D 2

Milling
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The Milling process ............................................... D5
Basic milling denitions ......................................... D6
Application of milling cutters .................................. D9
Milling direction ..................................................... D9
Cutter diameter position ...................................... D10
Entry and exit considerations ............................... D11
Entering angle ..................................................... D12
Methods for machining a cavity ............................ D14
Milling method recommendations ......................... D15
Application hints for milling ................................. D17
Achieving good surface nish in milling ................. D18
Countering vibrations in milling ............................. D19
When results are affected by vibration .................. D21
Selecting cutting data ......................................... D22
Terminology and units for milling ........................... D23
General milling formulas ...................................... D23
Formulas for specic milling cutters ...................... D24
Calculation of power consumption ........................ D25
Constant K for power calculations ........................ D26
Cuttting data calculations for milling ..................... D27
Circular interpolation ........................................... D31
Mounting dimensions for cutters .......................... D33
Insert mounting with Torx Plus .............................. D34
Tool wear ............................................................ D35
If problems should occur ..................................... D36
Selection and application process ........................ D38
Operations tool recommendations ..................... D40
Tool guide and selection ...................................... D42
CoroMill 245 ....................................................... D46
Insert geometries and grades .............................. D48
Tailor Made ......................................................... D51
CoroMill 290 ....................................................... D52
Insert geometries and grades .............................. D54
Tailor Made ......................................................... D56
CoroMill 390 ....................................................... D57
Insert geometries and grades .............................. D63
Shoulder, plunge milling and peck drilling .............. D64
Tailor Made ......................................................... D65
Turn-milling with CoroMill 390 ............................... D68
CoroMill 200 and 300 round insert cutters ........... D69
Contents
CoroMill 200 ....................................................... D70
Inserts and grades .............................................. D72
Ramping and helical interpolation ......................... D74
Tailor Made ......................................................... D75
CoroMill 300 ....................................................... D76
Inserts and grades .............................................. D79
Ramping and helical interpolation ......................... D80
CoroMill 216 ....................................................... D81
CoroMill ball nose cutter ...................................... D82
Machining recommendations ................................ D84
CoroMill 216F ..................................................... D85
CoroMill ball nose nsihing endmill ....................... D86
Machining recommendations ................................ D88
CoroMill 210 ....................................................... D89
CoroMills high feed facemill and plunging cutter .... D90
Tailor Made ......................................................... D92
High feed milling ................................................. D93
Plunge milling ..................................................... D94
CoroMill Century ................................................. D96
Insert geometries and grades .............................. D98
Cutter setting ...................................................... D99
Tailor Made ....................................................... D100
CoroMill 790 ..................................................... D101
Interpolation and ramping .................................. D104
Tailor Made ....................................................... D105
CoroMill 331 ..................................................... D106
Applications ...................................................... D108
Insert and grades .............................................. D110
CoroMill 331 with cassettes .............................. D114
Gang milling staggered ...................................... D115
Mounting and setting instructions ....................... D117
Tailor Made ....................................................... D119
T-Max Q-cutter ................................................... D126
Tailor Made ....................................................... D127
Heavy duty T-Max 45 .......................................... D129
Sandvik Auto and T-line cutters ........................... D131
Auto inserts ...................................................... D132
Sandvik AUTO-AF ............................................... D133
Mounting and setting ......................................... D134
Square shoulder Auto-FS .................................... D136
Milling
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Milling
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Auto CAP system ............................................... D137
T-Line milling cutters .......................................... D138
Sandvik Auto cylinder boring cutter ..................... D139
Tailor Made ....................................................... D140
Tailor Made Auto-AF ........................................... D143
CoroMill Plura solid carbide cutters ..................... D144
Selecting CoroMill Plura cutters .......................... D145
Endmill types and applications ........................... D146
Cutting data ...................................................... D154
Tailor Made ....................................................... D158
If probles occur CoroMill Plura ......................... D159
Regrinding ........................................................ D160
Application technique ........................................ D161
CoroMill Plura thread milling cutters ................... D162
Cutting data ...................................................... D164
Feed recommendations milling ........................ D165
Productivity parameters, HSM and 3D milling ...... D169
Cutting speed recommendations ........................ D170
Milling grades ................................................... D178
D 4
Milling
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D 5
Milling
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Milling
The milling process
Modern milling is a very universal machining method. During the past few years, hand-in-
hand with machine tool developments, milling has evolved into a method that machines
a very broad range of congurations. The choice of methods today in multi-axis machinery
is no longer straightforward in addition to all the conventional applications, milling is a
strong contender for producing holes, cavities, surfaces that used to be turned, threads,
etc. Tooling developments have also contributed to the new possibilities along with the
gains in producitivity, reliablity and quality consistency that have been made in indexable
insert and solid carbide technology.
