For Gear, Spline & Rack Manufacturing

INCH
Advanced Technologies for Gear, Spline and
Rack Manufacturing

Standard Inserts for

Spline Applications

Gear Milling System Advantages

Super Fast Machining Economical Solution

• At least 50% less machining cycle time over other • Absolute price/performance advantage over existing
methods technology
• Carbide inserts with Semi Partial & Partial designed
for single pass machining High Precision Machining for Tailor-made Inserts
For example:
Long Tool Life • Gears: Up to Class 7 according to DIN 3962 and
• Tough sub-micron grade coated inserts with up to 3 DIN 3967 or Class 11 according to AGMA
cutting edges • Involute Splines: According to DIN 5480 or ANSI B92.1
Straight Side Splines: According to ISO 14 and DIN 5463;
High Accuracy & Quality Machining 5464
• No need for additional machining
• High quality surface finish Simplified Machining
• Easy set-up and use on standard 3.5 axis
Shorter Delivery Times CNC milling machines
• Standard spline application tools according to ANSI
B9.1 available from stock
Tailor Made
• Tailor made tools according to the customer's
specifications

2
 CATALOG

The Vardex Gear Milling Concept _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 4

Gear Milling Ordering Code System _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 6

GEAR MILLING INSERTS

Gear Milling Tailor-made Inserts _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 7

Gear Milling Standard Inserts for Spline _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 8

TOOLHOLDERS
Toolholder - Weldon Shank for IC 1/4”U _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 10

Toolholder - Weldon Shank for IC 3/8”U _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 11

Toolholder - Shell Mill for IC 3/8”U _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 12

Toolholder - Shell Mill for IC 1/2”U _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 13

Toolholder - Shell Mill for IC 1/2”UT _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 15

Toolholder - Shell Mill for IC 5/8”U _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 16

Toolholder - Shell Mill for IC 5/8”UT _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 18

Gear Milling Toolholder - Disc Mill for IC 1/4”U _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 19

Gear Milling Toolholder - Disc Mill for IC 3/8”U _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 20

Solid Carbide Gear Milling _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 21

TECHNICAL DATA
Recommended Grades and Cutting Speeds _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 22

Gear Milling Request Form _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 23

3
Advanced Technologies for Gear, Spline and
Rack Manufacturing

The VARDEX Gear Milling Concept

• Advanced milling tools with multi-flute indexable carbide grade inserts for super fast machining
• Offering a competitive alternative to the traditional Hob system
• Tailor-made inserts and holders designed per customer application, with the exact required profile shape
(evolvent, involute or any other profile) to be transferred to the component

Major Applications

GEAR SPLINE RACK

VARDEX Gear milling tools VARDEX Spline milling tools VARDEX Rack milling tools
are suitable for machining are suitable for machining are suitable for covering
both straight and helical teeth both involute or straight-sided modules
covering modules from profiles, covering modules from from 0.5-6.0mm or
0.5-6.0mm or DP 128.0-4.0 0.5-8.0mm or DP 48/96-4/8 DP 128.0-4.0

4
Toolholder Range

End Mill Shell Mill Disc Mill Solid Carbide

| See pages 10-11 | See pages 12-18 | See pages 19-20 | See page 21
IC - 3/8"U, 1/2"U, 1/2"UT,
IC - 1/4", 3/8" 5/8"U, 5/8"UT IC - 1/4"U, 3/8"U
Z - 3-4 Z - 3-6 Z - 8, 10
D2 - 1.19"-1.42" D2 - 1.73"-3.35" D2 - 3.24"-3.54"

Tailor-made Inserts for Gear, Spline and Rack Applications

Tailor-made inserts for Gear, Spline and Rack
| See page 7

U Style UT Style
3 Cutting Edges 1 Cutting Edge

Standard Inserts for Spline Applications

Spline: According to Standard ANSI B92.1
| See page 8

Spline

5
Gear Milling Ordering Code System
Tailor Made Inserts for Gear, Rack and Spline
4 U T E DP 8/16 Z37 GM VBX 210/...
1 2 3 4 5 6 7 8 9 10
1- Insert Size 2 - Insert Style 3 - No. of Cutting Edges 4 - Application 5 - Module or DP
2 - IC1/4” U - U Style T - Single E - External DP - Diametral Pitch
3 - IC 3/8” None - 3 M - Module
4 - IC 1/2”
5 - IC5/8”

