Home

Milling Cutter User Guide

1. Add 10 50 80 45 70 40 65 8 20 9 14 40 70 35 45 30 60 m 25 45 20 40 20 35 15 25 15 25 12 20 Add 10 to 3 1525 1525 12 20 B primary 97 14 40 70 35 45 30 60 10 20 Add 10 20 28 Add 10 50 200 50 200 10 20 to 9 14 primary Cutter types cont TYPE CUTTER RANGE D Shell End Mills Roughing Note For Roughing End Mills see page 11 T Cutting Angles Use higher angles for smaller diameters reducing proportionately for larger diameters Brooke 33 Cutting Tools Limited END MILLS Feeds Per Tooth Sz mm Sz X 1 25 Sz X 0 78 ar 0 1Xd ar 0 25 Xd Table Shows Sz Values End Carbon Alloy Stainless Nimonic Mil Steels Steels Steels Alloys Ptanum 3 0 010 0 010 0 010 0 008 0 010 4 0 015 0 015 0 015 0 012 0 015 5 0 018 0 018 0 018 0 014 0 018 6 0 022 0 022 0 022 0 018 0 022 8 0 030 0 030 0 030 0 024 0 030 10 0 036 0 036 0 036 0 029 0 036 12 0 044 0 044 0 044 0 036 0 044 14 0 051 0 051 0 051 0 040 0 051 16 0 058 0 058 0 058 0 046 0 058 18 0 065 0 065 0 065 0 052 0 065 20 0 073 0 073 0 073 0 058 0 073 22 0 080 0 080 0 080 0 064 0 080 25 0 090 0 090 0 090 0 072 0 090 28 0 102 0 102 0 102 0 081 0 102 30 0 110 0 110 0 110 0 088 0 110 32 0 116 0 116 0 116 0 092 0 116 35 0 130 0 130 0 130 0 104 0 130 40 0 130 0 130 0 130 0 104 0 130 50 0 130 0 130 0 130 0 104 0 130
2. CUTTER TECHNICAL DATA TENSILE grin iege GRADE iiic E STRENGTH N mm FREE CUTTING 150 510 CARBON 0 3 to 0 4 Carbon 170 580 STEEL 0 3 to 0 4 Carbon 248 830 0 4 to 0 7 Carbon 206 675 0 4 to 0 7 Carbon 286 970 248 833 ALLOY STEEL 330 1137 381 1265 Martensitic Free Cutting 248 833 Std Grade 248 833 STAINLESS STEEL Austenitic Free Cutting As Supplied Std Grade NIMONIC Wrought 300 1030 ALLOYS Cast 350 1200 Titanium Comm Pure 170 510 Titanium Comm Pure 200 660 Titanium Comm Pure 275 940 TITANIUM Titanium Alloyed 340 1170 Titanium Alloyed 350 1200 Titanium Alloyed 380 1265 HSS Standard Grades 225 735 TOOL STEEL HSS Cobalt Grades 250 830 Hot Working Steel 250 830 Cold Working Steel 250 830 CAST Grey Malleable 240 800 IRONS Hardened 330 1137 30 Brooke Cutting Tools Limited PERIPHERAL SPEED RANGE Refer to explanatory notes on page 32 33 TF OUTIING ANGLES TYPE TYPE TYPE TYPE PRIMARY SECONDARY RADIAL A B D CLEARANCE CLEARANCE RAKE 30 40 28 40 24 32 30 40 24 32 24 32 20 26 24 32 Add 10 18 25 18 25 14 20 18 25 8 20 to 9 14 24 32 24 32 20 26 24 32 primary 16 25 16 20 12 20 16 25 16 20 16 20 12 16 16 20 Add 10 1248 12 18 10 15 10 16 8 20 to 9 14 primary 945 844 842 8 12 10 20 1216 8 15 10 20 540 5 10 4 8 5 10 Add 10 8 20 to 9 14 10 20 1216 8 15 10 20 primary 5
3. Tolerance js16 on cutting diameter and js14 on width see page 49 for tolerance tables Double Angle Cutter W EN LALLA AN NS 2 2 Z NAST 1447 U Tolerance js16 on cutting diameter and width see page 49 for tolerance tables Brooke Cutting Tools Limited 21 ARBOR MOUNTED CUTTER APPLICATIONS Staggered Tooth Side and Face Cutters As the name suggests side and face cutters have teeth on the periphery as well as on the sides Designed with rugged alternate helical teeth these cutters offer optimum performance when used for deep slotting with rapid stock removal the cutting action of the alternate helical teeth combined with the coarse pitched side teeth giving excellent qualities of smooth cutting efficient stock removal and good surface finish Straight Tooth Side and Face Cutters Intended for light Guts Srianow operations the straight tooth side and face cutter is often used in a straddle milling function where two parallel surfaces are machined simultaneously It is considered to be a compromise tool due to the reduced cutting action of its straight teeth which cause greater shock when meeting the workpiece than cutters with helical teeth 22 Brooke Cutting Tools Limited Cylindrical Cutters Intended for medium light surfacing cuts these helical cutters offer the benefits of shock reduction combined with a good cutting action Angle Cutters Pro
