Tungaloy Report No. 501-US High productive … · 2019-07-17 · TPTN07U2.00B0.75R0 CSPB-2.5SH IP-7D M-1000 New Square shoulder milling cutter with double-sided triangular inserts

MillLine

w w w . t u n g a l o y . c o m

High productive and cost-eff ective shoulder milling cutter Now available with 07 size insert for small parts

Tungaloy Report No. 501-US

A C C E L E R A T E D M A C H I N I N G

MillLine

w w w . t u n g a l o y . c o m / u s

New 07 geometry for superior surface fi nishing

broadens the application range of DoForce-Tri which

off ers maximum benefi ts in economy and performance

DOFORCE-TRI4

0.236"

0.433"

ap = 0.433"

ap = 0.236"

New

Workpiece material: carbon steel

Dep

th o

f cut:

ap

(In

ch)

Innovative insert design for improved productivityHigh efficiency Inserts are available in 2 sizes for maximum density and cutting depths over conventional double-sided 6-edged inserts

Size 07 Size 12Conventional double-sided 6-edged insert

High machining flexibility The cutting edge is configured with a large curve with an optimal inclination, providing not only effective chip evacuation during heavy stock removal but also low cutting force in light depth of cut for machining stability

Economy Precision insert molding technology provides high surface and wall finishing, while ensuring economy

Higher number of teeth

Smaller inserts provides up to 2x table feed over conventional inserts

Greater depths of cut Allows up to 2x depth of cut over the conventional insert of the same size

Economical shoulder mill with an innovative 6-edged geometry for maximum performance in various applications

5w w w . t u n g a l o y . c o m / u s

A CC E L E R A T E D M A C H I N I N G

New

INSERT TYPES

■ Size 07 Insert

■ Size 12 Insert

High insert density for efficiencyDoForce-Tri offers insert density of up to 2x as high as competitors' shoulder cutters of the same depth of cut, ensuring maximum efficiency thanks to its curved cutting edge with optimal inclination

Superior surface finishing Every cutting edge is built with a wiper, thanks to the innovative flank design

Conventional insert

2x insert density!

Optimized cutting edge ensures smooth entry and good surface finish

*Please see page 11 for instruction for use

Insert lineup for various applications

Depth of cut: ap = 0.236"

TNMU-MJwith built-in wipers

TNGU-MJwith built-in wipers

TNMU-MJRadius insert

TNMU-NMJSerrated insert*

1st choice Versatile geometry with

good surface finish

For close tolerance Strong cutting edge design with large corner

radius

Ensures free cutting and good chip control during

heavy milling

DOFORCE-TRI6

T U N G A LOY

T U N G A LOY

AH3135

T3225

AH120 T1215

T3225

AH3135

T1215

AH120

Grade lineup for various materials

- A total of four grades, including two new CVD grades

Special Surface Technology

- PVD grade for high fracture resistance - Most suitable for steel and stainless

steel in general cutting parameters

- CVD grade with excellent chipping and fracture resistance

- Most suited for steel and stainless steel at high-speed machining

Enhanced coating resistance to chipping and peeling

- Special surface post-treatment technology improves

surface smoothness

Superior wear resistance in high speed cutting

- A thick alumina (Al2O3) layer improves insert life in high

cutting temperature generated during high speed

machining

Enhanced coating resistance to peeling

- Strong adhesion between the carbide substrate and the

coating layer improves coating resistance to peeling

Steel

Steel

Stainless

Stainless

- PVD grade with well-balanced wear and fracture resistance

- Ideal for general machining of steel and cast iron

- CVD grade with outstanding wear and chipping resistance

- Best for cast iron at high-speed machining

Steel Cast iron Cast iron

Face milling Face millingShoulder milling Shoulder milling

Cutt

ing

sp

eed

: V

c (sfm

)

Cutt

ing

sp

eed

: V

c (sfm

)

High High

Low Low

Steel Stainless Cast iron



xx

600

400

200

0

4000

3000

2000

1000

0

3.2

1.6

0 150 300 450 600

xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

0707

102 %

120 %120 %

100 %

0.100" 0.200"

