mm 6/10 6 6
Threading
Cutter dia. (Dc), mm 32 – 250 40 – 250 80 – 500
Material
P M K P M K K
N S H S H
D
90°cutters CoroMill® 490 CoroMill® 290 CoroMill® 390
Milling
• T hin walled components
• Weak-fixtured components
• Where 90° form is required
E
Max. cutting depth (ap), mm 5.5 10.7 10/15.7
12 – 42/
Cutter dia. (Dc), mm 20 – 80 40 – 250
Drilling
400 – 200
Material
P M K P K P M K
N S H N S H
F
Round insert cutters CoroMill® 200 CoroMill® 300
Boring
• eneral purpose cutter
G
• Strongest cutting edge
• Many edges per insert G
• Especially suitable for heat-resistant
alloys, ISO S.
• Smooth cutting action Max. cutting depth (ap), mm 10 7/8
Tool holding/
Machines
10 – 42/
Cutter dia. (Dc), mm 25 – 160
25 – 125
Material
P M K P M K
N S H N S H H
60°– 65°cutters
Materials
See page D 150.
10°cutters
See page D 60.
I
Information/
D 57
Index

A General face milling – how to apply
How to apply
General turning

B
•C
onsider machine tool stability, spindle size and type (vertical or horizontal) and
available power.
• Use a cutter diameter that is 20 to 50% larger than the workpiece.
C
• Consider maximum chip thickness when positioning the cutter for optimum feed.
Threading
• Position the cutter off centre to produce the thinnest chip at exit.
• Program the cutter to roll into the cut and reduce the feed to obtain a smooth entry.
Milling
Roll into cut
E
• Apply down-milling for favourable chip formation, i.e. thick to thin chip.
• Avoid entries and exits through tool path programming.

Drilling
F
• Frequent entering and exiting the workpiece should be avoided if possible.
It can create unfavorable stresses on the cutting edge, or cause dwell and
chatter tendencies. It is recommended that you program a tool path that
keeps the milling cutter in full contact, rather than performing several parallel
passes. When changing direction, include a small radial tool path to keep
Boring
the cutter moving and constantly engaged.
G Keep cutter constantly

engaged.
Tool holding/
Machines
Intermittent face milling of surfaces with interruptions

• If possible, avoid milling over interruptions (holes or slots). Such intermittent
H cuts are demanding on the cutting edges as they cause multiple entries and
exits.
• Alternately, reduce the recommended feed rate by 50% over the workpiece Namnlöst-1 1
area that contains the interruptions.

Materials
Avoid milling over interruptions.

I ➤
Information/
D 58
Index
Namnlöst-1 1

General face milling – how to apply A
General turning
➤
Face milling of thin-walled and deflecting sections
•C onsider the direction of the main cutting forces in relation to the stability of the
workpiece and the fixture. B
• When milling axially-weak components, use a 90° shoulder milling cutter, as it

directs the major portion of the cutting forces in an axial direction.
• Alternately, use a light-cutting, face milling cutter.
• Avoid axial depths of cut that are smaller than 0.5–2 mm to minimize axial
forces.
• Use a coarse-pitched cutter to obtain the smallest possible number of edges in
cut.
• Use sharp, positive (-L) edges to minimize cutting forces. C
Threading
The hints summerized above are more thoroughly described in Getting started, see pages D 20–D 31.
D
Edging of thin sections using face milling cutters
• T he cutter should be positioned off centre for face milling operations on the edges of thin sections. The
cut becomes smoother and the cutting forces are directed more uniformly along the wall, which reduces
Milling
the risk of vibration.
• Select a cutter pitch for these operations that maintains more than one insert in the cut at all times.
• Use the lightest insert geometry possible (light instead of medium, or medium instead of heavy).
• Select a smaller insert radius and shorter parallel land to lower the risk of vibration in thin-walled
E
components.
• Use low cutting data, small cutting depth, ap, and low feed/tooth, fz.
Drilling
F
Boring
G
Tool holding/
Machines
H
Materials
For more information about cutter size, engagement and position in relation to the workpiece, and chip formation,
see Getting started, page D 22–D 25.
I
Information/
D 59
Index

A Hig feed milling – choice of tools
High feed milling

General turning
Face milling with a very high feed per tooth (up to 4 mm/tooth)
B is possible when using cutters that have small entering angles
or when using round insert cutters, due to the chip thinning
effect. Although the depth of cut is limited to less than 2 mm,

the extreme feed makes it a highly productive milling method.
Specific cutter concepts are dedicated for extreme high feed
milling at small axial depths of cut. A small entering angle is
the precondition required for applying a light and fast, high
feed.
C
Threading
D Choice of tools
CoroMill® 210 CoroMill® 316 CoroMill® Plura CoroMill® 200 CoroMill® 300
Milling
E
High feed cutters Round insert cutters
Max. cutting depth (ap), mm 1.2 – 2 1.3 1.3 10 7/8

Drilling
10 – 42/
Cutter dia. (Dc), mm 25 – 160 10 – 25 4 – 20 25 – 160
25 – 125
F Material
N S H N S N S H N S H N S H
Boring
CoroMill® 210 Note: Do not exceed the maximum recommended ap for

• The most productive high feed face mill with a 10° entering CoroMill 210, CoroMill Plura and CoroMill 316. For round
angle, allowing for very high feed per tooth, fz. insert and radius cutters, the ap value should be kept far
G below the maximum recommended value to allow high feed
CoroMill® Plura and CoroMill® 316 milling.
• More than double the feed rates compared to conventional
end mills at small depths of cut, ap. CoroMill® 200 and CoroMill® 300
Tool holding/
• High precision tools optimized for high speed machining of • Round insert cutters.
Machines
hardened steel. • Increased chip thinning effect at reduced axial cut.

• Roughing to semi-finishing of contours and asymmetrical • Smooth cutting action.
configurations at extreme feed rates. • General purpose cutters for tough or light conditions.
H
Materials
I
Information/
D 60
Index

Hig feed milling – how to apply A
How to apply
General turning
Cutters with a small entering angle
Maximum chip thickness is dramatically reduced by a low en- B
tering angle. This allows extremely high feed rates to be used

without over-loading the inserts.
For CoroMill 210:
• This is true despite the limited depths of cut allowed by the
ten degree entering angle; maximum 2.0 mm with the 14
mm insert, and 1.2 mm with the 9 mm insert.
• In very favorable conditions, a feed per tooth, fz, of up to 4
mm/tooth can be used, and metal removal rate values (Q) C
up to 1400 cm³/min can be achieved.
CoroMill
Note: Avoid machining all the way against a 90° shoulder, be- 210
cause the positive effect of a low approach angle will be lost,
Threading
i.e. the depth of cut will dramatically increase.
As always, the feed rate has to be reduced and adapted
depending upon specific conditions and to avoid vibrations, iC Dimensions, mm
which can damage the inserts. Uncut D
material
iC R b ap x
9 2.5 7.05 1.2 0.79
Milling
14 3.5 12.0 2.0 1.48
When using the CoroMill 210 in high feed applications, the

same cutting data can be programmed as would be used for a E
round insert cutter with an insert radius R, see table.
Drilling
Round insert cutters
When using high feed milling techniques with a round insert cutter, such as CoroMill
200 or CoroMill 300, the depth of cut should be kept low (max. 10% of insert F
diameter, iC, otherwise the chip thinning effect is reduced and the feed has to be
decreased, see illustration.
Note: When using round insert cutters, it is important to reduce the feed when
approaching a wall/shoulder, because the depth of cut suddenly increases.
Boring
G
Chip thickness, hex, varies with round inserts
and depends on the depth of cut, ap.
Tool holding/
Machines
Strong inserts for general roughing

• T he best performance is achieved when the depth of cut is smaller than 25% x
insert diameter, iC.
H
Namnlöst-1 1
Materials
On round inserts, the chip load and entering

angle vary with the depth of cut.
I
Information/
D 61
Index
Namnlöst-1 1

A Heavy duty face milling – choice of tools
Heavy duty face milling

General turning
These applications include rough milling of heavy forged or

B hot rolled material blanks, castings, and welded structures in
large gantry mills and powerful milling machines, or machining
centres.
Large amounts of material have to be removed, generating
high temperatures and high cutting forces, which places
specific demands on the milling inserts:
• Heavy loads on the main edge at full depth of cut.
C • Wear at the corner by the abrasive scale when cutting depth
approaches zero.
A 60º entering angle is optimal for a heavy duty milling cutter.
This design provides:
• Good depth of cut capacity, relatively even cutting forces and
Threading
a chip thinning effect that allows for high feed rates.

• The axial allowance of the design allows the insert to have
a generous parallel land, which generates good surface
D finishes.
Milling
Choice of tools
E
CoroMill® 360 CoroMill® 245-18 T-Max 45 CoroMill® 390-18 CoroMill® 300-20
Drilling
F Entering angle (kr), mm 60° 45° 45° 90° Round inserts
Max. cutting depth (ap), mm 13 / 18 10 12 15.7 10
Cutter dia. (Dc), mm 160 – 500 32 – 250 100 – 400 40 – 200 66 – 200
Boring
Material
S N S H H N S H S H
G
CoroMill® 360 CoroMill® 245, insert size 18
• Designed for efficient tool handling, which results in short • A medium duty face mill that provides the lightest cutting
Tool holding/
down-time and secure, quick insert indexing in the machine. ability.

Machines
• Depth of cut capability up to 18 mm, for good metal removal • Capable of cutting depths of 6–8 mm within a feed range of
and machining of uneven, wavy surfaces. 0.2 – 0.6 mm.
• High productivity – feed rates of 0.4 – 0.7 mm per tooth. • First choice face mill for tough conditions in larger machining
H • Generous parallel land for good semi-finishing results. centres.
• Strong insert corner to resist abrasive surface scale at small • Can be used with wiper inserts for milling surfaces with good
depths of cut. finishes.
• Cutter strength, for security in very demanding cuts.
Materials
I
Information/
D 62
Index

Heavy duty face milling – how to apply A
General turning
CoroMill® 390-18 T-Max 45
First coice for medium duty face and shoulder milling. A 45° high performance face mill, primarily designed to handle
demanding conditions in general, and operations involving long
CoroMill® 300, insert size 20
spindle overhang, where the feed per insert is limited by
A medium duty cutter with strong edges for tough conditions, vibration tendencies.
like milling through scale and interruptions. The round insert
geometry provides a smooth cutting action. •D epth of cut capability up to 12 mm and feed range up to B
Eight cutting edges can be utilized under favourable 0.5 mm allow for efficient metal removal.

conditions. • Thick inserts with 2 mm of parallel or wiper land, which can
Maximum depth of cut is 10 mm. The maximum recommended be axially adjusted, make this cutter a reliable roughing tool;
chip thickness varies widely up to 0.55 mm per tooth, although it is also capable of finish milling.
depending on the insert geometry and depth of cut. For • Spring loaded insert clamping mechanism for easy handling
complete information, see page D 162. and rapid insert indexing.
Threading
D
How to apply
Milling
Entrance into cut
Because of the tough conditions common in heavy duty milling, entrance into cut is often critical; E
it is preferable that it take place progressively.
• If possible, program the tool path for rolling into cut.
• If not, reduce the feed until the cutter is fully engaged.
Cutter position and size
Drilling
In heavy duty milling, where many passes often have to be performed to mill a large surface, it is
important to follow the recommendations regarding:
• Cutter position and engagement F
• Cutter size in relation to machine tool capacity
• Tool path, to avoid unfavorable exits
For recommendations, see Getting started, page D 22.
Boring
G
Tool holding/
Be observant of high temperatures

Machines
Demanding, heavy duty milling generates high temperatures. When magnetic tables are used to clamp the component, the
large volumes of chips that are produced will often be retained around the cutter. Consequences include interrupted or
partial chip evacuation, and re-cutting of chips, which are hazardous for tool life. To avoid this, keep the working area free of
chips. H
Prevent the vulnerable insert corners from rubbing against abrasive skin and scale by increasing the depth of cut to move
the surface contact point to the stronger main edge of the insert.
Note: When mounting indexing inserts with cutter, use gloves to avoid inconvenience or injury due to heat.
Materials
I
Information/
D 63
Index

A Finishing with wiper inserts – choice of tools
Finishing with wiper inserts

General turning
Excellent surface finishes can be achieved with standard

B inserts in combination with one or more wiper inserts. Wiper
inserts work most usefully at a high feed per revolution, fn,
in larger diameter cutters with extra close pitch and setting

facilities.
Feed per revolution can be increased approx. four times while
still maintaining good surface quality. Wiper inserts can be
used in milling in most materials to produce good surface
textures – even under unfavorable conditions.
C
Threading
D Choice of tools
CoroMill® 345 CoroMill® 245 CoroMill® 365 CoroMill® Century AUTO-AF AUTO-FS
Milling
E
Entering angle (kr), mm 45° 45° 65° 90° 75° 90°
Max. cutting depth (ap), mm 6 10 6 10 1 8.1

Drilling
Cutter dia. (Dc), mm 40 – 250 32 – 250 40 – 250 40 – 200 80 – 500 125 – 500
F Surface finish (Ra) < 1.0 < 1.0 < 1.0 < 1.0 < 1.0 < 1.0
Material
P K P M K P K P M K K K
N S H N S H
CoroMill® 245 CoroMill® Century

Boring
A wide range of wiper inserts are available for finishing of most A system for highly accurate setting allows the use of wipers
materials. Larger diameter cutters of cassette design have in more than one insert seat in larger cutters, and in all
facilities for axial setting. insert seats in smaller cutters, which provides for extreme
G productivity while maintaining the high surface finish. The
CoroMill® 345
insert grades available cover wiper finishing of most materials.
A wiper insert is available that has two right-hand and two
left-hand wiper edges. AUTO-AF
Tool holding/
All cutter sizes have adjustable cassettes with insert seats

Machines
CoroMill® 365
suitable for either L-type or F-type wipers, with a longer wiper
Two wiper inserts are available edge. Larger diameter cutters are of Cap design.
• One with two right and two left-hand edges
• One with an extra long wiper and with one right and one AUTO-FS
H left-hand edge. Larger diameter cutters are of Cap design and axially
adjustable by using shims. A wiper insert with four edges is
Larger diameter Cap cutter versions are axially adjustable by available.
using shims.
Materials
I
Information/
D 64
Index

Finishing with wiper inserts – how to apply A
How to apply
General turning
Mirror finish at high feeds
• When fn exceeds 80% of the length of the parallel land, bs, Surface roughness
B
on standard inserts, a wiper edge will improve the surface.

• When feed per revolution, fn, increases in large cutter
diameters with a higher number of inserts, the need for
Standard With one
wiper inserts becomes essential for maintaining surface Wiper insert
inserts only
finishes.
• T he cutter's axial run-out, which depends on spindle
inclination, cutter size, mounting and the accuracy of its C
setting, influences the waviness of the machined surface.
The crowned wiper land will compensate for this and fn = feed /revolution Feed fn
produce a step-free surface. A feed per revolution limited to
60% of the wiper land will ensure this. fn1 ≤ 0.8 x bs1 fn2 ≤ 0.6 x bs2
Threading
• A wiper land protrudes below the milling inserts by approxi-
mately 0.05 mm, when mounted in cutters with fixed insert
seats. For CoroMill cutters of cassette design, the wiper
edge can be adjusted to this position with great accuracy. bs1 bs2
D
The protrusion subjects wiper inserts to greater loads than
conventional inserts, which can lead to vibration. Therefore,
wipers should be used for light machining at moderate bs1
cutting depths and in limited numbers.
• Depth of cut should be light to limit the axial forces and to
Milling
reduce the risk of vibration. In finishing, the recommended
axial depth of cut is 0.8 – 1.0 mm.
• Extra care is required when mounting a wiper insert to E
correctly position its long edge.
Drilling
F
Example:
• The width of the parallel land, bs, on the insert is 1.5 mm.
• There are 10 inserts in the cutter, and the feed per tooth, fz, is 0.3 mm. Feed per
revolution, fn, will be 3 mm, i.e. twice the length of the parallel land.
• To ensure a good surface finish, feed per revolution should be a maximum of 80%
Boring
of 1.5 mm = 1.2 mm.
• A corresponding wiper insert will have a parallel land with a width of approx. 8 mm.
• Result: Feed per revolution could be increased from 1.2 mm to 60% of G
8 mm = 4.8 mm.
Note: Other limitations, such as machine power, must be taken into consideration.
Tool holding/
Machines
Additional hints to achieve a “mirror finish”

•U se high cutting speed and/or Cermet inserts to obtain a shiny surface.
• Use cutting fluid or oil mist for sticky ISO M and S materials.
• PVD-coated inserts with sharp edges and an ap of 0.5 – 0.8 mm produce the best H
surface finish.
Materials
I
Information/
D 65
Index

A Profile milling – application overview
Profile milling
General turning
B
Profile Milling
C
How to apply D 70
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 66
Index

Profile milling – application overview A
General turning
Turn milling
B
How to apply D 82

C
Threading
D
Milling
E
Drilling
Blade milling – Profile and turn milling F
Boring
G
Tool holding/
Machines
H
Materials
Milling
I
Information/
D 67
Index

A Profile milling – choice of tools
Profile milling
General turning
Profile milling covers multi-axis milling of convex and concave

B shapes in two and three dimensions.
The larger the component and the more complicated the

configuration to machine, the more important the process
planning becomes.
The machining process should be divided into at least three
operation types:
•R oughing/semi-roughing
C • Semi-finishing
• Finishing.
Super-finishing, often performed using high-speed machining

Threading
techniques, is sometimes required. Milling of remaining stock,

so called rest milling, is included in semi-finishing and finishing
operations.
D For best accuracy and productivity it is recommended to per- The finishing operation should be carried out in a 4/5-axis
form roughing and finishing in separate machines, and to use machine tool with advanced software and programming
dedicated cutting tools for each operation. techniques. This can considerably reduce, or even completely
eliminate, time consuming manual completion work. The final
result will be a product with better geometrical accuracy and a
higher surface structure quality.
Milling
Choice of tools
Drilling
F Roughing and semi-roughing cutters
CoroMill® Plura CoroMill® 316 CoroMill® 216

Boring
G
Tool holding/
Machines
Design VFD BNE Corner BNE BNE

corner radius
radius
H
Cutter dia. (Dc), mm 4 – 20 1 – 20 10 – 25 10 – 50
Max. cutting depth (ap), mm 38 13 44.6
P M K P M K P M K
Materials
Material
N S H N S N S H
VFD = Variable flute depth

I BNE = Ball nose end mill
Information/
D 68
Index

Profile milling – choice of tools A
General turning
Roughing and semi-roughing cutters B

CoroMill® 390 CoroMill® 300 CoroMill® 200 CoroMill® 790
Threading
Design Radius Toroid Round Round Radius
Cutter dia. (Dc), mm 12 – 200 10 – 42 25 – 125 25 – 160 25 – 54 40 – 100

D
Max. cutting depth (ap), mm 12 – 42 40 – 200 7/8 10 12/18
Material
P M K P M K P M K
N S H N S H N S H N
Milling
E
Finishing and super-finishing cutters
CoroMill® Plura CoroMill® 316 CoroMill® 216F CoroMill® 790
Drilling
F
Boring
Design VFD BNE Corner BNE BNE Radius
corner radius
radius
G
Cutter dia. (Dc), mm 4 – 20 1 – 20 10 – 25 8 – 32 25 – 54 40 – 100
Max. cutting depth (ap), mm 38 13 4.8 12/18

Tool holding/
Machines
Material
P M K P M K P M K P M K
N S H N S N S H N S H
BNE = Ball nose end mill H
Materials
I
Information/
D 69
Index

A Profile milling – how to apply
How to apply
General turning

B
The profile of the component should be studied carefully in order to select the right tools and find the best
suited maching method:
•D efine minimum radii and maximum cavity depth.

• Estimate the amount of material to be removed.
• Consider tool set-up and clamping of workpiece in order to avoid vibrations,
see page D 30.
C • All machining should be performed on dedicated machines to achieve good
geometrical accuracy on the profile.
• By using separate, accurate machine tools for finishing and super-finishing opera-
tions, the need for time-consuming manual polishing can be reduced, or in some
cases eliminated.
Threading
• Some advanced programming may be necessary to obtain large savings.

• Use CoroMill Plura end mill with high speed technique to machine near net shapes
and achieve the best possible finish, see page D 75.
D • Roughing and semi-finishing of large components are, as a rule, most productively
done with conventional methods and tooling. An exception is aluminium, for which
high cutting speeds are also used for roughing.
Milling
Vibrations – methods for their reduction

Vibration is an obstacle in milling deep profiles using long overhangs. Common
E methods to overcome this problem are to reduce depth of cut, speed or feed.
• Use stiff modular tools with good run-out accuracy.
• Modular tools increase the flexibility and possible number of combinations.
• Use damped tools or extension bars when total tool length, from the gauge line to
the lowest point of cutting edge, exceeds 4−5 times diameter at the gauge line.
Drilling
• Use extensions made of heavy metal, if bending stiffness must be radically

increased.
F • Use balanced cutting and holding tools for spindle speeds over 20,000 rpm.
• Choose the largest possible diameter on the extensions and adaptors relative to
the cutter diameter.
• 1 mm in radial difference between the holding and the cutting tool is enough.
Use oversized cutters.
• Plunge milling is an alternative method for milling with extra long tools, see
Boring
Dedicated methods, page D 116.
G
Tool holding/
Machines
H
Materials
I
Information/
D 70
Index

Profile milling – how to apply A
General turning
Extend tool length gradually
To maintain maximum productivity in roughing operations, where the final pass is
located deep in the component, it is important to work with a series of extensions
for the cutter.
B
•S
tart with the shortest extension, as longer extensions limit productivity and

tend to generate vibration.
•C
hange to extended tools at pre-determined positions in the program. The
geometry of the cavity determines the point of change.
• Adapt cutting data to each tool length to maintain maximum productivity.
Threading
Opening up from a solid workpiece
•W
hen opening up a cavity, it is important to choose a method • Use of round insert cutters (CoroMill 300 or CoroMill 200)
that minimizes ap, and also leaves a constant stock for the will generate smooth transitions between the passes and D
subsequent profile milling operation. leave less stock in more even quantities for the profiling
operation, resulting in a better component quality.
•S
houlder face/end mills or long edge cutters will leave a
stair-case stock that has to be removed. This generates • A third alternative is to use a high feed cutter (CoroMill 210)
varying cutting forces and tool deflections. The result is an to open the cavity. This will also result in a small, and even
Milling
uneven stock for finishing, which will influence the geome constant, stock, due to the small depth of cut, i.e. small
trical accuracy of the final shape. stair-case steps.
For more information, see page D 102. Methods for opening E
up and widening a hole.
Drilling
Square shoulder cutter Round insert cutter High feed cutter
F
– Larger and uneven stock remaining + Small stock remaining + Small stock remaining
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 71
Index

A
General turning Profile milling – how to apply
Contouring or copy milling tool paths?
The traditional and easiest method for programing tool paths • A considerably shorter machining time.
for a cavity is to use the normal copy milling technique, with
• Better machine and tool utilisation.
B many entrances and exits into the material. However, this
means that powerful softwares, machines and cutting tools • Improved geometrical quality of the machined shape.
are used in a very limited way.

• Less time-consuming finishing and manual polishing work.
An open minded approach to the choice of methods, tool
The initial programming work is more difficult and will take
paths, milling and holding tools is essential.
somewhat longer; however, this is quickly recouped as the
Instead of using programming techniques that are limited to machine cost per hour is normally triple that of a workstation.
"slicing off" material at a constant Z-value, it is highly advan
tageous to use contouring tool paths in combination with
C down-milling. The results include:
Threading
D
Contour milling Copy milling
Favourable Common
Milling
E
Drilling
+ Cutting speed control - ve

− Heavy load on the insert centre point
+ Enabling HSM
F + High feed rates
− Reduced feed rates
− Reduced tool life
+ Productivity
− Mechanical impact
+ Long insert life
− Form errors
+ Security
− Longer programs and cutting time
Boring
G
Tool holding/
Look ahead function

Machines
For both contouring and copy milling, it is preferred to use a

H machine with software that has look ahead functions to avoid
tool path deviations.
Materials
I
Information/
D 72
Index

General turning
Contouring
•U
se a contouring type of tool path as, such “Waterline
milling”, as the best method to ensure down milling.
•C
ontouring with the periphery of the milling cutter often B
results in a higher productivity, as more teeth are effectively

in the cut on a larger tool diameter.
• If the spindle speed is limited in the machine, contouring
will help maintain and control the cutting speed.
•C
ontouring also creates fewer quick changes in the work
load and direction. In high speed and feed milling, and in
hardened materials, this is of specific importance as the C
cutting edge and the process are more vulnerable to any
changes that can create differences in deflection or create
vibration.
• F or good tool life, stay in the cut continuously, and for as
Threading
long as possible.
Note! Avoid cutting with centre of the tool when cutting speed
is zero.
D
Milling
E
Drilling
Tool path strategy
F
Z – constant contouring, two axes. Helical contouring, three – five axes.
Roughing to finishing Finishing
Boring
G
Tool holding/
Machines
Waterline milling Z - constant countouring Countouring in a ramping tool path
• Common when CAM- controlled maximum scallop function is • Smooth changes of direction H
available
• Good form accuracy and surface finish
• Smooth engagement and retraction
• Controlled scallop height
• Easy programming
• Constant engagement
Materials
• Wide tool choice

• Short programs
• Short tool
I
Information/
D 73
Index

A
Copy milling
A copy milling tool path is often a combination of up- and down- • Use a feed speed control with a look ahead function.
milling, and requires a lot of unfavorable engagements and Otherwise, the deceleration will not be fast enough to avoid
B disengagements in the cut. damages to the tool centre.
Each entrance and exit means that the tool will deflect, leaving • T here will be a large contact length when the cutter hits the
an elevated mark on the surface. wall, with risk for deflection, vibration or tool breakage.
The cutting forces and the bending of the tool will then •W
hen using ball nose end mills, the most critical area is at
decrease, and there will be a slight undercutting of material the tool centre, since the cutting speed is zero. Avoid using
in the exit area. the tool centre area and apply point milling by tilting the
spindle or the workpiece to improve the conditions.
Conclusions:
C •C
opy milling along steep walls should be avoided as much
• It is somewhat better for the cutting process to perform
up-copying along steep walls as the chip thickness has its
as possible. When plunging, the chip thickness is large and
maximum at a more favourable cutting speed.
cutting speed should be low.
• T here is a risk of edge frittering at the tool centre, especially
Threading
when the cutter hits the bottom area.
D
Milling
E
Drilling
F
Risk for gouging Up-copying: At bottom of cavity: Down-copying:
Maximum chip thickness at Risk of frittering at tool centre. Form errors Large chip thickness at
recommended vc. are common, especially when using high very low vc.
D&M 04 Application technology speed machining technique.
Tool path strategy

Boring
7. Copy milling
G
 Surface errors
 Unfavourable
method
100 %
Tool holding/
 Reversing
100 %up
Machines
and down milling

 Alternating 50
deflection/ 100 %
20° forces %
cutting
45° 40 % 60 %
 Frequent accelerations and 45°
H decelerations limits level of
90°
productivity
 Shortens tool life
CoroMill  Requires more manual labour
Feed reduction to avoid shortened tool life
Materials
Reversed up and down-milling will expose the tool to alternating deflection and cutting forces.
By216-R
reducing 216-FthePlura feed rate Plurain the 300 critical 200 sections
390 of the tool path, the risk for edge frittering is
reduced, and a safer cutting process with longer tool life is echieved.
Please note, click on any of the icons above to access the relevant product family.
I
Information/
D 74
Index

General turning
B

Roughing
Semi-finishing
Threading
Finishing and super-finishing
D
Constant stock allows near net shape milling
Milling
A constant stock is one of the truly basic criteria for high and • The best quality in finishing is achieved when preceding
constant productivity in profile milling, especially when using operations leave as little and as constant an amount of E
high speeds. stock as possible.
• T o reach maximum productivity in these operations, common • T he goal should always be to come as close as possible to
in die and mould making, it is important to adapt the size of the requirements specified for the final shape.
the milling cutters to specific operations.
• Safe cutting process.
Drilling
• T he primary goal is to create an evenly distributed working
allowance, or stock, to obtain few changes in work load and
direction for each tool used. Benefits with a constant stock
F
It is often more favorable to de-escalate the sizes on different •S
ome semi-finishing and practically all finishing operations
cutters, from bigger to smaller, especially in light roughing and can be performed partially manned, or even sometimes
semi-finishing, instead of using only one diameter throughout unmanned.
each operation.
• Impact on the machine tool guide ways, ball screws and
spindle bearings will be less negative.
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 75
Index