4. V Co Hardness HRC M2 09 4 6 5 2 63 65 M35 0 9 4 6 5 2 5 64 66 M42 11 4 15 95 1 8 66 68 5 70 M9V 1 25 4 2 3 5 8 5 3 0 64 66 M2 is the standard High Speed Steel and is used where toughness is important together with a good standard of wear resistance and red hardness M35 is a development of M2 and contains 5 cobalt which gives improved hardness wear resistance and red hardness It may be used when cutting higher strength materials M42 can be heat treated to very high hardness levels of up to 70 HRC 1 000 HV although normally a slightly lower figure will be employed to retain toughness This steel is ideal for machining higher strength materials and work hardening alloys such as stainless steels nimonic alloys etc Despite its high hardness M42 has good grindability characteristics due to lower vanadium content M9V material is mainly used in the manufacture of machine taps because of its good wear resistance good grinding capabilities high hardness and excellent toughness Cutting tools may shatter eye protection should be worn Brooke 5 Cutting Tools Limited SURFACE TREATMENTS Bright Finish A bright finish tool has no surface treatment and is suitable for general purpose use Blue Finish A blue finish is achieved by steam tempering a thermal process which imparts a non metallic surface to the tool This surface is porous and by absorbing lubricant
5. 34 Brooke Cutting Tools Limited Sz ar d 0 5 Xd aa ar d Sz aa 0 5 X d Table Shows Sz Values Tool Cast Manganese Aluminium Copper Steels Irons Steels Alloys Alloys 0 009 0 010 0 008 0 013 0 013 0 013 0 016 0 012 0 019 0 019 0 016 0 022 0 014 0 023 0 023 0 020 0 028 0 018 0 028 0 028 0 027 0 036 0 024 0 039 0 039 0 032 0 040 0 029 0 046 0 046 0 040 0 045 0 036 0 057 0 057 0 046 0 056 0 040 0 066 0 066 0 052 0 064 0 046 0 075 0 075 0 058 0 070 0 052 0 085 0 085 0 065 0 080 0 058 0 092 0 092 0 072 0 088 0 064 0 104 0 104 0 080 0 095 0 072 1 117 0 117 0 091 0 110 0 081 0 132 0 132 0 100 0 120 0 088 0 143 0 143 0 104 0 127 0 092 0 150 0 150 0 117 0 142 0 104 0 170 0 170 0 117 0 142 0 104 0 170 0 170 0 117 0 142 0 104 0 170 0 170 Brooke 35 Cutting Tools Limited 36 ROUGHING END MILLS Peripheral Speed m min Feed Per Tooth Sz mm Table Shows Sz Values End Material Group Mill Size 1 2 3 4 6 0 008 0 008 0 009 0 010 8 0 013 0 013 0 015 0 015 10 0 017 0 020 0 020 0 021 12 0 023 0 025 0 025 0 033 14 0 026 0 030 0 030 0 037 16 0 030 0 038 0 038 0 044 22 0 032 0 040 0 040 0 048 25 0 035 0 042 0 042 0 050 28 0 035 0 045 0 042 0 050 30 0 040 0 045 0 045 0 056 32 0 042 0 050 0 050 0 064 35 0 013 0 013 0 015 0 015 38 0 045 0 057 0 057 0 070 40 0 045 0 057 0 057 0 070 45 0 047 0 059 0 060 0 075 50 0 060 0 074 0 075 0 090
6. 60 695 135 2100 64 790 150 2320 66 855 163 2510 68 940 179 2770 70 1075 197 3030 75 1480 80 1865 HRB Hardness Rockwell B HRC Hardness Rockwell C HV Vickers Also DPN VPN HB Hardness Brinell Also BHN Note These values should be treated as approximate only and are suitable for calculating speeds and feeds or for general information purposes Do not use for treated high speed steel 54 Brooke Cutting Tools Limited HARDNESS CONVERSION CHART FOR HIGH SPEED STEEL HV30 HRC HV30 HRC 736 59 3 4 856 64 1 2 741 60 862 63 3 4 746 60 1 4 869 65 752 60 1 4 876 65 1 4 757 60 1 2 883 65 1 2 763 61 890 66 769 61 897 66 775 61 1 4 905 66 1 2 780 61 1 2 912 67 786 61 3 4 919 67 792 62 927 67 1 4 798 62 1 4 934 67 1 2 804 62 1 2 942 68 810 62 3 4 950 68 817 63 958 68 1 2 823 63 1 4 966 68 1 2 829 63 1 2 974 69 836 63 3 4 982 69 1 2 842 64 990 69 1 2 849 64 1 4 999 70 Typical hardness M2 823 876 HV30 63 65 HRC M35 849 920 HV30 64 66 HRC M42 897 966 HV30 66 68 1 2 HRC Depending on the nature ofthe tool these hardnesses may be varied particularly in the case of special tools where different hardnesses may be specified Note Undue reliance should not be placed on a general conversion chart unless it has been tested for a particular material The above chart applies s