6- Module or DP 7 - No. of Gear/ Spline Teeth 8 - Product Line 9 - Grade 10 - Special Insert No.
M 0.5 - 6.0 Z... GM - Gear Milling VBX 210/...
DP 128.0 - 4.0

Standard Inserts for Spline

5 U E DP 8/16 N7 Z35-54 GM VBX
1 2 3 4 5 6 7 8 9 10
1- Insert Size 2 - Insert Style 3 - No. of Cutting Edges 4 - Application 5 - DP
2 - IC1/4” U - U Style None - 3 E - External DP - Diametral Pitch
3 - IC 3/8”
4 - IC 1/2”
5 - IC5/8” (Spline)

6- Module/DP Range 7 - Milling Cutter No. 8 - Teeth Range Gear 9 - Product Line 10 - Grade
32/64 - 8/16 N1 - N8 Zmin 10 - Zmax 135 GM - Gear Milling VBX

Weldon Shank Toolholders

GM E 4 S 100 W 119 - 197 2 U 215/... 32/64-24/48
OR
1 2 3 4 5 6 7 8 9 10 11 11
1- Product Line 2 - Holder Type 3 - No. of Flutes 4 - Clamping System 5 - Shank Diameter 6 - Shank Style
GM - Gear Milling E - End Mill 5 S - Screw 1.0", 1.25" W - Weldon Shank

7- Cutting Diameter [inch] 8 - Toolholder Overhang 9 - Insert Size (IC) 10- Insert Style 11 - Special Holder No. 11- DP Range
OR
1.19" - 1.42" 1.97" - 3.15" 2 - IC 1/4” U - U Style 215/... 32/64-16/32
3 - IC 3/8”

Shell Mill and Disc Mill Toolholders

GM S 4 S D173 075 3 U 215/... 20/40-16/32
OR
1 2 3 4 5 6 7 8 9 10 10
1- Product Line 2 - Holder Type 3 - No. of Flutes 4 - Clamping System 5 - Cutting Diameter [inch]
GM - Gear Milling S - Shell Mill 3 - 10 S - Screw 1.73" - 3.54"
D - Disc Mill

6- Drive Hole Diameter [inch] 7 - Insert Size 8 - Insert Style 9 - No. of Cutting Edges 10 - Special Holder No. 10 - DP Range
OR
.75", 1.0" 2 - IC1/4” U - U Style T - Single 215/... 32/64 - 8/16
3 - IC 3/8” None - 3
4 - IC 1/2”
5 - IC5/8”

6
Gear Milling Tailor-made Inserts
External
Circular Pitch
L L

IC IC

U Style - UT Style -
Module = Pitch / π 3 Cutting Edges 1 Cutting Edge
DP = 25.4 / Module
Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

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Based on the required customer application, VARDEX designs and supplies tailor-made inserts to suit a

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specific Module / DP as well as the exact number of teeth used on the component.

Tailor-made Inserts for Gear, Spline and Rack Applications hteet )N

O
D edistu

Insert Cutting
tooR
D

Application Module Diametral Pitch (DP) L Toolholder Page

retemai

Size Edges
)roniM(

GME4S100W125-197-2U215/... 10
0.5-1.0 26-52 1/4”U 11 3
retemai

GMD10SD335-100-2U215/... 19

Gear GME3S125W142-315-3U215/... 11
1.0-1.5 17-26 3/8"U 16 3 GMS4SD189-075-3U215/... 12
ucriC

