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    End Mill Training Website PDF

    Uploaded by

    Dejan Jovanovic
    The document provides information on end mill training. It discusses three key elements of a cutting tool: geometry, cutting tool, and balance for performance. It then defines various end mill terms like mill size, shank diameter, length of cut, and overall length. It also discusses end mill side and end clearances, flutes, chip pockets, teeth, cutting edge types, web thinning, back taper, and coatings. It provides information on specific Nachi end mill products, materials, coatings, and their advantages. It highlights the features of X's-Mill Geo, GS-Mill Hard, Mold Meister Ball and their performance advantages for machining hardened steels and molds/dies.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    End Mill Training Website PDF

    Uploaded by

    Dejan Jovanovic
    212 views64 pages
    The document provides information on end mill training. It discusses three key elements of a cutting tool: geometry, cutting tool, and balance for performance. It then defines various end mill terms like mill size, shank diameter, length of cut, and overall length. It also discusses end mill side and end clearances, flutes, chip pockets, teeth, cutting edge types, web thinning, back taper, and coatings. It provides information on specific Nachi end mill products, materials, coatings, and their advantages. It highlights the features of X's-Mill Geo, GS-Mill Hard, Mold Meister Ball and their performance advantages for machining hardened steels and molds/dies.

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    End Mill Training Website.pdf

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    The document provides information on end mill training. It discusses three key elements of a cutting tool: geometry, cutting tool, and balance for performance. It then defines various end mill terms like mill size, shank diameter, length of cut, and overall length. It also discusses end mill side and end clearances, flutes, chip pockets, teeth, cutting edge types, web thinning, back taper, and coatings. It provides information on specific Nachi end mill products, materials, coatings, and their advantages. It highlights the features of X's-Mill Geo, GS-Mill Hard, Mold Meister Ball and their performance advantages for machining hardened steels and molds/dies.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    212 views64 pages

    End Mill Training Website PDF

    Uploaded by

    Dejan Jovanovic
    The document provides information on end mill training. It discusses three key elements of a cutting tool: geometry, cutting tool, and balance for performance. It then defines various end mill terms like mill size, shank diameter, length of cut, and overall length. It also discusses end mill side and end clearances, flutes, chip pockets, teeth, cutting edge types, web thinning, back taper, and coatings. It provides information on specific Nachi end mill products, materials, coatings, and their advantages. It highlights the features of X's-Mill Geo, GS-Mill Hard, Mold Meister Ball and their performance advantages for machining hardened steels and molds/dies.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 64
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    The document discusses various aspects of end mill geometry, terms, coatings and materials.

    The three key elements of a cutting tool discussed are its geometry, balance, and that it is only as good as its weakest link.

    Some common end mill terms discussed include mill size or cutting diameter, shank diameter, length of cut or flute length, overall length, side clearance, end clearance, flutes, helix angle and chip pocket.

    End Mill Training

    Three Key Elements of a Cutting Tool

    Geometry

    Cutting Tool

    3 Elements Needed in
    a Good Cutting Tool
    Well Balanced For
    Best Performance
    Only Good as the
    Weakest Link

    End Mill Terms


    A - Mill Size or Cutting Diameter
    B - Shank Diameter
    C - Length of Cut or Flute Length
    D - Overall Length

    End Mill Terms Continued

    End Mill Side Clearance


    Primary (1st angle, 5- 9)
    Relief Adjacent to Cutting Edge

    Secondary (2nd angle, 14-17)


    Relief Adjacent to Primary Angle

    Tertiary (3rd)
    Additional Relief Provided Adjacent to the Secondary
    High Performance End Mills

    End Mill End Clearance


    Dish Angle
    Angle Between End of Cutting Edge
    and Perpendicular to the Cutter Axis
    Dish Ensures a flat Surface is
    Produced

    Gash (Notch)
    Secondary Cuts to Provide Chip
    Space at Corners and Ends
    Forming the End Cutting Edge when
    Feeding Axially