7. 080 160 18 0 088 0 090 0 100 18 32 0 090 0 090 0 190 200 8 18 0 093 0 093 0 194 18 32 0 101 0 101 0 102 250 8 18 0 107 0 107 0 110 18 32 0 105 0 105 0 106 Brooke Cutting Tools Limited Table Shows Sz Values Material Group 4 5 6 7 8 0 050 0 051 0 050 0 046 0 020 0 052 0 053 0 052 0 048 0 020 0 063 0 063 0 063 0 056 0 020 0 063 0 063 0 063 0 056 0 020 0 070 0 070 0 070 0 062 0 020 0 070 0 070 0 070 0 070 0 020 0 078 0 080 0 080 0 080 0 020 0 078 0 080 0 080 0 080 0 020 0 090 0 090 0 090 0 090 0 020 0 090 0 090 0 090 0 090 0 020 0 093 0 094 0 093 0 093 0 020 0 102 0 102 0 101 0 101 0 020 0 108 0 110 0 108 0 108 0 020 0 104 0 105 0 104 0 104 0 020 Brooke Cutting Tools Limited 39 40 SHELL END MILLS Feed Per Tooth mm Plain Tooth Table Shows Sz Values Cutting Tools Limited Cutter Material Group Type Diameter 1 2 3 40 0 080 0 080 0 080 P 50 0 080 0 080 0 080 L 63 0 100 0 100 0 100 A 80 0 100 0 100 0 100 100 0 100 0 100 0 100 N 125 0 100 0 100 0 100 160 0 105 0 105 0 105 R 40 0 060 0 060 0 060 U 50 0 070 0 070 0 070 G 63 0 075 0 080 0 070 H 80 0 100 0 100 0 100 100 0 110 0 110 0 110 125 0 115 0 115 0 115 160 0 120 0 120 0 125 Brooke Roughing Form 0 15d 0 25 d Table Shows Sz Values Material Group 4 5 6 7 8 0 080 0 080 0 080 0 08
8. 10 5 10 4 8 5 10 4 8 5 10 3 7 4 8 8 20 4410 0 primary Add 10 742 542 5 10 7 12 8 20 to 9 14 primary 10 20 10 20 8 15 10 20 10 16 10 20 8 13 10 16 Add 10 8 20 to 9 14 10 16 10 16 8 13 10 16 primary 10 16 10 16 8 13 10 16 16 20 16 20 12 16 20 28 Add 10 to 552 8 20 9 14 12 16 10 14 10 12 16 22 primary cont on page 32 Brooke 31 Cutting Tools Limited CUTTER TECHNICAL DATA cont TENSILE EDT GRADE HR STRENGTH N mm Wrought 55 ALUMINIUM ALLOYS Wrought 110 Cast 100 Brass Free Cutting Low Leaded COPPER Bronze Silicon As Supplied ALLOYS Manganese s Supple Aluminium Phospor Copper PLASTICS As Supplied Explanatory Notes Cutter types TYPE CUTTER RANGE End mills 2 3 amp Multi Flute T Slot Cutters A Dovetail amp Inverted Dovetail Cutters Woodruff Cutters Corner Rounding Cutters Side and Face Cutters B Single and Double Angle Cutters Slitting Saws Shell End Mills Plain Tooth 32 Brooke Cutting Tools Limited PERIPHERAL SPEED RANGE Refer to explanatory notes on page 32 33 T CUTTING ANGLES TYPE TYPE TYPE TYPE PRIMARY SECONDARY RADIAL A B C D CLEARANCE CLEARANCE RAKE 200 1500 120 180 50 180 Add 10 100 250 100 180 50 100 10 20 to 20 28 40 100 50 70 30 80 primary 40 70 35 45 30 60
9. AND FACE CUTTERS CYLINDRICAL CUTTERS Arbor Mounted Cutter Nomenclature Arbor Mounted Cutter Applications Hints for Successful Arbor Mounted Cutter Usage SLITTING SAWS Slitting Saw Applications Hints for Successful Slitting Saw Usage Tolerances Brooke Cutting Tools Limited 13 16 17 14 15 18 18 20 23 18 19 22124 28129 26 27 25 CONTENTS cont Page TECHNICAL INFORMATION Technical Data Chart 30 33 Feed per Tooth Chart 34141 Peripheral Speed to rpm Conversion Chart 42 43 Speed amp Feed Formulae 44 Climb vs Conventional Milling 45 46 General Tolerances 49 Problem Solving 47 Difficultto Machine Materials 50 Re Sharpening Hints 51 Useful Formulae Conversion Charts etc 52 60 IF YOU CANNOT FIND AN ANSWER TO YOUR PROBLEM IN THIS BOOKLET PLEASE CONTACT THE BROOKE FACTORY Brooke Cutting Tools Limited CUTTING TOOL MATERIALS Brooke cutting tools are manufactured from the finest steel available The heat treatment process is controlled by our Metallurgical laboratory using advanced computerised and electronic instrumentation High Speed Steel contains various elements such as Molybdenum Tungsten Cobalt and Vanadium and must be specially heat treated to produce the ideal combination of strength toughness and wear resistance BROOKE products are manufactured from one of the following High Speed Steels depending on the product and application C Cr W