GMD8SD354-100-3U215/... 20
hctiP ral

GMS4SD205-075-4U215/... 13
1.75-2.0 13-16 1/2"U 22 3
Rack GMS5SD275-100-4U215/... 14

3.0-3.5 7.5-9 1/2"UT 22 1 GMS6SD335-100-4UT215/... 15

GMS3SD237-075-5U215/... 16
2.25-2.75 9.5-12 5/8"U 27 3
GMS4SD315-100-5U215/... 17

3.5-6 4.5-7 5/8"UT 27 1 GMS6SD315-100-5UT215/... 18

GME4S100W125-197-2U215/... 10
0.5-1.25 48/96; 40/80; 32/64; 24/48 1/4”U 11 3
GMD10SD335-100-2U215/... 19

GME3S125W142-315-3U215/... 11
1.5-2.0 20/40; 16/32 3/8"U 16 3 GMS4SD189-075-3U215/... 12
Spline GMD8SD354-100-3U215/... 20

GMS4SD205-075-4U215/... 13
2.0-3.0 12/24; 10/20; 8/16 1/2"U 22 3
GMS5SD275-100-4U215/... 14

4.0-5.0 6/12; 5/10 1/2"UT 22 1 GMS6SD335-100-4UT215/... 15

GMS3SD237-075-5U215/... 16
3.0-4.0 8/16; 6/12 5/8"U 27 3
GMS4SD315-100-5U215/... 17

5.0-8.0 5/10; 4/8 5/8"UT 27 1 GMS6SD315-100-5UT215/... 18

7
Gear Milling Standard Inserts for Spline
External
Circular Pitch
L

IC
U Style -
3 Cutting Edges
ANSI B92.1 Standard

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According to Standard ANSI B92.1, there are 7 different diametral pitches available, ranging: DP32/64 to DP8/16.

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For each DP, there are 8 different types of inserts to select, according to the number of teeth on the spline.

Standard Inserts for Spline Applications hteet )N

O

Diametral EDP Milling Z - Range of

IC L Inch Ordering Code Toolholder Page
D edistu

tooR
D

Pitch (DP) (VBX) Cutter No. Teeth on Gear

retemai

2UEDP32/64Z10-11N1GM... 30100 N1 10-11

)roniM(
retemai

2UEDP32/64Z12-13N2GM... 30101 N2 12-13

2UEDP32/64Z14-16N3GM... 30102 N3 14-16
2UEDP32/64Z17-20N4GM... 30103 N4 17-20
DP32/64
ucriC

2UEDP32/64Z21-25N5GM... 30104 N5 21-25

2UEDP32/64Z26-34N6GM... 30105 N6 26-34
hctiP ral

2UEDP32/64Z35-54N7GM... 30106 N7 35-54

2UEDP32/64Z55-135N8GM... 30107 N8 55-135 GME4S100W119-197-2U32/64-24/48 (66673) 10
1/4"U .43"
2UEDP24/48Z10-11N1GM... 30108 N1 10-11 GMD10SD330-100-2U32/64-24/48 (66675) 19
2UEDP24/48Z12-13N2GM... 30109 N2 12-13
2UEDP24/48Z14-16N3GM... 30110 N3 14-16
2UEDP24/48Z17-20N4GM... 30111 N4 17-20
DP24/48
2UEDP24/48Z21-25N5GM... 30112 N5 21-25
2UEDP24/48Z26-34N6GM... 30113 N6 26-34
2UEDP24/48Z35-54N7GM... 30114 N7 35-54
2UEDP24/48Z55-135N8GM... 30115 N8 55-135
3UEDP20/40Z10-11N1GM... 30116 N1 10-11
3UEDP20/40Z12-13N2GM... 30117 N2 12-13
3UEDP20/40Z14-16N3GM... 30118 N3 14-16
3UEDP20/40Z17-20N4GM... 30119 N4 17-20
DP20/40
3UEDP20/40Z21-25N5GM... 30120 N5 21-25
3UEDP20/40Z26-34N6GM... 30121 N6 26-34
3UEDP20/40Z35-54N7GM... 30122 N7 35-54 GME3S125W126-315-3U20/40-16/32 (66676) 11
3UEDP20/40Z55-135N8GM... 30123 N8 55-135
3/8"U .63" GMS4SD173-075-3U20/40-16/32 (66678) 12
3UEDP16/32Z10-11N1GM... 30124 N1 10-11
3UEDP16/32Z12-13N2GM... 30125 N2 12-13 GMD8SD348-100-3U20/40-16/32 (66677) 20