Milling is principally metal cutting performed with a rotating, multi-edge cutting tool
which performs programmed feed movements against a workpiece in almost any direc-
tion. It is this cutting action that makes milling such an efcient and versatile machining
method. Each of the cutting edges remove a certain amount of metal, with a limited
in-cut engagement, making chip formation and evacuation a secondary concern. Most
frequently still, milling is applied to generate at faces as in facemilling - but other
forms and surfaces are increasing steadily as the number of ve-axis machining centres
and multi-task machines grow.
The main types of milling operations as seen from the effect on the component or from
a tool path point of view include:
1 facemilling
2 square-shoulder milling
3 prole milling
4 cavity milling
5 slot milling
6 turn milling
7 thread milling
8 cutting off
9 high-feed milling
10 plunge milling
11 ramping
12 helical interpolation
13 circular interpolation
14 trocidal milling
1 2 3 4 5 6 7
8 9 10 11 12 13 14
D 6
Milling
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Basic Milling denitions
A milling cutter will basically employ one
or a combination of the following basic
cutting actions: (A) radial, (B) peripheral
and (C) axial. Throughout the variations
in milling methods, one can trace back
the cutting action to these feed direc-
tions in relation to the axis of tool rota-
tion. For example:
Facemilling is a combined cutting action
by the cutting edges, mainly the ones on
the periphery and to some extent by the
ones on the face of the tool. The milling
cutter rotates at a right angle to the direc-
tion of radial feed against the workpiece.
Side and face milling uses mainly the
cutting edges on the periphery of the
tool. The milling cutter rotates round an
axis parallel to the tangential feed.
Plunge milling mainly uses the cutting edg-
es on the face or end of the tool as it is fed
axially, performing a partial drilling action.
To set-up the milling operation, a number
of denitions should be established.
These dene the dynamics of the rotat-
ing milling tool, with a specied diameter
(Dc), having largest diameters (Dc2 or
D3), moving against the workpiece, with
an effective cutting diameter (De), the
basis for the cutting speed.
Cutting speed (vc) in m/min indicates
the surface speed at which the cutting
edge machines the workpiece. This is a
tool oriented value and part of the cutting
data which ensures that the operation is
carried out efciently and within the rec-
ommended scope of the tool material.
Spindle speed (n) in rpm is the number
of revolutions the milling tool on the
spindle makes per minute. This is a ma-
chine oriented value which is calculated
from the recommended cutting speed
value for an operation.
D
c
D
c2
D
e
D
c
a
p
D
c
D
3
D 7
Milling
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Feed per minute also known as the table
feed, machine feed or feed speed (v)
in mm/min is the feed of the tool in re-
lation to the workpiece in distance per
time-unit related to feed per tooth and
number of teeth in the cutter.
Maximum chip thickness (hex) in mm
is the most important limitation indica-
tor for a tool, for an actual operation. A
cutting edge on a milling cutter has been
designed and tested to have a recom-
mended starting value and a minimum
and maximum value.
Feed per tooth (fz) in mm/tooth is a
value in milling for calculating the table
feed. As the milling cutter is a multi-edge
tool, a value is needed to ensure that
each edge machines under satisfac-
tory conditions. It is the linear distance
moved by the tool while one particular
tooth is engaged in cut. The feed per
tooth value is calculated from the recom-
mended maximum chip thickness value.
The number of available cutter teeth in
the tool (zn) varies considerably and is
used to determine the table feed while
the effective number of teeth (zc) is the
number of effective teeth. The material,
width of component, stability, power, sur-
face nish inuence how many teeth are
suitable.
Feed per revolution (fn) in mm/rev is a
value used specically for feed calcula-
tions and often to determine the nish-
ing capability of a cutter. It is an auxiliary
value indicating how far the tool moves
during the rotation.
Depth of cut (ap) in mm (axial) is what
the tool removes in metal on the face
from the workpiece. This is the distance
the tool is set below the un-machined
surface.
Cutting width (ae) in mm (radial) is the
width of the component engaged in cut by
the diameter of the cutter. It is distance
across the surface being machined or, if
the tool diameter is smaller, that covered
by the tool.