A
True cutting speed
If using a nominal diameter value of the tool when calculating the cutting speed of a
π × n × Dcap
ball nose or round insert cutter, the true cutting speed, vc, will be much lower, if the vc = m/min
1000
B depth of cut, ap, is shallow. Table feed and productivity will be severely hampered.
Base calculations of cutting speed on true or effective diameter in cut, Dcap.
Shoulder end mill Ball nose cutter Round insert cutter
C Dc = 6 mm Dc = 6 mm
vc = 250 m/min
vc = 250 m/min
n = 13 262 rpm
n = 36 942 rpm
Threading
Dc = Dcap = 6 mm Dcap = D3 - iC + √ iC² - (iC - 2 × ap )²

D Dcap = 2.15 mm
Dcap = 2 × √ ap × (Dc - ap)

Milling
Point milling – tilted cutter

E •W
hen using a ball nose end mill, the most critical area of the cutting edge is the
tool centre, where the cutting speed is close to zero, which is unfavorable for the
cutting process. Chip evacuation at the tool centre is critical, due to the narrow
space at the chisel edge.
• T herefore, tilting the spindle or the workpiece 10 to 15 degrees is recommended,
Drilling
which moves the cutting zone away from the tool centre.
- The minimum cutting speed will be higher.
- Improved tool life and chip formation.
F
- Better surface finish.
Boring
CoroMill® Plura and CoroMill® 316 - centre cutting cutters

Tool holding/
Machines
Central part, z = 2
H
Materials
Peripheral part, z = 4 Z=2 Z=4
To ensure four effective cutting edges, the cutter should be tilted approx. 10-15 degrees.
I
Information/
D 76
Index

General turning
Shallow cut
Allows higher cutting speed, vc, and feed/tooth, fz

When using a round insert or a ball nose cutter at a lower
depth of cut, the cutting speed, vc, can be increased due to B
the short engagement time for the cutting edge. The time for

heat propagation in the cutting zone becomes shorter, i.e. the
cutting edge and the workpiece temperature are both kept low.
Also, the feed/tooth, fz, can be increased, due to the chip
thinning effect, see Getting started, page D 20.
Shallow cut
C
Threading
Example shallow cut:
Non-tilted versus tilted cutter
This example show the possibilities for increasing the cutting D

speed when the ae/ap is small, and also the advantages of
using a tilted cutter.
CoroMill Plura ball nose cutter
Dc = 10 mm, grade GC 1610.
Material: Steel, 400HB
Milling
Cutting data recommendation for a deep cut ap - Dc/2 :
vc = 170 m/min
fz = 0.08 mm/r = hex
E
Operation Non-tilted cutter Tilted cutter (10°)
Drilling
• Semi-finishing ap = 2 mm Dc = 10 mm Dc = 10 mm
Dcap = 8 mm Dcap = 8.9 mm
The speed can be further increased by approx. 75% due to F
the shallow cut and short engagement time: vc = 300 m/min vc = 300 m/min
vc = 300 m/min n = 11 940 rpm n = 10 700 rpm
Feed per tooth, fz, is the same for both the non-tilted and hex = 0.08 mm hex = 0.08 mm
the tilted cutter, but the effective No of edges, zc, differs fz = 0.12 mm/tooth fz = 0.12 mm/tooth
near the centre as described on the previous page. zc = 2
Boring
zc = 4
fn = 0.24 mm/r fn = 0.48 mm/r
vf = 2 860 mm/min vf = 5 100 mm/min

G
• Super-finishing ae = 0.1 mm A non-tilted cutter is not recom- Dc = 10 mm

mended for super- finishing Dcap = 4.4 mm
Tool holding/
The cutting speed can be increased by the factor 3-5 due

Machines
to the extremely short contact time: vc = 850 m/min

vc = 5 x 170 = 850 m/min n = 61 100 rpm
hex = 0.02 mm
Note: In super-finishing a two teeth cutter zn = 2, should be Namnlöst-1 1
fz = 0.12 mm/tooth H
used to minimize the run-out. zc = 2
With this extremely small ap, the fz will be limited by the fn = 0.24 mm/r
surface finish demands. Therefore, hex must be disre-
garded. A good rule of thumb in super-finishing is to use vf = 14 600 mm/min
approx. the same fz as the ae.
Materials
fz = 0.12 mm/r
I
Information/
D 77
Index

A
Generation of sculptured surfaces
A ball nose cutter or a radius shaped cutting edge will form a

surface with a certain cusp height, h, depending on:
B • Width, ae, of cut
• Feed per tooth, fz.
Other important factors are the dept of cut, ap, which influ-
ences the cutting forces and the tool indicator reading of the
run-out – TIR. For best results:
•U se high precision HydroGrip chucks with Coromant Capto
coupling.
C
• Minimize tool overhang.
Threading
D
Down milling with a cutter tilted approx. 10° in two directions ensures
a good surface finish and a reliable performance.
Milling
Roughing and semi-roughing Finishing and super-finishing

E If the feed per tooth is much smaller than the width and depth It is beneficial to achieve a smooth, symmetrical surface
of cut, the surface generated will have a much smaller cusp texture in all directions, which can be easily polished after-
height in the feed direction. wards, regardless of the polishing method selected.
This is obtained when fz ≈ ae.
Always use a tilted two teeth-cutter in super-finsishing to
Drilling
achive the best surface texture.
F
Boring
G
Tool holding/
Machines
H
Materials
I
Semi-roughing with fz much smaller than ae. Super-finishing with a tilted cutter and fz equal to ae.
Information/
D 78
Index

Profile milling A
General turning
B

C
CoroMill® Plura CoroMill® 390
Threading
D
Milling
E
Drilling
CoroMill® 300 CoroMill® 316 F
Boring
G
Tool holding/
Machines
H
Materials
I
CoroMill® 300 toroid CoroMill® 216
Information/
D 79
Index

A Turn milling – choice of tools
Turn milling
General turning
Turn milling is defined as the milling of a curved surface while

B rotating the workpiece around its centre point.
Eccentric forms or shapes that differ considerably from those

that conventional milling or turning methods produce can often
be turn milled. The method allows for high metal removal with
superb chip control.
•A
cylindrical surface can be produced only when feeding the
milling cutter in a radial direction during rotation.
C •B
y simultaneously moving the cutter in two directions, it is
possible to produce eccentric surfaces, e.g. cams on shafts.
•M
ovement in more than 2 axes requires a tool with ramping
capabilities.
Threading
• To machine a conical shape, 5 axes are required.

• T urn milling of complex profiles, e.g. turbine blades, requires
simultaneous movement in 5 (or 4) axes, 2 or 3 for the work-
D piece and 1 or 2 for the tool.
• It is possible to produce components, such as turbine
blades, by feeding the cutter in more than 2 axes while
simultaneously rotating the component.
Milling
Choice of method
Drilling
Face turn milling – 4/5 axes Periphery turn milling – 3/4 axes
F Main method for external machining. Same principle as for circular milling/ramping, but with
component rotating.
Used mainly for internal features.
Boring
G
Tool holding/
Machines
H + hort tool extensions

S + Internal machining
+ Smaller tool diameters/low torque + Cylindrical surface
+ External/slender components + Narrow slots
+ Profiling + Thread milling
Materials
− Not a natural cylindrical surface + Roundness

− Internal. − Profiling
− Larger diameters/high torque
I − Long overhangs.
Information/
D 80
Index

Turn milling – choice of tools A
Choice of tools
General turning
Turn milling cutters for roughing B

90° end mill Long edge 45° face mill High feed Round insert
CoroMill® 390 CoroMill® 390LE CoroMill® 245 CoroMill® 210 CoroMill® 300
Depth of cut – (ap) ++ +++ ++ – +
Threading
Width of cut – (ae) ++ ++ ++ – +++
Table feed – (vf) ++ + ++ +++ +++ D

Metal removal – Q (cm3/
min.)
+ +++ ++ + +++
Bottom cutting + – – – +++
Milling
Power/stability ++ – ++ + +++
Surface finish +++ + +++ – ++

E
Difficult materials + + ++ ++ +++
Rough to finish +++ + +++ – ++
Drilling
Turn milling cutters for finishing
F
90° solid end mill 90° indexable insert end 90° indexable insert face Round insert
CoroMill® Plura mill CoroMill® 390 mill CoroMill® Century CoroMill® 300
Boring
G
Surface flatness +++ +++ +++ +
Tool holding/
Number of wipers 4 1 1 to full 0

Machines
Feed per tooth – + +(*+++) ++

Metal removal – Q (cm2/
min.)
– + +(*+++) ++ H
Against shoulder +++ +++ +++ –
Difficult material + + + +++

Materials
Narrow profile +++ + + –
* Only when cutting axially and fully loaded with wipers.

I
Information/
D 81
Index

A Turn milling – how to apply
How to apply
General turning
Cutter position - rectangular inserts/wiper

B
In face turn milling, one wiper insert is used to generate the Location of cutter
straight line contact between the cutter and the machined

surface in order to create the cylindrical part of the compo- Width of cut
nent. Because the milled surface is convex, the wiper land
has to be flat instead of crowned. To cover the full width of the
cutter, the tool has to be placed with at least two offsets, first
Ew1 during first revolution of the work piece and then moved to
Ew2 for a second cut.
C
1 = First cut
Threading
2 = Second cut
D
Milling
Cutter position - round inserts/non wiper

For producing the flatest possible surface, a small diameter
E cutter with a width of cut, ae, less than 40% of the effective
cutter diameter, Dc, is optimal.
However, the ae needs to be increased in order to obtain the
best productivity. This can be done by increasing:
• Cutter diameter
Drilling
• Ratio of radial engagement – ae/Dc.
F To gain acceptable cusp height, the cutter needs to be offset

from the centre. The amount of offset depends on the ae, and
is taken from the diagram for the respective ae/Dc.
Boring
G
Tool holding/
Machines
H
Namnlöst-1 1 2009-08-31 09:29
Materials
I
Information/
D 82
Index

Turn milling – how to apply A
General turning
Offset and width of cut
For milling a surface that is wider than the cutter diameter, it
is necessary to remain in the initial position and then to move B
the cutter in the axial direction to the required length, which

is, however, not more than 80% of the aez1 per revolution. If a
90° shoulder is required, the cutter has to move to second a
position, Ew2.
C
Wiper width Width of cut
Threading
D
Milling
Infeed principle
The milling tool should be fed into the workpiece in the radial direction. The workpiece rotation speed
should correspond to the feed/tooth recommended for the insert. The cutter should be fed out axially. E
Drilling
vf/2
vf/2 vf
F
Boring
G
Tool holding/
Machines
Programming
Detailed information about turn milling programming is provided in the Turn Milling application guide,
C-2920:26. Contact your local Sandvik Coromant representative for more information.
H
Materials
I
Information/
D 83
Index

A Slot and thread milling – application overview
Slot and thread milling

General turning
B
Side and face milling
C Choice of tools D 87
How to apply D 88
Threading
D
Milling
E
Drilling
Thread milling
Boring
G
How to apply D 97
Tool holding/
Machines
H
Materials
I
Information/
D 84
Index

Slot and thread milling – application overview A
General turning
B

End milling of slots
Choice of tools D 91 C
How to apply D 92
Threading
D
Milling
E
Drilling
F
Boring
G
Tool holding/
Machines
H
Materials
Milling
I
Information/
D 85
Index

A Slot milling – comparsion of cutter concepts
Slot milling
General turning
Slot milling is an operation in which side and face milling are

B often preferred to end milling.
•S lots or grooves can be short or long, closed or open,

straight or non-straight, deep or shallow, wide or narrow.
• Tool selection is normally determined by the width and depth
of the slot and, to some extent, length.
• Available machine type and frequency of operation
determine, whether an end mill, long edge cutter or side and
C face milling cutter should be used.
• Side and face cutters offer the most efficient method for
milling large volumes of long, deep slots, particularly when
horizontal milling machines are used. The growth of vertical
milling machines and machining centres, however, means
Threading
that end mills and long edge cutters are also frequently used
in a variety of slot milling operations.
D
Milling
E
Comparison of cutter concepts
Side and face milling End milling
Drilling
F
Boring
G
Tool holding/
+ pen slots
O + losed slots
C
Machines
+ Deep slots + Shallow slots

+ Adjustable width/tolerances + Non-linear slots
+ Gang milling + Versatility – additional methods:
+ Cutting off • Trochoidal slot milling for difficult materials (hard steels, HRSA,
H + Large product range for different widths/depths etc.)
• Plunge milling as a problem solver for long tool overhangs
–C losed slots • Additional semi-finishing/finishing operations can be added
– Linear grooving only easily
– Chip evacuation • An endmill can be used for operations other than slot milling
–D eep slots
Materials
– High forces
– Vibration sensitive if deflected
I
Information/
D 86
Index

Side and face milling – choice of tools A
General turning
Side and face milling cutters can handle long, deep, open
slots in a more efficient manner, and provide the best stability
B
and productivity for this type of milling. They can also be built

into a “gang” to machine more than one surface in the same
plane at the same time.
Threading
Choice of tools D
Side milling cutters
Milling
CoroMill® 331 CoroMill® 329 T-Max Q-cutter CoroMill® 327 CoroMill® 328
Drilling
Max. cutting width (ap), mm 10/26.5 2.5 – 4 6.1 5.15 5.15
Max. cutting depth (ar), mm 34.0/114.5 18 119 6.5 5.0
40 – 125/
F
Cutter dia. (Dc), mm 125 – 160 80 – 315 9.7 – 27.7 39 – 80
80 – 315
Material
N S H N S H N S H N S H N S H
Boring
G
CoroMill® 331 CoroMill® 327
Multi-purpose cutter with high precision capability. The most Internal grooving and chamfering in holes over 10 mm in
Tool holding/
productive cutter for producing slots and for cutting off. Wide diameter. Full radius for standard seal rings, and circlip
Machines
slots can be produced by several CoroMill cutters mounted grooves and chamfering.
together in a gang.
CoroMill® 328
CoroMill® 329 General grooving, circlip grooving and chamfering in holes over
Versatile tool for producing accurate slots, plain bottom 39 mm in diameter. General grooving externally and internally. H
grooves and for cutting off.
T-Max® Q-cutter
Complementary cutter for narrow slots and plain bottom
Materials
grooves. Basic choice for cutting off.
I
Information/
D 87
Index

A Side and face milling – how to apply
How to apply
General turning

B
• Choose cutter size, pitch and position so that at least one edge is in the cut at all times.
• Check chip thickness to achieve the optimum feed per tooth.
• Reduce feed on entry due to thick chip exit.
C • In demanding milling, check the requirements for power and torque.
• Stiff arbors and overhang are very important in applications in which arbors have a free end.
Fixture and arbor support must be strong to handle up-milling cutting forces.
Threading
Down-milling
• First choice method.
D • Use a firm stop in the direction of tangential cutting forces to prevent them from forcing the
workpiece down against the table. The feed direction corresponds with the cutting forces,
which means that rigidity and eliminating backlash are also important, since the cutter has a
tendency to climb.
Milling
Up-milling:
• Alternative in applications where problems arise due to insufficient rigidity, or when working on
E exotic materials.
• Solves problems generated by weak set-ups and chip jamming in deeper grooves.
Fly-wheel:
Drilling
• Good complement for weak set-ups and when available power and torque are low.
• Position the flywheel as close to the tool as possible.
F • Strengthening the workpiece mounting is always a good investment.
Boring
Milling open slots using side and face milling cutters

Calculating feed per tooth
G A critical factor in peripheral milling using side and face milling
cutters, like CoroMill 331, is achieving a suitable feed per
tooth, fz. Insufficient values cause serious disadvantages, so
that extra care should always be taken when calculating this.
Tool holding/
Machines
The feed per tooth, fz, should be decreased for deeper slots
and increased for shallower ones in order to maintain the
recommended maximum chip thickness.
H For information about how to optimize feed, see Getting
started, Maximum chip thickness, peripheral milling,
page D 20.
Materials
I ➤
Information/
D 88
Index

Side and face milling – how to apply A
General turning
➤
Example:
When full slotting with a CoroMill 331 with an insert size 05 and geometry PL, maximum chip ae/Dc (%) fz (mm/tooth)
thickness should be 0.10 mm which equals: 25 0.12
Note: Because two inserts work together to cut the full slot width, feed is calculated using 10 0.17 B
half the number of inserts zn.

5 0.23
Depth of cut
In general, a CoroMill 331 will machine slots to a depth ae of 4 x width ap. For deeper slots, a
special cutter can be ordered, see page D 186. If deeper slots are to be machined, feed per
tooth should be decreased. If the slot is shallower, increase feed. C
Note: The depth of a slot can be limited by the diameter of the arbor boss, the deformation
strength of the driving keys, and the capacity of the chip pockets.
Threading
Fly-wheel – on horizontal machines D
Only a few teeth are engaged at any one time in side and face milling
operations, which can generate heavy torsional vibrations due to the
intermittent machining. This is detrimental to the machining result and to
productivity.
Milling
•E mploying a fly-wheel is often a good solution for reducing these
vibrations.
• Problems caused by insufficient power, torque and stability in the machine E
are often solved by the correct use of fly-wheels.
• The need for a fly-wheel is greater in a small machine with low power, or
in a machine with greater wear, than in a larger, more stable and powerful
machine.
Drilling
• Position the fly-wheel as close to the tool as possible.
• Using a fly-wheel results in smoother machining, which in turn leads to a
reduction in noise and vibration, and a longer tool life.
• In addition to up-milling, a fly-wheel can be fitted to the arbor on which the F
milling cutter is set up.
• In order to further improve stability when side and face milling, use the
largest possible fly-wheel that the application permits.
• Combining a number of round carbon steel discs, each with a centre hole
and key groove to fit the arbor, remains the best method for constructing
Boring
a fly-wheel.
• The effect of the weight of a fly-wheel increases as the diameter of the
fly-wheel increases. This means that if circumstances permit a large G
diameter, the weight of the fly-wheel can be reduced.
• Fly-wheel weight can, if necessary, be distributed over several fly-wheels
where space permits.
Tool holding/
• Higher spindle speeds and a larger cut reduce the need for a fly-wheel.
Machines
• Use the smallest possible milling cutter diameter – spindle speed can be
increased for a particular cutting speed.
H
Materials
I
Information/
D 89
Index

A
General turning Side and face milling – how to apply
Gang milling using cutters mounted in a staggered pattern
CoroMill 331 cutters, CoroMill 329, T-Max Q-cutter and CoroMill 328 versions that
have bore mounting with keyways can be arranged in a staggered pattern for milling
B more than one slot at the same time.
Displacing the cutters half a pitch in relation to each other assists in avoiding
vibration. This also reduces the need for fly-wheels.
C
Threading
D One of the keyways is displaced from the centre-line by half a pitch.
Milling of narrow and shallow slots and grooves

Milling
The CoroMill 327/328 cutters have multiple edge inserts that

are available in shapes to fit most types of small grooves.
E Common applications include the machining of internal circlip
and sealring grooves, and of small straight or circular external
grooves, particularly on components that cannot be rotated.
Drilling
F
Internal grooving
•A smooth entrance should be programmed when using circular milling.
• Consider the relationship between the cutter diameter and the hole diameter, Dc/
Dw. The smaller the relationship, the larger the engagement will be.
Boring
G
Cutting speed and chip thickness recommendations for CoroMill® 327
Tool holding/
vc, m/min:
Machines
P 200 (150-400)
M 100 (80-160)
H K 250 (200-400)
hex, mm:
0.04 (0.01 – 0.07)
Materials
Suitable cutting data for CoroMill 328 are recommended on

page D197.
I
Information/
D 90
Index

End milling of slots – choice of tools A
End milling of slots
General turning
End milling is selected for shorter, shallower slots, especially
closed grooves and pockets, and for milling key-ways.
B

End mills are the only tools that can mill closed slots that are:
• Straight, curved or angled
• Wider than tool diameter, designated pockets.
Heavier slotting operations are often performed using long
edge milling cutters.
Threading
Choice of tools D
End milling and long edge cutters
Milling
CoroMill® 690 CoroMill® 390 CoroMill® 490 CoroMill® 316 CoroMill® Plura
Drilling
Max. cutting depth (ap), mm 112 15.7/85 5.5 11 38
Cutter dia. (Dc), mm 50 – 84 12 – 42/32 – 200 20 – 80 10 – 25 2 – 20

F
Ramping* No Yes No Yes Yes
Material
S P M K P M K P M K P M K
N S H S H N S N S H
Boring
*Ramping is a suitable method for closed slots, see Dedicated methods, page D 104.
G
Tool holding/
Machines
H
Materials
I
Information/
D 91
Index

A End milling of slots – how to apply
How to apply
General turning

B
•U
se light-cutting end mills with a long predictable tool life mounted in high-performance
chucks.
•M
inimize the distance from the tool chuck to the cutting edge to achieve the shortest
possible overhang.
C
• For long tool overhangs, make shallow cuts with heavier feeds.
Threading
•C
onsider feed per edge to produce satisfactory chip thickness. Use coarse pitch cutters to
avoid thin chips, which can cause vibrations, bad surfaces and burr formation.
D
•U
se the largest possible tool size to achieve the best diameter/length relationship for
stability.
Milling
• Use down-milling as often as possible to achieve the most favorable cutting action.
E
•M
ake sure to evacuate chips out of the groove. Use compressed air to avoid chip
congestion.
Drilling
• Use Coromant Capto coupling for best stability and support towards the spindle.
F
For information about how to enhance the milled groove or pocket to the required shape and
quality, see Dedicated methods, page D 120.
Boring
G
Grooving using end milling cutters
Machining a groove or slot, often called full slotting, involves three machined faces:
Tool holding/
• Slots closed at both ends are pockets, requiring end mills that can work in the
Machines
axial direction. For more information about pocketing, see page D 115.
• F ull slotting with an end mill is a demanding operation. The axial cutting depth
should be generally reduced to around 70% of the edge length. Machine rigidity
H and chip evacuation should also be considered in determining the best method for
the operation.
•E
nd mills are sensitive to the effects of cutting forces. Deflection and vibration may
be limiting factors, especially at high machining rates and with long overhangs.
Materials
I
Information/
D 92
Index

End milling of slots – how to apply A
General turning
Keyway slotting
This operation requires some specific guidance, in addition to

the general recommendations for milling of straight surfaces
and grooving. B
A slot milled in a single step will not have a perfectly square

form due to the direction of the cutting forces and the
tendency of the tool to bend.
The best accuracy and productivity will be achieved if the
operation employs an undersized end mill, and is divided into
two steps:
1. Key slot milling – roughing of full slot. C
2. Side milling – finishing all around the slot, using up-milling
to create true square corners.
The radial depth of cut should be kept low in finishing
operations to avoid deflection of the cutter, which is a major
Threading
cause of bad surface finish and/or deviation from a true
90° shoulder.
Key slot milling in two steps.
Milling
E
Methods for opening up a closed slot or pocket in a solid blank
In preparation for milling long and narrow, full-width slots, linear ramping is the most
common method, after drilling, for opening up a pocket.
Drilling
For shallow slots, peck milling can also be an alternative. Circular ramping is used
for milling wider slots and pockets. For more information, see Dedicated methods,
page D 102.
F
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 93
Index

A
General turning End milling of slots – how to apply
Comparison of three different methods

Conventional slot milling Trochoidal milling Plunge milling
B
C
+ Conventional 3-axes machines can be used +G enerates low radial cutting forces - less +A problem solver in vibration sensitive
+ High removal rates under stable conditions vibration sensitivity applications:
+ Simple programming + Minimal deflection when milling deep slots • with long tool overhangs
+ Wide choice of tools + A productive method for: • in deep slotting
Threading
– Generates high radial cutting forces • machining hard steels and HRSA (ISO • with weak machines or set-ups
– Vibration sensitive – deep slots require H and S) – Low productivity under stable conditions
repeated passes • vibration sensitive applications – Requires a rest milling/finishing operation
+ The slot width should be maximum 70% of – End cutting might obstruct chip evacuation
D the cutter diameter, Dc
+ Good chip evacuation
– Limited choice of tools
+ Low heat generation

– More programming is required
Milling
E
For more information, see Dedicated For more information, see Dedicated
methods, page D 121. methods, page D 116.
Drilling
Rough slotting with long edge milling cutters

•C utters with large metal removal capacity are generally used for rough machining.
F • Shorter versions may produce slots up to a depth equal to the diameter, in stable and powerful milling
machines.
• Use stable ISO 50 spindles, as these cutters are more likely to accommodate considerable radial
forces.
• Check power and torque requirements, as these are often limiting factors for optimum results.
• Consider the optimal pitch for each type of operation.
Boring
G
Tool holding/
Pitch
L M H
Machines
Application area: Long set-up Universal Short set-up

Shoulder milling: Deep ap /ae Medium ap /ae Moderate ap /ae
H Slot milling: Moderate ap Limited –
vc m/min: ➡
➡
➡
Materials
Longer designs are primarily intended for edging operations, see Shoulder milling,
page D 50.
I
Information/
D 94
Index
Thread milling – choice of tools A
Thread milling
General turning
Thread milling in non-rotating components is a good alternative
to tapping, and can also be an alternative to thread turning.
B

With CoroMill thread milling cutters, it is possible to create
threads very near to a shoulder or bottom of a hole.
The interrupted cut in milling provides good chip control in
long-chipping materials.
Threading
Choice of tools D
CoroMill Plura end mill cutters as well as CoroMill 327 and CoroMill 328 offer
geometries optimized for thread milling.
Milling
CoroMill® Plura CoroMill® 327 CoroMill® 328 E
Drilling
Pitch, mm 0.7 – 3 1 – 4.5 1.5 – 6
F
Cutter dia. (Dc), mm 3.2 – 19 11.7 – 21.7 39 – 80
Material
P M K P M K P M K
N S H N S H N S H
Boring
General information
G
•S elect the shortest tool whenever possible.
• The ordering information provides the smallest internal thread size that each tool can produce. The same
thread mill can also be used for any larger size threads of the same pitch. See Main catalogue for more
Tool holding/
information.
Machines
H
Materials
For information about thread standards and thread turning vs thread milling, see Threading, Chapter C.
For pre-drilling recommendations, see Information/Index, Chapter I, Thread charts.
I
Information/
D 95
Index

A
General turning Thread milling – choice of tools
Use of CoroMill® cutters for threading

Advantages
• ame tool for right and left-hand threads.
S
• Same tool for a wide range of thread diameters with no upper limit for bore size.
B • Full thread close to the bottom of blind holes as well.
• Can be adjusted to specified tolerances.
• Preferred solutions for long reach requirements and to avoid vibration.

• Good chip control.
• Good chip evacuation provides secure performance.
• Provide favorable results in hardened materials, and when machinability and chip
formation are bad.
• Internal cutting fluid supply facilitates threading in difficult to machine materials.
C • In the event of tool breakage , it is easy to remove the cutter without damage to
the workpiece.
Disadvantages
Threading
• T hread milling cutters will always produce feed marks. Depending on pitch size,
hole size and radial immersion, the thread will deviate from the perfect profile.
• Relatively high cutting forces with the CoroMill Plura can cause tool deflection and
slightly distorted/tapered threads.
D • Pitch is individual for each CoroMill Plura.
Milling
E
Drilling
Singlepoint threading with CoroMill® 327 and CoroMill® 328

F •S ame insert for different pitches.
• Low cutting forces make these cutters a good alternate choice for internal
medium to large threads, and for when stability is bad – such as for milling
threads requiring long tool overhangs and/or in thin walled components.
• Low power requirements.
Boring
• First choice for creating larger, external threads on asymmetric components.

• For small batch sizes and mixed production.
G
Tool holding/
Machines
H
Multipoint threading with CoroMill® Plura
•C ompletes a thread in only one single 360° pass.
• For selection of tools, cutting data and for programming, see the CoroMill Plura Guide.
Materials
I
Information/
D 96
Index

Thread milling – how to apply A
How to apply
General turning
General
•A
lways engage and retract the CoroMill Plura, the CoroMill 327 and the CoroMill
328 following a smooth tool path.
B

• Down-milling is preferable.
•W
hen milling threads in hardened steel or in other difficult to cut materials, it may
be necessary to separate the operation into several passes by reducing ae or fz.
Right-hand threads
Threading
All cutters are initially positioned as close as possible to the
bottom of the hole and then moved counter-clockwise up-
wards.
D
Pitch
Left-hand threads
Milling
Milling a left-hand thread follows in the opposite direction,
from top to bottom, yet, also in a counter-clockwise path.
Pitch
Drilling
Down-milling is recom-
mended.
Thread profile deviation
Boring
• T hread milling cutters will create a negligible, small form error
thread profile. G
• This depends on the relationship between the threading
diameter and cutting diameter, and also on the pitch.
• A good rule is that the relationship between the threading
Tool holding/
diameter and the cutting diameter should be no less than 1.5.