10. edges to their original geometry using correct procedures Suitable wheel selection to ensure correct surface finish and stock removal Consult wheel suppliers for specific recommendations Remember that milling cutters are precision tools and must be handled carefully Damage due to incorrect handling or storage can be seen as a flaw upon the milled surface of a workpiece Grinding should be needed only as a result of dulling due to use Regrinding to remove damage caused by rough handling must be considered to be a wasted process which reduces the life of a cutter Correct clearance angles and radial rakes can be obtained from data given on page 30 31 amp 33 Rake Primary cT Secondary Brooke 51 Cutting Tools Limited Radial _ g GENERAL INFORMATION INCH MILLIMETER CONVERSION TABLE 0 1 2 mm mm mm O w ul 25 400 50 800 164 0 397 25 797 51 197 132 0794 26 194 51 594 3 64 14191 26 591 51 991 116 1588 26 988 52 388 564 1 984 27 384 52 784 3 33 2381 27 781 53 181 74 w 2 778 28 178 53 578 18 2 v 3175 28 575 53 975 9 64 3572 28 972 54 372 532 3 969 29 369 54 769 11 68 4 366 29 766 56 166 3 16 4762 30 162 55 562 13 64 5 159 30 599 55 959 732 5 556 30 956 56 356 15 64 5 953 31 353 56 753 14 6350 31 750 57 150 17 64 6 747 32 147 57 547 9 32 7 144 32 544 57 944 19 6
11. off the machine Where possible check workpiece condition and hardness Check chucks and collects regularly ensuring that they are in good condition Always clean cutter shanks and collets prior to assembly Check that cutters are running true The most likely cause of cutter run out is damaged chucks and collets Maintain cutters in a sharp condition to ensure maximum stock removal surface finish and maximum power requirement Re sharpen immediately when signs of wear are visible since regrinding is then a relatively quick operation requiring little stock removal and with resulting increase in tool life See page 51 for resharpening details Cutter storage is of paramount importance due to the brittle nature of the hardened cutting edges of all cutting tools Poor storage often causes damage such as chipping of the cutting edges and breakage of corners resulting in a tool which is useless As in all machining operations cleaniless is essential The best machining results are produced by cutters operating at the correct speed and feed to suit the material being worked See page 30 for technical data 12 Brooke Cutting Tools Limited SHANK CUTTERS SHANK CUTTER NOMENCLATURE SHANK DIAMETER THREAD 20 T P I WHITWORTH RIGHT HAND SIE E ad s lt RECESS z DIAMETER z nui P pes amp I Li F 5 2 o ad 7 Yn c 9 SIDE
12. 0 0 022 0 080 0 080 0 080 0 080 0 022 0 100 0 100 0 100 0 100 0 022 0 100 0 100 0 100 0 100 0 022 0 100 0 100 0 100 0 100 0 022 0 100 0 100 0 100 0 100 0 022 0 105 0 105 0 105 0 105 0 022 0 060 0 060 0 060 0 060 0 022 0 075 0 075 0 075 0 075 0 028 0 080 0 080 0 080 0 080 0 031 0 100 0 100 0 100 0 100 0 039 0 110 0 110 0 110 0 110 0 039 0 115 0 115 0 115 0 115 0 042 0 120 0 120 0 120 0 120 0 044 Brooke Cutting Tools Limited 41 PERIPHERAL SPEED METRES PERI 5 10 20 30 40 Dia R luti nini evolutions 1 0 1591 3182 6364 9546 12728 2 0 795 1590 3182 4770 6360 3 0 530 1060 2120 3180 4240 4 0 398 795 1590 2385 3180 5 0 318 636 1272 1908 2544 6 0 265 530 1060 1590 2120 7 0 227 455 910 1365 1820 8 0 199 398 796 1194 1592 9 0 177 353 706 1059 1412 10 0 159 318 636 954 1272 11 0 145 289 578 867 1156 12 0 133 265 530 795 1060 13 0 122 245 490 735 980 14 0 114 227 454 681 908 15 0 106 212 424 636 848 16 0 100 199 398 597 796 18 0 89 177 354 531 708 20 0 80 159 318 477 636 22 0 73 145 290 435 580 24 0 67 133 266 399 532 26 0 61 122 344 366 488 28 0 57 144 228 342 456 30 0 53 106 212 318 424 35 0 45 91 182 273 364 40 0 40 80 160 240 320 45 0 35 70 140 210 280 50 0 32 64 128 192 256 63 0 25 50 100 150 200 75 0 21 42 84 126 168 100 0 16 32 64 96 128 42 Brooke Cutting Tools Limited TO rpm CONVERSION CHART Cutting Tools Limited 50 60 70 80 90 100 per Minute 159
13. 10 19092 22274 25456 28638 31820 7950 9540 11130 12720 14310 15900 5300 6360 7420 8480 9540 10600 3975 4770 5565 6360 7155 7950 3180 3816 4452 5088 5724 6360 2650 3180 3710 4240 4770 5300 2275 2730 3185 3640 4095 4550 1990 2388 2786 3184 3582 3980 1765 2118 2471 2824 3177 3530 1590 1908 2226 2544 2862 3180 1445 1734 2023 2312 2601 2890 1325 1590 1855 2120 2385 2650 1225 1470 1715 1960 2205 2450 1135 1362 1589 1816 2043 2270 1060 1272 1484 1696 1908 2120 995 1194 1393 1592 1791 1990 885 1062 1239 1416 1593 1770 795 954 1113 1272 1431 1590 725 870 1015 1160 1305 1450 665 798 931 1064 1197 1330 610 732 854 976 1098 1220 570 684 798 