3UEDP16/32Z14-16N3GM... 30126 N3 14-16

3UEDP16/32Z17-20N4GM... 30127 N4 17-20
DP16/32
3UEDP16/32Z21-25N5GM... 30128 N5 21-25
3UEDP16/32Z26-34N6GM... 30129 N6 26-34
3UEDP16/32Z35-54N7GM... 30130 N7 35-54
3UEDP16/32Z55-135N8GM... 30131 N8 55-135

8
Gear Milling Standard Inserts for Spline (con't)
External
Circular Pitch
L

IC
U Style -
3 Cutting Edges
ANSI B92.1 Standard
Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

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htgneL t evo
(r
hteet )N
Standard Inserts for Spline Applications
O

Diametral EDP Milling Z - Range of

IC L Inch Ordering Code Toolholder Page
D edistu

tooR
D

Pitch (DP) (VBX) Cutter No. Teeth on Gear

retemai

4UEDP12/24Z10-11N1GM... 30132 N1 10-11

)roniM(
retemai

4UEDP12/24Z12-13N2GM... 30133 N2 12-13

4UEDP12/24Z14-16N3GM... 30134 N3 14-16
4UEDP12/24Z17-20N4GM... 30135 N4 17-20
DP12/24
ucriC

4UEDP12/24Z21-25N5GM... 30136 N5 21-25

4UEDP12/24Z26-34N6GM... 30137 N6 26-34
hctiP ral

4UEDP12/24Z35-54N7GM... 30138 N7 35-54

4UEDP12/24Z55-135N8GM... 30139 N8 55-135 GMS4SD190-075-4U12/24-10/20 (66679) 13
1/2"U .87"
4UEDP10/20Z10-11N1GM... 30140 N1 10-11 GMS5SD264-100-4U12/24-10/20 (66680) 14
4UEDP10/20Z12-13N2GM... 30141 N2 12-13
4UEDP10/20Z14-16N3GM... 30142 N3 14-16
4UEDP10/20Z17-20N4GM... 30143 N4 17-20
DP10/20
4UEDP10/20Z21-25N5GM... 30144 N5 21-25
4UEDP10/20Z26-34N6GM... 30145 N6 26-34
4UEDP10/20Z35-54N7GM... 30146 N7 35-54
4UEDP10/20Z55-135N8GM... 30147 N8 55-135
5UEDP8/16Z10-11N1GM... 30148 N1 10-11
5UEDP8/16Z12-13N2GM... 30149 N2 12-13
5UEDP8/16Z14-16N3GM... 30150 N3 14-16
5UEDP8/16Z17-20N4GM... 30151 N4 17-20 GMS3SD223-075-5U8/16 (66681) 16
5/8”U 1.06” DP8/16
5UEDP8/16Z21-25N5GM... 30152 N5 21-25 GMS4SD299-100-5U8/16 (66682) 17
5UEDP8/16Z26-34N6GM... 30153 N6 26-34
5UEDP8/16Z35-54N7GM... 30154 N7 35-54
5UEDP8/16Z55-135N8GM... 30155 N8 55-135

9
Toolholder - Weldon Shank for IC 1/4”U

D D2

L2 D1
L3≤L1
L1
L

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions inch
Size Edges Flutes

IC L L1 D D1 D2 *L2 Z Insert Screw Torx Screwdriver

(max) (ref) (ref)
SN2T HK2T
1/4”U 3 GME4S100W125-197-2U215/... 4.53 1.97 1.00 1.22 1.25 .20 4
(70036) (70227)

Spline Toolholders – For Standard Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code EDP Dimensions inch
Size Edges Flutes