Machines
H
Materials
I
Information/
D 97
Index

A
General turning Thread milling – how to apply
External threading
– CoroMill® 327 and CoroMill® 328
All threading inserts are primarily used for internal threading. However, all partial
profile inserts (v-profile) can be used for external threading as well.
B Note: Be aware of the depth of the thread.
Example:
CoroMill 327 with ordering code 327R12-22 100VM-TH.
Recommendation:
• Pitch 1 to 2 mm (minimum 1, maximum 2)
• ar maximum 1.2 mm
C Conclusion:
• For internal threading, pitch 2 is enough, since ar is 1.2 mm
(ar maximum 1.2 mm).
• For external threading, pitch 2 is not enough, since ar is 1.4 mm
(ar maximum 1.2 mm).
Threading
• Use pitch 2.5 to 3.5 to produce the threads.
D
Milling
Machine tool requirements

E
• Thread milling requires a machine tool capable of simultaneous movements in the
X, Y and Z axes.
• The X and Y axes determine the diameter of the thread, while the Z axis will control
the pitch.
• Thread milling is preferably performed dry.
Drilling
• Different micro-lubrication systems, which use compressed air along with

small amounts of special types of oil, can be favorably employed to assist
F in chip evacuation.
Boring
G Programming
General
The cutting diameter of each tool has to be considered carefully when the operation
Tool holding/
is programmed.
Machines
•P rogramming with radius correction allows for easy adjustment of thread

tolerances.
• In case a thread tolerance is produced too tightly, compensation can be applied by
H a small adjustment (reduction) of the radius correction value.
Materials
I
Information/
D 98
Index

Thread milling – how to apply A
General turning
CoroMill® Plura
CoroMill Plura has an individual radius programming (RPRG)
value marked on the shank of the tool.
• T he RPRG value indicates each cutter's exact pitch diameter
and the radius correction required for optimum thread
quality.
B

• The RPRG value is normally entered into the tool memory
offset.
• Using the RPRG will prevent the first thread from being too
large, as long as the operational conditions are good.
C
Tool radius programming value.
Threading
D
Cutting data recommendations
• In internal applications, the periphery of the tool will rotate
faster than centre-line of the tool.
Milling
• Programming of the feed rate (mm/min) on most milling
machines is based on the centre-line of the spindle. This
fact must be included in the calculations for the thread
milling in order to avoid shortened tool life, vibration, or
E
complete breakdown.
• CoroMill Plura thread milling cutters have a larger surface
area contact than end mills of equal lengths, and often a
less favorable length to diameter ratio.
Drilling
• The same cutting speed that is used for conventional end
mills can be used for thread milling cutters.
• For shallow cuts, the feed rate should not exceed 0.15 to
produce a good thread surface.
F
vfm × (Dm – Dcap)
vf =
Dm
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 99
Index

A Dedicated methods – application overview
Dedicated methods
General turning
B
Peck milling
Linear ramping How to apply D 119

C
How to apply D 108

Threading
D
Milling
E
Drilling
F Circular ramping
Circular milling
Boring
How to apply D 110
G
Tool holding/
Machines
H
Chamfering
Materials
How to apply D 127
I
Information/
D 100
Index

Dedicated methods – application overview A
General turning
Closed pockets
Choice of tools D 125 B

How to apply D 125
Plunge milling
Threading
D
How to apply D 117
Cavity milling
How to apply D 115
Milling
E
Drilling
F
Boring
G
Slicing methods
Tool holding/

Machines
How to apply D 121
H
Materials
Milling
I
Information/
D 101
Index

A Dedicated methods – overview
Overview - holes and cavities

General turning
Creating openings in a solid workpiece

B
Linear ramping Peck milling

Threading
Opening a slot
Linear ramping (2-axis simultaneously) is always to be preferred in comparison to peck milling.
Peck milling is an alternative method, but it often produces long chips and generates undesirable cutting forces on the cutter.
D
Milling
E
Drilling
Drilling Circular ramping Ramping a cavity
F Opening a hole or a cavity

Drilling is the traditional and fastest method for producing a • hen a range of hole sizes are to be machined.
W
hole, but chip breaking can be a challenge in some materials, • Limited tool magazine space to store many drill sizes.
and it lacks the flexibility to produce varying diameters and • Production of blind holes, when a flat bottom is required
Namnlöst-1 1
non-round shapes. 2009-08-31 09:29:34
• Non-rigid, thin walled components.

Boring
Circular ramping (3-axis simultaneously) is a less productive • Interrupted cuts.

method compared with drilling, but can be a good alternative • Materials difficult to drill, due to chip breaking and chip
G in case of: evacuation.
• L arge diameter holes when machine power is limited. • No cutting fluid is available.
• Smaller series production. A rule of thumb for diameters • Cavities/pockets (“non-round holes”).
Tool holding/
larger than 25 mm: milling is cost efficient up to a series of

Machines
approx. 500 holes.
Namnlöst-1 1
Materials
I
Information/
D 102 Namnlöst-1 1 2009-08-31 09:29:34

Index

Dedicated methods – overview A
General turning
Widening a hole or a cavity

Boring Circular ramping Circular milling
C
Widening a hole
Boring is normally the fastest method, for the same reasons as drilling, but milling is sometimes a good alternative, see previous
page. Two alternate milling methods can be used: Circular ramping (3-axis) or circular milling (2-axes). Circular ramping is to be
prefered when the hole is deeper than ap max, or in vibration sensitive applications. Also the roundness/concentricity of the hole
Threading
becomes better when ramping, especially at long overhangs. Roundness will be improved if the workpiece is rotated instead of
moving the milling cutter in a circular path in both circular ramping and milling operations.
Widening a cavity
Internal shoulder milling and plunge milling require a starting
hole and should be compared to ramping a cavity directly into
Milling
a solid block, see previous page.
•R amping (3-axes) has an advantage because it only requires
one tool and can produce 3D-shapes, making is suitable in E
profile milling. If applied with high feed techniques (light
and fast), the cutting forces will be directed in a favorable
manner that minimizes vibration problems.
• Plunge milling often solves problems with long overhangs
Internal shoulder milling Plunge milling
Drilling
and/or deep cavities.
• Internal shoulder milling requires more programming than
Namnlöst-1 1 2009-08-31 09:29:34
plunge milling, but is faster.

F
Boring
G
Tool holding/
Machines
Plunging in corners Slicing technique – light Slicing in corners Trochoidal

and fast H
Rest (remaning stock) milling

When the roughing of a cavity is completed, stock often remains, especially in corners. Plunge milling with a smaller cutter is
Materials
Namnlöst-1 1 2009-08-31 09:29:34
one method for coming closer to the finished shape. Slicing (light and fast) is another technique often used in corner milling.
Trochoidal milling is one type of slicing technique that is also used for milling slots, pockets etc.
I
Information/
D 103
Index

A Linear ramping (2-axes) / circular milling (2-axes) / circular ramping (3-axes)
Linear ramping (2-axes)

General turning
Linear ramping is commonly used as an efficient way to ap-

B proach the workpiece when machining closed slots/pockets/
cavities, and it eliminates the need for a drill.
Linear ramping is defined as simultaneous feeding in the axial

direction (Z) and in one radial direction (X or Y), i.e. two-axes
ramping.
Circular ramping is always prefered to straight ramping (full
slotting), because the radial cut is reduced and allows for pure
C down-milling and better chip evacuation.
A counter-clockwise rotation ensures down-milling.
Threading
Linear ramping for opening a closed slot.
D
Milling
Circular milling (2-axes)

Drilling
F Circular milling is an alternate method to the traditional use of

boring tools. Circular milling can be performed by moving most
90 degree cutters in a circular tool path.
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 104
Index

Linear ramping (2-axes) / circular milling (2-axes) / circular ramping (3-axes) A
Circular ramping (3-axes)
General turning
Feeding the cutter in a circular ramping path, moving
simultaneously in the X , Y and Z directions, is often used for
B
opening up a cavity/pocket. It is also an alternate hole making

method to drilling and boring, see comparison on page D 102.
Circular ramping in a solid workpiece.

P = pitch (mm/rev)
Threading
D
Milling
Circular ramping to widen a hole.
E
Drilling
Circular ramping - first choice cutters
Hole diameter (mm) F
20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
Flat bottom CoroMill® Plura/CoroMill® 316 CoroMill® 390 CoroMill® 210
P CoroMill®
Boring
Plura/
Through hole CoroMill® 390 CoroMill® 210
CoroMill®
316

G
M Through hole
CoroMill®
Plura/
CoroMill® 300
CoroMill®
316
Tool holding/

Machines
K Through hole
CoroMill®
Plura/
CoroMill®
316

H
N Through hole
CoroMill®
Plura/
CoroMill®
316
Materials
S Through hole
CoroMill®
Plura/
CoroMill®
316 I
Information/
D 105
Index

A Dedicated methods – choice of tools
Choice of tools
General turning
Cutters that can perform linear ramping can also perform circular ramping.
Note: When machining a blind hole, the minimum Dm will be larger if a flat bottom
B profile is required. It can be calculated using the formula specified on page D 111.
Linear ramping
CoroMill® Plura CoroMill® 316
VFD, Helix 50° Corner radius end mill
C Circular Linear Circular Linear
Max. hole depth < ap ap < 0.55 x Dc
Hole quality H7 H7 Max.

Threading
Through hole ap = 0.9 x Dc Through hole ap = 0.55 x Dc

Dc alt. D3 Circular ramping
(mm) Dm P Dm P
min mm/r a° lm
min mm/r a° lm
D
4 4.8 0.26 6.7 30.6
6 7.2 0.43 6.7 46.0
8 9.6 0.53 6.7 61.3
10 12 0.66 6.7 76.6 12 0.78 10 31.2
hole depth
12 14.4 1.39 10 61.2 14.4 0.89 10 37.4
Milling
16 19.2 1.77 10 81.7 19.2 1.1 10 49.9

20 24 2.21 10 102.1 24 1.37 10 62.4
E 25 30 1.65 10 78.0
P = pitch

Drilling
Insert size 11 and 18* re=0.8 mm Insert size 17 with re=0.8 mm Insert size 16 with re=0.8 mm Insert size 22 with re=0.8 mm
F Circular Linear Circular Linear Circular Linear Circular Linear
Max. hole depth < l3** < l3** < l3** < l3**
Hole quality H9 Max. H9 Max. H7 Max. H7 Max

ap = 10 / 15*
Through hole Through hole ap = 15 mm Through hole ap = 12 mm Through hole ap = 18 mm
Boring
mm
Dc alt. D3
(mm) Dm P Dm P Dm P Dm P
min mm/r a° lm min mm/r a° lm
min mm/r a° lm
min mm/r a° lm
G 12 14 0.4 6.0 99
16 20 2.0 10.5 54
20 24 2.0 5.5 104
Tool holding/
25 39 3.0 5.0 114 33 6.0 15.5 59 28.8 4.3 19 45.7

Machines
32 53 3.3 3.6 159 47 4.5 6.7 135 42.8 8.1 13 66

36 61 2.7 2.6 220 50.8 9.3 11 78
40 78* 7.0* 6.8* 132* 63 4.0 3.9 231 58.8 10.2 9 89 51 11.5 18 74
44 86* 6.5* 6.0* 149* 60.8 10.8 8 101 59 13.7 16 84
H 50 98* 6.0* 5.5* 163* 83 1.0 2.8 323 78.8 11.6 7 118 71 15.7 13 100
54 106* 4.5* 5.0* 179* 86.8 11.9 6 130 79 11.7 12 111
63 124* 4.0* 4.0* 225* 109 1.6 2.1 430 97 18 9 134
66 130* 3.5* 3.7* 243* 103 18 9 141
80 158* 3.0* 3.1* 290* 143 1.6 1.6 565 131 18 7 176
Materials
* Insert size 18 has dedicated ramping geometries -xMR

I
** Note: If oversized cutters then depth can be up to 3xD.
Information/
D 106
Index

Dedicated methods – choice of tools A
General turning
CoroMill® 210 CoroMill® 300 B

Insert size 09 Insert size 14 Insert size 08 Insert size 10
Circular Linear Circular Linear Circular Linear Circular Linear
Max. hole depth < l3** < l3** < l3** < l3**
Hole quality H13 Max. H13 Max. H13 Max. H13 Max.
Through hole ap = 1.2 mm Through hole ap = 2.0 mm Through hole ap = 4 mm Through hole ap = 5 mm C
Dc alt. D3
min mm/r a° lm
min mm/r a° lm
min mm/r a° lm
min mm/r a° lm
25 32 1.2 14.5 4.6 36.4 2 8.0 28.5 32.4 2.5 13.5 20.8
Threading
32 46 1.2 8 8.5 50.4 2 5.0 45.7 46.4 2.5 7.5 38.0
35 52 1.2 7 9.7 56.4 2 4.0 57.2
36 54 1.2 7 9.7
40 66.4 2 3.5 65.4 52.4 2.5 6.5 43.9 D
42 66 1.2 5 13.7 70.4 2 3.0 76.3 62.4 2.5 5.0 57.2
50 82 1.2 3.5 19.6 86.4 2 2.5 91.6 66.4 2.5 4.5 63.5
52 86 1.2 3.3 20.8 76 2 5.8 19.6 90.4 2 2.0 114.5
63 108 1.2 2.6 26.4 98 2 3.8 30.1 112.4 2 1.5 152.8
66 114 1.2 2.4 28.6 104 2 3.2 35.7 118.4 2 1.5 152.8
Milling
80 132 2 2.4 47.7 146.4 2 1.0 229.2
CoroMill® 300
Drilling
Insert size 12 Insert size 16 Insert size 20
Circular Linear Circular Linear Circular Linear F

Max. hole depth < l3** < l3** < l3**
Hole quality H13 Max. H13 Max. H13 Max.
Through hole ap = 6 mm Through hole ap = 8 mm Through hole ap = 10 mm
Boring
Dc alt. D3
(mm) Dm P Dm P Dm P
min mm/r a° lm
min mm/r a° lm
min mm/r a° lm
32 42.6 3 12.0 28.2

G
34 46.6 3 11.5 29.5
35 48.6 3 10.5 32.4
Tool holding/
40 58.6 3 8.0 42.7

Machines
42 62.6 3 7.5 45.6

50 78.6 3 5.5 62.3
52 82.6 3 5.0 68.6 75.6 4 7.0 65.2
63 104.6 3 3.5 98.1 97.6 4 5.0 91.4
66 110.6 3 3.5 98.1 103.6 4 4.5 101.6 96 5 9.4 60.5 H
80 138.6 3 2.5 137.4 131.6 4 3.5 130.8 124 5 6.7 85.2
100 171.6 4 2.5 183.2 164 5 4.8 119.2
125 221.6 4 1.5 305.5 124 5 3.5 163.5
Materials

I
Information/
D 107
Index

A
General turning Dedicated methods – choice of tools
CoroMill® 200
Insert size 10 Insert size 12 Insert size 16 Insert size 20
Circular Linear Circular Linear Circular Linear Circular Linear
B Max. hole depth < l3** < l3** < l3** < l3**
Hole quality H13 Max. H13 Max. H13 Max. H13 Max.
Through hole ap = 5 mm Through hole ap = 6 mm Through hole ap = 8 mm Through hole ap = 10 mm

Dc alt. D3
min mm/r a° lm
min mm/r a° lm
min mm/r a° lm
min mm/r a° lm
25 32 2.5 13 22
C 32 42 3 13 26
40 58 3 9.5 32 50 4 13 35
50 78 3 6.5 49 70 4 11 35 62 5 13 43
63 104 3 4.5 68 96 4 7 48 88 5 11 45
80 138 3 3.5 98 130 4 5 70 122 5 7 67
Threading
100 178 3 2.5 137 170 4 3.5 102 162 5 5 95

125 220 4 2.5 131 212 5 3.5 127
160 282 5 2.5 191
D
Milling
E
How to apply
Two axes ramping – linear
Drilling
A demanding cutting process

There are three cutting processes that occur simultaneously during the ramping
F operation:
1) Periphery cutting with the leading insert.
2) Bottom cutting with the leading insert.
3) Bottom cutting with the trailing insert.
Boring
The cutting forces are both axial and radial.

There is also added stress on the tool due to full slotting, which means that
ae=Dc, creating large radial forces and long chips.
G
Tool holding/
Machines
H
Materials
I
Information/
D 108
Index

Dedicated methods – how to apply A
General turning
Machining recommendations
•R educe feed to 75% of normal.
• When slot milling is performed directly after ramping, it is important to continue at a lower feed, for a
distance that corresponds to the cutter diameter, until the trailing insert has stopped cutting.
• Use cutting fluid to help with chip evacuation.
• Reduce the radius on the tool to reduce the area of contact.
B

• Straight ramping should be limited to narrow slots less than 30 mm wide, if access for helical ramping is
limited.
Progressive ramping C
When ramping in several passes to produce a deep slot,
the productivity can be easily increased by ramping in both
directions (progressive ramping) instead of ramping in only
Threading
one (single pass ramping).
Note: When feeding the cutter at the maximum ramping angle,
it must be lifted the distance h before changing direction. This
prevents damage to the central part of the cutter body. D
Single pass ramping.
Milling
Tool path correction:
E
h = Tang a (Dc - (2 x iW))
Drilling
F
Progressive ramping at maximum ramping angle.
Boring
Insert radius affects maximum ramping angle
Example CoroMill® 790
G
The curves in the diagram are valid for minimim and maximum radii. For intermediate radii, please interpolate.
(a) Ramping angle

Tool holding/
Machines
30°
rε = 0.5 mm
25°
rε = 6.35 mm
20° H
15°
rε = 0.5 mm = Insert size 22
10°
rε = 5.0 mm
= Insert size 16
Materials
5°
0°
20 30 40 50 60 70 80 90 100 110 120 130
Tool diameter, Dc mm I
Information/
D 109
Index

A
General turning Dedicated methods – how to apply
Circular ramping – hole making

Circular ramping (also called helical interpolation, spiral interpolation, orbital drilling,
etc.) is an alternative to drilling.
It is a simultaneous movement in a circular path (X and Y) together with an axial feed
B (Z) at a defined pitch.
Compared to linear ramping (full slotting), helical interpolation is a much smoother
process because the radial cut is reduced, it allows for pure down-milling, and
provides better chip evacuation.
A counter-clockwise rotation ensures down-milling.
C
Threading
D Process considerations
There are three key considerations in circular ramping: if not correctly applied, problems will occur.
1. Cutter diameter selection for hole size
2. Pitch per revolution
3. Feed rate
Milling
E
1. Cutter diameter selection for hole size
Drilling
F
Boring
G
Tool holding/
Machines
The cutter size selection is very Cutter diameter is too small and will If the cutter is too large, the insert does
H important when using cutters that leave a core in the middle – like not inscribe the centre line of the hole,
are not centre cutters. trepanning. This is acceptable for large and a pip will be formed which will foul
cut-outs (‘man holes’) but the core on the bottom of the cutter.
Cutter diameter ensures that the insert
needs to be supported as it drops off.
cuts over the centre line of the hole.
Materials
I
Namnlöst-1 1 2009-08-31 09:29:34
Information/
D 110
Index

General turning
Maximum diameter hole
• T he maximum hole diameter, Dm, which can be produced in
one continuous spiral, is 2 x D3.
• This is full slotting and will leave a pip in the centre of a
blind hole.
• The pip is removed by feeding to centre for a flat bottom. B

C
Threading
Max. hole diameter Dm
Max. Dm = D3 x 2 D
Dm
Min. D3 =
2
Milling
Minimum diameter flat bottom
E
• To ensure that no pip is left on the bottom of a blind hole, the insert radius size needs to be considered.
• If the cutter is too big, the pip cannot be removed by feeding to centre.
• For CoroMill 390, the wiper length, bs, also needs to be added to the radius size.
Drilling
F
Boring
G
Tool holding/
Machines
CoroMill® 390 – CoroMill® 300 –

min. hole diameter Dm min. hole diameter Dm
Materials
Dm Dm
Max. D3 = + (re + bs) Max. D3 = + 0.5 iC
2 2
Min. Dm = (D3 – (re + bs )) x 2 Min. Dm = (D3 – 0.5 iC) x 2
I
Information/
D 111
Index

A
Minimum diameter through hole

• T he minimum diameter that avoids collision of the cutter body due to
non-centre cutting.
• b is the maximum stepover allowed for plunging, and is the same for the
maximum overlap.
B • For round inserts, b should be calculated as
b = 0.8 x iC.
• Pip cannot be removed.
C
Threading
D b
CoroMill® 390 – CoroMill® 300 –

min. hole diameter Dm min. hole diameter Dm
Milling
Dm Dm
Max. D3 = +b Max. D3 = + 0.8 iC
2 2
E Min. Dm = (D3 – b) x 2 Min. Dm = (D3 – 0.8 iC) x 2
2. Pitch (P)
Drilling
The pitch can never be larger then the maximum ap for the cutter concept, and
depends on the hole diameter, the cutter diameter and the ramp angle.
F
Boring
3. Feed rate
G
The feed value always depends on the hex-value which corresponds with the
peripheral feed rate, vfm. However, many machines require a tool centre feed, vf,
which has to be calculated accordingly:
Tool holding/
Machines
H Dvf
fz = hex vfm = n × fz × zc vf = × vfm
Dm
Dvf = programmed cutter path

Materials
Programmed feed rate:

vfm = when using radius compensation
I vf = when using the tool centre feed
Information/
D 112
Index

General turning
Widening an existing hole
Widening an existing hole can be performed either by circular ramping or circular
milling.
Circular ramping – 3 axes
• onstant ramping.
C B
• No entry or exits.

• Cutter constantly engaged.
• Ramping action – bottom cutting.
First choice:
• Depth of hole is greater than the maximum ap for tool.
• Best hole concentricity and roundness.
• In vibration sensitive applications. C
Dvf = Dm – Dc
Threading
D
Circular milling – 2 axes
•C onstant Z.
• Entering and exiting for each level.
• Rolling entrance into cut should be
Milling
programmed.
• Hole tolerance is not as good as helical.
• Step marks at each pass.
E
First choice:
• Program tool path more than 360 degrees to avoid
step marks.
• Only one pass is required.
Dvf = Dm – Dc
– Cutter with high ap capability (CoroMill Plura,
Drilling
CoroMill 390 long edge cutter). Dvf
– Shallow hole. Dvf1 =
2
• Ramping capability poor or nonexistent – long edge Namnlöst-1 1
F
without axial support.
Boring
G
Tool holding/
Machines
H
Materials
Entrance into cut – rolling into cut ensures thin chips on exit.
Low engagement angle – reduces vibrations and ensures high
productivity.
I
Information/
D 113
Index

A
Calculating feed
Feed needs to be reduced due to:
• Increased ae relative to straight cutting, which reduces the chip thinning effect.
• Peripheral feed is greater than the tool centre feed.
• Calculate feed based upon Dvf.
B
hex Dvf
fz = vfm = n × fz × zc vf = × vfm
sin ß Dm
C
Threading
D
Circular external milling/ramping
Compared to internal circular milling/ramping:
• The tool centre feed, vf, is increased instead of reduced.
Milling
• The radial depth, ae, becomes much smaller when milling externally, therefore, a
higher cutting speed can be used.
E • hex is calculated in the same way as for edging.
• The programming technique is otherwise very similar to internal milling of holes.
For complete information, calculations and formulas, see Information/Index,
Chapter I.
Drilling
F External circular ramping (3-axes).
vfm × (Dm + Dcap) Dw - Dm

Boring
vf = ae eff =
Dm 2
G
Tool holding/
Machines
H
External circular milling (2-axes).
Materials
I
Information/
D 114
Index

General turning
Opening up/widening a cavity or pocket
There are two clear strategies:
1. Circular ramping (3-axes) – small ap
Use a cutter with a small entering angle, CoroMill 210 or corresponding CoroMill B
316 or CoroMill Plura high feed cutters. A round insert cutter is another alternative.

For more information, see High feed milling, page D 60.
This “light and fast” technique provides an excellent metal removal rate and is the
first choice for less stable machines (acc. to ISO 40) and when the cavity has a
profiled shape, i.e. die and mould.
Note: Avoid machining all the way against a 90° shoulder because the effect of a
low approach angle will be lost, i.e. the depth of cut increases dramatically.
C
Cutting parameters:
• aximum cutter diameter = 1.5 x component corner radius
M
• Circular ramp to depth – counter-clockwise
Threading
• Roll into the next cut
• Radial cut – max. ae = 70% Dc
• Axial cut for round insert cutter 25% iC
• Tool path radius in the corner = Dc
D
• Reduce corner feed, see page D 26.
Milling
Ramping counter-clockwise tool path.
E
2. Circular milling (2-axes) – large ap
Drill a hole, and then change to a shoulder end mill or a long edge cutter. A typical
application area is found in aerospace framing – titanium machining.
Drilling
Application hints
Ensure good chip evacuation to prevent re-cutting of chips/chip jamming:
• Horizontal spindle (ISO 50) is prefered. F
• High pressure coolant or compressed air with through tool coolant.
• Dc should be no greater than 75% of hole dia. Use a large axial cut – maximum ap
= 2 x Dc.
The drilled hole should be entered in a circular path:
Boring
• Control radial engagement, maximum ae = 30% of Dc.
Control radial engagement to minimize vibration in corners, and to maximize
productivity: G
• Use the largest radius possible in the corners, spiral morph programming.
• Use the largest Dc possible and complete rest milling separately at no greater
than 1.5 x the corner radius.
Tool holding/
Machines
H
Materials
Small corner radius. Spiral morph

programming.
I
Information/
D 115
Index

A Plunge milling – choice of tools
Plunge milling
General turning
In plunge milling, the cutting is performed at the end of the

B tool instead of at the periphery, which is advantageous due
to the change in the direction of the cutting forces from
predominately radial to axial. In general, plunge milling is an

alternate method when side millling is not possible due to
vibrations. For example:
• hen the tool overhang is greater than 4 x Dc
W
• When the stability is bad
C • For semi-finishing of corners
• For difficult to cut materials like titanium.
It can also be an alternative when machine power or torque is
a limitation.
Threading
Note: Under favorable conditions plunge milling is not the first

choice due to a lower metal removal rate.
D
Milling
E
Choice of tools
Cutter selection is determined primarily by the diameter. Plunge drilling
CoroMill 210 and Coromant plunge cutter R215 are dedicated Plunging with drilling tools can be more effective up to approx.
for plunging. Dc = 35 mm, see Drilling, Chapter E.
Drilling
F Feed per tooth Cutter dia.

Concept Application Insert size (mm) (mm) fz Max. step over b range (mm) Dc
First choice for roughing with long 09 0.1 8 25 – 66

CoroMill® 210
overhang 14 0.15 13 52 – 160
Boring
Coromant plunge Heavy duty – large diameter with

25 0.15 22 80 – 160
cutter R215 long overhang
G
CoroMill® Plura Small deep corner radii – 0.05 100% Dc 1 – 25
Tool holding/
Machines
CoroMill® 316 Small deep corner radii – 0.05 100% Dc 10 – 25
H 11 5.5 12 – 80
CoroMill® 390 Slotting and roughing corners 0.15
17 8.5 25 – 125
CoroMill® 490 Roughing corners 08 0.15 2 mm 20 – 125

Materials
CoroMill® 300 Slotting in difficult materials 5 ～ 20 0.15 80% iC 10 – 200

I
Information/
D 116
Index

Plunge milling – how to apply A
How to apply
General turning
Cutting process
Plunge milling varies considerably from traditional milling. It B
uses the end of the tool to cut instead of the periphery, which

beneficially changes the direction of the cutting forces from
predominantly radial to axial. It can be compared to a boring
operation with interrupted cuts.
Power consumption and noise are low.
Threading
Plunge milling = interrupted Traditional milling. Mainly radial
boring. Axial cutting forces. forces.
D
ae
Milling
s
Drilling
General hints
•H orizontal machine facilitates chip evacuation.
• Start milling from bottom and work up. F
• Use cutting fluid or compressed air to facilitate chip
evacuation.
• In comparison with traditional methods, plunge milling
requires a lower feed per tooth.
• Ensure that more than one tooth is engaged.
Boring
• Use extra close pitch cutters.
• Use maximum ae – depending on insert size.
• Use s = 0.75 x Dc when moving sideways. G
• Gradually decrease plunge depth to minimize vibration.
= program table feed
• Use a "hook program" to prevent re-cutting on the return
stroke. Feed 1 mm away from wall at the end of the cut. = rapid traverse
Tool holding/
Note: A drilling cycle is not recommended due to re-cutting

Machines
Avoid re-cutting on return stroke. Gradually decrease plunge depth.

which can cause vibration during retraction.
• Always strive to leave a constant stock for a subsequent
finishing operation.
D3 x ae x vf x kc
H
Pc =
60 × 106
➡
Materials
s x ae x vf x kc
Pc =
60 × 106
➡
Power consumption calculation.
I
Information/
D 117
Index

A
General turning Plunge milling – how to apply
Slots
•P lunging is an effective technique for machining deep and closed slots.
• Chip evacuation becomes essential. A horizontal set-up and the use of cutting fluid
or compressed air will assist in this process.
B • A drill is recommended for deep and narrow slots, as it provides the best chip
evacuation and highest step-over rate, see chapter E.
Cavities/pockets
Threading
•C hip evacuation is critical, just like in closed slotting.