    Gash Angle
    Relief Angle of the Gash Feature

    End Mill Flutes


    Evacuate Chips
    Outward
    Not Upward like a Drill

    Two or More Flutes


    Usually Spiral Helix
    Shape

    Low Helix 10-20


    Harder Material 35 HRC +

    Normal (GP) Helix 2830


    High Helix 40+
    Stringy Chips

    Chip Pocket and # Teeth

    End Cutting Edge Types

    Cutting Edge Type

    End Mill Web Thinning


    The Web is Non-Cutting
    Consume Power and
    Torque to PLow Through
    the Work
    Thinning Reduces These
    Thinned Using Gash

    Web Thickness
    Secondary
    Clearance

    Primary Clearance

    Gash Too Far


    Behind Center

    Gash Too Far


    Ahead of Center

    Back Taper

    is Tapered Towards the Shank


    Aids in Plunging/Drilling
    Compensate for Deflection

    Visual Index
    ~ 30
    40- 45
    15- 20

    Pg. 8 & 9

    Helix
    Angle
    # Flutes/Center
    Cutting or Non
    Center Cutting
    Type of
    Material
    Type of
    Coating

    Specs
    /Sizes
    H=High Helix (40)
    N= Normal Helix (30)
    L= Low Helix (15)

    Speeds &
    Feeds

    End Mill Diameter Tolerance

    Pg. 210

    Specs/Sizes EX 9263X & 9267X

    Speeds/Feeds EX 9263X & 9267X

    Nachi Materials
    HSS = High Speed Steel
    General Purpose
    Symbol=

    EXs L231, L261,


    L211, L215, & L271

    HSSCo = Cobalt High Speed Steel


    HSS With Added Cobalt for Wear Resistance
    Symbol=
    EXs L6231HD, L6450, L6485, L6406, L6484, L6486, L6488,
    L6403, L6402, L6404, L6231X, L6211X, L6367X, L6303X, L6231,
    L6233, L6230, L6213, L6210, L6211M, 6367, L6303, & L6307

    Nachi Materials
    Carbide = Tungsten Carbide
    Compacted & Sintered 3 X Stiffer than Steel
    Symbol=

    EXs L9382, L9384, L9386, L9398,


    L9422, L9399, L9423, L9408, L9321, L9322,
    L9324, L9338, L9366, L9368, L9340, L9332, L9330,
    L9378, L9302, L9390, L9360, L9261X, L9265X, L9271X,
    L9275X, L9263X, L9267X, L9273X, L9277X, L9251X, & L9221X

    Coatings Advantages

    Better Wear Resistance


    Better Toughness
    Better Heat Resistance
    Better Lubrication

    Coatings Development and Approx.


    Temperature Max

    900C
    12-1300C
    700C
    600C

    Nachi Coatings

    SG-Coating = TiN + TiCN (Multi Layer Coating)


    Service Temperature= 700C
    Color= Gold YelLow
    Symbol=
    EX L9261X, L9265X, L9271X, L9275X, L9263X, L9267X,
    L9273X, L9277X, L9251X, L9221X, L6231X, L6211X, L6367X, & L6303X

    AG-Coating = TiALN (Multi Layer Coating)


    Service Temperature= 900C
    Color= Violet-Gray
    Symbol=
    EX L6485, L6406, L6484,
    L6486, L6488, L6403, L6402, & L6404

    Nachi Coatings

    Xs-Coating = TiALN (Multi Layer Coating) for End Mills


    Service Temperature= 900C
    Color= Violet-Gray
    Symbol=
    EX L9408, L9321, L9322,
    L9324, L9338, L9366, L9368, L9340, & L9332

    GS-Coating = TiALN + Al-Ti-Cr (Multi Layer Coating)


    Service Temperature= 1100C
    Color= Violet-gray
    Symbol=
    EX L9382, L9384, L9386,
    L9398, L9422, L9399, & L9423