New

New

CUTTING PERFORMANCE

Cutter

Insert

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Width of cut

Coolant

Machine

Cutter

Insert

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Width of cut

Coolant

Machine

: EPTN07M025C25.0R04 (ø1", z = 1)

: TNMU070308PER-MJ / AH3135

: 1055 (180 HB)

: Vc = 660 sfm

: fz = 0.004 ipt

: ap = 0.06"

: ae = 0.06"

: Dry

: Vertical M/C, CAT50

: TPTN12M050B22.0R04 (ø2", z = 2)


TNMU120708PER-NMJ / AH3135

: S55C / C55 (180 HB)

: Vc = 500 sfm

: fz = 0.006 ipt

: ap = 0.10", 0.20"

: ae = 1.2"

: Dry

: Vertical M/C, CAT50

Cutt

ing

fo

rce: F

(N

)C

utt

ing

fo

rce: F

(N

)

■Low cutting force

Unique cutting edge configuration can reduce cut-ting force to the same level produced by positive insert when ap ≤ 1.5 mm

The -MJ style insert ensures freer cutting than positive insert at light depths of cut. While the -NMJ insert provides lower cutting force at greater depths of cut.

Built-in wiper provides quality surface finishing, while also prolonging insert life.

Cutter

Insert

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Width of cut

Coolant

Machine

: EPTN07M025C25.0R04

(ø1", z = 4、Competitor: z = 5)


: S55C / C55 (180 HB)

: Vc = 660 sfm

: fz = 0.004 ipt

: ap = 0.12"

: ae = 0.60"

: Dry

: Horizontal M/C, CAT40

Surf

ace r

oug

hness: R

a (µm

)

■High surface quality

Size 07 insert

Size 07 insert

Size 12 insert

Competitor's positive insert

Competitor's Competitor's positive positive insertinsert

Competitor's Competitor's positive insert positive insert

(z = 5)(z = 5)

Competitor's Competitor's positive positive insertinsert

Tool life due to excessive wearTool life due to excessive wear

Tool life due to Tool life due to excessive wearexcessive wear

MJMJ

MJMJ

NMJNMJ

Competitor's negative insert

Depth of cut: ap (Inch)

Cutting length (ft)

DOFORCE-TRI8

15

10

5

0

H

0 20 40 60

0 20 40 60

0 20 40 60

New

New

New

CUTTING PERFORMANCE

Cutter

Insert

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Width of cut

Coolant

Machine

Cutter

Insert

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Width of cut

Coolant

Machine

Cutter

Insert

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Width of cut

Coolant

Machine

Cutter

Insert

Workpiece material

Cutting speed

Feed per tooth

Depth of cut

Width of cut

Coolant

Machine

: EPTN07U1.00C1.00R04

(ø1", z = 4)


: 1055 (180 HB)

: Vc = 660 sfm

: fz = 0.004 ipt

: ap = 0.12" x 3

: ae = 0.25"

: Dry


: EPTN07U1.00C1.00R04

(ø1", z = 4)


: 1055 (180 HB)

: Vc = 660 sfm

: fz = 0.004 ipt

: ap = 0.12"

: ae = 0.60"

: Dry


: EPTN07U1.00C1.00R04

(ø1", z = 4)


: No.250B

: Vc = 660 sfm

: fz = 0.004 ipt

: ap = 0.12"

: ae = 0.60"

: Dry


: TPTN12U2.00B0.75R05

(ø2", z = 5)


: SUS304 / X5CrNi18-9

: Vc = 500 sfm

: fz = 0.006 ipt

: ap = 0.20"

: ae = 1.20"

: Dry


Gap

H (µm

)

■Wall accuracy

■Long tool life

Tool life for steel

Tool life for cast iron

Tool life for stainless steel

Optimized cutting edge provides good wall accuracy

Size 07 insert




Size 07 insert

Size 12 insert

Tool life (min. / edge)



Size 07 insert

Tool lifeTool life

2 times!2 times!

Tool lifeTool life

10 times!10 times!