IC L L1 D D1 *L2
D2 (ref) Z Insert Screw Torx Screwdriver
SN2T HK2T
1/4”U 3 GME4S100W119-197-2U 32/64-24/48 66673 4.65 1.97 1.00 1.22 1.19 .20 4
(70036) (70227)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

10
Toolholder - Weldon Shank for IC 3/8”U

D D2

L2
L3≤L1
D1
L1
L

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions inch
Size Edges Flutes

IC L L1 D D1 D2 *L2 Z Insert Screw Torx Screwdriver

(max) (ref) (ref)
SN3T HK3T
3/8”U 3 GME3S125W142-315-3U215/... 5.75 3.15 1.25 1.35 1.42 .28 3
(70038) (70228)

Spline Toolholders – For Standard Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code EDP Dimensions inch
Size Edges Flutes

IC L L1 D D1 *L2
D2 (ref) Z Insert Screw Torx Screwdriver
SN3T HK3T
3/8”U 3 GME3S125W126-315-3U 20/40-16/32 66676 5.75 3.15 1.25 1.35 1.26 .28 3
(70038) (70228)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

11
Toolholder - Shell Mill for IC 3/8”U

d(H6) D1

L2

H D2

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions inch
Size Edges Flutes

IC D1 D2 *L2 Torx
Insert Screw Screwdriver Holder Screw
(max) (ref) d (H6) H (ref) Z
SN3T HK3T 3/8-24x1.5
3/8”U 3 GMS4SD189-075-3U215/... 1.80 1.89 .75 1.57 .26 4
(70038) (70228) (70264)

Spline Toolholders – For Standard Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code EDP Dimensions inch
Size Edges Flutes

IC *L2 Torx
Insert Screw Screwdriver Holder Screw
D1 D2 d (H6) H (ref) Z
SN3T HK3T 3/8-24x1.5
3/8”U 3 GMS4SD173-075-3U 20/40-16/32 66678 1.63 1.73 .75 1.57 .26 4
(70038) (70228) (70264)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

12
Toolholder - Shell Mill for IC 1/2”U

d(H6) D1

L2
H D2

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions mm
Size Edges Flutes

IC D1 D2 *L2 Torx
Insert Screw Screwdriver Holder Screw
(max) (ref) d (H6) H (ref) Z

SN4T HK4T 3/8-24x2.0

1/2”U 3 GMS4SD205-075-4U215/... 1.59 2.05 .75 1.97 .43 4
(70039) (70241) (70302)

Spline Toolholders – For Standard Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code EDP Dimensions inch
Size Edges Flutes

IC *L2 Torx
Insert Screw Screwdriver Holder Screw
D1 D2 d (H6) H (ref) Z

SN4T HK4T 3/8-24x2.0

1/2”U 3 GMS4SD190-075-4U12/24-10/20 66679 1.57 1.90 .75 1.97 .43 4
(70039) (70241) (70302)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

13
Toolholder - Shell Mill for IC 1/2”U

d(H6) D1 D2

L2

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions inch
Size Edges Flutes
D1 D2 d *L2 Insert Screw Torx Holder Screw
IC (max) (ref) (H6) H (ref) Z Screwdriver
SN4T HK4T 1/2-20x1.5
1/2”U 3 GMS5SD275-100-4U215/... 2.70 2.75 1.00 1.97 .35 5
(70039) (70241) (70224)

Spline Toolholders – For Standard Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code EDP Dimensions inch
Size Edges Flutes
*L2 Insert Screw Torx Holder Screw
IC D1 D2 d (H6) H (ref) Z Screwdriver
SN4T HK4T 1/2-20x1.5
1/2”U 3 GMS5SD264-100-4U12/24-10/20 66680 2.31 2.64 1.00 1.97 .35 5
(70039) (70241) (70224)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

14
Toolholder - Shell Mill for IC 1/2”UT

d(H6) D1 D2

L2

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions inch
Size Edges Flutes

IC D1 D2 *L2 Torx
Insert Screw Screwdriver Holder Screw
(max) (ref) d (H6) H (ref) Z
SN4T HK4T 1/2x20x1.5
1/2”UT 1 GMS6SD335-100-4UT215/... 3.27 3.35 1.00 1.97 .40 6
(70039) (70241) (70224)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