• Use a horizontal set-up and cutting fluid or compressed air.
• Chip evacuation can be further improved by driling the largest possible start hole.
1.5 x Dc is recommended.
D • Reduce feed in the first two plunge steps.
• Move sideways and try to prevent full slotting.
Milling
Corners
Plunge milling of the remaining stock (rest milling) after a roughing operation in deep
Drilling
90 degree corners can be advantageous.

The CoroMill Plura, CoroMill 390 end mill or the Coromant U Plunge drill (see Drilling,
Chapter E) are all suitable. The drill allows cuts of up to 75% of the cutter diameter,
F which can be advantageous in narrow corners.
Boring
Corner machining
Tool holding/
Machines
Dc = 12.7 mm
Start radius =
H 16 mm
Materials
End radius = 6 mm
I
Information/
D 118
Index

Peck milling – choice of tools A
Peck milling
General turning
Peck milling is an alternative to ramping for opening up in solid
material.
B

However, it requires excessive power, produce long chips and
places undesirable cutting forces on the cutter and should
therefore only be used when:
• T he machine lacks ramping capability
• Producing short closed slots.
Threading
Choice of tools D
Milling
E
11: 1.0 mm 16: 1.1 mm
Max. drill depth 0.9 x Dc 0.55 x Dc
17: 1.5 mm 22: 1.2 mm
Cutter dia. (Dc), mm 2 − 25 10 − 25 12 − 40 25 − 100
Drilling
Centre cutting (drilling) Yes Yes No No
Material
P M K P M K P M K P M K F
N S H N S H N S H N S H
Boring
How to apply
G
Centre cutting - drilling end mills (end milling cutter)
The drill depth of a centre cutting end mill is limited by the length of
the chip flute, and also by the the chip evacuation capability. For deeper
Tool holding/
slots, use a peck cycle. When drilling, use a low feed: approx. 50% of
Machines
the feed recommended for milling. Note: consider ap max for full slotting
milling.
Non-centre cutting end milling

CoroMill 390 and 790 are non-centre cutting end mills that can be used
Materials
for a peck milling cycle. Note that the drill depth is very limited. Use a
coarse pitch cutter for maximum chip room.
Max. drill depth I

Information/
D 119
Index

A Slicing methods – choice of tools
Slicing methods
General turning
These milling methods were originally developed for roughing

B and semi-roughing of difficult materials, like hard steels, ISO H,
and HRSA-materials, and ISO S, but can also be used in other
materials, especially in vibration sensitive applications.

The techniques are based on a small radial depth of cut, ae,
which:
• Generates a low radial cutting force that places less demand
on stability and enables a large depth of cut, ap.
C • Means that only one tooth is in cut at a time, which
minimizes vibration tendency.
• Reduces the heat in the cutting zone due to the short con-
tact time, making it possible to use higher cutting speeds.
• Generates a small chip thickness, hex, but a high feed, fz.
Threading
It can be divided into:

• trochoidal milling – primarily used for machining slots.
D • slicing – usually used for semi-roughing of corners.
Both these slicing methods have proven to be very secure and
productive methods.
Milling
Choice of tools
Drilling
CoroMill® Plura CoroMill® 316 CoroMill® 490 CoroMill® 390 CoroMill® 390 CoroMill® 690
F Long edge cutter Long edge cutter
Boring
Max. cutting depth (ap), mm 7.0 − 54.0 5.5 − 13.0 5.5 15.7 71.0 112.0
G Cutter dia. (Dc), mm 2 − 25 10 − 25 20 − 66 12 − 40 32 − 200 50 − 100
Material
P M K P M K P M K P M K P M K S
N S H N S H N S H N S H
Tool holding/
Machines
Comments:
• The most commonly used tool for slicing operations is the CoroMill Plura.
H • CoroMill 316, CoroMill 490 or CoroMill 390 are alternatives when the depth of cut
is lower.
• The slicing technique can also be used with long edge cutters that combine small
ae with large ap.
Materials
I
Information/
D 120
Index

Slicing methods – how to apply A
How to apply
General turning
B

Slicing uses a higher cutting speed, vc, and an axial cut, ap, but with only small radial C
engagements, ae, and feed per tooth, fz. This is possible due to:
Factor Effect Benefit
Threading
• T hin chip thickness • L ower cutting force/deflec- •D eeper axial cuts
• Small arc of engagement tion • Higher speeds
• Reduced temperature at
cutting zone
D
Milling
Trochoidal milling E
Application area
An excellent method for slotting when vibration is a problem; it is also suitable for
rough milling of confined cavities, pockets and grooves.
Drilling
Definition
Trochoidal milling can be defined as circular milling that includes simultaneous F
forward movements. The cutter removes repeated "slices“ of material in a sequence
of continuous spiral tool paths in its radial direction.
It requires specialized programming and machine tool capabilities.
The tool is programmed with a roll entry into and exit from cut, with the radial pitch,
Boring
w, kept low, which means that:
• T he controlled arc of engagement generates low cutting forces, which enable high
axial depths of cut. G
• The whole cutting edge length is utilized, ensuring that the heat and wear are
uniform and spread out, leading to longer tool life than traditional slot milling.
• Due to the short arc of engagement, multi-edge tools are used, which enable high
Tool holding/
table feeds with secure tool life.

Machines
• The maximum radial cut, ae, should not exceed 20% of the cutter diameter.
H
ap ≤ 2 x Dc
ae = small
Materials
vf = high
Namnlöst-1 1
vc = u
p to 10 times that of
conventional methods
I
Information/
D 121
Index

A
General turning Slicing methods – how to apply
For groove widths less than 2 x Dc

max
The tool is programmed on a continuous spiral path that feeds in the radial
direction to form a groove or a profile. The feed is constant, with a continuously
varying radial cut. 50% of the time the tool is out of cut.
B Considerations
1) The radial cut is constantly changing and, at the greatest immersion, it is
higher than the programmed step over, w.

2) It is important to keep the cutter diameter to a slot width ratio below 70%,
and the radial pitch, w, below 10% of Dc.
3) T he feed is constant, however, the tool centre feed, vf, varies from the
periphery feed, vfm. When the feed is programmed based on the tool centre,
C then the peripheral feed must be calculated.
Threading
D
Cutting parameters vfm = n × fz × zn
• Max. cutter dia Dc = 70% slot width
• Step over w = max. 10% Dc
• Radial cut max. ae = 20% Dc Dvf = Dm – Dc
Milling
• Axial cut ap = up to 2 x Dc
• Start feed per tooth fz = 0.1 mm Dvf
vf = × vfm
E Calculate programmed feed vf Dm
Machining cases using trochoidal milling

1 – Narrow groove – Inconel 718 (44HRC)
Drilling
Number of slots/component 24
F Width 12 mm
12
8
Length 25 mm
Depth 16 mm 0.8
Tool life 10 slots

Boring
Time/slot 1'35"
G Tool – R216.24-08050-EAK 19P 1620
Depth of cut ap 16 mm Tool centre dia. Dvf 4 mm

Tool holding/
Cutter dia. Dc 8 mm Step over w 0.67 mm

Machines
Number of teeth zn 4 Feed per tooth fz 0.09 mm
Cutting speed vc 75 m/min Periphery feed vfm 1047 mm/min
H Spindle speed n 2984 m/min Tool centre feed vf 349 mm/min
Trochoidal milling provides a far more secure process, when compared to traditional
Materials
slotting or plunging, with increased tool life and reduced tooling costs, as a 12 mm
tool replaces a 8 mm tool.
I
Information/
D 122
Index

Slicing methods – how to apply A
General turning
For grooves wider than 2 x Dc
A continuous spiral path, such as those programmed for the narrow groove where
50% of the time is spent with the tool out of the cut, can be optimized as the groove,
becomes wider:
1. Roll into cut – programmed radius (radm) = 50% of Dc. B
2. G1 with ae = 0.1 x Dc.

3. Roll out of cut – programmed radius (radm) = 50% of Dc.
4. Rapid movement to next start position.
5. Repeat cycle.
Cutting parameters C
• Radial depth
– CoroMill Plura ae = 10% Dc
Groove
– CoroMill 390/490 ae = 20% Dc
width
• Axial cut ap = up to 2 x Dc
Threading
• Start feed per tooth fz = 0.1 mm
• Radius feed radfv = 0.5 x G1
D
2 – Wide groove – Scallop
Ø8
Number of slots/component 8
Width 45 mm 45
15
Milling
10 rad
Depth 16 mm
Thickness 4 mm E
Tool 1 – CoroMill 390 – Ø 16 mm Tool 2 – CoroMill Plura – Ø 12 mm
Drilling
R390-016A16-11H R216.24-12050AK26P
R390-11T308M-PL 1620
1030 F
a) Stainless steel – 316
Tool Diameter, Dc mm zn vc n fz vf ap ae Q
Time
m/min r/min mm mm/min mm mm cm³/min min+sec
Boring
CoroMill 390 16 2 200 3978 0.15 1194 5 2 11.9 0'25''
CoroMill Plura 12 4 170 4509 0.06 1082 5 1 5.4 1'00''

G
b) HRSA – Inconel 718 (44 HRC)
Tool Diameter, Dc mm zn vc n fz vf ap ae Q
Time
cm³/min min+sec
Tool holding/
m/min r/min mm mm/min mm mm

Machines
CoroMill 390 16 2 30 597 0.10 119 5 2 1.2 2'45''
CoroMill Plura 12 4 75 1989 0.08 637 5 1 3.2 1'15''
H
CoroMill® 390 vs CoroMill® Plura
• Stainless steel – CoroMill 390 offers the fastest time – 140% faster than CoroMill Plura.
In stainless steel, the CoroMill 390 performed without material "clogging" or jamming in the flutes, which allowed for a faster
radial cut, ae, and higher feed per tooth, fz, than the CoroMill Plura.
Materials
• HRSA – CoroMill Plura was 120% faster than CoroMill 390.

In the harder HRSA, the extra teeth and high helix of the CoroMill Plura produced a much smoother operation.
I
Information/
D 123
Index

A
General turning Slicing methods – how to apply
Slicing – corner milling

Application area
Slicing is a semi-roughing technique used in corner milling where the larger tool used
in the previous operation could not reach.
B Definition
Unlike trochoidal milling, no roll into or from cut is required, as the radial cut builds
from zero to a maximum in the middle, and then drops back to zero again.
Multiple passes successively remove material, ensuring consistent low radial
immersion/engagement angle and low cutting forces.
Considerations:
C Feed rate reduction in corners:
• As with all radius contouring, when programming with a tool centre feed, vf, the
feed rate needs to be reduced relative to the tool periphery feed, vfm, to maintain a
constant feed per tooth.
• Depth of cut can become too great to be able to run at same high feed as with
Threading
straight line cutting, depending upon cutter diameter to corner radius relationship.
• However, the ratio between programmed cutter path diameter, Dvf, and hole diam-
eter, Dm, is constantly increasing towards the finished corner radius; which means
D that the feed needs to continually decrease for each pass. Slicing Conventional
• Process becomes unstable and vibration occurs.
• A machine tool with good dynamic stability and tool centre feed reduction control is
essential for successful milling of internal corners.
vfm = n × fz × zn
Milling
Dvf = Dm – Dc
E Dvf
vf = × vfm
Dm
Drilling
Dvf and vf continually decreased for each pass Angle of corner

F radw radw radw
radm radw (20 mm) (20 mm)
fin. rad radm radm
ae max radm
ae tot (6 mm) (6 mm)
θ ae max
θ θ
Boring
Dc Dc
w Namnlöst-1 1
G
Dvf
Dvf w
ae tot
Tool holding/
w = radial step over

Machines
radm = component end radius ae tot = 5.8 mm ae tot = 14 mm

radw = component start radius
H Cutting parameters
Typical values for a CoroMill Plura R216.24-xxx50-xxK xxP
• Maximum cutter diameter Dc = 1.75 x radm
• Radial step over w = 10% Dc
• High axial cut ap = up to 2 x Dc For the same start and end radii, the number of passes required will
• Start feed per tooth fz = 0.1 mm vary depending upon the corner angle.
Materials
• Cutting speed – approx. 3-6 times the normal recommendation. For corners with angles less than 60˚, plunging using the CoroMill 390
or a plunge drill can be a good solution, see page D 118.
I
Information/
D 124
Index

Closed pockets/angles – choice of tools A
Closed pockets/angles
General turning
Closed angles, less than 90 degrees, are a common
component feature in pockets and cavities. A machine with
B
4- or 5-axes is needed to machine a closed angle.

4-axes:
If only one side of the pockes has a closed angle and the bot-
tom shape is flat.
5-axes:
If there is a corner with closed angles on both sides. If there is
a radius at the bottom profile. C
Threading
Choice of tools D
CoroMill® Plura
Milling
E
Max. cutting depth (ap), mm 10.0 – 45.0
Cutter dia. (Dc), mm 3.8 – 15.18
Drilling
Material
P M K
N S H Milling of a blisk impellar is one application
example of milling closed angles.
F
How to apply
Boring
Machining recommendation
1. Prior to the radius machining, shoulder milling of the wall should be performed G
with a square end mill for best stability.
2. The radius is machined with a ball nose end mill.
Tool holding/
Machines
Namnlöst-1 1 2009-08-31 09:29:34
H
Materials
Use a square end mill for best stability when The final machining of the radius should be
machining the peripheral wall. performed with a conical ball nose end mill.
I
Information/
D 125
Index

A Chamfering – choice of tools
Chamfering
General turning
Chamfers, V-cuts, undercuts, preparation for welding, and

B deburring operations along the workpiece edges are frequent
operations. Depending upon the type of machine and set-up,
these operations can be performed in a varity of ways. A small

face mill, a long edge cutter, an end mill or a dedicated cham-
fering cutters can be used.
C
Threading
D Choice of tools
Dedicated chamfering cutters
CoroMill® Plura CoroMill® 316 CoroTurn® XS CoroMill® 327 CoroMill® 328 U-Max
Milling
Entering angle (degrees) 30, 45, 60 15, 30, 45, 60 30 45, 60 60 45, 60
Drilling
Max. chamfer depth 7.4 6.5 0.6 1.7 1.8 7.9
F Back chamfering min. hole

diameter (mm)
– – 6 12 40 27
Material
P M K P M K P M P M K P M K P M K
N S H N S N S N S H N S H N S H
Boring
G Complementary cutters for chamfering

In 4- and 5-axes machines, where the spindle or the workpiece can be tilted, a
number of tools can be used for chamfering and deburring such as:
Tool holding/
•9 0 degree end mills such as CoroMill Plura, CoroMill 316, CoroMill 390, CoroMill
Machines
490, CoroMill 790

• 45 degree face mills such as CoroMill 245 and CoroMill 345
• For large chamfers, long edge cutters can be used.
H
Materials
I
Information/
D 126
Index

Chamfering – how to apply A
How to apply
General turning
Cutting data
Normally the depth of cut, ap, and width of cut, ae, are small in relation to the B
cutter diameter. This means the higher cutting speed recommendations for small

engagement should be used. The feed per tooth, fz, can also be considerably
increased, see page D 21. The demands of the surface finish limit fz.
Threading
D
Chamfering a hole
With CoroMill 327, CoroMill 328 and CoroTurn XS, it is possible to chamfer the hole
after completing the threading operation, using the same tool and insert.
Milling
This is performed using a circular milling path, see the programming sequence
below.
E
Drilling
F
Boring
G
Tool holding/
Machines
Zero point for

1. Position the cutter centrally over the drilled 3. Interpolate 360° tool length and
hole, with the cutter rotating, and move radius.
axially to flange depth (Z = flange height – 4. Feed back to hole centre
chamfer size). 5. Retract cutter H
2. Feed the cutter to engage with the radius
compensation (Y = hole radius).
Materials
Note: To adjust chamfer size, alter Z position (do not adjust diameter as this can cause rubbing
on the hole).
I
Information/
D 127
Index

A Milling – trouble shooting
Trouble shooting
General turning
B Tool wear
Look at the edge, analyze the wear and optimize the cutting data from your conclusion.
Cause Solution
C Flank wear
Rapid wear causing poor surface finish or out of •R educe cutting speed, vc
tolerance. • Select a more wear-resistant grade
• Increase feed, fz
•C utting speed too high
• Insufficient wear resistance
Threading
• Feed, fz, too low
D Excessive wear causing short tool life. • Increase feed, fz

• Down milling
• Vibration • Evacuate chips effectively using compressed air
• Re-cutting of chips • Check recommended cutting data
• Burr formation on component
• Poor surface finish
• Heat generation
Milling
• Excessive noise
E
Uneven wear causing corner damage. • educe run-out below 0.02 mm
R
• Check chuck and collet
• T ool run-out • Minimize tool protrusion
• Vibration • Fewer teeth in cut
• Short tool life • Larger tool diameter
• Bad surface finish • For CoroMill Plura and CoroMill 316, select a higher
Drilling
• High noise level helix geometry (gp ≥45°)

• Radial forces too high • Split axial cutting depth, ap, into more than one pass
• Reduce feed, fz
• Reduce cutting speed, vc
F • HSM requires shallow passes
• Improve clamping of tool and workpiece
Boring
Crater wear
Excessive wear causing a weakened edge. Cutting edge • Select an Al203 coated grade
breakthrough on the trailing edge causes poor surface • Select a positive insert geometry
G finish. • First reduce the speed to obtain a lower temperature,
and then reduce the feed
•D
iffusion wear due to cutting temperatures that are too
high on the rake face
Tool holding/
Machines
Plastic deformation
Plastic deformation of edge, depression or flank •S elect a more wear resistant (harder) grade
H impression, leading to poor chip control, poor surface • Reduce cutting speed, vc
finish and insert breakage. • Reduce feed, fz
• Cutting temperature and pressure too high
Materials
I
Information/
D 128
Index

Milling – trouble shooting A
General turning
Cause Solution
Chipping
The part of the cutting edge not in cut is damaged by chip • elect a tougher grade
S
hammering. Both the top side and the support for the • Select an insert with a stronger cutting edge B
insert can be damaged, leading to poor surface texture • Increase cutting speed, vc

and excessive flank wear. • Select a positive geometry
• Reduce the feed at the beginning of cut
• The chips are deflected against the cutting edge • Improve stability
Small cutting edge fractures (frittering) causing poor • Select a tougher grade
surface finish and excessive flank wear. • Select an insert with a stronger geometry C
• Increase cutting speed, vc, or select a positive geometry
•G rade too brittle • Reduce feed at the beginning of the cut
• Insert geometry too weak
• Built-up edge
Threading
Notch wear D
Notch wear causing poor surface finish and risk of edge •R educe cutting speed, vc
breakage. • Select a tougher grade
• Increase cutting speed, vc
•W ork hardening materials
• Skin and scale
Milling
Thermal cracks
Small cracks perpendicular to the cutting edge causing •S elect a tougher grade with better resistance to thermal
E
frittering and poor surface finish. shocks
• Cutting fluid should be applied copiously or not at all, for
Thermal cracks due to temperature variations caused by: more information, see Getting started, page D 28.
• Intermittent machining
• Varying cutting fluid supply
Drilling
Built-up edge (B.U.E) F
Built-up edge causing poor surface finish and cutting edge • Increase cutting speed
frittering when the B.U.E. is torn away. • Change to a more suitable insert geometry
•C utting zone temperature is too low.
• Very sticky material, such as low-carbon steel, stainless
steels, and aluminium.
Boring
G
Workpiece material is welded to the cutting edge due to: • Increase cutting speed, vc
• L ow cutting speed, vc • Select a positive geometry
Tool holding/
• Low feed, fz • Use oil mist or cutting fluid

• Negative cutting geometry
Machines
• Poor surface finish
H
Materials
I
Information/
D 129
Index

A
General turning Milling – trouble shooting
Cause Solution
Vibration
(see also Getting started, page D 30)
B • Weak fixture •A ssess the direction of the cutting forces and provide adequate support or
improve the fixture
• Reduce the cutting forces by decreasing the cutting depth, ap

• Select a coarse and differentially pitched cutter with a more positive cutting
action
• Select a L-geometry with a small corner radius and small parallel land
• Select a fine-grain, uncoated insert, or a thinner coating
• Avoid machining where the workpiece has poor support against the cutting
forces
• Axially weak workpiece •C onsider a square shoulder cutter (90-degree entering angle) with positive
geometry
Threading
• Select an insert with L-geometry

• Decrease axial cutting force – lower depth of cut, smaller corner radius and
parallel land
• Select a coarse-pitch cutter with differential pitch
D • Check tool wear
• Check tool holder run-out
• Improve clamping of tool
Milling
• Too long tool overhang •M inimize overhang

• Use coarse-pitch cutters with differential pitch
E • Balance radial and axial cutting forces – 45 degree entering angle, large
corner radius or round insert cutter
• Increase feed per tooth
• Use a light-cutting insert geometry – L/M
• Reduce axial depth of cut, af
• Use up-milling in finishing
• Use oversize cutters and Coromant Capto coupling adaptors
Drilling
• For CoroMill Plura and CoroMill 316, try a tool with fewer teeth and/or a
higher helix angle
• Milling square shoulder with weak • elect smallest possible cutter diameter
S
Boring
spindle • Select positive and light cutting cutter and insert

• Try up-milling
• Check spindle deflection to see if acceptable for machine
G
• Irregular table feed • T ry up-milling

Tool holding/
• Tighten machine feed mechanism: adjust the feed screw on CNC machines.
Machines
Adjust the locking screw or replace the ball screw on conventional machines.
H • Cutting data •R educe cutting speed, vc

• Change cutting depth, ap
• Bad stability •R educe overhang

• Better stability
Materials
• Vibration in corners • Program large corner radii with reduced feed rate
I
Information/
D 130
Index

Milling – trouble shooting A
General turning
Cause Solution
Chip jamming
Common obstacle when full slotting – • Improve chip evacuation by using rich and well directed cutting fluid or
especially in long-chipping materials compressed air
• Insert corner damage
• Reduce feed, fz B
• Split deep cuts into several passes
• Edge chipping and breakage

• Try up-milling in deep slotting
• Re-cutting of chips • Use coarse pitch cutters
• Use CoroMill Plura and CoroMill 316 with two or maximum three cutting
edges and/or a higher helix angle
C
Re-cutting of chips
Appears in full slotting and pocketing •E vacuate chips effectively by compressed air or copious cutting fluid flow –
– especially in titanium. Also common preferably supplied internally through the tool
Threading
when milling deep cavities and pock- • Change cutter position and tool path strategy
ets on vertical machines. • Reduce feed, fz
• Split deep cuts into several passes
• Cutting edge fractures
• Harmful for tool life and security
• Chip jamming D
Milling
Unsatisfactory surface finish
E
• Excessive feed per revolution • et cutter axially or classify inserts. Check height with indicator
S
• Check spindle run-out and cutter mounting surfaces
• Decrease feed per rev to max. 70% of the width of the parallel land
• Use wiper inserts if possible (finishing operations)
Drilling
• Vibration • See section “Vibration”
F
• Built-up edge formation • Increase cutting speed, vc, to elevate machining temperature
• Turn off cutting fluid
• Use sharp cutting edge inserts, with smooth rake side
• Use positive insert geometry
• Try a cermet grade with higher cutting data
• Back-cutting • Check spindle tilt (Tilt spindle approx 0.10 mm/1000 mm) Boring
G
• Axial run-out TIR of spindle should not exceed 7 microns during finishing
• Reduce the radial cutting forces (decrease the depth of cut, ap)
• Select a smaller cutter diameter
• Check the parallelism on the parallel lands and on wiper insert used (should
Tool holding/
not be standing on ”heel or toe”)

Machines
• Make sure the cutter is not wobbling – adjust the mounting surfaces
H
• Workpiece frittering • Decrease feed, fz
• 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
Materials
geometry
• Choose a sharp insert
• Monitor flank wear to avoid excessive wear
I
Information/
D 131
Index

A
General turning Milling – trouble shooting
Cause Solution
Burr formation
•M aterial specific – HRSA/stainless • Use large radius giving low insert entry angle
steel • Keep depth of cut below radius
B • Notch main wear mechanism • CoroMill 300 – maximum ap = 0.25 x iC
• CoroMill 390 radius inserts – max.
• ap = 0.5 x radius
Machine power
C Be aware of the power curve as the • o from close to coarse pitch, i.e. fewer teeth
G
machine may lose efficiency if the rpm • A positive cutter is more power efficient than a negative cutter
is too low. • Reduce cutting speed before table feed
• Use a smaller cutter and make several passes
The power requirements in milling vary • Reduce depth of cut, ap
with the:
Threading
• Amount of metal to removed

• Average chip thickness
• Cutter geometry
• Cutting speed.
D For more information about power and
torque, see Getting started, page
D 11.
Milling
E
Drilling
F
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 132
Index

Products – milling

A Milling – CoroMill® 490
CoroMill® 490
General turning
The first choice for light cutting square shoulder milling −S

hallow shoulder milling and repeated passes with
high accuracy
B
− Shallow face milling with low axial pressure
− Near net shape milling
C − T he cost effective alternative to CoroMill 390 when

ramping capability and corner radii are not required
Threading
D
Cylindrical/Weldon Coromant Capto® coupling/HSK Arbor
Milling
E
Insert size 08 mm
Cutter dia. (Dc), mm 20 – 40 20 – 84 / 20 – 80 40 – 125

Drilling
Max. cutting depth (ap), mm 5.5 (repeated passes ≤ 4)
F Material
P M K P M K P M K
H H H
Insert geometries
Boring
ISO L M H
G P M-PL M-PM M-PH
M E-ML E-MM
K M-KL M-KM M-KH

Tool holding/
N
Machines
S
H M-PL M-PM
H
Applications
Repeated shoulder milling Edging/contouring Face milling

Materials
D 48 D 50 D 54
I Thin walls Slot milling Circular milling

D 52 D 84 D 113
Information/
D 134
Index

Milling – CoroMill® 490 A
General turning
Wiper technology for higher accuracy in peripheral milling
B
CoroMill 490 is designed with the insert edges slightly crowned to

compensate for deflection that might occur during operation and
for minor variations in the manufacturing precision of the tool.
Due to this geometry, angular distortion during edging or milling
shoulders, is minimized, and discernible steps between repeated
passes are avoided. To achieve this, a maximum ap of 3-4 mm
should not be exceeded.
C
Threading
Performance for higher productivity on small machines D
Light cutting performance provides an optimal utilization of weak
machine tools. This feature also facilitates use of the cutter on
extended tool assemblies.
Milling
E
Drilling
Undersized shanks for use in small tool holders
Undersized shanks for larger diameter cutters, using 8 mm
inserts, allow these to fit into smaller tool holders. F
Boring
G
Tool holding/
Machines
Oversized end mills for accessibility

H
Oversized versions of CoroMill 490 enhance the accessibility
and provide natural clearance to tight fixtures.
Materials
I
Information/
D 135
Index

CoroMill® 390
General turning
Versatile shoulder milling and slotting – deep or shallow,

light or heavy
B
C
Threading
Light cuts and profiling 11 mm inserts

-11
• Generally the first choice for cutter
Milling
• Light cuts and profiling.

diameters up to 80 mm and ap
• Semi-roughing and finishing operations. up to 5-6 mm. Enables the use of mm
E • Wide range of light cutting conventional and radius inserts. close pitch cutters at high table
feeds.
• Inserts sizes -11 and -17 with the most light cutting edges.
• Wiper insert -11 for finish turn milling.
• Silent Tools vibration dampening.
Drilling
• Most efficient on machining centres and multi-task machine 17 mm inserts

-17
tools with ISO 40 spindles. • First choice for ap larger than
F 5-6 mm and when more light
cutting performance is required. mm
Boring
Wide and heavy cuts 18 mm inserts