Tool lifeTool life

3.5 times!3.5 times!

Competitor's positive insert




DCSFMSDCONMSKWW

DC

b

90°(KAPR)

CBDP

APMX LF

DCSFMSDCONMSKWW

DC

b

90°(KAPR)

CBDP

APMX LF

GAMP = +4.2°~ +4.7°, GAMF = -15.4°~ -11.2°

GAMP = +4.2°~ +4.7°, GAMF = -15.4°~ -11.2°

Inch APMX DC CICT DCSFMS LF DCONMS CBDP KWW b WT(kg)

TPTN12U2.00B0.75R05 0.433 2.000 5 1.850 1.575 0.750 0.750 0.315 0.197 0.890 TNMU120708PER-MJ





Inch APMX DC CICT DCSFMS LF(1) DCONMS CBDP KWW b WT(kg)

TPTN07U2.00B0.75R08 0.256 2.000 8 1.850 1.575 0.750 0.750 0.315 0.197 0.930 TNMU0703...

R

R R

R

R R

TPTN12

TPTN07

TPTN12U**R... CSPB-3.5 H-TB2W BLDIP15/S7 M-1000

TPTN07U2.00B0.75R0 CSPB-2.5SH IP-7D M-1000

New

Square shoulder mi l l ing cutter with double-sided tr iangular inserts

Square shoulder mi l l ing cutter with double-sided tr iangular inserts

(1) The value is true with R0.8 insert. For R0.4, please refer to page 11.

Air hole

Air hole

Insert

Insert

SPARE PARTS

Designation Clamping screw Grip Torx bit Lubricant

SPARE PARTS

Designation Clamping screw Wrench

※ Torque (lb・ft): CSPB-3.5 = 2.58

※ Torque (lb・ft): CSPB-2.5SH = 0.81

With

With

With

With

With

With

Lubricant

DOFORCE-TRI10

EPTN07

EPTN12

Inch APMX DC CICT DCONMS LS LH LF(1) WT(kg)

EPTN07U0.75C0.75R02 0.256 0.750 2 0.750 2.500 1.000 3.500 0.370 TNMU0703..

EPTN07U0.75C0.75R02L 0.256 0.750 2 0.750 4.750 1.670 6.420 0.710 TNMU0703..

EPTN07U1.00C1.00R03 0.256 1.000 3 1.000 3.000 1.500 4.500 0.880 TNMU0703..

EPTN07U1.00C1.00R03L 0.256 1.000 3 1.000 5.700 3.000 8.700 1.720 TNMU0703..

EPTN07U1.00C1.00R04 0.256 1.000 4 1.000 3.000 1.500 4.500 0.880 TNMU0703..

EPTN07U1.25C1.25R04 0.256 1.250 4 1.250 3.000 1.500 4.500 1.390 TNMU0703..

EPTN07U1.25C1.25R05 0.256 1.250 5 1.250 3.000 1.500 4.500 1.390 TNMU0703..

Inch APMX DC CICT DCONMS LS LH LF WT(kg)

EPTN12U1.25C1.25R03N 0.433 1.250 3 1.250 3.000 1.500 4.500 1.560 TN*U12...

EPTN12U1.50C1.25R04N 0.433 1.500 4 1.250 3.000 1.500 4.500 1.780 TN*U12...

GAMP = +4.2°~ +4.7°, GAMF = -15.4°~ -11.2°

GAMP = +4.2°~ +4.7°, GAMF = -15.4°~ -11.2°

DC

LHAPMX

LFLS

DCONMS

90°(KAPR)

DC

LHAPMX

LFLS

DCONMS

90°(KAPR)

R

R R

R

R R

EPTN12... CSPB-3.5 H-TB2W BLDIP15/S7 M-1000

New

EPTN07... CSPB-2.5SH IP-7D

Square shoulder end mi l l with double-sided tr iangular inserts

Square shoulder end mi l l with double-sided tr iangular inserts

Air hole

Air hole

Insert

Insert

SPARE PARTS

Wrench Clamping screw Grip Torx bit Lubricant

SPARE PARTS

Designation Clamping screw Wrench

(1) The value is true with R0.8 insert. For R0.4, please refer to page 11.