The average chip thickness (hm) is a
useful value in determining specic cut-
ting force and subsequently power calcu-
lations. It is calculated in relation to the
type of cutter engagement involved.
f
z
h
m
h
ex
a
e
a
e
a
r
a
p
a
e
a
sp
E
L
a
e
a
e
a
p f
z
f
n
D 8
Milling
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The removal rate (Q) is volume of metal
removed per time in cubic-mm and can
be established using values for cutting
depth, width and feed.
The machining time (Tc) or period of cut-
ter engagement is the machining length
(lm) divided by the table feed.
The specic cutting force (kct) is a power
calculating factor taking into account the
material in question and for a chip thick-
ness value. It relates to machinability as
well as feed rate and cutting speed.
Power (Pc) and efciency () are ma-
chine tool oriented values where the net
power can be calculated to ensure that
the machine in question can cope with
the cutter and operation.
As regards cutting geometry in milling,
the entering angle (
r
), or the major cut-
ting edge angle, of the cutter is the domi-
nant factor affecting the cutting force di-
rection and chip thickness. The choice of
insert geometry has been simplied into
three practical areas of varying cutting
action effects : Light (L), general purpose
(M) and tough (H) geometries.
Pitch (u) is the distance between teeth
on the cutter. It is the distance between
one point on one cutting edge to the same
point on the next edge. Milling cutters are
mainly classied into coarse (L), close
(M) and extra close (H) pitches, as well
as extra, extra close pitch. The different
pitches affect operational stability, power
consumption and suitable workpiece ma-
terial. A differential pitch means an un-
equal spacing of teeth on the cutter and
is a very effective means with which to
counter vibration tendencies.
L H M
L H M
Entering angle variation of milling cutter.
Light cutting geometry -L
Sharp, positive cutting edge.
Smooth cutting performance.
Low feed rates.
Low machine power.
Lower cutting force requirements.
Coarse pitch (-L)
Reduced number of inserts, with
differential pitch, for best
productivity when stability and
power are limited.
Extended tooling.
Small machines, i.e. taper 40.
General purpose geometry -M
Positive geometry for mixed
production.
Medium feed rates.
Tough geometry -H
For highest security requirements.
High feed rates.
Close pitch (-M)
General purpose milling and
mixed production.
Extra close pitch (-H)
Maximum number of inserts for
best productivity under stable
conditions.
Short chipping materials.
Heat resistant materials.

r
90
45 10
D 9
Milling
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Application of milling cutters
Milling direction
During the milling operation, the work-
piece is fed either with or against the
direction of rotation and this affects the
nature of the start and nish of the cut.
In Down milling (1) (also called climb
milling), the workpiece feed direction is
the same as that of the cutter rotation at
the area of cut. The chip thickness will
decrease from the start of the cut until it
is zero at the end of the cut in peripheral
milling.
In Up milling (2) (also called conven-
tional milling), the feed direction of the
workpiece is opposite to that of the cut-
ter rotation at the area of cut. The chip
thickness starts at zero and increases to
the end of the cut.
In Up milling, with the insert starting
its cut at zero chip thickness, there are
high cutting forces which tend to push
the cutter and workpiece away from each
other. The insert has to be forced into
the cut, creating a rubbing or burnishing
effect with friction, high temperatures
and often contact with a work-hardened
surface caused by the preceeding insert.
Forces will also tend to lift the workpiece
from the table.
In Down milling, the insert start its cut
with a large chip thickness. This avoids
the burnishing effect with less heat and
minimal work-hardening tendencies. The
large chip thickness is advantageous
and the cutting forces tend to pull the
workpiece into the cutter, holding the in-
sert in the cut.
During milling, chips will sometimes
stick or weld to the cutting edge and be
carried around to the start of the next
cut. In Up milling, the chip can easily be
trapped or wedged between the insert
and workpiece, which can then result
in insert breakage. In Down milling, the
same chip would be cut in half and not
damage the cutting edge.
Down milling is preferred wherever the
machine tool, xturing and workpiece will
allow.
Down milling, however, makes certain
demands on the process in that forces
tend to pull the cutter along while they
hold the workpiece down. This needs
the machine to cope with table-feed
play through back-lash elimination. If the
tool pulls into the workpiece, feed is in-
creased unintentionally which can lead
to excessive chip thickness and edge
breakage. Up milling should be selected
in such cases. Also when large varia-
tions in working allowance occur, up mill-
ing may be advantageous. Fixturing has
to be adapted to hold the workpiece cor-
rectly as well as having the right cutter
size for the job. The direction of cutting
forces are, however, more advantageous
as regards vibration tendencies.