15
Toolholder - Shell Mill for IC 5/8”U

d(H6) D1 D2

L2

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions mm
Size Edges Flutes

IC D1 D2 *L2 Torx
Insert Screw Screwdriver Holder Screw
(max) (ref) d (H6) H (ref) Z

SN5TM HK5T 3/8-24x2.0

5/8”U 3 GMS3SD237-075-5U215/... 2.30 2.37 .75 2.05 .52 3
(70041) (70229) (70302)

Spline Toolholders – For Standard Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code EDP Dimensions mm
Size Edges Flutes

IC *L2 Torx
Insert Screw Screwdriver Holder Screw
D1 D2 d (H6) H (ref) Z

SN5TM HK5T 3/8-24x2.0

5/8”U 3 GMS3SD223-075-5U8/16 66681 1.85 2.23 .75 2.05 .52 3
(70041) (70229) (70302)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

16
Toolholder - Shell Mill for IC 5/8”U

d(H6) D1 D2

L2
H

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions inch
Size Edges Flutes
D1 D2 *L2 Insert Screw Torx Holder Screw
IC (max) (ref) d (H6) H (ref) Z Screwdriver
SN5TM HK5T 1/2-20x1.5
5/8”U 3 GMS4SD315-100-5U215/... 3.10 3.15 1.00 2.13 .44 4
(70041) (70229) (70224)

Spline Toolholders – For Standard Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code EDP Dimensions inch
Size Edges Flutes
*L2 Insert Screw Torx Holder Screw
IC D1 D2 d (H6) H (ref) Z Screwdriver
SN5TM HK5T 1/2-20x1.5
5/8”U 3 GMS4SD299-100-5U 8/16 66682 2.61 2.99 1.00 2.13 .44 4
(70041) (70229) (70224)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

17
Toolholder - Shell Mill for IC 5/8”UT

d(H6) D1 D2

L2
H

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions inch
Size Edges Flutes

IC D1 D2 *L2 Torx
Insert Screw Screwdriver Holder Screw
(max) (ref) d (H6) H (ref) Z
SN5TM HK5T 1/2-20x1.5
5/8”UT 1 GMS5SD315-100-5UT215/... 3.07 3.15 1.00 1.97 .39 5
(70041) (70229) (70224)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

18
Gear Milling Toolholder - Disc Mill for IC 1/4”U

D1 D2

L2

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions inch
Size Edges Flutes

IC D1 D2 d (H6) H *L2 Z Insert Screw Torx Screwdriver

(max) (ref) (ref)
SN2T HK2T
1/4”U 3 GMD10SD335-100-2U215/... 3.30 3.35 1.00 .98 .49 10
(70036) (70227)

Spline Toolholders – For Standard Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code EDP Dimensions inch
Size Edges Flutes

IC D1 D2 d (H6) H *L2 Z Insert Screw Torx Screwdriver

(ref)
SN2T HK2T
1/4"U 3 GMD10SD330-100-2U 32/64-24/48 66675 3.13 3.30 1.00 .98 .49 10
(70036) (70227)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

19
Gear Milling Toolholder - Disc Mill for IC 3/8”U

D1 D2

L2
H

Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

For Tailor-made Gear, Rack and Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions inch
Size Edges Flutes

IC D1 D2 d (H6) H *L2 Z Insert Screw Torx Screwdriver

(max) (ref) (ref)
SN3T HK3T
3/8”U 3 GMD8SD354-100-3U215/... 3.45 3.54 1.00 .98 .33 8
(70038) (70228)

Spline Toolholders – For Standard Spline Inserts Spare Parts

Insert Insert No. of
Cutting Ordering Code EDP Dimensions inch
Size Edges Flutes

IC D1 D2 d (H6) H *L2 Z Insert Screw Torx Screwdriver

(ref)
SN3T HK3T
3/8”U 3 GMD8SD348-100-3U 32/64-24/49 66677 3.24 3.48 1.00 .98 .33 8
(70038) (70228)

* L2 (ref) is measured from the center of the profile to the end of the toolholder.
The L2 value is for reference purposes only. For an exact measurement, please use the Controller pre-settings.