With

With

With

With

With

With

With

Without

Without

※ Torque (lb・ft): CSPB-2.5SH = 0.81

※ Torque (lb・ft): CSPB-3.5 = 2.58



TNGU12-MJ/TNMU12-MJ TNMU07-MJ

TNMU12-NMJ TNMU12**R-MJ

RE

LE

S

BSICRE

LES

BSIC

RE

LE

S

BSIC RE

LE

S

IC

New

New

New

0.0087"

LF, L

H

A

B

B

A

B

A

or

AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA

A B

RE APMX LE IC S BS

AH

12

0

AH

313

5

T12

15

T3

22

5

TNMU070304PER-MJ 0.016 0.256 0.256 0.224 0.161 0.024

TNMU070308PER-MJ 0.032 0.256 0.256 0.224 0.161 0.024

TNGU120708PER-MJ 0.032 0.433 0.472 0.375 0.277 0.046

TNMU120708PER-MJ 0.032 0.433 0.472 0.375 0.277 0.046

TNMU120708PER-NMJ 0.032 0.433 0.472 0.375 0.277 0.046

TNMU1207R16PER-MJ 0.063 0.433 0.472 0.375 0.277 -

P � � �M � �K � �N

S � �H

INSERT

Designation

:First choice

:Second choice

Coated

Steel

Stainless

Cast iron

Non-ferrous

Superalloys

Hard materials

• : New product

•: Line up

To obtain good wall accuracy, the serrated inserts must be

arranged in alternative order on the cutter so that the same

serrated edge will not cut the same surface twice, generating

steps on the wall. One of the serration grooves (marked in red)

on the cutting edge has an irregular shape, and this must be

placed alternatively as shown below as A and B.

Notes

■LF and LH dimensions for R0.4 mm(R0.016"), size 07 insert

Add 0.0087" to LH and LF

measurements when R0.4 mm

(R0.016") insert is usedThe groove in red is asymmetric

for easy identification

Check the insert orientations

if steps are produced on the

wall surface.

This position is

A or B

Insert orientation for odd

number of teeth

■Serrated size 12 insert

DOFORCE-TRI12

ISO

- 200 HB AH3135 330 - 820 0.003 - 0.008

- 300 HB AH3135 325 - 755 0.003 - 0.006

30 - 40 HRC AH3135 325 - 590 0.003 - 0.006

- AH3135 295 - 655 0.003 - 0.006

150 - 250 HB AH120 455 - 820 0.003 - 0.008

150 - 250 HB AH120 360 - 655 0.003 - 0.006

- AH3135 65 - 195 0.003 - 0.006

- AH120 65 - 130 0.003 - 0.004

New

Low carbon steel

(1018, 1026, etc.)

Carbon steel and alloy steel

(1055, 4140, etc.)

Prehardened steel

(H-13, P-20, etc.)

Stainless steel(304, 316, etc)

Grey cast iron

(Class 25, Class 30, etc.)

Ductile cast iron

(60-40-18, 80-55-06, etc.)

Titanium alloys

(Ti-6AI-4V, etc.)

Heat-resistant alloys

(Inconel718, etc.)

First choice

First choice

First choice

First choice

First choice

First choice

First choice

First choice

Cutting speedVc (sfm)

Feed per toothfz (ipt)