-18
Tool holding/
• A tough cutting edge solution for

Machines
• Roughing and semi-finishing operations.

applications requiring extra strength
• Wide range of radius inserts. and high security, especially for mm
• The -18 insert has a tougher edge for higher feeds and high feeds. Most suitable for arbor
H heavier applications. mounted shoulder cutters and long
edge cutters.
• Wiper insert -18 for rough turn milling.
• Inserts dedicated for ramping.
Materials
• Most effective on rigid spindles, ISO 50 and similar.
I
Information/
D 136
Index
General turning
End mills and shoulder face mills
Cylindrical Dampened Coromant Capto® coupling

Cutter dia. (Dc), mm Cylindrical/Weldon Cylindrical
16 – 80 40 – 84
12 – 40 20 – 32
Threaded coupling Coromant Capto
16 – 42 20 – 40
C
Insert size, mm -11 -17 -11 -11 -18
Max. cutting depth (ap), mm 10 15.7 10 10 15.4/15.7
Threading
Shoulder face mills Long edge cutters
Arbor
Coromant Capto®
coupling Cylindrical Arbor
D
Milling
E
Cutter dia. (Dc), mm 40 – 80 40 – 125 50 – 200 32 – 66 44 – 100 32 – 40 40 – 54 44 – 200
Insert size, mm -11 -17 -18 -11 -18 -11 -11 -18
Max. cutting depth (ap), mm 10 15.7 15.4/15.7 36 – 45 43 – 71 36 – 45 36 – 54 43 – 71
Drilling
Namnlöst-1 1 2009-08-31 09:29:34
Insert geometries Radius insert standard options

F
CoroMill® 390-11 and CoroMill® 390-17
PCD
ISO L M H TW *) insert mm
Boring
P M/E-PL M-PM M-PH E-PLW
M E-ML M/E-MM M-MH
K M-KL M-KM M-KH

mm
G
N E-NL E-KM E-PLW E-P4-NL, E-P6-NL
S E-ML E-MM E-PLW

Tool holding/
mm
H
Machines
M/E-PL M-PM E-PLW
CoroMill® 390-18
ISO L M TW *) Ramping H
P H-PL -PM H-PTW -PMR
M H-ML -MM H-PTW -MMR
K H-KL -KM H-KTW -KMR

Materials
Intermediate corner radii are offered

N H-PL H-PTW Tailor Made in steps of 0.1 mm for the
S H-ML M-MM H-PTW insert sizes -11 and -17.
H H-PL M-PM H-PTW *) TW = Turn mill wiper I

Information/
D 137
Index

A
General turning Milling – CoroMill® 390
CoroMill® 390 cutters for dedicated applications
• Oversized cutters for natural clearance and accessibility close to

shoulders and tight fixtures.
B • Cutters with integrated Coromant Capto coupling and adaptors
provide the optimal rigidity for use on extended tool assemblies.
• Silent Tools vibration dampening for increased metal removal

and improved surface finish, when using slender tools.
• Turn milling, roughing and finishing, using one or more dedicated
wiper inserts avilable in size 11 and 18 and radius 0.8 and 1.6.
C
Threading
D
Milling
E Maximum depth of cut for different operations

Insert size Insert -11 Insert -17 Insert -18
Cutter diameter (Dc), mm 12 16 20 25 32 40–80 25 32 40 50 63–125 40–200

Drilling
Shoulder milling, max. (ap), mm 9.0 9.5 9.4 9.3 9.2 5.9 15.2 15.1 15.0 14.9 9.6 15.7
Plunge milling, max. (ae), mm 5.5 8.5 1.1

F
Peck milling, max. (ap), mm 1.0 1.5 Not recommended
Boring
Applications
G
End mill and square shoulder cutter
Main application areas: Complementary application areas:
Tool holding/
Machines
Repeated shoulder milling General shoulder milling General face milling Peck milling
D 48 D 44 D 57 D 119
H Ramping Turn milling Plunge milling Slot milling

D 104 D 80 D 116 D 86
Long edge cutter

Materials
I Deep shoulder milling Edging/contouring Slot milling Circular ramping

D 48 D 50 D 86 D 105
Information/
D 138
Index

CoroMill® 290
General turning
General purpose/shoulder face mill − A basic cutter for ISO K applications
− Four edge economy B

High security
− Shim protected insert seats
− Strong cutting edges
Threading
D
Milling
Cutter dia. (Dc), mm 40 – 80 50 – 250
E
Max. cutting depth (ap), mm 10.7 10.7
P K *) P K *)
Material
Drilling
*) The grade assortment includes CBN and Ceramic inserts.
F
Insert geometries
CBN
ISO L M H Ceramic
inserts
Boring
M-PL M-PM M-PH
M
K M-KL M-KM M-KH 20E 08E G
N
S
Tool holding/
H
Machines
Applications H
Square shoulder milling Face milling Slot milling

Materials
D 44 D 54 D 86
Face milling of thin walls

D 52
Circular ramping
D 105
I
Information/
D 139
Index

CoroMill® 690
General turning
The cutter for high productivity titanium profiling − Cutting fluid supply, individual to each insert pocket
B − F ully controlled flow and pressure through threaded

holes - either for nozzles or plug screws
−H
igh fluid pressure facilitates chip removal and
reduces the heat in the cutting zone
−A
rich fluid flow prevents re-cutting of chips and
provides a longer cutter body life, particularly on the
front insert pockets
− Good plunge milling and ramping performance
C − Insert bottom shaped for rigid location, allowing for

undisturbed chip flow
−C
utter pitches –L, –M and –H for more information,
see Getting started, page D 17.
Threading
D
Coromant Capto® coupling/HSK Arbor
Milling
E
Cutter dia. (Dc), mm 40 – 66 63 – 84 100
Insert size (iC), mm 10 14 14

Drilling
Max. cutting depth (ap), mm 53 – 105 61 – 84 61
F Material S S
Insert geometries
Boring
ISO L
G P
M
K
Tool holding/
N
Machines
S -SL
H
H
Applications
Materials
I Shoulder milling Edging/contouring Slot milling

D 42 D 50 D 86
Information/
D 140
Index

General turning
CoroMill® 690, designed for titanium milling

C
Threading
Due to titanium’s heat resistance, cooling by using cutting fluid, CoroMill 690 is designed with an internal cutting fluid supply to
is vital during machining, so as not to overheat the cutting every insert pocket, at the periphery as well as the end of the
edge and tool face. cutter, to eliminate these problems. D
During the cutting process, the chips tend to stick to the Supplying cutting fluid to all the insert pockets in the long edge
cutting edge and will often be re-cut, causing edge line cutter requires, however, high pump volumes and pressure
chipping and shortened life. capability.
Milling
E
As an option, the holes in the CoroMill 690 insert seats can
Drilling
be plugged by screws, if fluid is not required in that seat at
that time. This irestricts the number of holes through which
fluid is supplied, allowing for maximum flow where required.
F
Alternately, nozzles can be mounted to reduce the hole size.
This reduces the pump flow required by increasing the pres-
sure at each nozzle, which also provides a more predictable
operation process and a longer tool life.
If the machine has the capacity to supply high pressure fluid
Boring
(HPC, 70-100 bar), it is advantageous to apply this together
with nozzles. The improved cooling of the cutting edge will
provide the required security to increase the cutting speed. G
Tool holding/
Machines
H
Materials
I
Information/
D 141
Index

A Milling – Coromant finishing long edge cutter
Coromant finishing long edge cutter

General turning
−P
rovides indexable insert cost efficiency along with
good surface finish and precision that is close to
B what solid carbide and brazed long edge cutters can
produce
−H
igh precision ground inserts and tight cutter body
tolerances ensure consistent performance and part
quality
− Light cutting inserts reduce the power requirements
− Restricted for finishing operations only
− T he inserts overlap each other, rendering them half as
C effective at reducing cusp height (zn = zn/2)
Threading
D
Milling
Insert geometries
E Cutter dia. (Dc), mm 50/80 ISO L

18 19
Max. cutting depth (ap), mm 100/150 side end
P -PL -PL2
Max. (ae), mm 1.5 – 2.0
M -ML -ML2
Drilling
Recommended (ae) 0.2 – 0.5 K -PL -PL2
N -AL -2
F Feed range, (fz), mm/tooth 0.13 – 0.15
S -ML -ML2
Surface finish, (Ra) 0.6 – 1.2 H -ML -ML2
P M K
Material
N S H
Boring
G Surface quality with indexable insert long edge milling cutters

Sandvik Coromant finishing cutter Conventional cutter
Tool holding/
Machines
No sharp steps or discernible cusps are generated when

passes are repeated, as lon as recommended feed and max.
H ae are not exceeded.
Maximum cusp height, h: 0.03-0.04 mm.
Materials
Applications
I Edging/contouring Deep shoulder milling Circular milling

D 50 D 48 D 105
Information/
D 142
Index

CoroMill® 790
General turning
Basic shoulder milling cutter for non-ferrous materials −G
enerates straight shoulders with minimal mismatch
and very low cusps when passes are repeated
− Effective rough and semi-finish ramping
B

−A
“power effective” tool, capable of high metal
removal rates per kW
−S
ecurity against high radial forces generated at
excessive speeds
Insert size 16 mm −A
ccurate and safe location of the cutting edges
eliminates the effect of the insert tolerances and
the resulting run-out
mm
−O
pen insert location for undisturbed chip flow at
C
heavy cuts
Insert size 22 mm
− High ramping capability
Threading
mm
D
Coromant Capto® HSK type A/C Cylindrical Arbor
coupling
Milling
E
Cutter dia. (Dc), mm 25 – 54 40 – 100 25 – 50 50 25 – 40 50
Insert size -16 -22 -16 -22 -16 -16
Max. cutting depth (ap), mm
Drilling
• Roughing 12/15 18 12/15 18 12/15 12/15
• Finishing (2/3 of roughing) 8 12 8 12 8 8
Max. feed (fz), mm/tooth F

• Roughing 0.2 0.3 0.2 0.3 0.2 0.2
• Finishing 0.15 0.15 0.15 0.15 --- ---
Radial surface finish (Ra) 0.5 0.5 0.5 0.5 0.5 0.5
Boring
Material Insert geometries P M K N S H
• Roughing L -NL
M -NM
G
• Finishing L -PL -PL -PL -NL -PL -PL
Tool holding/
Insert recommendations
Machines
• 22 mm inserts for extreme metal removal rates and 16 mm inserts for smaller machines.
• Insert grade H13A for aluminium and GC1010/GC1030 for finish milling of all other materials.
H
Applications
Shoulder milling Slot milling

Materials
D 44 D 86
Circular milling Linear ramping I

D 113 D 104
Information/
D 143
Index

A Milling – CoroMill® Century
CoroMill® Century
General turning
Light cutting face mills for high speed finishing − Aluminium and steel bodies
B −E
asy micro and macro settings for high precision
surfaces
− Intensified chip evacuation through accelerated

fluid flow
C
Serrated insert and cassette interfaces Wiper insert options for:
− Safe performance − Face milling
Threading
− Reduced run-out and effect of − Turn milling

tolerances
D
Coromant Capto® HSK Arbor Cassette design Arbor
coupling
Steel body Steel body Aluminium body Steel body Aluminium body
Milling
Cutter dia. (Dc), mm 40 – 125 40 – 80 50 – 200 160 – 500

Drilling
Max. cutting depth (ap), mm

• Carbide 2 / 10 2 / 10 2 / 10
F • PCD 2/5 2/5 2/5
• CB 1.2 1.2 1.2
Material
• First choice K N N K N N
Boring
• Complementary P M S H P M S H
Precision setting, mm
G
• Micro 0.1 0.1 0.1
• Macro − − 1.0
Tool holding/
Machines
Surface finish (Ra) <1 <1 <1
Insert geometries
H ISO L W *) TW *)
Applications
P -PL -PW -PTW
M -PL
Materials
General face milling K -KL -KW -KTW

D 57
N
Namnlöst-1 1 200
-NL -NW
I
*) W = Wiper
S -PL
Shoulder milling
D 44 TW = Turn mill wiper H -KL (CBN) -KW (CBN)
Information/
D 144
Index

Milling – CoroMill® Century A
General turning
Insert mounting and setting
1 2 3
Max.
0.25N B

All cutters; micro setting range 0.1 mm. Measuring equipment. Be observant.
Cassette versions: macro setting range Note: All measuring procedures, in which the Insert edges for cutting aluminium are very
1.0 mm. insert edges are positioned in direct contact sharp and fragile. Polycrystalline diamond C
with the point of a dial indicator, carry an PCD edges are particularly sensitive to all
The axial position of the inserts is easily inherent risk of insert damage. unskillful handling.
micro set in both types of cutters with high
accuracy. Optical setting by projecting the cutting edge Maximum acceptable contact pressure
is recommended. between the contact point and the edge
In cassette versions, a macro setting can
Threading
should not exceed 0.25 N. Quality is
also be carried out. Note: CoroMill Century cutter with inserts provided by qualified linear gauges.
mounted should always be protected by the
cover (C) when not in use.
A
4 5 6
Milling
E
B
Namnlöst-1 1 2009-08-31 09:29:34
Lubricate insert screws (A) with Molykote. Mount inserts. Determine highest positioned insert.
Drilling
Make sure serrations in insert seats are free Make sure the correct corner geometry has Raise the position of this insert, by approxi-
from dirt and damage. Keep serrations dry. been selected. Tighten insert screw to the mately five microns, by turning the adjusting
recommended torque, see Main catalogue. screw (B) carefully clockwise.
Use the measuring equipment to check the The parallel land of wiper inserts should be
F
position of the parallel land of each insert. adjusted to a level 0.05 mm below the zero
position of conventional inserts.
Note: Always use new insert screws when
7 changing PCD inserts. The parallel land of the wiper insert should be
adjusted to a level of 0.03 - 0.05 mm below
the zero position of conventional inserts.
Boring
G
Zero set indicator at this level. Cassette version of the CoroMill® Century face mill
Tool holding/
Adjust position of all remaining inserts to

Machines
Macro setting of the cassettes may be performed along with the micro setting of the inserts.
this zero level in same manner as indicated This generally follows the procedure outlined above.
above.
Note: If the zero position is exceeded, return
to a level of about five microns below zero
and repeat setting.
H
Loosen screws for the
wedge and adjust the
height of the cassette.
Materials
I
Information/
D 145
Index

CoroMill® 345
General turning
Cost efficient high performance face mill for small to medium −D

ouble sided cost efficient inserts with eight positive
depths of cut in ISO P, M, and K materials edges
B −W
iper insert with two right-hand and two left-hand
wiper edges
−P
rogressive edge geometry provides a light and soft
cutting action at small depths of cut, and a tough
max. ap 6 mm resistance at larger depths of cut
−S
maller cutters with cutting fluid through to each
insert pocket
− Four cutter pitches as standard
C − F or optimal use on small, low powered milling
machines as well as small to large machining
centres and multi-task machines
Threading
D
Coromant capto® Arbor Cylindrical
coupling
Milling
E
Cutter dia. (Dc), mm 40 – 100 40 – 250 40 – 50
Max. cutting depth (ap), mm 6 6 6

Drilling
Material
P M K P M K P M K
S H S H S H
F
Note: CoroMill 365 is the first choice for cast iron milling in the automotive industry.
Insert geometries
Boring
ISO L M H Wiper
G P E-PL, M-PL M-PM M-PH -W
M E-PL
K M-KL M-KM M-KH -W

Tool holding/
N
Machines
S E-PL
H E-PL, M-PL M-PM

H
Applications
General face milling Chamfering Milling with long overhang

Materials
D 57 D 126 D 30
I Intermittent milling
D 58
Information/
D 146
Index

General turning
High security insert and shim for predictable face milling
Insert geometry designed for safer use of eight edges.

• At large depths of cut, chip hammering will often damage the following edge that is
indexed in position for cutting. B
The CoroMill 345 insert geometry protects against this, which allows more edges

to be fully utilized.
Shim designed for insert seat protection and full support of the insert
• Ensures longer life for the cutter body.
• Safe use of positive inserts with advanced geometry. C
Mounting instruction:
The shim should be mounted with both indicating arrows directed towards each side
Threading
of the insert pocket.
Cutter pitch
Wide choice of cutter pitches improves
Milling
machine utilization and productivity.
E
Differential pitch. All H pitch cutters are Even pitch.
available with even
pitches. Cutters larger
than 160 mm are also
Drilling
available in a differen-
tial pitch version.
Positive cutting action
Boring
By featuring a more positive axial inclination at small depths of cut, the CoroMill 345
offers a soft cutting action with low axial pressure on the workpiece. As the depth of cut
increases, a more upright part of the cutting edge is engaged, providing the insert with a G
more substantial structure for high security, especially in tougher cuts.
Tool holding/
Machines
Internal cutting fluid supply

Internal cutting fluid supply to each insert for best performance when machining
demanding workpiece materials will ensure:
H
• Good chip evacuation
• A secure milling process
• Predictable performance
• Good surface finish.
Materials
Note: The screws for internal cutting fluid must be ordered separately.
I
Information/
D 147
Index

CoroMill® 245
General turning
Light cutting face mills for heavy roughing and mirror finishing − Roughing, semi-finishing and finishing
B
C
Threading
D
Arbor Cylindrical
Milling
E
Insert size (iC), mm Cutter dia. (Dc), mm
12 50 – 250 32 – 80
Drilling
18 80 – 250
F Max. cutting depth (ap), mm 6 / 10 6
P M K P M K
Material
N S H N S H
*) The grade assortment includes CBN and Ceramic inserts.
Boring
G
Insert geometries
Ceramic CBN PCD
ISO L M H Wiper
Tool holding/
inserts inserts inserts

Machines
P E-PL, M-PL M-PM M-PH E-W
M E-ML K-MM, M-MM E-W
H K E-KL, M-KL M-KM M-KH E-W -E -E
N E-AL E-W -E
S E-ML, E-PL, M-PL M-PM, K-MM, M-KM E-W
H E-PL, M-PL M-PM M-PH, M-KH E-W -E -E

Materials
I
Information/
D 148
Index

General turning
CoroMill® 245-12 CoroMill® 245-18
First choice in ISO N for 45° First choice in all ISO areas for
face mills. larger depths of cut (> 6 mm) Up to 10 mm B
Up to 6 mm
for 45° face mills.

Complement in ISO P, M and K
First choice for face milling Suits bigger machines.
with ceramic inserts. Cassette solution available.
First choice with advanced
materials (PCD and CBN) for
45° concepts.
Threading
Wiper inserts for all CoroMill® 245 versions
Fixed pocket face mills:
12 and 18 mm wiper insert options to combine with precision D
ground milling inserts for mirror finish face milling and turn
milling.
Adjustable face mills with exchangable cassettes:
Facilities for setting within 1.0 mm allows the use of 18 mm Wiper option
Milling
wiper inserts together with direct pressed economy inserts.
For setting, follow the same procedure as described for the
CoroMill Century face mill, see page D 145. E
Drilling
F
Setting within
1.0 mm
Boring
CoroMill® 245 - Face mill with exchangeable cassettes
G
• Cutter dia. 160-500 mm for insert size – 18.
• Maximum ap 10 mm.
Tool holding/
Machines
Applications
H
General face milling Chamfering Machining with long overhang
D 57 D 126 D 30
Materials
Face milling to mirror finish Demanding intermittent machining Turn milling

D 65 D 58 D 80
For face milling application hints, see page D 58. I

Information/
D 149
Index

CoroMill® 365
General turning
Cost efficiency in milling cast iron and steel − Multi-edge inserts provide cost efficient production
B
−R
eliable and predictable milling process with thick and
robust, but light cutting inserts
−W
iper insert alternatives optimized for smaller and
larger cutters
C − Screw or wedge clamping of inserts
− F or roughing to semi-finishing in both large series

65° production and in applications where high metal
removal rate is critical
Threading
6 mm
D
Coromant Capto® Arbor Arbor Arbor
coupling
Milling
Cutter dia. (Dc), mm 40 – 60 50 – 160 80 – 250 250 - 500 *)

Drilling
Max. cutting depth (ap), mm 6 6 6 6
Clamping Screw Screw Wedge Wedge *)

F P K P K P K P K Arbor 315 - 500
Material Cap design 250 - 500
H H H H CIS Arbor 160 - 500
Boring
Insert geometries
G ISO L M W *)
P -PL -PM -PW4, -PW8
K -KL -KM -KW4, -KW8

Tool holding/
H -PL -PM *) W = Wiper

Machines
Applications
Materials
I Face milling Demanding intermittent machining

D 57 D 58
Information/
D 150
Index

General turning
Milling inserts
Cost effective inserts with eight true cutting edges.
B
Right- or left-hand design available.

Wiper technology for improved surface quality
Two optional wiper inserts in neutral design are available for
finishing.
• Inserts with 4 mm wiper length have two right- and two
C
left-hand edges.
• Inserts with 8 mm wiper length have one right- and one
left-hand edge.
Threading
bs 2 bs 1
To generate a good surface, it is important to ensure that the D
feed per revolution (fn = fz x zn) is less than 80% of the wiper
length (bs 2). Naturally the larger the diameter cutter, the
greater the fn, which requires in turn a larger bs.
Milling
E
Two options for the same face mill provide optimal performance for milling cast iron or steel
Wedge clamped inserts Screw clamped inserts
• L arger diameter cutters with closer pitches for high density • Smaller diameter cutters.
Drilling
of inserts. • Primarily for milling ISO P materials.
• Cap version of cutter in diameter 250-500 mm to be quoted.
• For milling short-chipping materials with less need for large
chip pockets. F
• Extra rigid clamping of the inserts.
Boring
Mounting the insert
• Clean the insert seat thoroughly before starting. G
•P
lace thumb (1), then index finger (2) on the insert and push into the
insert seat.
Tool holding/
• Ensure contact against the three support points in the insert seat.
Machines
• Tighten the screw (3) to a torque of 6 Nm.
Mounting the wedge H

• Screw the screw (4) into the cutter body with four turns of the Allen key
•P
lace wedge over the screw and screw until the wedge is flush with the
cutter body.
Materials
• In principle, the same procedure should be used for mounting screw
clamped inserts.
I
Information/
D 151
Index

A Milling – Sandvik AUTO
Sandvik AUTO
General turning
Roughing and finishing milling cutters

B
C
Threading
D
Auto Rough Auto-AF Auto-FS
Milling
E
Entering angle (Kr), mm 45° 75° 90°
Rake Negative Positive Negative

Drilling
Cutter dia. (Dc), mm 125 – 500 80 – 500 125 – 500
Max. cutting depth (ap), mm 6.0 1.0 8.1

F
Material
P K P K P K
N S H N S H N S H
Auto Rough Auto-AF Auto-FS

Boring
•E
xtra close pitch face milling cutter • Adjustable
face milling cutter for • F ixed pocket face milling cutter
primarily intended for roughing and finishing cast iron components, designed for square shoulder cast iron
G semi-finishing cast iron components. demanding high quality surface applications demanding fine surface
finishes. finishes at high feed rates.
• Easy high precision setting, within
±0.002 mm.
Tool holding/
Machines
H
Applications
Auto Rough Auto-AF/-FS
Materials
Roughing face milling Finishing face milling

D 57 D 64
I Intermittent machining
D 58
Information/
D 152
Index

Milling – Sandvik AUTO A
General turning
Auto inserts general information
• T he large number of inserts enable large table feeds, which
Auto rough
B
provides very good, cost efficient machining.

• T riangular inserts for Auto Rough are available in several
different geometries, optimized for different operations.
•A
ll inserts are double-sided, providing six right-hand and L -WL
six left-hand cutting edges for excellent, cost efficient M -KM -CA -65
machining. H -AN
• F or detailed information about Auto inserts, see C

Main catalogue. Auto-AF Auto-FS
Threading
-L -F (Wiper) SBEN SBEX SBEX-11
Wiper Strong Light
edge cutting
D
Spacers for adjusting spindle inclination
Milling
The parallel land of the insert can be adjusted according to Spindle inclination/spacer thickness
spindle inclination.
Spindle inclination E
Spacers mounted in the support body for spindle inclination 0.1:1000 mm
0.1:1000 are shown below: or 1 µ/10 mm
0.3 Dc
315 400 500
Drilling
Cutter dia. (Dc) Spacer (mm)
0.2
250 0.02 F
315 0.05
355 0.05
400 0.02 and 0.05
500 0.02 and 0.05 0.1
Boring
Note: For other spindle inclinations, contact your Sandvik
Coromant representative.
0 G
Spacer (mm)
0 0.1 0.2 0.3
Tool holding/
Space dimensions for different spindle inclinations

Machines
Note: If the centering sleeve or backing ring must be replaced,

or if the supporting surface must be re-ground, adjust the
H
44±0.01 mm dimension with spacers.
Materials
1. Centering sleeve
2. Spacer
3. Backing ring I
Information/
D 153
Index

A
General turning Milling – Sandvik AUTO
Mounting and setting

Requirements: 1. asette
C
2. Eccentric pin
Diabase surface plate
3. Key (eccentric pin adj.)
Micro-indicator 4. Cassette screw
B Key 265.2-821 5.
6.
Cassette washer
Cassette key
Key 5680 048-07 (30IP) 7. Insert screw
Torque wrench 8. Insert screw key

Tighten cassette screws to approx. 2 Nm.
C
Mounting
1. Apply Molykote on insert screw head and thread.
Threading
2. Clean insert seat thoroughly before starting.

3. Ensure contact against the three support points in the
insert seat.
D 4. Tighten the insert screw to the recommended torque,
see Main catalogue.
Milling
E
Tool setting
1. Place cutter on the diabase surface plate.
2. Locate the highest point on the insert edge with the flat
contact point of the micro indicator.
Drilling
3. Turn eccentric pin and move the cassette with insert to

a zero reading on the indicator.
F 4. Tighten cassette screws to recommended torque,
see Main catalogue.
5. Loosen eccentric pin to set insert height and to prevent
risk of axial run-out.
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 154
Index

CoroMill® 360
General turning
Heavy duty face milling cutter for high productivity under − High metal removal
demanding conditions − Feed rates 0.4-0.7 mm per tooth B
−O
ne pass milling of long and uneven surfaces with

abrasive scale or interruptions possible
−S
eparate cassettes for each insert size for use in the
same cutter body reduces inventory
−E
xchangeable insert cassettes, with serrated inter-
faces, provide for safe, accurate location and easy
handling
− Indexing the inserts and changing the cassettes in
the machine reduces down time
C
Threading
13 mm 18 mm
Milling
Cutter pitches
E
Cutter dia. (Dc), mm 160 – 500
Insert size (iC), mm Max. cutting depth (ap), mm
19 13
Drilling
28 18
Material P M K S
Differential Even F
Insert geometries
Boring
ISO H
P -PH G
M -MH
K -KH
Tool holding/
N
Machines
S -MH
H
H
Applications
Materials
Face milling
D 57
Demanding intermittent machining
D 58
Heavy duty face milling I
D 62
Information/
D 155
Index

A Milling – T-Max® 45
T-Max® 45
General turning
High metal removal in powerful milling machines −4

5° entering angle and strong inserts enable
machining under demanding conditions and at long
B overhangs
−2
mm parallel lands and secondary cutting edges
provide effective back-cutting facility
C − Axially adjustable within 5 µm
− Wiper inserts for finishing machining

Threading
D
Insert geometries
ISO M H W *)
Milling
P -31, -32 -11 -1W

Cutter dia. (Dc) 100 – 400
E M -31, -32 -11 -1W
Max. cutting depth (ap), mm 12 K -31, -32 -11 -1W
P M K
N -11
Material
N S H S -32 -11
*) W = Wiper H
Drilling
-31, -32 -11 -1W

F The equipment below should be available to facilitate the work.
Equipment to be ordered separately Equipment to be ordered from Equipment delivered with T-Max 45:
from Sandvik Coromant: Sandvik Coromant: 1. T-key (265.2-821)
1. Removal key for bayonet washer 1. Dial indicator with surface plate 2. Indexing lever
(260.7-857) 2. Inspection point (gauge)
Boring
2. Key for relocking shim (260.7-855) 3. Torque wrench

3. Hexagonal key (174-815) 4. Molycote
4. Indexing lever (260.7-856M)
G 5. Cleaning agent
Tool holding/
Machines
Axial adjustment
The cutter is axially adjustable within 5 μm. Axial adjustment can be performed by two screws acting against
the tab on the back of the shim. In case of damage, the shim can normally be replaced without influencing
axial setting.
H
Materials
Applications
I General face milling Intermittent machining

D 57 D 58
Information/
D 156
Index

Milling – T-Max® 45 A
General turning
Dismantling
1. To dismantle inserts, use the indexing lever.
2. Loosen setting screws two turns, use the T-key.
3. Remove the retaining screws, use the T-key.