912 1026 1140 530 636 742 848 954 1060 455 546 637 728 819 910 400 480 560 640 720 800 350 420 490 560 630 700 320 384 448 512 576 640 250 300 350 400 450 500 210 252 294 336 378 420 160 192 224 256 288 320 Speed and Feed Formulae _ D rpm i 1000 S 52 2 m V 1000 S Sn 5 rpm S Sz Z rpm 6 5 Y 1000 p 3 1416 V speed m min D cutter diameter mm rpm revolutions min Sn feed revolution mm S feed minute mm Sz feed tooth mm 2 number of teeth on cutter V chip volume cm min depth of cut mm length of cut mm 44 Brooke Cutting Tools Limited CLIMB OR CONVENTIONAL MILLING From the very beginning of the milling process it was found practi cal to always rotate the end mill in the oppo
14. 321 D x 0 866 D side x 2 E x 1 1547 Side Dx0 5 D x 0 067 OCTAGON E side x 2 4142 D x 0 9239 D side x 2 6131 E x 1 0824 Side Dx0 3827 D x 0 038 Brooke 57 Cutting Tools Limited Areas of Plane Figures SQUARE s A 7 area S2 1 2 d2 5 0 7071d s d 1 4145 1414 RECTANGLE A 7 area A ab a a b Ld b 0 b b a A RIGHT ANGLED TRIANGLE A area bc 2 0 b c ACUTE ANGLED TRIANGLE A 7 area bh b a y aue C y IfS 1 a b c then A S 8 a S b S c 58 Brooke Cutting Tools Limited OBTUSE ANGLED TRIANGLE A 7 area bh b _ a A S S a S b c CIRCLE A area C circumference A 01 3 1416 d 0 7854 4 C 2 r 6 2832 3 14164 6 2832 3 1416 0 564 gt d C 3 1416 0 7854 1 128 REGULAR HEXAGON area radius of circumscribed circle r radius of inscribed circle A 2 5988 2 598R 3 464 5 1 155 r 0 8665 0 866R The construction of a regular hexagon forms six equilateral triangles thus the area of the hexagon can also be found by calculating the area of the equilateral triangle and multiplying the result by six Brooke 59 Cutting Tools Limited To
15. 4 7 541 32 941 58 341 516 7 938 33 338 58 738 21 60 8334 33 734 59 134 11 32 8 731 34 131 59 531 23 64 9 128 34 528 59 928 3 8 9 525 34 925 60 325 2564 9 922 35 322 60 722 13 32 10319 35 719 61 119 27164 10716 36 116 61 516 76 11 112 36 512 61 912 2964 11 509 36 909 62 309 15 32 11 906 37 306 62 706 31 64 12 303 37 703 63 103 52 Brooke Cutting Tools Limited 3 mm 76 200 76 597 76 994 77 391 77 788 78 184 78 581 78 978 79 375 79 772 80 169 80 566 80 962 81 359 81 756 82 153 82 550 82 947 83 344 83 741 84 138 84 534 84 931 85 328 85 725 86 122 86 519 86 916 87 312 87 709 88 106 88 503 INCH MILLIMETER CONVERSION TABLE cont 1 2 33 64 _ 17 32 _ 35 64 9 16 37 64 19 32 39 64 5 8 41 64 21 32 43 64 11 16 45 64 23 32 47 64 3 4 49 64 25 82 51 64 13 16 53 64 27 32 55 64 7 8 57 64 29 32 59 64 15 16 61 64 31 32 63 64 0 1 mm mm 12 700 38 100 13 097 38 497 13 494 38 894 13 891 39 291 14 288 39 688 14 684 40 084 15 081 40 481 15 748 40 878 15 875 41 275 16 271 41 671 16 668 42 068 17 066 42 466 17 462 42 862 17 859 43 859 18 256 43 656 18 653 44 053 19 050 44 450 19 447 44 847 19 844 45 244 20 241 45 641 20 638 46 038 21 034 46 434 21 431 46 831 21 828 47 228 22 225 47 625 22 622 48 022 23 019 48 01
16. 9 23 416 48 816 23 812 49 212 24 209 49 609 24 606 50 006 25 003 50 403 Brooke Cutting Tools Limited 2 mm 63 500 63 897 64 294 64 691 65 088 65 484 65 881 66 278 66 675 67 071 67 468 67 866 68 262 68 859 69 056 69 453 69 850 70 247 70 644 71 041 71 438 71 834 72 231 72 628 73 025 73 422 73 019 74 216 74 612 75 009 75 406 75 803 3 mm 89 900 89 297 89 694 90 091 90 488 90 884 91 281 91 678 92 075 92 471 92 868 92 266 93 662 94 859 94 456 94 853 95 250 95 647 96 044 96 441 96 838 97 234 97 631 98 028 98 425 98 282 99 019 99 616 100 012 100 409 100 806 101 203 53 APPROXIMATE HARDNESS AND TENSILE STRENGTH CONVERSIONS TENSILE STRENGTH HRB HRC HV HB Tons MPa or inch N mm 50 95 90 21 320 55 100 100 23 350 60 110 105 25 390 65 120 110 27 420 70 130 120 29 450 75 140 130 31 480 80 150 140 34 520 85 165 160 37 570 90 185 175 40 620 95 205 195 45 690 100 20 230 220 50 770 22 240 230 53 820 24 255 240 56 860 26 265 250 59 910 28 280 265 62 960 30 295 280 65 1000 32 310 290 68 1050 34 325 310 72 1110 36 345 325 75 1150 38 360 345 78 1200 40 380 365 83 1280 42 405 385 88 1360 44 425 405 92 1420 46 450 430 96 1480 48 480 455 102 1540 50 505 480 108 1670 52 545 112 1720 54 580 117 1800 56 615 122 1890 58 655 130 2000