20
Solid Carbide Gear Milling

External
Circular Pitch
D2

Module = Pitch / π
DP = 25.4 / Module Image for illustration only. Final D2 and D1 values for tailor made toolholders will be supplied with the toolholder.

negnaT
htgneL t evo
(r
hteet )N
Solid Carbide Tool Benefits
Small Tool Cutting Diameter
O

• Excellent solution for applications that

D edistu

tooR
D

require cutting close to the shoulder

retemai
)roniM(

• High RPM and fast feed

retemai

Solid Carbide Tool

• Guarantees higher accuracy
Multi-flute Tool
ucriC

• Enables fast machining

hctiP ral

Tool Range
• Cutting Diameter Range: .23"-.75” (5.9-19.9mm)
• Module: 0.5-3.0
• DP: 52-13

For Tailor-made Gear, Rack and Spline Inserts

Shank Diameter Gear & Rack Module Range, Max Spline Module Range, Max
Inch mm Module Diametral Pitch (DP) Module Diametral Pitch (DP)

1/4” 6 0.5 DP52 0.8 DP40/80

5/16” 8 0.6 DP44 1.0 DP32/64

3/8” 10 0.8 DP32 1.25 DP24/48

1/2” 12 1.0 DP26 1.5 DP20/40

5/8” 14 1.25 DP22 1.75 DP16/32

5/8” 16 1.5 DP18 2.0 DP12/24

3/4” 18 1.75 DP15 2.5 DP10/20

3/4” 20 2.0 DP13 3.0 DP8/16

21
Recommended Grades, Cutting Speeds Vc [ft/min] and Feed f [inch/tooth]

Vardex No.
Vc [ft/min]
Material Hardness Feed f
Group Material Brinell HB VBX/ VTX [inch/tooth]
1 Low carbon (C=0.1-0.25%) 125 328 - 689 .0079 - .0126
2 Unalloyed steel Medium carbon (C=0.25-0.55%) 150 328 - 590 .0079 - .0126
3 High Carbon (C=0.55-0.85%) 170 328 - 558 .0060 - .0090
4 Non hardened 180 197 - 295 .0067 - .011

P
Steel
5
6
Low alloy steel
(alloying elements≤5%)
Hardened
Hardened
275
350
262 - 492
230 - 459
.0060 - .011
.0060 -.0098
7 High alloy steel Annealed 200 197 - 426 .0060 - .0087
8 (alloying elements>5%) Hardened 325 227 - 361 .0051 - .0083
9 Low alloy (alloying elements <5%) 200 328 - 558 .0060 - .0087
Cast steel
10 High alloy (alloying elements >5%) 225 230 - 394 .0047 - .0087
11 Stainless steel Non hardened 200 328 - 558 .0060 - .0087
12 Ferritic Hardened 330 328 - 558 .0063 - .0091

M
13 Stainless steel Austenitic 180 230 - 460 .0060 - .0098
14 Austenitic Super Austenitic 200 230 - 460 .0047 - .0079
Stainless 15 Stainless steel Non hardened 200 230 - 460 .0063 - .0094
Steel 16 Cast Ferritic Hardened 330 230 - 460 .0047 - .0079
17 Stainless steel Austenitic 200 230 - 394 .0060 - .0087
18 Cast austenitic Hardened 330 230 - 394 .0047 - .0079
28 Ferritic (short chips) 130 197 - 426 .0063 - .0095
Malleable Cast iron
29 Pearlitic (long chips) 230 197 - 394 .0060 - .0087