B

4. Turn the cutter over and loosen the locking nuts.
5. Loosen the support screw two turns, use key for relocking
the shim.
6. Turn the cutter over, depress the clamping mechanism and
remove the shim.
C
Threading
Assembling
1. Set the dial indicator (with help from a control system or D
gauge blocks) to 62.98 mm.
2. Depress the clamping mechanism and mount shim in its
seat.
3. Lock the retaining screws with about 9 Nm, use the T-key.
Check that the shim is properly located in its seat.
Milling
4. Mount the master insert.
5. Pre-set the shim and master insert to 10 µm using the
screw. E
6. Loosen the clamp pressure on the insert and press firmly
into position. Continue pre-setting to +20 µm.
7. Finely adjust the master insert using the screw to ±2.5 µm,
use torque key to 9 Nm.
Note: If a tolerance of 0 ±2.5 µm is not obtained, the initial
Drilling
value should be increased from +20 µm to 25-30 µm.
Repeat fine adjustment.
8. Turn the cutter over and secure the locking nut. F
Note: The same cutting edge on the master insert must
always be used when setting, because the parallel lands For spare parts and accessories, see Main catalogue.
can have different tolerances.
Boring
G
Tolerances Insert setting
Insert: ±13 µm Inserts are designed for specific seats.
Tool holding/
Shim: ±10 µm Note: Do not mount a LNCX insert in a Wiper seat.

Machines
Basic setting: ±5 µm
A new T-Max 45, delivered from stock, has a maximum Wiper in correct seat LNCX in correct seat
tolerance of 5+26 = 31 µm. H
In a cutter, in which one or more shims have been changed
without carrying out a new basic setting, the maximum
tolerance is 5+26+20 = 51 µm.
Materials
I
0.11 ± 0.06
Information/
D 157
Index

CoroMill® 210
General turning
A roughing cutter with capability for high feed milling −C

utting forces are primarily directed towards the
spindle, providing stable cutting action that is
B practically free of vibration or deflecting side forces
−A
problem-solver for operations where extended
tooling is required
− A high feed cutter for both face and plunge milling
−1
0˚ entering angle produces a thin chip, enabling
a feed per insert of up to 4 mm per tooth, when
operating tangentially
−C
onstant maximum chip thickness when plunging
C produces less risk of vibration compared with radius
design inserts
Threading
D
Coromant Capto® Arbor Cylindrical MSSC
coupling
Milling
E
Cutter dia. (D3), mm 36 – 66 52 – 86 50 – 63 63 – 160 25 – 42 25 – 42
Insert size, mm 9 14 5 14 9 9
Drilling
ae / ap (mm) 8/1.2 13/2 8/1.2 13/2 8/1.2 8/1.2
F Material
P M K P M K P M K P M K
S H S H S H S H
Insert geometries
Boring
ISO M
G P M-PM, E-PM
M M-MM, E-MM
K M-KM, E-KM
Tool holding/
N
Machines
S E-MM, M-MM, E-KM

H M-PM, E-PM
H
Machine tool recommendations

• Taper 50 machines, corresponding size and larger.
Materials
• Taper 40 machines, at low spindle speed, rpm, and with non-ceramic bearings.
I
Information/
D 158
Index

General turning
Methods for avoiding scallops, remaining stock, when face milling
B
• If ae exceeds Dc, a surface with scallops will be produced.

• Maximum ap is easily exceeded when milling over scallops;
this should be avoided.
• Maximum ap should not be exceeded. <ap
• If machining over scallops, feed rate should, if possible, be

reduced by 50%.
• A flat surface will only be achieved if ae is less than or equal C
to Dc.
Threading
D
Milling a flat surface using successive passes
Milling
Cutter diam-
eter (D3),
Cutting diameter, (Dc), for milling a
flat surface
E
mm
iC 09 iC 14
(Dc), mm (Dc), mm
25 10.9 -
Drilling
32 17.9 -
Dimensions, mm
36 21.9 -
42 27.9 -
l = iC s re ap ae bs

50
52
35.9
37.9
-
28
F
9.4 4.0 1.2 1.2 8 1.0
63 48.9 39
66 51.9 42 14.5 4.76 1.2 2.0 13 1.0
80 65.9 56
82 67.9 58
100 - 76
Boring
G
Tool holding/
Machines
H
Applications
High-feed milling Plunge milling Circular ramping

Materials
D 60 D 116 D 105
Ramping
D 104 I
Information/
D 159
Index

A Milling – Coromant Plunge cutter
Coromant Plunge cutter

General turning
Power efficient milling with high metal removal rates −A

complement to CoroMill 210 for larger radial
depths of cut
B −H
igh strength insert, engineered with helical cutting
edge enables an increased removal rate with
a smooth cutting action

−C
utting forces are directed axially up the machine
spindle, imposing less fatigue and stress on the
machine spindle and facilitating work with extended
tooling
− Robust design
C −O
ptimum performance is obtained with ISO 50
machine tools, or similar
Threading
D
Coromant Capto® Arbor Insert geometries
coupling
ISO M
Milling
P -PM
M -PM
E
K -PM
N -PM
S -PM
Cutter dia. (Dc), mm 80 – 85 100 – 160
H -PM
Drilling
Maximum (ae), mm 22 22
F Material
P M K P M K
N S H N S H
High productivity Low stress on machine spindle

• High insert strength, engineered with helical cutting edge • Cutting forces are directed axially up the machine spindle,
enables an increased removal rate. imposing less fatigue and stress on the machine spindle.
Boring
• Large insert enables faster cycle times with fewer passes. Maximum stability
Superior chip flow • To obtain the best results, choose the shortest length, l1,
G • Insert design and large flute areas permits excellent chip and largest diameter, Dc, as possible.
evacuation. • Use Coromant Capto mounting for optimal stability.
Low power consumption and low noise
Tool holding/
• Strong cutter bodies and helical cutting edge inserts trans-

Machines
late into a very smooth and quiet cutting action.

• More cubic inches of material can be removed without high
horsepower.
Applications
Materials
I Plunge milling
D 116
Information/
D 160
Index

CoroMill® 200
General turning
A robust multi purpose cutter for roughing and difficult conditions −S
trong cutting edges, resistant to tough conditions
with interruptions (holes, gaps etc.) and/or abrasive
scale (skin) B

− Insert geometries for high chip removal rates – large
ap and fz
− For larger machines with good stability and power
C
− Best utilized on ISO 50 (40) machine spindles
Threading
− Requires rigid set-ups and workpiece clamping
D
Cylindrical Arbor Insert geometries
ISO L M H
Milling
P -PL -PM -PH
M -ML -MM -MM
K -KL -KM -KH E

Cutter dia. (D3), mm 25 – 50 50 – 160
N -PM -PM
S -ML -MM
Insert size (iC), mm Max. cutting depth (ap), mm

H -PL
Drilling
10 5 5
12 6 6 F
10 12 16 20
16 8 8
20 10 10
Boring
0.05 0.6 mm
P M K P M K
Material
N S H N S H
G
Tool holding/
Machines
H
Applications – CoroMill® 200 and CoroMill® 300
Materials
Face milling Profiling

D 57 D 68
Linear ramping Circular ramping

D 105
I
D 104
Information/
D 161
Index

CoroMill® 300
General turning
CoroMill® 300, versatile and light cutting end mills and face mills A comprehensive product range of cutters for roughing
to high feed semi-finishing.
B − L ow power requirements make both stable and weak
powered machines more efficient
− L ight cutting action allows for smooth entries and

exits and for vibration free use of extended tool
set-ups.
− Precision ground inserts for high accuracy
−E
nd mills and face mills in neutral or positive designs
and toroid cutter options in neutral design
C − L arge insert option, iC 20 mm, for heavy roughing and
with the cost efficiency of eight indexings
Threading
Insert size (ic), mm 05 07 07 08 10 12 16 20

Milling
Neutral design/toroid end mills

E Diameter (D3), mm
10 − 32
Max. cutting depth (ap), mm 0.7 1.0 1.5 1.2 2.0 5.0 8.0
Positive design
Drilling
*) Diameter (D3), mm
10 − 200
F Max. cutting depth (ap), mm 4.0 5.0 6.0 8.0 10.0
*) Diameter (D3), mm
End mills 25 − 40
Face mills
Boring
-Coromant Capto coupling 35 − 100

-Arbor 40 − 200
Neutral MSSC end mills 10 − 42
G
Positive design for end milling and face milling Insert geometries
Tool holding/
Machines
•E
nd mills with superior accessibility and cutting action in all feed directions for
ISO L M H
multi-axis machining of complicated forms.
• L ight cutting action also allows for extra close pitched positive face mill versions P -PL -PM -PH
H with small inserts for high productivity at high speeds combined with high table M -ML -MM -MH
feeds.
K -KL -KW -KH
N -PL -PM
S -ML -MM -MH

Materials
H -PL -PM
Applications
I Same as for CoroMill 200, see page 161.
Information/
D 162
Index

General turning
Toroid cutters in neutral design
B
The toroid end mills operate with two round inserts, positioned

so that each insert overlaps, or almost overlaps, at the centre
line of the cutter.
This design eliminates the unfavorable cutting action that
takes place at the tool centre of Ball Nose end mills, where
the cutting speed drops to zero.
The operating part of a toroid cutting edge is not subjected to
a zero cutting speed at any point. C
Always calculate true cutting speed, vc. For more information,
see Profiling, page D 76.
Roughing
Threading
CoroMill 200/CoroMill 300
Semi-finishing D
CoroMill 300
Milling
E
Safe cutting action and accessibility in narrow pocket milling.
• Small diameter end mills with all shank styles.
• T oroid cutters can considerably improve productivity and
are very suitable for light roughing, rest milling and semi-
Drilling
finishing operations.
• Good plunge milling and ramping performance.
F
•E
xcellent for profiling, when a constant stock is a pre-
requisite for milling near net shape.
•R
educed risk for vibration when using slender and extended
tooling.
Boring
Toroid cutters can replace Ball Nose end mills in many opera-
tions, if the perfect conditions for a high productive and safe G
cutting process are available.
• A more productive solution when copy milling on 3D-profiles.
Tool holding/
• Larger radial cut capability, requiring fewer passes.

Machines
• Increased tool cost efficiency, by up to six cutting edges per

insert.
•H
igher feed per tooth at shallow depths of cut – because,
with a toroidal shape, the cutting takes place at the H
periphery.
• Generates higher surface quality.
Materials
I
Information/
D 163
Index

A Milling – CoroMill® 216 Ball Nose end mill
CoroMill® 216 Ball Nose end mill

General turning
For rough and semi-finish profiling −C

utter with two edges for effective and general
contouring and copy milling
B − Depths of cut up to 44 mm
− Feed per tooth up to 0.6 mm
Insert options
+0.07 M - tolerance inserts for higher security and
M D3 heavier cuts
−0.23
+0.0 E - tolerance inserts with sharper edges for
E D3
C −0.20 higher precision suitable for semi-finishing
Threading
D3
D
Cylindrical Weldon Threaded Insert geometries
ISO M
Milling
P -M
E M -M
K -M
Cutter dia. (D3), mm 10 – 32 12 – 50 10 – 32 N -M
Max. cutting depth (ap), mm 8.6 – 28.6 10.8 – 44.6 8.6 – 28.6
S -M
H
Drilling
-M
P M K P M K P M K
Material
N S H N S H N S H
F
Boring
G Limitations Edge tolerance

During full slotting, the bottom profile generated will not -M -E
from a perfect radius. This form error, which appears at the
R A B R A B
centre cutting zone of the tool, can be minimized by using
Tool holding/
5 – – 5 0.15 <0.01
the E-tolerance inserts. 6 1.4 0.07 6 0.15 <0.01
Machines
8 1.7 0.09 8 0.15 <0.01

10 2.2 0.12 10 0.15 <0.01
12.5 3.0 0.1 12.5 0.15 <0.01
15 3.9 0.20 15 0.15 <0.01
16 3.5 0.22 16 0.15 <0.01
H 20
25
3.6
3.8
0.24
0.26
20
25
0.15
0.15
<0.01
<0.01
Applications
Materials
I Profiling Ramping
D 104
Full slot milling
D 68 D 86
Information/
D 164
Index

Milling – CoroMill® 216F Ball Nose finishing A
CoroMill® 216F Ball Nose finishing
General turning
A profiling cutter providing excellent surface finish and accuracy − Performance similar to solid carbide end mills
− Steel shank version for general profiling

B

− Stiff carbide shank for high precision demands
− A cutter for near net shape milling
− Insert for contour milling of hardened steel

C
Threading
ap
ae
D
Cylindrical Insert geometries
ISO L
Milling
P -L
M -L
E
Cutter dia. (Dc), mm 8 − 32 K -L
Insert size (iC), mm 8 10 12 16 20 25 30 32

N -L
S -L
Drilling
Tolerance (iC), mm + 0/- 0.016 -L
Max. cutting depth (ap), mm 1.2 1.5 1.8 2.4 3.0 3.7 4.5 4.5
F
Material
P M K
N S H
Optional inserts = Dc
Boring
R216F-xxx E-L geometry insert for profile finishing of steel, stainless
steel and grey or nodular cast iron, aluminium, Kirksite and graphite.
G
Tool holding/
Machines
Note:
By applying accurate programming techniques, the
finishing cutter may, in many operations, replace con-
H
ventional Ball Nose end mills and greatly improve the
surface quality, often, at much higher feeds.
Materials
Applications
Profiling I
D 68
Information/
D 165
Index

A Milling – CoroMill® 327 and CoroMill® 328
CoroMill® 327 and CoroMill® 328

General turning
Versatile tools with different diameters and pitches for CoroMill® 327
B non-rotating components − Internal grooving, slot milling and threading in holes
over 10 mm diameter
− Front mounted inserts positioned in grooves for safe

and stable mounting
− Through cutting fluid for improved chip evacuation
CoroMill® 328
−E xternal grooving, slot milling and threading
− Internal grooving, slot milling and threading in holes
C over 39 mm diameter
− Indexable cutting edges for highly productive, cost
efficient machining
− Inserts mounted in pockets for safe and stable
mounting
Threading
D
CoroMill® 327
Grooving and Circlip grooving Grooving Chamfering Threading
Milling
circlip grooving * with chamfer * Full radius
E
Drilling
Cutter dia. (Dc) 9.7 – 27.7 21.7 11.7 – 21.7 11.7 / 21.7 11.7 – 21.7
Max. cutting depth (ar), mm 6.5 2.0 4.5 1.7 2.5

F
Max. cutting width (la), mm 0.7 – 5.15 1.1 – 4.15 1.0 – 4.0 1.2 / 2.0
Radius (re) 0, 0.1, 0.2 0.1, 0.2 0.5 – 2.0 Non radius
Cutting edges (zn) 3, 6 3 3 3 3, 6

Boring
Material
G N S H N S H N S H N S H N S H
Profile Pitch 1 – 4.5
V-profile 60° (partial profile)
Metric 60° (full profile)
Whitworth 55° (full profile)
Tool holding/
Machines
Steel or solid carbide shanks

H
CoroMill 327 is used with steel or solid carbide shanks, available in four diameters and
overhangs from 74 to 160 mm. Use:
• Steel shanks for general machining when the milling conditions are good.
Materials
• Solid carbide shanks to provide lower deflection, enabling longer overhangs and tougher
machining with minimized vibration.
I
Information/
D 166
Index

Milling – CoroMill® 327 and CoroMill® 328 A
General turning
CoroMill® 328
B
Circlip grooving * Circlip grooving Threading

with chamfer *
C
Cutter dia. (Dc) 39 – 80 39 – 80 39 – 80
Max. cutting depth (ar), mm 3.0 – 5.0 3.0 3.2
Threading
Max. cutting width (la), mm 1.3 – 5.15 1.1 – 5.15
Radius (re) 0.1, 0.15 0.1, 0.15 Non radius

D
Cutting edges (zn) 2, 3, 5, 8 2, 3, 5, 8 2, 3, 5, 8
Material P M K P M K P M K
N S H N S H N S H
Milling
Profile Pitch 1.5 – 6
V-profile 60°
*) For CoroMill 327 and CoroMill 328 - widths and tolerances according to DIN 471/472.
Drilling
Radius compensation F
When programming with tool centre feed, the periphery feed can be far too high.
Make sure to program with radius compensation to ensure the correct feed.
For more information about programming for threading, see Slot milling, page D 98.
Boring
Tool maintenance - CoroMill® 327
Clean the tip-seat before use to provide the maximum insert support. G
For new tool holders, pre-load the screw by mounting and un-mounting the inserts
a few times prior to cutting.
Tool holding/
Machines
H
Materials
Applications
Shallow slotting and grooving Threading Chamfering I

D 86 D 95 D 126
Information/
D 167
Index

CoroMill® 329
General turning
Grooving cutter
− First choice for cutting depths ≤18 mm
B
−V
ersatile tool for producing accurate slots, plain
bottom grooves, and for cutting off
− Inserts positioned in line produce superb chip

evacuation and allows high table feed
C
Threading
D
Milling
E Cutter dia. (Dc), mm 125 – 160
Max. cutting width (ap), mm 2.5 – 4.0
Max. cutting depth (ar), mm 18

Drilling
Material
P M K
N S H
F
Insert geometry recommendations
The CoroMill 329 is used with CoroCut 2 inserts with V-shaped form.
Boring
-CM First choice is the -CM geometry for all materials.
G
Tool holding/
-TF Good chip control and surface finish, due to the

Machines
wiper design.
The CoroMill 329 has integrated screw clamping for stable and
secure clamping of the inserts. Place thumb on the insert and
push into the insert seat. Use a screwdriver (Torx Plus) to clamp
(unclamp) the insert.
H
Applications
Materials
I Shallow slotting and grooving

D 90
Information/
D 168
Index

Milling – T-Max® Q-Cutter A
T-Max® Q-Cutter
General turning
Cutters for slotting and cutting off −C
omplementary cutter for narrow slots, plain bottom
grooves and for cutting off
B

− Inserts positioned in line produce superb chip
evacuation enabling high table feed
− Complementary tool for deeper cutting
− T ool options designed to individual customer
Threading
requirements are available
Milling
Cutter dia. (Dc), mm 80 – 315 E
Max. cutting width (ap), mm 6.0
Max. cutting depth (ar), mm 119
Drilling
Material
P M K
N S H
F
Insert geometry recommendations
T-Max Q-Cutter is used with Q-Cut inserts.
Boring
AA First choice is the 330.20 AA, a close tolerance insert
with a geometry and grade range adapted for milling
operations.
G
4E Use N151.2-4E for low carbon materials.
Tool holding/
Machines
5E Use N151.2-5E for copper and aluminium.
H
Use the key tool for quick and easy clamping.
Applications
Materials
Slot milling I
D 86
Information/
D 169
Index

CoroMill® 331
General turning
-
Multi-purpose side and face milling cutter with high-precision –S
pring loaded cassettes provide easy setting for
capability desired width
B
– C
utters delivered within 0.01 mm width. To achieve
a close tolerance, use the H tolerance inserts
–R
ound insert options and a vast assortment of
corner radii
C – Inserts with 8 edges for facing operations.

Entering angle 88°
– Close pitch, fixed pocket design

Threading
Easy precision setting – Open pockets facilitate easy chip flow
D
Code key guide, see page D 177.
Applications
Milling
Max. cutting width
Double half Shoulder Circular

E Slotting/Cutting off side milling milling Facing Gang milling Back-facing ramping
(ap), mm
Cutter and insert type

Cutter dia. (Dc) mm
N331.35-...S...
Drilling
10
40 – 125
F
N331.32-...S...
26.5
80 – 315
Boring
N331.32-...Q...
26.5
G 80-315
N331.32-...A...
Tool holding/
Machines
10
40-100
H N331.52-...S...
33.8
200-315
Materials
N331.32-...Q...
N331.32-...S...
10.1
I
60-315
Information/
D 170
Index

General turning
Insert geometries and grades
B
Extra positive Reinforced cutting edge Insert geometries

ISO L M H
P -PL -PM -PH
M -ML -MM
K -KL -KM -KH

C
Light Heavy
N -NL
Light machining Heavy machining S -ML -MM

Low cutting forces Highest edge security
Low feed rates High feed rates H -PL -PM -PH
Threading
Close tolerance
Milling
Medium
General use in most materials

E
Drilling
Reduced cutting edge length for Tailor Made inserts
When slotting use the smallest width of the cutter. F
1.4 4.4
The overlap is the most critical factor to optimize. 06 08
Reduced cutting edge length reduces overlapping, which in
turn reduces wear in the overlapping zone, producing better
chip control and reducing power consumption by up to 10%.
Boring
Tailor Made insert options with reduced cutting edge length
an available on request.
G
ap : 11 ap : 11
Tailor Made insert with Standard insert
Tool holding/
reduced edge length size 08

Machines
Calculation of cutting edge

length: H
ap
asp = + 0.2
2
For more information about how to use the CoroMill 331 see:
Materials
General slotting and use of fly-wheel, page D 89.

Back-facing, page D 49.
I
Information/
D 171
Index

A
2-edges 8-edges
Insert radius, re Insert radius, re
Insert size 0.5 0.8 1.52 2.29 3.05 4.83 6.35 Insert size 0.8 2.0
04
B
05
08
11
C 13
14
Threading
Insert style
Most types of inserts are in neutral (N) style. Radius inserts are in neutral style as well, but, in versions with larger radii, are also
D available in either left (L) or right (R) hand styles.
Cutter bodies, cassettes and inserts to combine for all applications

Milling
Half side and face mill Full side and face mill
E Right-hand cutter Right-hand cutter
Left-hand cassette
Drilling
Left-hand cassette
F Right-hand Right-hand
cassette cassette
For more information about choice of cutter type, see page D 49.
Boring
Cassettes for inserts with radius smaller than 1.55 mm

G Width Insert size Right-hand cassette Left-hand cassette
CM, 6-8 04 5321 240-15 5321 240-16
DM, 8-10 05 5321 240-13 5321 240-14
Tool holding/
EM, 10-12 08 5321 240-01 5321 240-02

Machines
FM, 12-15 08 5321 240-03 5321 240-04

KM, 15-17.5 11 5321 240-07 5321 240-08
LM, 17.5-20.5 11 5321 240-07 5321 240-08
QM, 20.5-23.5 14 5321 240-09 5321 240-10
H RM, 23.5-26.5 14 5321 240-09 5321 240-10
QM, RM with square insert 13 5321 260-01 5321 260-02
Cassettes for double half side and face mill

Materials
Width (aBp), mm Insert size Right-hand cassette Left-hand cassette

MM, MMR/L abp 27.2-30.2 11 5321 240-05 5321 240-06
I NM, NMR/L abp 30.8-33.8 11 5321 240-07 5321 240-08
Information/
D 172
Index
General turning
*R
ight-hand cassette = RC
Cassettes for inserts with radius from 1.55 - 6.50 mm Left-hand cassette = LC
x A B D E
B
Cutter Insert radius 1.55 - 2.60 2.61 - 3.50 4.51 - 5.50 5.51 - 6.50

body
Width (ap), mm Insert size * RC * LC * RC * LC * RC * LC * RC * LC

CMx 6.0-8.0 04 5321 240-15.11 5321 240-16.11 - - - - - -
DMx 8.0-10.0 05 5321 240-13.11 5321 240-14.11 5321 240-13.22 5321 240-14.22 - - - -
EMx 10.0-12.0 08 5321 240-01.11 5321 240-02.11 5321 240-01.22 5321 240-02.22 - - - -
FMx 12.0-15.0 08 5321 240-03.11 5321 240-04.11 5321 240-03.22 5321 240-04.22 - - - - C
KMx 15.0-17.5 11 5321 240-07.11 5321 240-08.11 5321 240-07.22 5321 240-08.22 5321 240-07.44 5321 240-08.44 5321 240-07.55 5321 240-08.55
LMx 17.5-20.5 11 5321 240-07.11 5321 240-08.11 5321 240-07.22 5321 240-08.22 5321 240-07.44 5321 240-08.44 - -
QMx 20.5-23.5 14 5321 240-09.11 5321 240-10.11 5321 240-09.22 5321 240-10.22 5321 240-09.44 5321 240-10.44 5321 240-09.55 5321 240-10.55
Threading
RMx 23.5-26.5 14 5321 240-09.11 5321 240-10.11 5321 240-09.22 5321 240-10.22 5321 240-09.44 5321 240-10.44 - -
Cutter body radius modification
- 2.0 4.0 5.0
Cassettes for round and square inserts
Milling
Insert Cutter body radius
Cutter body Width (ap), mm size Neutral cassette modification
Round - E
EMQ 10.0-12.0 10 5321 250-02 4
FMQ 12.0-15.0 12 5321 250-03 5
KMQ 15.0-17.5 16 5321 250-05 6
Drilling
Note: The cutter
diameter, Dc will be
Square Right-hand cassette Left-hand cassette 3.2 mm larger with

the 4 edge square
QM, RM 13 5321 260-01 5321 260-02 insert. F

Example
Boring
Ordering a cutter for a slot with 14 mm full width and 3 mm corner The same modfication has to be made on cassettes orginally ordered
radii: for small radius inserts. Information about radius sizes can be found
under spare parts in the Main catalogue.
The cutter diameter should be 125 mm and have keyway mounting.
3. Choose inserts G
1. Choose cutter 10 inserts of size 08 will fit into the cutter. 5 pcs of these will be
Code: N331.21-125S40FM 14.00 cutting the left side of the slot and 5 on the right. In this case, with
This cutter has 10 inserts and 10 corresponding cassettes. large radii inserts, they are right and left-hand styles:
Tool holding/
2. Choose cassette L331.1A-08 45 30 H-WL

R331.1A-08 45 30 H-WL
Machines
From the column in the table "Cassettes for radius from

1.55-6.50 mm" you learn that a "B" should be added to the
cutter code: N331.21-125S40FMB 14.00
A cutter ordered with this code will be delivered with 5 pcs of
right- hand cassettes, type 5321240-03.22, and 5 pcs of left-hand H
style, type 5321240-04.22. Inserts with radii from 2.61-3.50 mm
can be used in these cassettes. The cutter is set to a width of
14 mm +/- 0.01.
Note: If larger radii inserts/cassettes (from re 2.61 mm, and round
inserts) are used in a cutter body that was orginally ordered for small
Materials
radius inserts, the cutter body has to be modified. The value is found
in the table - "Cutter body radii modification".
I
Information/
D 173
Index

A
Limitations when using inserts with large corner radius

Full slot milling
B Insert size Calculated - ap

04 ap = re + 4.6
05 ap = re + 6
08 ap = re + 8
11 ap = re + 11
C
Form error at the bottom of the profile.
When adjusting a cutter, that has inserts with a larger corner radius, within its lower
setting range, the shape of the slot may receive a small notch at the intersection
between the radius and the bottom.
Threading
D
Cutters mounted together for milling wider slots
Cutters mounted with a bore that have keyways can be modi-

fied to fit tight together for milling a wider slot. It is preferable
Milling
to use cutters with two keyways, which enable a staggered

mounting pattern.
For more information, see Slotting, page D 90.
E
For mounting two standard cutters together:
• On one side of each cutter, modify the hub by grinding it, as
shown in the illustration.
Drilling
• The hub on cutter 1 should be ground on its right side.

Cutter 2 is reversed and its hub has to be ground on its left
F side. The cutters are mounted with the ground hubs facing
each other.
• The hubs should be ground until 1.2 mm is left. To overlap
correctly, the insert edge should be set 0.9 mm out from the
hub.
Boring
Axial width of cut, ap:

Tool holding/
Machines
A large width of cut increases cutter stability, but also the need for facilitated chip evacuation.
Radial depth of cut, ae:
H In general, standard CoroMill 331 cutters will cut slots to a depth of up to four times the width.
A deeper cut increases the need for higher chip evacuating capacity, and therefore the need for a
Tailor Made or engineered cutter with larger chip pockets.
Depth of cut is limited by the arbor boss diameter, as well as the risk of overloading the driving keys.
The workpiece material greatly influences the various requirements.
Materials
I
Information/
D 174
Index

General turning
Facilitated chip evacuation
Full slot milling with round insert cutter
ae max. iC/2 ae more than iC/2
Max. axial depth of cut ap, = insert size (iC/2)

B
Max. radial depth of cut ae, = ap
zn

zeff =
2
Note: The contact length of the cutting edge

is 180°.
C
For slots deeper than iC/2, a 0.5 mm adjustment of each cassette is recommended. This will widen the
slot 0.5 mm and reduce the contact length for each insert to 90˚, which produces a more favorable chip
formation and evacuation, and reduces vibration and power consumption.
Threading
Effective number of teeth, zc: D
Full side and face mill: zc = zn/2
Half side and face mill: zc = zn
Milling
Tailor Made and engineered products for wider slots E
The standard CoroMill 331 cutters are designed with a Different spread patterns can be chosen to cover slot widths
maximum of two rows per effective teeth. with more than two inserts. This is applicable for Tailor Made
and engineered cutters.
Drilling
As standard and Tailor Made, the cutter can have up to
14 inserts, size 8 mm (08), per effective cutting edge row, The cutter can be optimized by reducing the number of effec
up to a maximum width of 105 mm. tive cutting edges, which reduces cutting forces and also
reduces table feed while maintaining the same feed per cutting F
edge. This is useful in weak set-ups, weak components and/or
fixtures, or overhangs.
Boring
Tailor Made and engineered cutters Standard cutter
G
Tool holding/
Machines
H
Materials
For more information about engineered products, see D 186.