Down-milling and up-milling.
D 10
Milling
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The selection of milling cutter diameter
is usually made on the basis of the work-
piece width with the power availability
of the machine also being taken into ac-
count. The position of the cutter in rela-
tion to the workpiece engagement and
contact the cutter teeth have are vital
factors for successful operation.
There are three principal types of milling
cutter/workpiece relationship situations:
Firstly, when the workpiece width is larger
than or the same as the cutter diam-
eter, leading to thin chips at entry/exit
or when several passes are required.
(Typical of when the workpiece surfaces
are very large or the cutter diameter too
small for the application).
Secondly, (2) where the cutter-diameter
is somewhat larger than the workpiece
width, as is often case in facemilling.
(20 to 50% - often representing the ideal
situation especially in facemilling.)
Thirdly, (3) where the diameter is consid-
erably larger than the width of cut, with
cutter axis well outside the workpiece
width. (This is often the case with side
and facemilling, long edge milling and
endmilling.)
In facemilling especially, the workpiece
width should inuence the milling cutter
diameter. The cutter diameter should
not be the same as the workpiece
width a diameter 20 to 50% larger
than the workpiece width is normally
recommended.
If several passes need to be taken,
these should be taken in a way that cre-
ates the diameter/width relationship
of approximately 4/3 and not the full
diameter at each pass as this helps to
ensure good chip formation and suit-
able cutting edge load.
In the ideal situation, with the cutter be-
ing sufciently larger than the workpiece
width, the milling cutter should always
be positioned slightly off-centre. Being
close to the centre is advantageous in
that the cut which each insert takes is
at its shortest and that entry and exit of
cuts are good from a chip formation and
shock-load point of view. However, when
the tool is positioned dead on centre, a
disadvantageous situation arises. Radial
forces of even magnitude will uctuate in
direction as the cutting edges go in and
out of cut. The machine spindle can vi-
brate and become damaged, inserts may
chip resulting in poor surface nish.
Moving the cutter slightly off-centre will
mean a more constant force direction - a
type of pre-loading is achieved when the
cutter is against the workpiece.
Cutter diameter and position
Avoid positioning cutters on-centre.
D 11
Milling
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Each time one of the milling cutter inserts
enters into cut, the cutting edge is sub-
jected to a shock load, which depending
upon the chip cross-section, workpiece
material and type of cut. The right type
of initial contact, and nal contact, be-
tween edge and material is an important
aspect of the milling process. Position-
ing the cutter right as regards entry and
exit of the cutting edges is important.
In the rst situation (1), the centre-line
of the cutter is well outside the work-
piece width and the impact at the en-
try is taken up by the outermost tip of
the insert, which means that the initial
shockload is taken up by the most sen-
sitive part of the tool. The cutter also
leaves the cut with this tip last, which
means that the cutting forces are acting
on the outermost tip until the insert sud-
denly emerges from the workpiece. This
is shock-unloading of forces.
In situation (2), the centre-line of the
cutter is in line with the workpiece
edge. The insert is leaving cut when the
chip thickness is at its maximum, with
shock-loads very high at entry and exit.
In situation (3), the centre-line of the cut-
ter is well inside the workpiece width.
The initial impact at the entry of cut is tak-
en up further along the cutting edge, away
from the sensitive tip. Also at the exit, the
insert leaves the cut more gradually.
The way that the cutting edge leaves the
workpiece material is important. As the
end of cut is approached, the remaining
material may give way, somewhat reduc-
ing the insert clearance. Also a momen-
tary tensile force created along the face
of the insert as the chip pulls away and
often giving rise to a burr on the work-
piece. This tensile force puts the cutting
edge security at risk.
This situation is acute when the centre-
line of the cutter coincides with, or is
close to, the edge of the workpiece. In
this situation the milling cutter should
leave the workpiece at a positive angle
to the cutting edges, not negative. A
complication arises when there are voids
in the workpiece surface. In this case, a
stronger cutting edge is often the solu-
tion, and also the pitch or cutter geom-
etry may have to be re-considered. The
milling operation should be looked at as
a whole, considering all the different as-
pects, to arrive at the most suitable cut-
ter and insert type.
Entry and exit considerations
Effect of exit angle on cutting edge.
Entry and exit variation with cutter position.
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