17. Brooke Cutting Tools Limited Peripheral Speeds Material Cutter Speed Group Material Types m min 1 Steels up to 500N mm 28 40 Malleble Cast Iron up to 120 HB 2 Steels of 500 800 N mm 24 32 Non Alloyed Tool Steels Pure Titanium 3 Steels of 800 1200 N mm 18 25 Hot Working Steels Cast Iron of 120 180 HB 4 Stainless Steels 12 18 Titanium Alloys Annealed Cast Iron of more than 180 HB 5 Titanium Alloys Hardened 7 12 6 Brass and Bronze Cast 35 45 7 Brass and Bronze Rolled 45 70 8 Plastics and similar 200 250 Table Shows Sz Values Material Group 5 6 7 8 0 013 0 008 0 006 0 006 0 020 0 012 0 009 0 009 0 030 0 017 0 013 0 012 0 037 0 024 0 016 0 013 0 047 0 026 0 021 0 015 0 053 0 033 0 024 0 019 0 060 0 038 0 025 0 022 0 063 0 040 0 028 0 025 0 065 0 040 0 028 0 025 0 068 0 040 0 030 0 028 0 080 0 044 0 036 0 035 0 020 0 012 0 009 0 009 0 086 0 048 0 040 0 035 0 090 0 048 0 040 0 038 0 094 0 048 0 042 0 040 0 119 0 060 0 052 0 047 Brooke 37 Cutting Tools Limited 38 SIDE AND FACE CUTTERS Staggered Tooth Feed Per Tooth mm Table Shows Sz Values Cutter Cutter Material Group Diameter Width 1 2 3 over to 63 3 10 0 050 0 051 0 051 10 18 0 052 0 054 0 054 80 4 12 0 063 0 063 0 070 12 20 0 064 0 064 0 070 100 5 14 0 069 0 069 0 070 14 25 0 070 0 069 0 070 125 7 16 0 077 0 078 0 080 16 28 0 078 0 078 0
18. MILLING CUTTERS USER GUIDE BROOKE TECHNICAL SERVICES This handbook is intended to help you get maximum performance from BROOKE cutting tools Whilst the information covers most common uses and problems it is not possible to deal with every situation Our trained sales representatives are available to further assist and advise fully backed up by factory technical services FULL SPECIFICATIONS IN BROOKE CATALOGUES Brooke Cutting TOOLS Ltd is a world class manufacturer producing precision cutting tools to international standards and specifications which include British Standard DIN ISO ANSI and JIS Full details of specifications are listed in our catalogues which are available from leading Industrial Distributors or directly from the Brooke factory PRODUCT RANGE STANDARDS amp SPECIALS The BROOKE range consists of nearly 13 000 standard items and we have a cutting tool available for almost every application Sometimes a special tool is needed and our product engineers at the BROOKE factory can design a special purpose tool to do the job These can also be manufactured to customers specifications or to a sample Brooke Cutting Tools Limited CONTENTS SELECTION OF STEELS SURFACE TREATMENTS END MILLS End Mill Nomenclature End Mill Applications Hints for Successful End Mill Usage Tolerances SHANK CUTTERS Shank Cutter Nomenclature Shank Cutter Applications Tolerances ARBOR MOUNTED CUTTERS SIDE
19. TEETH HELIX ANGLE CUTTER DIAMETER Brooke 13 Cutting Tools Limited Types of shank cutters Dovetail Cutter Tolerance js16 on cutting diameter see page 49 for tolerance tables Inverted Dovetail Cutter Tolerance js16 on cutting diameter see page 49 for tolerance tables Corner Rounding Cutter Tolerance H11 on radius and js14 on cutting tip see page 49 for tolerance tables 14 Brooke Cutting Tools Limited T Slot Cutter Tolerance d11 on metric cutting diameter and width Tolerance h12 on fractional cutting diameter and width see page 49 for tolerance tables Woodruff Cutter Tolerance h11 on metric cutting diameter and e8 on width see page 49 for tolerance tables Tolerance on fractional diameter is size 0 381 0 127 and on width is size 0 000 0 025 Brooke 15 Cutting Tools Limited SHANK CUTTER APPLICATIONS Dovetail Cutters These angle cutters have right hand cutting straight teeth and non plunging end teeth They are used wherever dovetails or angles are required and are available in a range of angles and diameters Corner Rounding Cutters 4 m Straight tooth cutters with right hand cutting teeth Intended to produce a true convex up to 90 of arc 16 Brooke Cutting Tools Limited T Slot Cutters Shank type cutters with right hand cutting alternate helical peripheral teeth as well as teeth on either face Intended for opening out existing slo