I
Information/
D 175
Index


General turning
Requirements:
• Micro-indicator

• Projector
B
Mounting
Note: Use these mounting instructions when the cutter has

been completely taken apart for cleaning or repair.
1. Lubricate both ends of the wedge screws with Molykote.
2. Fasten each wedge screw 1 turn from underneath the
wedge.
C 3. Fasten all wedges in the cutter body, without tightening
them.
4. Lubricate the insert screws with Molykote.
5. Fasten all insert screws, 3-5 turns in the cassettes.
Threading
6. Mount all cassettes.

7. Make sure that the cassettes are as far down as possible
in the seats.
8. Make sure that all cassettes are evenly positioned, with the
D wedges within +/-0.1 mm axially.
9. Tighten the wedge screws to the correct torque = 6 Nm.
(Cutters with diameters smaller than 110 mm = 5 Nm).
10. Make sure that none of the screws protrude beyond any
of the wedges.
Milling
11. On cutters with diameters 127 mm or smaller, ensure that

none of the screws are protruding beyond the bore.
12. Loosen all wedge screws.
E 13. Tighten all wedge screws to the correct torque = 4 Nm.
(Cutters with diameters smaller than 110 mm = 3 Nm).
Drilling
F
Boring
G Mounting the insert

Zero setting of micro-indicator:
E + ap
1. Clean insert seat thoroughly before commencing. 2
2. Ensure contact against bottom of face of seat.
3. Tighten wedge screw. E = Total width of cutter over hub
Tool holding/
ap = Cutting width
Machines
4. Lubricate wedge screw with Molykote before re-using.
Tool setting
H The CoroMill 331 is easy to preset. The accuracy of the
pre-setting is limited only by the available equipment.
Using a micro-indicator is recommended, or preset the
CoroMill 331 in a projector. Use this formula to calculate
the height of the gauge-block combination when setting the
Materials
micro-indicator.
I ➤
Information/
D 176
Index

General turning
➤
Tool setting continued Diameter, (mm) Torque, (Nm)
1. Loosen the wedge screw half a turn.

80-100 5
2. Push the cassette by hand so that it protrudes above the cutter body.
3. Place the cutter on the surface plate. Locate the flat contact point of the
125-315 6
B
micro-indicator onto the parallel land of the insert.

4. Tap the cassette carefully until the micro-indicator shows zero.
5. Tighten the wedge screw.
6. Repeat the procedure, compensating for movement. Tighten the wedge
screw to the correct torque for the cutter diameter (see table at right).
Note: To avoid distortion of 80 mm diameter cutters, mounting should be

performed in three steps: C
a: Basic tightening of all screws.
b: Second tightening to 4 Nm.
c: Final tightening to 5 Nm.
Threading
7. L oosen the wedge screw half a turn.
8. Distribute the protrusion evenly on both sides of the cutter.
9. Eliminate the axial run-out on the front side of the cutter by pushing the D
cassette to the zero point.
10. Tighten the wedge screws.
11. Set back side of cutter to required tool width.
Milling
E
Drilling
F
Boring
G
Tool holding/
Code key for cutters

Machines
32. = Full side and face mill, cassette design

35. = F ull side and face mill, fixed pocket design H
52. = Half side and face mill, cassette design
Diameter
N 331 .32 – 200 Q40 CM Slot width

Materials
R = Right-hand Mounting type and size

N = Neutral A = Cylindrical
L = Left-hand S = Bore with keyway
Q = Arbor
I
Information/
D 177
Index

A Milling – CoroMill® Plura
CoroMill® Plura
General turning
Solid carbide end mills for highest productivity in all materials −O

ptimized geometries for roughing, finishing,
and applications profiling, chamfering and threading
B
−V
ariable flute depth (VFD) design for optimum core
stiffness and chip space
−D
eveloped to provide optimized rigidity for finishing to
super-finishing performance
C
− Highest productivity in all materials and applications
Threading
−C
an be ordered as engineered product or Tailor Made
design to individual customer requirements.
D
Applications
Depending on operation, use this table to find the suitable CoroMill Plura end mill.
Milling
Method First choice cutter
(1) General milling, roughing, semi-finishing

E
Shoulder milling Slot milling Face milling
D 42 D 85 D 55
Variable flute depth (VFD) design. Helix angle
Axial/plunge milling Pocket milling Ramping -50°.
Drilling
D 116 D 100 D 100

(2) Roughing, high feed
F
Face milling Ramping
D 55 D 100 High feed cutter (HFC) design. Helix angle -50°.
(3) Roughing
Boring
Slot milling Pocket milling Ramping

G D 85 D 100 D 100 Kordell design. Helix angle -40°.
(4) Profiling Roughing

Tool holding/
Machines
Pocket milling
D 100 Large radius cutter, VFD. Helix angle -50°.
Semi-finishing and finishing

H
Profiling
D 66
Ball Nose end mill (BNE) design. Helix angle -30°.
Materials
(5) Finishing
Shoulder milling Face milling Circular ramping

I D 42 D 55 D 100
Multi-edge end mill. Helix angle -50°.
Information/
D 178
Index

Milling – CoroMill® Plura A
General turning
First choice Complementary
K B
B
(1) (2) (3) (5)

50° variable flute
Design depth
Conventional High feed Kordell Multi-edged
Application General General Roughing Roughing Finishing
Geometry P, H A, P, N P, H B, K, U H, L
Helix angle (degree) 50º 25º, 30º, 45º 50º 30º, 40º, 45º 30º, 50º, 60º C
Cutter dia. (Dc) 2 – 25 1 – 25 4 – 20 6 – 25 3 – 20
Max. cutting depth (ap), mm 7.0 – 54.0 3.0 – 90.0 0.2 – 1.3 7.0 – 45.0 8.0 – 38.0
Threading
Corner radius (re), dia, mm 0.2 – 4 Non radius 0.5 – 2 Non radius 0.5 – 2
2, 4, 5, 6, 8, 10,
Cutting edges (zn) 3, 4, 5 2, 3, 4, 5, 6 4 3, 4, 5, 6, 8
12, 14, 16 D
Material
S H N S H S H N S S H
Additional information Centre cutting Centre cutting Non-centre cutting With/without centre cutting Non-centre cutting
Differential pitch With/without cutting fluid
Milling
With/without cutting
fluid, radius
Namnlöst-1 1 2009-08-
Drilling
(4)
F
Design Corner radius Ball Nose Chamfer 45°, 60° Slotting Flat end Pitch 0.5 – 3
Application Hard steel milling Profiling Chamfering Key slot milling Turn milling*) Threading*)
Geometry G A, G, P, N G P N N, H
Boring
Helix angle (degree) 30º 30º, 40º 0º 30º 30º
3.2 (M4) –
G
Cutter dia. (Dc) 2 – 16 0.4 – 20 4–8 2 – 20 6 – 12
19 (M24)
Max. cutting depth (ap), mm 2.0 – 16.0 0.4 – 45 0.5 – 7.4 3.0 – 20.0 10.0 – 16.0 8.4 – 50.0
Tool holding/
Machines
Corner radius (re), dia. mm 0.2 – 3 0.1 – 10 0.5 – 6 Non radius 0.5 – 1
Cutting edges (zn) 2, 4 2, 3, 4 3, 4, 5, 6 2, 3 4 3, 4, 5, 6
P P M K P M K P M K P M K P M K
H
Material
H N S H S H N S S N S H
Additional information Centre cutting Centre cutting Centre cutting Centre cutting Metric 60°
With/without
cutting fluid
Materials
*) For more information about Turn milling, see page D 80, and Thread milling, see page D 95.
I
Information/
D 179
Index

A
General turning Milling – CoroMill® Plura
Geometry recommendations
Geometry P and N γ0 =9° to 12° Geometry K γ0 = 9° to 12°
• First choice for general machining in steel • First choice for roughing materials <28 HRc
<48 HRc, stainless steel, titanium, HRSA, • Wave-shaped periphery for reduced chip size
B cast iron and aluminium (Kordell)
• Straight cutting edges • Core diameter, 60% for good combination of
• Core diameter, 50% (P) 60% (N) strength and chip clearance
• Positive rake angle 9° to 12° for reduced • Positive rake angle 9° to 12° for reduced
cutting forces. cutting forces.
Geometry L γ0 = 4° to 6° Geometry B γ0 = 4° to 7°
C • First choice for finishing in steel <48 HRc, • Alternative choice for roughing in titanium
stainless steel, titanium, HRSA, cast iron • Straight cutting edges with notches for reduced
and aluminium chip size
• Straight cutting edges • Core diameter, 60% for good combination of
• Core diameter, 70% for increased bending strength and chip clearance
strength • Positive rake angle 4° to 7° for reduced cutting
Threading
• Positive rake angle 4° to 6° for reduced forces.

cutting forces.
D Geometry G γ0 = -3° to 3° Geometry U γ0 = 9° to 12°

• First choice for roughing to super-finishing in • First choice for aluminium
steel 35 to 58 HRc • Wave-shaped periphery for reduced chip
• Straight cutting edges size (Kordell)
• Core diameter, 70% for increased bending • Positive rake angle 9° to 12° for reduced
strength cutting forces.
Milling
• Rake angle of -3° to 3° for high edge strength

and soft cutting action.
E
Geometry H γ0 = <-11° Geometry A γ0 = 12° to 15°
• Roughing to super-finishing in steel 48 to 63 HRc • Alternative choice for aluminium
• Straight cutting edges • Straight cutting edges
• Core diameter, >75% for maximum bending • Positive rake angle 12° to 15° for reduced
Drilling
strength cutting forces.

• Rake angle of -11° to -21° for maximum edge
strength.
Code key
R 21 6 . 2 4 - 100 50 D C K 22 P
Boring
Explanation of a CoroMill Plura Code:

G 21 = End mill
6 = Drilling function
2 = Square form with corner radius
Tool holding/
Machines
4 = No. of teeth (zn), 1-9, A if 10-32

100 = Cutter diameter in mm (Dc)
H 50 = Helix angle in degrees (γp)

D = Corner radius (rε)
C = Shank type
K = Length of shank in mm (l²)
Materials
22 = Max. cutting depth in mm (ap)

Use the PluraGuide for selec-
P = Geometry tion of tool and correct cutting
I data and for programming,
C-2948:063.
Information/
D 180
Index

Milling – CoroMill® Plura A
General turning
Teeth recommendations
• Use 4 teeth for best productivity
• Use 3 teeth for best stability
B
Grade recommendations

ISO P M K ISO N
GC1620, GC1630,
GC1640 Dry Wet H10F Dry Wet
Finishing CG1620 CG1620 Finishing H10F CG1620

C
Semi-finishing GC1630 GC1630 Semi-finishing H10F GC1630
Roughing GC1640 GC1640 Roughing H10F GC1640
Threading
ISO S ISO H
GC1620, GC1630,
Dry Wet GC1610, GC1620 Dry Wet D
GC1640
Finishing CG1620 Finishing

GC1610
Semi-finishing GC1630 Semi-finishing
Milling
Roughing GC1640 Roughing GC1620
E
Regrinding of CoroMill® Plura
Regrinding of solid end mills is recommended when the cutting edge has
chipped, or is worn to the point where burrs and surface finish on the work-
Drilling
piece become unacceptable.
Recommended maximum wear before regrinding appears in the table below.
F
Tool diameter (Dc), mm 4–6 7–9 10 – 14 15 – 20 25
Boring
Max. diameter wear, mm 0.05 0.07 0.09 0.14 0.20
Max. corner wear, mm 0.20 0.30 0.40 0.50 0.70 G

Note: If wear exceeds these recommendations, the tool may have to be cut, causing a
reduction in length. If the wear is too severe, reconditioning may not be possible.
Tool holding/
Machines
H
Materials
Contact your Sandvik Coromant representative for more information about the
reconditioning services available.
I
Information/
D 181
Index

CoroMill® 316
General turning
Exchangeable head milling system −O

ptimized geometries for roughing, finishing, profiling
and chamfering
B −E
xchangeable head milling system for shortened index
time to increase output and raise productivity
− Full face and taper contact for best stability

− Coupling designed to minimize bending
−V
arious heads fit one shank for ultimate versatility and
reduced inventory
−W
ide range of shank options for best combination of
C accessibility and stability
Threading
D
Applications
Depending on application, use this table to find the suitable CoroMill 316 end mill.
Milling
Method First choice cutter
(1) General milling, roughing, semi-finishing

E
Shoulder milling Slot milling Face milling
D 42 D 85 D 55
Corner radius end mill
Axial/plunge milling Pocket milling Ramping
Drilling
D 116 D 100 D 100

(2) Roughing, high feed
F
Face milling Ramping
D 55 D 100 High feed end mill
(3) Roughing
Boring
Slot milling Pocket milling Ramping

G D 85 D 100 D 100 Kordell end mill
(4) Profiling Roughing

Tool holding/
Pocket milling
Machines
D 100
Corner, large radius end mill
Semi-finishing and finishing
H
Profiling
D 66
Ball Nose end mill
Materials
(5) Finishing
I Shoulder milling Face milling Circular ramping

D 42 D 55 D 100 Multi-edged end mill
Information/
D 182
Index

General turning
First choice Complementary
(1) (2) (3) (4) (5)
Design Corner radius Corner radius High feed Kordell Ball Nose Multi-edged
B

Application General General Roughing Roughing Profiling Finishing
Geometry P P P K G L
Helix angle (degree) 50º 10º 40°, 50º 40º, 45º 10º, 40º 50º
Grade GC1030 GC1030, H10F GC1030 GC1030 GC1030, H10F GC1030 C

Cutter dia. (Dc) 10 – 25 10 – 16 10 – 25 10 – 25 10 – 25 10 – 25
Max. cutting depth (ap), mm 5.5 – 13 8 – 13 0.7 – 1.6 5.5 – 13.5 5.5 – 13 5.5 – 13.5
Threading
0.5 – 3 (dia. 10) 0 – 2.5 (dia. 10) 1.5 (dia. 10 – 12) 0.4 (all dia.) 5 (dia. 10) 0, 1 (dia. 10-12)
Radius (re), (dia. mm) 0.5 – 4 (dia. 12 – 0 – 3 (dia. 12) 2 (dia.16 – 20) 6 (dia. 12) 0, 1, 1.5 (dia. 16 –
20) 0 – 4 (dia. 16) 3 (dia. 25) 8 (dia. 16) 25)
10 (dia. 20)
12.5 (dia. 25) D
Cutting edges (zn) 3, 4 2 4 4, 5, 6 2, 4 6, 8
Material P M K P M K P M K P M K P M K P M K
Milling
N S N S N S N S N S N S
Additional information Centre cutting Centre cutting Non-centre cutting Centre cutting Centre cutting Non-centre cutting
Coarse pitch With/without radius
Problem solver E
Drilling
Chamfer
F
Design 15°, 30°, 45°, 60°
Chamfer radius Corner radius
Application Chamfering Chamfering Aluminium milling
Geometry G G U
Boring
Helix angle (degree) 0º, 10º 0º 45º
Grade GC1030 GC1030 H10F

G
Cutter dia. (Dc) 10 – 16 10 – 25 10 – 25

Tool holding/
Machines
Max. cutting depth (ap), mm 1.2 – 7.5 1.5 – 8 5.5 – 13
Radius (re), (dia. mm) Non radius 1.5 – 3 (dia. 10) 0 – 2.5 (dia. 10)
3 – 4 (dia. 12) 0 – 4 (dia. 12-25)
4 – 6 (dia. 16)
6 (dia. 20)
8 (dia. 25)
H
Cutting edges (zn) 2, 4, 6, 8 4 3

Materials
Material P M K P M K
N S N S N
Additional information Centre cutting
With/without radius
I
Information/
D 183
Index

A
Geometry recommendations
For detailed information about geometry, see CoroMill Plura, page D 180.
B
Code key
316 - 12 S M 3 50 - 120 05 P E12 - A 20 - S S - 120

Code key for exchangeable milling heads: Code key for tool holders:
12 = Size of EH coupling E12 = Size of EH coupling
C
S = Straight 90 degree A = Cylindrical holder type
M = Length of head (medium) 20 = Holder diameter in mm (dmm = 20)
3 = Number of teeth (zn = 3) S = Type of holder (Straight)
Threading
50 = Helix angle in degrees (γp) S = Holder material (Steel)

120 = Cutting diameter in mm (Dc) 120 = Length of holder in mm (l2)
D 05 = Corner radius (rε = 0.5)

P = Geometry
Milling
Recommendations with different tool length

Drilling
Tool length < 3 × Dc 4 × Dc 10 × Dc > 12 × Dc

F Stable conditions Quite stable Low stability Very low stability
Comparable with Not as stable as
solid carbide. solid carbide
Steel shank applica- All types of inserts High feed High feed High feed Material: Steel, 43.5 HRc
Boring
tions and applications. Profiling Profiling Profiling Shank diameter: 10 – 32 mm

Chamfering Chamfering Chamfering Style: Straight 90°, Conical 80°, 85° and 89°
Shoulder milling Limited shoulder Not suitable for Length: 65 – 250 mm
G Limited slot milling milling shoulder milling
Tool holding/
Solid carbide shank All types of inserts All types of inserts High feed High feed Material: Solid carbide
Machines
applications and applications. and applications. Profiling Profiling Shank diameter: 10 – 25 mm

Chamfering Chamfering Style: Straight 90°, Conical 89°
Shoulder milling Limited shoulder Length: 100 – 200 mm
Limited slot milling milling
Coupling size Key

Materials
E10 5060 093-01

E12 5060 093-02
E16 5060 093-03
E20 5060 093-04
I E25 5060 093-05
Information/
D 184
Index

General turning
Teeth recommendations
• Use 4 teeth for best productivity
• Use 3 teeth for best stability
B
Speed and feed recommendations

C
CoroMill® 316 GC1030 ae ≤ 1.0 × Dc ap ≤ 0.5 × Dc ae ≤ 0.3 × Dc ap ≤ 0.5 × Dc ae ≤ 0.005 × Dc
ISO CMC HB vc m/min vc m/min vc m/min
Threading
01.1 125 190 280 630
P 01.2 150 170 255 580
01.4 210 150 225 510
02.1 175 165 245 555
02.2 300 100 150 340 D
03.11 200 170 250 570
03.22 380 80 120 280
M 05.11 200 70 110 240

05.21 200 55 85 190
05.51 230 45 70 155
Milling
K 07.1 130 120 180 395
08.1 180 130 190 420
08.2 245 110 160 380
09.1 250 105 155 350 E
N 30.22 90 1000 1100 1300
S 20.22 350 25 35 80
23.22 350 40 80 150
Drilling
Feed recommendations
F
CoroMill® 316 GC1030 ae ≤ 1.0 × Dc ap ≤ 0.5 × Dc ae ≤ 0.3 × Dc ap ≤ 0.5 × Dc ae ≤ 0.005 × Dc Boring

G
Dc mm fz mm/tooth fz mm/tooth fz mm/tooth
10 0.045 0.070 0.120

Tool holding/
12 0.055 0.085 0.140

Machines
16 0.065 0.110 0.160
20 0.080 0.130 0.180
25 0.100 0.160 0.200 H

Materials
Use the PluraGuide for selection of tool and correct I

cutting data and for programming, C-2948:063.
Information/
D 185
Index

A Milling – extended offer
Extended offer
General turning
B Tailor Made products

The Tailor Made program covers variants of the standard CoroMill products, e.g.
insert size, No. of inserts in the cutter, pitch and mounting type, tool length, etc.
For more advanced solutions, engineered products can be quoted.
Engineered products
C Engineered milling products can be cost effective solutions in mass production, in
which one tool can replace several standard tools, or when advanced component
designs require a specific cutter or insert geometry.
In addition to the standard and Tailor Made
program a multitude of variants on the
Threading
CoroMill Plura solid carbide end mill concept

are available.
D
CoroMill® cutters with cassettes
The CoroMill cassette system – developed for medium to large diameter face mills –
makes handling easy and at reduced costs.
Milling
It also makes the choice of parameters (such as size, height, pitch and entering
angle, and also insert type and size) freely and individually adaptable to specific
conditions.
E Exchangeable cassettes:
• Simplify maintenance and reduce costs, as only a small part of the tool has to
be replaced in case of damage.
• Enable easy adjustments for optimal surface finish or for the production of
functional, all purpose, surface textures.
Drilling
• With safe cassette locking using wedges – easy to replace.

• With accurate macro-setting using an easy to handle device.
F • With micro-setting option.
• With low run-out and safe performance at high rotational speeds using the well
proven, serrated cassette interfaces.
• Serrations also guarantee that precision is maintained when adjusting the insert
position.
• Enable the use of a wide insert assortment, including: standard inserts, wiper
Boring
inserts, Tailor Made inserts.

Standard cassetts in engineered cutter bodies, or engineered cassettes in standard
G cutter bodie, offers a high degree of flexibility.
Tool holding/
Machines

Materials
Based on the CoroMill 331 concept, a variety of engineered cutter solutions

can be made, utilizing cassettes and standard or tailor made inserts.
I
Information/
D 186
Index

Milling – extended offer A
General turning
Gear cutting
Gear cuttting is one of many areas in which Sandvik Coromant offers optimized milling solutions:
•P roductive cutters for both roughing and finishing of gear wheels.
• Cutters in external or internal design with high precision inserts.
B

C
Threading
D
Cutters for roughing and finishing, respectively
Compressor screw rotor machining
Milling
Compressor screw rotor machining is another area in which
Sandvik Coromant has extensive experiences in applications
all over the world.
Form milling cutters have been developed to perform roughing
E
and semi-finishing of compressor screw rotors for air or
refrigeration compressors in one operation. These tools are
designed and manufactured to meet the needs of specific
production processes.
Drilling
F
Crank- and Camshaft machining
Boring
Extremely short machining times, high product quality and a very
secure production process for crank- and camshafts puts very high
demands on the tooling used. Sandvik Coromant provides reliable G
tooling for the all the common methods in the high volume production.
Internal- and external milling cutters with simple cutter body design
and a stable, exchangeable segment system, as well as internal
Tool holding/
milling cutters with fix pockets are offered, this in combination with
Machines
inserts in the best performing grades, contribute to a very reliable

and cost efficient tooling solution.
For turn-turn broaching the cassettes and discs are designed to
allow individual assembly of all tool positions - and the most efficient
H
mounted number of sister tools. The cassettes themselves are stable,
simple to exchange and easy to clean.
Materials
I
Information/
D 187
Index

A Milling – grade information
Grade information
General turning
The cutting tool materials are generally divided into basic and complementary
grades, indicated in an ISO/ANSI chart, and are described by the relation between
wear resistance and toughness.
B
•B asic grades cover a wide range of applications and should be the first choice.
• Complementary grades contribute to widths and other alternatives within the

range.
C
The position and form of the grade symbols Wear resistance

Centre of the field of Recommended field of
indicate the suitable field of application application application
Threading
= Basic grades = Complementary grades Toughness
D
Steel
Basic grades Complementary grades
Milling
E
Drilling
F
GC4230 (HC) – P25 (P10-P40) GC1030 (HC) – P30 (P25 – P50) GC2030 (HC) – P25 (P15 – P35)
• All-round grade for modern machining with a • PVD coated carbide grade. GC1030 is the first • PVD coated carbide grade for milling of low carbon
good balance of security and productivity. Coated choice in unstabl conditions such as long edge, steels that tend to create built-up edge. Also very
carbide grade for light to heavy milling (both wet chip jamming, deep shoulder and end milling, long suitable for 90 degree milling in mixed materials.
and dry) in unalloyed and low alloyed steels. First overhang, turn mill operations, etc. Can be used
Boring
choice in face milling and an optimizer for higher as a backup choice in tough operations. In com- GC2040 (HC) – P40 (P30 – P50)
productivity in shoulder milling. bination with periphery ground inserts, the first
• Coated carbide grade for milling of steels, when a
choice for sticky materials, e.g. low carbon steel.
combination of sharp cutting edges and a tough
GC4220 (HC) – P15 (P05-P25)
G • Coated carbide grade optimized for best produc GC1025 (HC) – P10 (P05 – P20)
grade is needed at low speeds. Very useful for
small batch production of mixed materials.
tivity in steel milling. Grade for dry machining with • PVD coated carbide grade for light milling of steel.
high chip removal rate. In combination with periphery ground inserts, the GC3040 (HC) – P20 (P10 – P30)
first choice for sticky materials, e.g. low carbon
• Coated carbide grade with very good abrasive wear
GC4240 (HC) – P40 (P30 – P50) steels.
Tool holding/
resistance, for rough milling of steel at medium to

• Tough coated carbide grade for demanding opera- high speeds.
Machines
tions in steel milling. For end mill and square CT530 (HT) – P20 (P05 – P30)
shoulder concepts, grade GC4240 should be • Cermet grade for light milling operations, mainly SM30 (HW) – P30 (P20 – P40)
used in more stable conditions, such as short without coolant. The high resistance to plastic
• Uncoated carbide grade for medium to rough
overhangs, face milling, shallow shoulder milling, deformation and smearing/built-up edge make
milling at low to moderate cutting speeds. Good
H etc. For other concepts, grade GC4240 is the first
or backup choice in tough operations. Benefits
it suitalble for a wide cutting speed range. Ideal
grade for Wiper inserts.
edge security in hard materials and in unstable
conditions.
of security. Suitable for small batch production of
mixed material. Workes well both with or without
coolant. GC1010 (HC) – P10 (P05-P30)
• PVD coated carbide grade for milling within
application area of typical pre-hardened and
Materials
plastic mould steel, from 36 HRc and above.
I
Information/
D 188
Index

Milling – grade information A
General turning
Letter symbols specifying the designation of Ceramics: Diamond:
hard cutting materials:
CA xide ceramics containing primarily
O DP Polycrystalline diamond ¹)
aluminium oxide (Al2O3).
Hardmetals: Boron nitride:
CM ixed ceramics containing primarily aluminium
M
HW ncoated hardmetal containing primarily
U oxide (Al2O3) but containing components other BN Cubic boron nitride ¹)
tungsten carbide (WC). than oxides.
1) Polycrystalline
diamond and cubic boron nitride B
HT ncoated hardmetal, also called cermet,
U CN itride ceramics containing primarily silicon
N are also called super-hard cutting materials.

containing primarily titanium carbides (TIC) or nitride (Si3N4).
titanium nitrides (TIN) or both.
CC Ceramics as above, but coated.
HC Hardmetals as above, but coated.
C
P ISO P = Steel N ISO N = Non-ferrous material
M ISO M = Stainless steel S ISO S = Heat resistant super alloys
Threading
K ISO K = Cast iron H ISO H = Hardened steel
D
Austenitic/martensitic stainless steel
Milling
E
Drilling
F
GC1025 (HC) – M15 (M10 – M20) GC2040 (HC) – M30 (M20 – M40) SM30( HW) – M30 (M25 – M35)
• PVD coated carbide grade for light milling of stain- • Coated carbide grade for milling of stainless • Uncoated carbide grade for medium to rough
less steel. In combination with periphery ground steels with abrasive tendencies, e. g. cast milling at low to moderate cutting speeds.
inserts, the first choice for sticky and work- components, ferritic/martensitic stainless Good edge security in unstable conditions.
hardening materials. steels and PH-steels at medium speeds.
Boring
Also useful for small batch production of GC4230 (HC) – M15 (M10 – M25)
mixed materials.
GC1030 (HC) – M15 (M10 – M20) • Coated carbide grade for light to heavy milling
in martensitic stainless steels.
• PVD coated carbide grade for light milling of stain- GC4240 (HC) – M40 (M20 – M40)
less steel. In combination with periphery ground
• Coated carbide grade for medium to heavy
G
inserts, the first choice for sticky and work-
operations in stainless steel castings. Very
hardening materials.
suitable for small batch production of mixed
materials.
GC2030 (HC) – M25 (M15 – M35)
Tool holding/
• PVD coated carbide grade for milling of stainless CT530 (HT) – M20 (M10 – M30)
Machines
steels (mainly austenitic types) at medium to high • Cermet grade for light milling of austenitic/duplex
speeds. In combination with positive geometries, stainless steels. The high resistance to plastic
also suitable for heat resistant material and deformation/smearing/built-up edge makes it
titanium. suitable for a wide cutting speed range in dry
conditions.
H
Materials
I
Information/
D 189
Index