    Nachi Coatings

    DLC-Coating = Diamond Like Carbon


    Service Temperature= 600C
    Color= Black
    Symbol=
    EX L9330, L9378, L9302,
    L9390, L9360, L6231HD, & L6450

    Metric
    Conversion
    Table
    Last Page of the
    Nachi Catalog
    Can use formula
    mm/25.4=
    English
    English X 25.4=
    mm

    Variable Helix-Variable Index End Mills


    Genac VGX End Mill
    High Performance
    Carbide
    AG Coated

    Variable Helix-Variable
    Index Reduce Vibration
    Faster Feed Rates
    Improved Surface Finish

    Drill/End Mill Selection Tool

    Hi-Performance End Mills

    Hi-Performance End Mills

    Product Review

    Xs-Mill Geo
    Xs-Mill Slot
    GS-Mill Hard & GS-Mill Hard Ball
    Mold Meister Ball
    AG-Mill Roughing/AG-Mill Heavy
    DLC -Mill
    Standard High Speed End Mills

    Geo X-Mill
    Features:
    Unique Flute Geometry
    Resulting in Fast Groove Milling
    and Excellent Chip Evacuation
    Tough Micro Grain Carbide and
    TIALN Coating Equals Longer
    Tool Life
    Multifunctional End Mill for
    High Speed Roughing and
    Precise Side Milling
    Work Materials:
    Carbon Steels, Alloy Steels, PreHardened Steels, Stainless Steels,
    Nickel Alloys, Titanium Alloys,
    Cast Irons

    Feature of Geo X Mill


    Geometry of Geo X Mill

    Geo X Mill Design

    Conventional End Mill Design

    Background of -Mill Geos


    Development

    Futures Required for End Mills

    HSCHFC Requires High


    RPM Machining Center

    High Efficient
    Machining by
    Conventional
    Machines

    Cost down
    Short Life Cycle of Products
    (PC, Mobile Phone
    Flexible Manufacturing due to
    Various User Needs
    Short Delivery Time of Mold & Die

    Flexibility
    Multipurpose

    Example

    Critical Feed Test

    End Mill Flutes


    Rotation Feed
    Cut Depth Slotting
    Material DRY(No Air BLow)

    Chip Shape

    End Mill Flutes


    Rotation Feed
    Cut Depth Slotting
    Material DRY(No Air BLow

    Difference of Flute Geometry


    -Mill Geo

    Brand

    Xs Mill Geo Series


    Xs-Mill Geo, Geo Radius
    Xs-Mill Geo Ball
    Xs-Mill Geo Micro Ball
    Xs-Mill Geo Long Shank
    Xs-Mill Geo Slot

    Xs-Mill Geo
    High Speed Machining Wide Range
    Materials
    Wide Range of High Speed Milling from Carbon
    Steel to Hardened Steel - Thanks for the Best
    Combination with Multilayered TiAlN Coating Film
    and Tough Carbide Substrate

    Easy Chip Control


    High Speed Grooving, and Drilling with the 4 Flutes
    Mill Thanks to NACHIs Unique Flute Geometry

    Ridged and Tough


    Unique Flute Geometry and Wide Land on the
    Cutting Edge
    Tough Cutting Edge Extremely High Milling Speed
    and Excellent Finishing Surface
    Stable Milling

    Milling

    Chipping

    Broken

    Smooth FLowing Chips


    Xs Mill Geo
    Competitor A
    Competitor B

    Feed(mm/min)

    Conditions
    End Mill : 10mm
    Material : SKD11(180HB)

    Speed
    : 80m/min
    Coolant : Dry

    Feature of Geo X Mill


    Cross Section of Xs Mill Geo
    Wide and Tough

    Small
    Smooth Concave

    Geo X Mill

    Conventional

    X-Mill Geo Slot


    Features:
    3- 4 Times Faster Grooving
    than Conventional End Mill
    Unique Design of End Teeth
    Provide Excellent Chip FLow
    Well Balanced 3-Flutes make
    Efficient Slotting Possible
    Non-Step Slotting of 1D Depth
    Possible
    Work Materials:
    Carbon Steels, Alloy Steels,
    Pre-Hardened Steels,
    Hardened Steels, Stainless
    Steel, Nickel Alloys, Titanium
    Alloys, Cast Irons