20. ates and often benefits are obtained from using corner radii and chamfers These materials respond well to the conventional cutting method but rigidity of machine and setup are critical Light finishing cuts are to avoided but where necessary should be taken at a feed rate as high as possible to meet with surface finishing requirements It is crucial thatthese materials be worked and rubbing ofthe cutter against the workpiece should be avoided Selection of speed and feed rates is of great importance Coolant must be used in large volume and be directed atthe cutting area Benefits are often obtained from a higer coolant concentration or from using cutting oils Work Hardening Steels such as some stainless and manganese steels can be successfully machined by using the same techniques as described for stainless steels above 50 Brooke Cutting Tools Limited RESHARPENING AND CARE OF MILLING CUTTERS The productivity of a milling machine depends to a large degree on the efficiency of the milling cutter Best results in both production and cutter life are obtained by sharpening cutters correctly and care fully and by taking proper care in handling and storage A correctly sharpened cutter requires less driving power produces better quality work and gives longer service than an incorrectly or hastily sharpened cutter The following factors should be considered Correct handling and storage to prevent damage Restoration of the cutting
21. convert Multiply by From To hp kw 0 7457 Kw hp 1 3410 Ibs inch kPa 6 8948 Kpa Ibs inch 0 1450 m min ft min 3 2810 ft min m min 0 3048 inch mm 25 4 mm inch 0 03937 inch2 cm2 6 45 cm inch 0 155 inch cm 16 39 cm inch 0 061 kg Ibs 2 2046 Ibs kg 0 4536 gallons litres 4 546 litres gallons 0 22 60 Brooke Cutting Tools Limited 9 0 CUTTING TOOLS Quality and Service to Industries Worldwide ISO 9002 Brooke Cutting Tools Princess Street Sheffield 54700 Tel 44 0 114 261 7200 Fax 44 0 114 261 7370 Email info castlebrooke co uk Website www castlebrooke co uk Brooke Cutting Tools Limited
22. duced with light duty straight teeth these cutters are used mainly for cutting dovetails serrations and angled slots on less difficult materials Brooke 23 Cutting Tools Limited Shell End Mills With helical peripheral teeth these cutters fillthe gap between normal shank cutters and the much larger facing cutters this cuttter is better suited to light medium cuts in a facing or stepping operation with its plain bore Shell End Mill Roughing As the name implies these cutters with their helical teeth and roughing profile are particularly efficient in areas where large volumes of stock must be removed at high speed and where tough materials are to be worked 24 Brooke Cutting Tools Limited SLITTING SAWS Slitting Saw Plain Tolerance js16 on cutting diameter and js10 on width see page 49 for tolerance tables Slitting Saw Side Chip Clearance Tolernace js16 on cutting diameter and js10 on width see page 49 for tolerance tables Brooke 25 Cutting Tools Limited SLITTING SAW APPLICATIONS Slitting Saw Plain Intended for shallow cutting off operations these saws have straight teeth on the periphery and are tapered on width towards the bore to prevent binding They are available in either coarse or fine pitch to suitthe type and section of materials to be cut Slitting Saws Side Chip Clearance Intended for optimum production of deep narrow slots and for sawing operations th