A Milling – grade information
Cast iron
General turning
B
C GC3040 (HC) – K30 (K20 – K40) K20W (HC) K25 (K15-K35) H13A (HW) – K25 (K15 – K30)
• Tough coated carbide grade for demanding milling • Coated carbide grade for medium to rough milling • Uncoated carbide grade with wear resistance and
of cast iron e.g. nodular cast iron, wet conditions of grey cast iron under wet conditions. To be used toughness for light to medium milling at moderate
or high tensile iron. Long predictable tool life at at low to medium speeds. cutting speeds. Ideal choice for milling of ferritic
low to medium cutting speeds. nodular cast iron.
K15W (HC) – K15 (K10 – K25)
Threading
GC3220 (HC) – K20 (K05 – K25) • Coated carbide grade for milling of grey cast iron GC1010 (HC) – K10 (K05-K25)
• CVD coated carbide grade for medium to rough under wet conditions. To be used at medium • PVD-coated carbide grade for finishing milling in
milling of grey cast iron, mainly under dry condi- speeds. grey and nodular cast iron. A long tool life can be
tions. Long predictable tool life at medium to high predicted with a sustained surface finish.
D cutting speeds. CC6190 (CN) – K15 (K05 – K20)
• Silicon nitride ceramic grade for roughing to semi- GC4220 (HC) – K25 (K15 – K30)
GC1020 (HC) – K20 (K15 – K35) finishing of grey cast iron at high cutting speeds. • Coated carbide grade for light to heavy milling
• PVD coated carbide grade for medium to rough of cast iron at medium speeds. To complement
milling of grey and nodular cast iron under wet K20D (HC) - K20 (K10-K30) GC3000 grades in operations.
conditions. To be used at medium to high speeds
• MTCVD coated grade for medium to rough milling
with predictable tool life. GC4230 (HC) – K30 (K25 – K35)
of cast iron. Mainly without coolant. Long tool life
Milling
with high speed capability. • Coated carbide grade for light to heavy milling of
CB50 (BN) – K05 (K01 – K10) nodular cast iron.
• CB50 is a cubic boron nitride tipped grade. It pro- H1P (HW) – K05 (K01 – K10)
vides a high edge toughness combined with good GC4240 (HC) – K35 (K30 – K40)
E wear resistance. CB50 is well suited for machining
of cast iron under favourable conditions.
• Uncoated carbide grade for finishing of cast iron,
bronze and brass. Also suitable for wiper inserts. • Coated carbide grade for medium to heavy opera-
tions at low speeds where the demand for tough-
ness is high.
Drilling
F
Non-ferrous metals, plastics, wood
Boring
G
Tool holding/
CD10 (DP) – N05 (N01 – N10) CT530 (HT) – N15 (N10 – N25) H10F (HW) – N20 (N15 – N25)
Machines
• Polycrystalline diamond tipped grade for machining Cermet grade mainly recommended at high RPM Uncoated carbide grade suitable for milling aluminium
of non-ferrous and non-metallic materials. Provides when milling aluminium due to the low tendency for alloys in combination with "sharp" cutting edges.
long tool life, clean cut and good surface finish. built-up edge and low weight of the inserts.
GC1030 (HC) - N15 (N10-N25)
H10 (HW) – N10 (N05 – N15) GC1025 (HC) – N15 (N10 – N25) PVD coated carbide grade for rough milling of
H • Uncoated fine-grained carbide grade, that provides PVD coated carbide grade for rough milling of aluminium alloys in combination with ground cutting
excellent edge sharpness for milling aluminium. aluminium alloys in combination with ground cutting edges.
edges.
H13A (HW) – N15 (N10 – N20)
• Uncoated carbide grade suitable for milling
aluminium alloys in combination with "sharp"
Materials
cutting edges.
I
Information/
D 190
Index

Milling – grade information A
Heat-resistant alloys/Titanium alloys
General turning

GC1025 (HC) – S15 (S10 – S20) GC2030 (HC) – S25 (S15 – S35) GC2040 (HC) – S30 (S20 – S40)
• PVD coated carbide grade for milling heat resistant • PVD coated carbide grade for semi-finishing to • Coated carbide grade for milling of cast heat-
super alloys at medium speeds. Good resistance light roughing of heat resistant super alloys at low resistant alloys. C
to built-up edge and plastic deformation. speeds.
H10F (HW) – S30 (S25 – S35) GC1030 (HC) – S15 (S10 – S20) H13A (HW) – S20 (S15 – S25)
• Uncoated carbide grade with good abrasive
• Uncoated carbide grade with fine grain sizes. High • PVD coated carbide grade for milling of heat resi
wear resistance and toughness for milling heat
notch wear resistance makes it suitable for milling stant super alloys at medium speeds. Good resi
Threading
resistant alloys at moderate cutting speeds and
of aerospace materials, e.g. titanium. stance to built-up edge and plastic deformation.
feeds.
Hardened steel
Milling
Drilling
CB50 (BN) – H05 (H01 – H10) GC1030 (HC) - H10 (H10-H20) GC3040 (HC) – H25 (H20 – H30) F
• CB50 is a cubic boron nitride tipped grade. It • PVD coated carbide grade for milling hardened • Coated carbide grade for rough milling hardened
provides a high edge toughness combined with components at low feeds and moderate speeds. steel at fair conditions and low to medium speeds.
good wear resistance. CB50 is well suited for
machining hardened steel under favorable GC4220 (HC) – H25 (H15 – H30) GC1025 (HC) – H15 (H10 – H20)
conditions.
• Coated carbide grade for light roughing under • PVD coated carbide grade for milling hardened
favorable conditions of hardened steels, components at low feeds and moderate speeds.
Boring
CC6190 (HC) – H10 (H05 – H15) up to HRc 60. Can handle high temperatures.
• Silicon nitride ceramic grade suitable for semi- H1P (HW) – H10 (H05 – H15)
finish milling of chilled cast iron at medium to
CT530 (HT) – H25 (H10 – H25) • Uncoated carbide grade for finishing chilled cast
high speeds.
• Cermet grade for finish milling of hardened steel
iron at medium speeds. G
GC1010 (HC) – H10 (H05-H25) components at low to medium speeds.
• PVD-coated carbide grade for machining in
hardened steel. Can handle large portion of
machining demands, from roughing to finishing
Tool holding/
operations. Due to exeptional plastic deformation

Machines
resistance, thermal crack resistance and good

wear resistance, the grade can withstand long
periods in cut. Suitable for machining hardened
steel from 36 HRc and above.
H
Materials
I
Information/
D 191
Index

A
General turning Milling – feed recommendations
Shoulder milling Feed per tooth, fz (mm/tooth) Max. chip thickness, hex (mm)
κr = 90° Starting Starting

B Insert geometry Insert size value (min.- max.) value (min.- max.)
CoroMill® 490
M-PL 0.10 (0.05 – 0.15) 0.10 (0.05 – 0.15)

M-PM 0.17 (0.10 – 0.20) 0.17 (0.10 – 0.20)
M-PH 0.22 (0.15 – 0.25) 0.22 (0.15 – 0.25)
E-ML 0.15 (0.12 – 0.18) 0.15 (0.12 – 0.18)

E-MM 08 0.17 (0.15 – 0.20) 0.17 (0.15 – 0.20)
M-MM 0.17 (0.15 – 0.20) 0.17 (0.15 – 0.20)
M-KL 0.10 (0.05 – 0.15) 0.10 (0.05 – 0.15)

M-KM 0.17 (0.10 – 0.20) 0.17 (0.10 – 0.20)
C M-KH 0.25 (0.15 – 0.30) 0.25 (0.15 – 0.30)
R490
CoroMill® 390 E-PL Light 11 0.08 (0.05 – 0.12) 0.08 (0.05 – 0.12)
E-ML 0.10 (0.05 – 0.15) 0.10 (0.05 – 0.15)
E-KL 0.08 (0.05 – 0.12) 0.08 (0.05 – 0.12)
Threading
E-NL 0.20 (0.10 – 0.30) 0.20 (0.10 – 0.30)

M-PL Light 11 0.08 (0.05 – 0.15) 0.08 (0.05 – 0.15)
M-KL 0.10 (0.08 – 0.15) 0.10 (0.08 – 0.15)
E-PL Light 17 0.08 (0.05 – 0.12) 0.08 (0.05 – 0.12)
D E-ML 0.10 (0.05 – 0.15) 0.10 (0.05 – 0.15)
E-KL 0.08 (0.05 – 0.12) 0.08 (0.05 – 0.12)
R390 E-NL 0.20 (0.10 – 0.30) 0.20 (0.10 – 0.30)
M-PL Light 17 0.08 (0.05 – 0.15) 0.08 (0.05 – 0.15)
M-KL 0.10 (0.08 – 0.15) 0.10 (0.08 – 0.15)
E-PM Medium 0.10 (0.08 – 0.15) 0.10 (0.08 – 0.15)
E-MM 11 0.13 (0.08 – 0.20) 0.13 (0.08 – 0.20)
Milling
E-KM 0.12 (0.12 – 0.20) 0.12 (0.12 – 0.20)

M-PM Medium 0.10 (0.08 – 0.15) 0.10 (0.08 – 0.15)
M-MM 11 0.13 (0.08 – 0.20) 0.13 (0.08 – 0.20)
(0.12 – 0.20) (0.12 – 0.20)
E M-KM
E-PM Medium
0.12
0.10 (0.08 – 0.15)
0.12
0.10 (0.08 – 0.15)
E-MM 17 0.15 (0.08 – 0.20) 0.15 (0.08 – 0.20)
E-KM 0.15 (0.12 – 0.20) 0.15 (0.12 – 0.20)
M-PM Medium 0.10 (0.08 – 0.15) 0.10 (0.08 – 0.15)
M-MM 17 0.15 (0.08 – 0.20) 0.15 (0.08 – 0.20)
M-KM 0.15 (0.12 – 0.20) 0.15 (0.12 – 0.20)
Drilling
M-PH Heavy 11 0.12 (0.08 – 0.20) 0.12 (0.08 – 0.20)

M-MH 0.16 (0.08 – 0.22) 0.16 (0.08 – 0.22)
M-KH 0.15 (0.12 – 0.22) 0.15 (0.12 – 0.22)
M-PH Heavy 17 0.20 (0.15 – 0.35) 0.20 (0.15 – 0.35)
F M-KH 0.20 (0.15 – 0.35) 0.20 (0.15 – 0.35)
H-PL Light 18 0.10 (0.05 – 0.19) 0.10 (0.05 – 0.19)
H-ML 0.10 (0.05 – 0.19) 0.10 (0.05 – 0.19)
H-KL 0.10 (0.05 – 0.19) 0.10 (0.05 – 0.19)
M-PM Medium 18 0.20 (0.08 – 0.30) 0.20 (0.08 – 0.30)
M-MM 0.20 (0.08 – 0.30) 0.20 (0.08 – 0.30)
M-KM 0.20 (0.08 – 0.30) 0.20 (0.08 – 0.30)
Boring
E PCD 11 0.15 (0.10 – 0.25) 0.15 (0.10 – 0.25)

E PCD 17 0.15 (0.10 – 0.25) 0.15 (0.10 – 0.25)
G CoroMill® 290 M-PL Light 0.08 (0.05 – 0.15) 0.08 (0.05 – 0.15)
M-KL 0.10 (0.08 – 0.15) 0.10 (0.08 – 0.15)
}
E-PL 0.06 (0.05 – 0.09) 0.06 (0.05 – 0.09)
E-KL Light 12 0.08 (0.07 – 0.12) 0.08 (0.07 – 0.12)
E-ML 0.10 (0.08 – 0.15) 0.10 (0.08 – 0.15)
Tool holding/
R290 M-PM 0.17 (0.10 – 0.20) 0.17 (0.10 – 0.20)

Machines
M-KM Medium 12
rε = 0.8
M-KM
M-PL
M-ML Light 12 0.17 (0.10 – 0.20) 0.17 (0.10 – 0.20)
H R290.90 M-KL
M-WL
rε = 2.0
M-PM
M-MM Medium 12 0.12 (0.08 – 0.15) 0.12 (0.08 – 0.15)
M-KM
M-WM
M-PH
Materials
M-KH Heavy 12 0.25 (0.10 – 0.30) 0.25 (0.10 – 0.30)

M-WH
E Ceramic 0.10 (0.05 – 0.15) 0.10 (0.05 – 0.15)
I E CBN 0.10 (0.05 – 0.18) 0.10 (0.05 – 0.18)

Information/
D 192
Index

Milling – feed recommendations A
General turning
Shoulder milling Feed per tooth, fz (mm/tooth) Max. chip thickness, hex (mm)
κr = 90° Insert geometry

Insert
size
Starting
value (min.- max.)
Starting
value (min.- max.)
B
CoroMill® 690

M-P-SL 10 0.10 (0.05 – 0.2) 0.10 (0.05 – 0.15)
M-E-SL
M-P-SL 14 0.12 (0.05 – 0.2) 0.12 (0.05 – 0.15)

M-E-SL
C
Coromant finishing long edge -PL2
-PL
-ML2
-ML 18*/19 0.15 (0.05 – 0.2) 0.12 (0.02 – 0.08)
Threading
-2
-AL
* 18 end cutting

insert D
CoroMill® 790 H-NL 16 0.2 (0.1 – 0.3) 0.2 (0.1 – 0.3)

H-NM 16 0.3 (0.1 – 0.4) 0.3 (0.1 – 0.4)
Milling
H-PL 16 0.15 (0.10 – 0.20) 0.05 (0.02 – 0.08)
R790
H-NL 22 0.3 (0.10 – 0.40) 0.3 (0.10 – 0.40)
H-NM 22 0.6 (0.20 – 0.60) 0.6 (0.20 – 0.60)
H-PL 22 0.15 (0.10 – 0.20) 0.05 (0.02 – 0.08)
E
Drilling
CoroMill® Century
R590 -NL CD10 0.15 (0.05 – 0.30) 0.15 (0.05 – 0.30)

F
-NL H10 0.20 (0.10 – 0.40) 0.20 (0.10 – 0.40)
AUTO-FS
Boring
SBEN
R/L262.4 SBEX Finishing 0.17 (0.1 – 0.3) 0.17 (0.1 – 0.3)
R/L262.42 SBEX-11
G
Tool holding/
T-Line
Machines
R260.90 CDE Roughing 0.17 (0.1 – 0.3) 0.17 (0.1 – 0.3)
H
Materials
I
Information/
D 193
Index

A
Face milling Feed per tooth, fz (mm/tooth) Max. chip thickness, hex (mm)
Starting Starting
B κr = 75° - 10° Insert geometry Insert size value (min.- max.) value (min.- max.)
CoroMill® 345
E-PL
E-ML
E-KL Light 13 0.15 (0.07 – 0.20) 0.10 (0.07 – 0.14)
M-PL
M-KL
M-PM
M-MM Medium 0.30 (0.15 – 0.45) 0.21 (0.10 – 0.32)
M-KM
C M-PH
M-KH
Heavy 0.45 (0.35 – 0.55) 0.32 (0.25 – 0.39)
0.40 (0.30 – 0.50) 0.28 (0.21 – 0.35)
CoroMill® 245 E-PL

E-ML
E-KL
} Light
0.14 (0.08–0.21) 0.10 (0.06 – 0.15)
Threading
0.11 (0.07–0.17) CT530, H13A, H10 0.08 (0.06 – 0.12)

R245
M-PL
Light 0.17 (0.08 – 0.21) 0.12 (0.06 – 0.15)
M-KL
D M-PM, M-KM Medium 0.24 (0.10 – 0.28) 0.17 (0.07 – 0.20)
M-PM, M-KM 0.12 (0.08 – 0.18) CT530, H13A 0.09 (0.06 – 0.13)
K-MM 0.23 (0.10 – 0.28) 0.16 (0.07 – 0.20)
M-PH
Heavy 0.35 (0.10 – 0.42) 0.25 (0.07 – 0.30)
M-KH
Milling
E-AL 0.24 (0.10 – 0.28) 0.17 (0.07 – 0.20)
E Ceramic 0.21 (0.10 – 0.30) CC6190 0.15 0.07 – 0.20

E E CBN 0.14 (0.07 – 0.21) CB50 0.10 (0.06 – 0.15
E PCD 0.14 (0.07 – 0.21) CD10 0.10 (0.06 – 0.15
CoroMill® 365 -PL 0.20 (0.12 – 0.28) 0.18 (0.11 – 0.25)

-PM 0.22 (0.15 – 0.28) 0.20 (0.14 – 0.25)
Drilling
15
-KL 0.22 (0.12 – 0.35) 0.20 (0.11 – 0.32)
-KM 0.25 (0.15 – 0.35) 0.23 (0.14 – 0.32)
F
Boring
Sandvik AUTO TNHF-WL 0.17 (0.08 – 0.21) 0.12 (0.06 – 0.15)

TNEF-WL
G R/L260.3
TNHF-CA
TNEF-CA
0.24 (0.1 – 0.42) 0.17 (0.07 – 0.30)
TNHF-65 0.24 (0.1 – 0.28) 0.17 (0.07 – 0.20)

TNEF-65
TNJN 0.35 (0.1 – 0.70) 0.25 (0.07 – 0.50)
TNEN 0.24 (0.1 – 0.28) 0.17 (0.07 – 0.20)
Tool holding/
TNCN
Machines
AUTO-AF N260.8-F
N260.8-L 0.16 (0.08 – 0.21) 0.15 (0.08 – 0.20)
H R/L260.8
R/L260.82
Materials
I
Information/
D 194
Index

General turning
Face and plunge milling Feed per tooth, fz (mm/tooth) Max. chip thickness, hex (mm)
κr = 75° - 10° Insert geometry

Insert
size
Starting
value (min.- max.)
Starting
value (min.- max.)
B
19

CoroMill® 360 PM 0.45 (0.3 – 0.7) 0.40 (0.25 – 0.60)
MM 28
KH
Threading
T-MAX® 45 LNCX -11 0.35 (0.10 – 1.0) 0.25 (0.07 – 0.70)
-31 0.35 (0.10 – 0.70) 0.25 (0.07 – 0.50)
R260.7 -32 0.35 (0.10 – 0.70) 0.25 (0.07 – 0.50)
Milling
CoroMill® 210 Face milling
M-PM 09 1.0 (0.4 – 2.0) 0.17 (0.07 – 0.35)
M-KM
M-MM
14 1.5 (0.5 – 3.0) 0.26 (0.08 – 0.52)
E
R210 E-PM Plunge milling
E-MM 09 0.15 (0.01 – 0.2) 0.17 (0.07 – 0.35)
E-KM 14 0.20 (0.10 – 0.25) 0.26 (0.08 – 0.52)
Drilling
F
Coromant plunge cutter LPMH-PM 25 0.20 (0.10 – 0.30)

LPMH-MM
Boring
G
Tool holding/
Machines
H
Materials
I
Information/
D 195
Index

A
Round insert and Ball Nose Feed per tooth, fz (mm/tooth) Max. chip thickness, hex (mm)
Insert Starting Starting

Insert geometry size, iC value (min.- max.) value (min.- max.)
B
Round
-PL
CoroMill® 200 -ML Light 10 – 20 0.08 (0.05 – 0.12)
-KL
R200
-PM
-KM
Medium 10 – 20 0.17 (0.10 – 0.20)
-MM
C -WM
-PH
-KH Heavy 10 – 20 0.25 (0.10 – 0.30)
-WH
CBN 12 0.10 (0.05 – 0.15)

Threading
Ceramic 12 – 16 0.20 (0.07 – 0.30)
CoroMill® 300 E-PM Light 8 0.13 (0.05 – 0.15)

10 0.13 (0.05 – 0.15)
D R300
E-MM
12 Face milling round insert 0.15 (0.05 – 0.20)
16 (ap<iC/2) mm. 0.18 (0.05 – 0.20)
20 0.2 (0.05 – 0.25)
E-PM Medium 5 hex × iC 0.08 (0.05 – 0.12)
E-MM 7 fz = 0.10 (0.05 – 0.15)
8 2 × √ ap × iC − ap² 0.13 (0.05 – 0.20)
10 0.18 (0.05 – 0.25)
Milling
12 0.18 (0.05 – 0.25)

16 0.2 (0.05 – 0.30)
20 0.25 (0.05 – 0.40)
E M-PM
M-MM
Medium 8
10
0.13
0.15
(0.07 – 0.20)
(0.07 – 0.25)
Side milling (ae<Dcap/2) and round
12 insert (ap<iC/2) mm. 0.15 (0.07 – 0.25)
16 0.18 (0.07 – 0.25)
20 hex × iC × Dcap 0.20 (0.07 – 0.30)
fz =
M-PH Heavy 8 4 × √ ap × iC × ap² × √ Dcap × ae − ae² 0.15 (0.07 – 0.25)
M-MH 10 0.20 (0.07 – 0.30)
Detailed feed table, see
Drilling
M-KH 12 0.20 (0.07 – 0.30)

Main catalogue. 16 0.25 (0.07 – 0.40)
20 0.35 (0.07 – 0.55)
F Ball Nose
CoroMill® Ball Nose -12 .. M-M 0.10 (0.08 – 0.21)

-16 .. M-M 0.10 (0.08 – 0.21)
-20 .. M-M 0.15 (0.08 – 0.25)
-25 .. M-M
Feed per tooth (mm/tooth), cutter
0.15 (0.08 – 0.25)
-30 .. M-M centered. 0.17 (0.08 – 0.28)
Boring
-32 .. M-M 0.17 (0.08 – 0.28)

R216 -40 .. M-M Dc × hex 0.20 (0.10 – 0.42)
-50 .. M-M fz = 0.25 (0.10 – 0.42)
Dcap
G
-10 .. E-M 0.10 (0.05-0.21)
-12 .. E-M 0.10 (0.05-0.21)
-16 .. E-M 0.10 (0.05-0.21)
Tool holding/
-20 .. E-M 0.15 (0.05-0.25)

-25 .. E-M 0.15 (0.05-0.25)
Machines
Feed per tooth (mm/tooth), side

-30 .. E-M 0.17 (0.05-0.28)
-32 .. E-M milling.
0.17 (0.05-0.28)
-40 .. E-M 0.20 (0.05-0.35)
-50 .. E-M
D3 × hex
fz = √D ² – (D 0.20 (0.05-0.35)
cap – 2 × ae)²
H cap
CoroMill® Ball Nose Finishing -08 .. E-L 0.12 (0.10-0.25) 0.07 (0.05-0.18)
-10 .. E-L 0.12 (0.10-0.25) 0.07 (0.05-0.18)
Materials
-12 .. E-L 0.15 (0.15-0.35) 0.09 (0.07-0.22)

-16 .. E-L 0.17 (0.15-0.35) 0.11 (0.07-0.25)
-20 .. E-L 0.17 (0.15-0.35) 0.11 (0.07-0.25)
R216F -25 .. E-L 0.20 (0.15-0.40) 0.13 (0.07-0.29)
I -30 .. E-L
-32 .. E-L
0.20
0.20
(0.15-0.40)
(0.15-0.40)
0.13
0.13
(0.07-0.29)
(0.07-0.29)
Information/
D 196
Index

General turning
Slot milling Feed per tooth, fz (mm/tooth) Max. chip thickness, hex (mm)
Insert Starting Starting

Side and face mills Insert geometry size value (min. - max.) value (min. - max.)
B
CoroMill® 327 -GM

-GMM
-GC 06, 09,
-CH 0.15 (0.07 – 0.25) 0.06 (0.02 – 0.1)
12, 14
-TH
-THM
-RM
C
CoroMill® 328 -GM
-GC 13 0.15 (0.1 – 0.2) 0.1 (0.05 – 0.15)
-TH
Threading
CoroMill® 329 Seat size
D
-D, -E 0.1 (0.07 – 0.17) 0.07 (0.05 – 0.12)
-F, -G
-H, -J, -K
Milling
CoroMill® 331 -PL, ML, -KL, 04, 05 0.15 (0.05 – 0.22) 0.10 (0.05 – 0.15) E
-WL, -NL 08, 11, 13, 14 0.18 (0.07 – 0.22) 0.12 (0.08 – 0.15)
N/R331.32 04, 05 0.19 (0.08 – 0.29) 0.13 (0.08 – 0.20)

R331.35 -PM, -MM, -KM, -WM
08, 11, 13, 14 0.25 (0.1 – 0.29) 0.17 (0.10 – 0.20)
R/L331.52
RCHT/RCKT
Drilling
-PL, ML, -KL 0.11 (0.07 – 0.17) 0.08 (0.05 – 0.12)
-WM, -PM, -MM -KM 0.24 (0.10 – 0.28) (0.10 – 0.20)
-WH, -KH, -PH
0.17
F
0.35 (0.10 – 0.42) 0.25 (0.10 – 0.30)
T-MAX® Q-Cutter For slotting
330.20 330.20 -AA 2–4 0.09 (0.02 – 0.12) 0.06 (0.02 – 0.06)
Boring
-AA 5–6 0.09 (0.02 – 0.12) 0.08 (0.02 – 0.13)
-XE 0.09 (0.02 – 0.12) 0.08 (0.02 – 0.13)
G
Tool holding/
Machines
H
Materials
I
Information/
D 197
Index

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MILLING

Milling different materials D 32

Profile and turn milling D 66

Slot and thread milling D 84

Dedicated methods D 100

Trouble shooting D 128

10° – 75° face and plunge milling cutters D 146

Round insert cutters D 161

Ball nose cutters D 164

Slot, groove, side/face and

Solid carbide and exchangeable head cutters

Extended offer D 186

Grade information D 188

Feed recommendations D 192

F When the first CoroMill cutters were introduced in the early

• Smaller, less stable machines - light and fast milling

MTG09 Milling D1-D21.indd 2 2009-11-24 13:06:53

Parting and grooving

MTG09 Milling D1-D21.indd 3 2009-11-24 13:07:07

1. The milled configuration

In addition to all the conventional applications, milling is a

The machine is of great importance for the choice of milling

driven tools, and machining centres often have turning

capability. CAM developments mean that 5-axis machines are

MTG09 Milling D1-D21.indd 4 2009-11-24 13:07:12

Parting and grooving

Advantages Advantages Advantages

multi-spindle machines machines

MTG09 Milling D1-D21.indd 5 2009-11-24 13:07:13

Application overview – milling

Profile and turn milling

F Slot and thread milling

Radial slot milling Axial slot milling Thread milling

see page D 100

Linear and circular ramping

MTG09 Milling D1-D21.indd 6 2009-11-24 13:07:32

90° shoulder milling cutters

Parting and grooving

CoroMill® 690 CoroMill® 790 CoroMill® Century CoroMill® 290

CoroMill® 345 CoroMill® 360 CoroMill® 365 Auto D 152

Page D 146 D 155 D 150

milling and the T-Max 45 for heavy machining.

MTG09 Milling D1-D21.indd 7 2009-11-24 13:07:36

Page D 178 D 182 D 164 D 162

Slot, groove, side/face and thread milling cutters

Page D 95 D 166 D 168 D 170

MTG09 Milling D1-D21.indd 8 2009-11-24 13:07:38

Parting and grooving

Safety precautions – danger points

Warning! Max spindle revolution

MTG09 Milling D1-D21.indd 9 2009-11-24 13:07:38

Machines for milling

Vertical machining centre with a fifth B-axis.

Small vertical machining centers:

• Can work with longer and heavier tool set-ups.

Multi-task machine with 5 axes.

considered. Namnlöst-1 1 2009-08-31 09:29:34

I Vertical and horizontal 3-axis machines.

MTG09 Milling D1-D21.indd 10 2009-11-24 13:07:45

Parting and grooving

ISO 40/Coromat Capto size C6 – Dc 100 mm.

ISO 30/Coromat Capto size C4 – Dc 50 mm.

extreme stability and the smallest possible protrusion.

• Smaller, less stable machines - light and fast milling

• Can work with longer and heavier tool set-ups.

• eneral choice for face milling.

• F or larger depths of cut, it is better to use square inserts with a constant kr of B

• CVD coated grades applied

• Do not position the cutter symetrically on the centre line.

• Available spindle power must also be considered, because