    Geo Slot Geometry

    Slotting Milling by Geo Slot

    Smooth Chip Evacuation


    Material: Carbon Steel-Thin Plate)
    New

    After 120 Grooves

    Geo Mill
    Slot

    Competitor
    B

    Geo Mill Slot Chip Evacuation Good Even After 120


    Grooves Milling

    GS Mill Hard
    GS Mill Hard

    Milling Up to 70HRc

    Features:
    High Speed Machining of
    Hardened Steels
    For Machining Hardened Steels
    up to 70 Hrc
    Nachis New GS Hard Coat
    (Al-Ti-Cr Based Coating)
    3 Times Tougher AntiOxidization at 1,100C
    Work Materials:
    Pre-Hardened Steels, Mold
    Steels, Hardened Steels H13, D2,
    M3 (45-60 Hrc)

    Features of GS-Mill Hard


    Geo Flute Geometry to Increase Both Chip Evacuation and Higher Rigidity
    Corner Chamfering to Minimize the Corner Wear
    New GS Hard Coating to Dissipate Heat and Smoother Chip Evacuation
    Ultra Micro Grain Carbide for Better Abrasion Resistance

    Current

    Geo Type

    Smooth Curvature Enables


    Better Chip Evacuation
    Wider Land Width Increases
    Tool Rigidity

    Section

    Invention on Corner Edge


    The Corner Chamfering Minimizes
    the Corner Wear Effectively

    Performance of GS-Mill Hard

    Movie

    Dia Flute Dry


    /min
    mm/min
    amm
    r
    MaterialSKD()

    SKD61(53HRC) Ultra High Speed

    GS Mill Hard Ball


    Durable Tool Life
    Newly Developed GS Hard Coating with
    High Resistance to Wear and Lubrication
    Reduces Friction
    High TRS by Ultra-Micro Grain Carbide
    Protects Chipping as Well as Wear
    Excellent Work Surface

    Accurate Surface
    The Ball Nose Accuracy is Applied by
    +37m
    The One-Pass Grinding Guarantees
    Excellent Surface Even on the
    Perpendicular Wall
    Work Materials:
    Pre-Hardened Steels, Mold Steels, Hardened
    Steels H13, D2, M3 (45-60 Hrc)

    One Pass Grinding from


    Ball Nose to Outer Tooth

    High Performance Milling SFM=750 RPM=9500 Feed= 80 ipm


    (End Mill R4, Mold Steel, 53HRC, R4, Radial Depth= 4mm, axial
    Depth=.025

    For Mold & Die

    Machining to Zero with the


    Mold Meister Ball End Mill

    Features of Mold Meister Ball


    Features:
    Precision Carbide End Mill
    Best Suited for Machining to
    Zero
    Seamless Ball Tolerance
    Drastically Reduces Polishing
    Time
    High Precision Ball Tolerance
    3u, Ball Accuracy Range
    180
    Highly Suitable for Mold and
    Die Work
    Work Materials:
    Pre-Hardened Steels, Mold
    Steels, Hardened Steels H13,
    D2, M3 (45-60 Hrc)

    Appearance of Mold Meister Ball

    Seamless
    One Pass Grinding

    Actual Measurement of Competitors Accuracy


    Competitor A R1
    Nominal
    A

    Competitor B R3
    Nominal
    B

    Nachi R1
    Nominal 3

    Nachi Inspection Sheet


    Inspection Sheet with all End
    Mills
    Highly Accurate Milling is
    Possible with this Tool