Workpiece materials GradesHardness Priority

STANDARD CUTTING CONDITIONS: Size 07 inser ts



ISO

- 200 HB AH3135 MJ 328 - 820 0.003 - 0.012

- 200 HB T3225 MJ 328 - 984 0.003 - 0.012

- 200 HB AH3135 NMJ 328 - 820 0.003 - 0.006

- 300 HB AH3135 MJ 328 - 755 0.003 - 0.012

- 300 HB T3225 MJ 328 - 919 0.003 - 0.012

- 300 HB AH3135 NMJ 328 - 919 0.003 - 0.006

30 - 40 HRC AH3135 MJ 328 - 591 0.003 - 0.010

30 - 40 HRC T3225 MJ 328 - 656 0.003 - 0.010

30 - 40 HRC AH3135 NMJ 328 - 591 0.003 - 0.006

- AH3135 MJ 295 - 656 0.003 - 0.010

- T3225 MJ 295 - 820 0.003 - 0.010

- AH3135 NMJ 295 - 656 0.003 - 0.006

150 - 250 HB AH120 MJ 459 - 820 0.003 - 0.012

150 - 250 HB T1215 MJ 459 - 984 0.003 - 0.012

150 - 250 HB AH120 NMJ 459 - 820 0.003 - 0.006

150 - 250 HB AH120 MJ 361 - 656 0.003 - 0.010

150 - 250 HB T1215 MJ 361 - 820 0.003 - 0.010

150 - 250 HB AH120 NMJ 361 - 656 0.003 - 0.006

- AH3135 MJ 70 - 200 0.003 - 0.008

- AH3135 NMJ 70 - 200 0.003 - 0.006

- AH120 MJ 70 - 130 0.003 - 0.007

- AH120 NMJ 70 - 130 0.003 - 0.006

TNMU120708PER-NMJ < 0.008

Low carbon steel

(1018, 1026, etc.)

Carbon steel and alloy steel

(1055, 4140, etc.)

Prehardened steel

(H-13, P-20, etc.)

Stainless steel(304, 316, etc)

Grey cast iron

(Class 25, Class 30, etc.)

Ductile cast iron

(60-40-18, 80-55-06, etc.)

Titanium alloys

(Ti-6AI-4V, etc.)

Heat-resistant alloys

(Inconel718, etc.)

First choice

Priority on wear resistance

For low cutting force

First choice



First choice



First choice



First choice



First choice



First choice


First choice


Chip-breaker

Cutting speedVc (sfm)

Feed per toothfz (ipt)

Workpiece materials GradesHardness Priority

Note: For NMJ chipbreaker, use a feed rate that satisfies the following theoretical chip thickness:

Designation Chip thickness (Inch)

STANDARD CUTTING CONDITIONS: Size 12 inser ts

DOFORCE-TRI14

EPTN07U1.25C1.25R05 (ø1.5", z = 5) EPTN07U1.00C1.00R04 (ø1", z = 4)TNMU070308PER-MJ TNMU070308PER-MJ

AH3135 AH120

1067 6000.0024 0.003137.8 27.20.08 0.160.94 0.89

EPTN07U1.00C1.00R04 (ø1", z = 4) EPTN07U1.00C1.00R04 (ø1", z = 4)TNMU070308PER-MJ TNMU070308PER-MJ

AH3135 AH3135

1000 6600.0046 0.005170.9 51.10.008 0.080.63 1.0

0.4

0.3

0.2

0.1

0

5.0

4.0

3.0

2.0

1.0

0

5.0

4.0

3.0

2.0

1.0

0

3.0

2.5

2.0

1.5

1.0

0.5

0

6601000

Workpiece type

CutterInsertGrade

Workpiece type

CutterInsertGrade

Workpiece material

Workpiece material

Results

Results

Cu

ttin

g

co

nd

itio

ns

Cu

ttin

g

co

nd

itio

ns

Cutting speed: Vc (sfm)

Feed per tooth: fz (ipt)

Feed speed: Vf (ipm)


Width of cut: ae (Inch)

Method of machining

Coolant

Machine






Method of machining

Coolant

Machine

MR

R (In

ch

3/m

in)

MR

R (In

ch

3/m

in)

MR

R (In

ch

3/m

in)

MR

R (In

ch

3/m

in)

PRACTICAL EX AMPLES: Size 07 inser ts New

SS400 304

GroovingAir

Horizontal M/C, BT40

Face milling Emulsion

Horizontal M/C, CAT30

MRR has been improved by 3.2x over the competitor's positive inserts thanks to higher number of teeth on the cutter increasing feed per tooth. No sacrifi ce for surface quality.