K
Cast Iron
30
31
Grey cast iron
Low tensile strength
High tensile strength
180
260
197 - 426
197 - 328
.0060 - .0087
.0060 - .0087
32 Ferritic 160 197 - 410 .0039 - .0079
Nodular SG iron
33 Pearlitic 260 164 - 295 .0060 - .0087
34 Aluminium alloys Non aging 60 328 - 820 .0118 - .0197
35 Wrought Aged 100 328 - 590 .011 - .0197

N(K)
Non-Ferrous
36
37
Aluminium alloys
Cast
Cast & aged
75
90
492 - 1312
492 - 918
.011 - .0197
.0098 - .0157
Metals 38 Aluminium alloys Cast Si 13-22% 130 262 - 492 .011 - .0197
39 Copper and Brass 90 394 - 689 .0118 - .0197
40 Copper alloys Bronze and non leaded copper 100 394 - 689 .011 - .0197
19 Annealed (Iron based ) 200 66 - 148 .0035 - .0059

S(M)
Heat
20
21
High temperature alloys
Aged (Iron based)
Annealed (Nickel or Cobalt based)
280
250
66 - 98
49 - 66
.0028 - .0051
.0031 - .0059
22 Aged (Nickel or Cobalt based) 350 33 - 49 .0031 - .0059
Resistant
Material 23 Pure 99.5 Ti 400Rm 230 - 459 .0028 - .0051
Titanium alloys
24 α+β alloys 1050Rm 66 - 164 .0028 - .0051

H(K)
Hardened
25
Extra hard steel Hardened & tempered
45-50HRc 49 - 148 .002 - .0047

26 51-55HRc* 49 - 131 .002 - .0047

Material
* Note: Special tools, which are not listed in this catalog, are required for extra hard steel (51-55HRc).

Grade Application Sample

VBX TiCN coated carbide grade. Excellent grade for general use.
Indexable Insert
VTX TiAIN coated carbide grade. Excellent grade for general use and hardened materials.

Solid Carbide VTH TiCN coated carbide grade. Excellent grade for general use.

Other grades are available upon request.

22
 Distributor Name

ENQUIRY No.
NEUMO Ehrenberg Group

Request Form*
* Please submit a completed version of this form with each request (a drawing is recommended).
For Rack, Straight Spline, Worm or other special forms, a drawing must be supplied with all relevant dimensions!
Basic Dimensions R (D2/2)

1 | Gear / Spline Standard

2 | Class of Accuracy
3 | Module (M) / Diametral Pitch (DP)
4 | Number of Teeth
5 | Pressure Angle Limitation

6 | Helix Angle
Tool Radius (R) < Tool Exit Limitation
7 | Direction of Helix (RH/LH)
R (D2/2)
8 | Pitch Diameter (REF)
9 | Major Diameter Max: Min:
10 | Minor Diameter Max: Min:
11 | Form Diameter (For Spline only)
12 | Fillet Radius Exit Arc

13 | Root Type (For Spline only) Fillet Root Flat Root

One of the following must be supplied: Tool Radius (R) < Exit Arc

14a | Measurement Over Pins Ø: Max: Min:

14b | Tangent Length Over (N) Teeth N: Max: Min:
14c | Actual - Tooth Thickness Max: Min:

Additional Information
15 | For Tool Exit Limitation, a detailed component drawing must be supplied!
16 | Exit Arc Radius (R)
Pin Diameter
17 | Material Hardness (During machining)
18 | Material Designation
Pressure Angle

Involute
er

Flat Root Spline

et
iam
)D
de
t si
Ou

eter
r(

Diam
aj o

(Root)
Minor
M

Measurement
Form Diameter Fillet Radius Pi tc
hD
iam
Over Pins
e te
r

Fillet Root Spline Involute

Tooth Thickness

Fillet Radius

Form Diameter Fillet Radius

Tangent length
over (N) teeth
For Gear, Spline & Rack Manufacturing

Vargus USA Tel: +1-800-828-8765 221-01321

[email protected] INCH EA
1149 Barberry Drive +1-608-756-4930
www.vargususa.com 02/2019
Janesville, WI 53545 U.S.A Fax: +1-608-741-7125 EDITION 04W