    Easy Compensation

    Reduce Time for Polishing


    and Rectification Drastically

    Tool Life Comparison in Hardened Steel Milling


    Conditions

    Cutting Length Only 5m

    Material SKD11(60HRC)
    Speed V=151m/min (S=12,000min-1)
    Feed F=1,400mm/min (f=0.058mm/t)
    Cut Depth =0.5mm, Pf=0.4mm
    DRY(Air BLow) Vertical MC(BT40)

    Cutting Length 20m


    Competitor A

    Wear in R (m)

    150

    Competitor B

    100

    Cutting Length 25m


    50

    NACHI Mold Meister

    0
    0

    10
    20
    Cutting length(m)

    30

    AG Mill Roughing (For Roughing Operations)


    Features:
    Increased Performance in
    Roughing Operations
    Improved Chip Breaking
    Action with Both Fine and
    Heavy Tooth Serrations
    Made from HSS-Co Material
    Next Generation TiALN
    Coating for Improved
    Performance and Extended
    Tool Life
    Higher Radial Depths of Cut
    due to Improved Tool
    Geometry and Tooth Serrations

    Features of Material and Coating


    Wear
    Resistance

    Compatibility

    Chipping
    Resistance

    High Alloyed Cobalt HSS


    Appearance of AG-Mill
    Roughing Regular Length Short

    AG Coating

    Heat Resistance
    Fine Pitch
    Oxidization
    High Hardness Nick
    High Toughness

    * Excellent Chipping and Wear Resistance Compared to HSS Co TICN:


    This image cannot currently be displayed.

    Work Materials:

    Suitable for Semi-Finish Operations in Structural Steels, Carbon Steels,


    Alloy Steels, Molds Steels, Stainless Steels, Nickel Alloys, Titanium,
    and Cast Iron
    Available in Fractional & Metric Sizes
    Fractional Size Range: - 2
    Metric Size Range: 6mm 50mm

    AG Mill Heavy (Roughing & Finishing)

    Features:
    Increased Performance in
    Semi-Finish Operations
    Made from HSS-Co Material
    Next Generation TiALN
    Coating for Improved
    Performance and Extended
    Tool Life
    Higher Radial Depths of Cut
    due to Improved Tool
    Geometry and Tooth
    Serrations in Semi-Finish
    Operations
    Excellent for Roughing in
    Nickel Alloys, Titanium,
    Inconel and Stainless

    * 3X the Tool Life than Regular TiCN HSS-Co End Mills.

    Work Materials:
    Suitable for Semi-Finish Operations in Structural Steels, Carbon Steels,
    Alloy Steels, Molds Steels, Stainless Steels, Nickel Alloys, Titanium,
    and Cast Iron
    Available in Fractional & Metric Sizes
    Fractional Size Range: - 2
    Metric Size Range: 3mm 50mm

    DLC Mill for Aluminum


    Dry Milling of Aluminum
    DLC (Diamond Like Carbon) is an Amorphous
    Material with High Hardness and Low Friction
    and has Similar Characteristics to Diamond
    Coating

    Excellent Chip Evacuation


    Dry Machining and Extra Long Tool Life is
    Achieved with DLC Coating

    Materials
    Aluminum 1060, 6061, Aluminum Alloys 4032,
    5052, 7075, and Copper Alloys.

    Series
    L6231HD 1/8 to 1, 2 Flute, HSS-Co
    L9330 1.5 to 20mm, 2 Flute, Carbide

    Genac VGX End Mills


    Variable Helix-Variable Index

    Variable Helix-Variable Index End Mills


    Genac VGX End Mill
    High Performance
    Carbide
    AG Coated

    Variable Helix-Variable Index Reduce


    Vibration
    Faster Feed Rates
    Improved Surface Finish

    Materials
    Carbon Steel, Medium Alloys, Stainless Steel,
    Titanium, Thigh Tem Alloys, and Cast Iron

    Series
    L6000 1/8 to 1, 4 Flute, Carbide
    L6100 1/4 to 1, 4 Flute, Carbide, Extended Length
    L6200 1/8 to 1, 4 Flute, Carbide, Ball Nose

    Thank You

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