The light cutting geometry provided 1.8x greater MRR on a BT30 spindle over com-petitor's positive inserts. No compromise for tool life and surface fi nishing quality

Machine part Machine part

GroovingAir


MRR has been improved by 1.3x over the competitor's positive inserts thanks to higher number of teeth and increased feed per tooth

Bearing housing

No.250B 100-70-03

Competitor

Competitor Competitor

Competitor

ProductivityProductivity

3.23.2 times!times!


1.81.8 times!times!


1.31.3 times!times!


1.61.6 times!times!

Face millingAir

Vertical M/C, CAT40

Inserts' free cutting action eliminated chat-ter despite higher number of cutting edges, improving MRR by 1.6x

Bracket



TPTN12J080B25.4R06 (ø80mm, z = 6) EPTN12M040C32.0R04N (ø40mm, z = 4)TNMU120708PER-MJ TNMU120708PER-NMJ

AH120 AH3135

660 8400.008 0.005538.0 44.00.197 0.1571.57 1.06

TPTN12U2.50B0.75R06 (ø2.5", z = 6) TPTN12U2.00B0.75R05 (ø2", z = 5)TNGU120708PER-MJ TNGU120708PER-MJ

AH120 AH3135

500 6000.008 0.00637.4 31.50.236 0.1180.8 1.2

300

250

200

150

100

50

0

5

4

3

2

1

0

15

12

9

6

3

0

9

7

5

3

0

(z = 5)

660

Workpiece type

CutterInsertGrade

Workpiece material

Workpiece material

Results

Results

Cu

ttin

g

co

nd

itio

ns

Cu

ttin

g

co

nd

itio

ns






Method of machining

Coolant

Machine






Method of machining

Coolant

Machine

Workpiece type

CutterInsertGrade

Carrier Cylinder

Face millingEmulsion


Face milling, Shoulder millingAir

Vertical M/C, CAT40

(z = 3)Competitor

Pearlitic cast iron (250 HB) 1045

The combination of special insert geometry and grade for inserts in DoForce-Tri series helps extend tool life compared to the com-petitor.

Optimized geometry of the DoForce-Tri insert reduces cutting force and allows more inserts to be used on a single cutter body, which improves productivity.

PRACTICAL EX AMPLES: Size 12 inser ts

Too

l Life (p

cs/c

orn

er)

MR

R (In

ch

3/m

in)

MR

R (In

ch

3/m

in)

MR

R (In

ch

3/m

in)

Shoulder millingEmulsion


Shoulder millingNone


The competitor's shoulder mill chattered at high cutting parameters. DoForce-Tri's helical cutting edges produced high wall accuracy at double cutting speed and 1.7x greater depth of cut.

DoForce-Tri's -NMJ chipbreaker with serra-tions reduced cutting force eliminatingchatter. MRR has been improved to double the depth of cut with long and stable tool life.

FCD600 / GGG60 / 600-3 S45C / C45

Mold base Machine part

Competitor

Competitor Competitor


1.81.8 times!times!


1.81.8 times!times!


2.72.7 times!times!

Tool lifeTool life

2.42.4 times!times!

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Distributed by:

Jul. 2019 (TJ)

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Tungaloy America, Inc.3726 N Ventura Drive, Arlington Heights, IL 60004, U.S.A.

Inside Sales: +1-888-554-8394

Technical Support: +1-888-554-8391

Fax: +1-888-554-8392www.tungaloy.com/us

Tungaloy Canada432 Elgin St. Unit 3, Brantford, Ontario N3S 7P7, CanadaPhone: +1-519-758-5779 Fax: +1-519-758-5791

www.tungaloy.com/ca

Tungaloy de Mexico S.A.C Los Arellano 113, Parque Industrial Siglo XXIAguascalientes, AGS, Mexico 20290Phone:+52-449-929-5410 Fax:+52-449-929-5411

www.tungaloy.com/mx

Documents

Tungaloy Report No. 501-US High productive … · 2019-07-17 · TPTN07U2.00B0.75R0 CSPB-2.5SH IP-7D M-1000 New Square shoulder milling cutter with double-sided triangular inserts