23. ese saws have alternate helical teeth on the periphery combined with side teeth to ensure efficient stock removal clean cutting action and good surface finish 26 Brooke Cutting Tools Limited HINTS FOR SUCCESSFUL SLITTING SAW USAGE d 2 times depth of cut It is recommended that side plates be used with slitting saws Brooke Cutting Tools Limited 27 HINTS FOR SUCCESSFUL ARBOR MOUNTED CUTTER USAGE Some of the many factors governing efficient use of bore cutters are 1 Condition of machine 2 Machine power available 3 Machine capacity 4 Nature of the workpiece Attention should be given to these factors prior to commencement When using arbor mounted cutters the following points should be observed Taper drive of arbor should be in good condition and fit correctly into machine drive Arbor and bushes should be kept in good and clean condition dirty bushes cause run out of cutters Arbors should be oiled and carefully stored when not in use bent arbors are useless and expensive to replace Cutters should run true to prevent overloading of one or two teeth and extensive regrinding later Fit the cutter as closely as possible to the machine column with a support as near to the cutter as the workpiece will allow Running bushes and support bearings should be kept clean and in good running condition particularly with regard to the bush faces Lack of support will cause damage to the cu
24. helps prevent rusting reduces friction and cold welding resulting in increased tool life Steam tempered products can successfully be used at slightly increased machining rates or on more difficult to machine materials Gold Oxide This is a metallic brown coloured surface treatment achieved by a low temperature temper and is normally only used on cobalt products for identification purposes Nitriding Nitriding imparts a hard surface to the tool and is used for prolonging tool life and machining difficult to machine materials Because nitriding makes the edge more brittle care must be exercised in the type of application Nitrided tools are normally also steam tempered Titanium Nitride Coating TiN TiN coating is a very hard gold coloured surface coating a few microns thick which is applied by means of a complex process called Physical Vapour Deposition PVD by advanced modern equipment The coating is non metallic and therefore reduces cold welding In certain applications increased speed and feed rates can be achieved because of a The hardness of the coating b The reduction in cutting force required due to a decrease in friction between the tool and the workpiece Tool performance will deteriorate after re sharpening 6 Brooke Cutting Tools Limited TiCN Titanium Carbonitride The addition of carbon to TiN results in a significant increase in the hardness of TiCN over TiN TiCN also has a much lower coefficie
25. nt offriction which enhances the surface finish of components machined with TiCN coated tools higher productivity can be achieved on a wide range of materials but in particular stainless steel titanium and nickel based alloys TiALN Titanium Aluminium Nitride In addition to a higher hardness than both and TICN the aluminium in the coating imparts a much greater oxidation stability This is as a result of a very thin film of Aluminium Oxide being formed on the surface of the TiALN The film is self repairing leading to additional increased service life These improvements allow the coating to withstand much higher temperatures which in turn allows increased cutting conditions especially useful when machining Cast Iron and tough steels Brooke 7 Cutting Tools Limited END MILLS END MILL NOMENCLATURE OVERALL LENGTH CUTTING LENGTH CUTTING SHANK DIAMETER DIAMETER END HELIX TEETH ANGLE Shank Options Plain Shank Tolerance h7 on metric shank diameter see page 49 for tolerance tables THREAD LENGTH Threaded Shank Tolerance h8 on metric Fractional shank diameter THREAD 20 T P WHITWORTH FORM Flatted Shank Tolerance h6 on metric shank diameter see page 49 for tolerance tables 8 Brooke Cutting Tools Limited Typical End Mill Options Two Flute End Mill Tolerance e8 on cutting diameter see page 49 for tolerance tables Ball Nose End Mill Tolerance e8 on cut
26. on plunging type Designed for general purpose use they have right hand cutting right hand helical teeth and are used in stepping and profiling applications They can also be used on slots where the plus tolerance of the cutting diameter is not critical Roughing End Mills Shank type cutters with right hand cutting right hand helical teeth on the periphery with roughing profile and with heavy duty end teeth These cutters are robust and durable even under heavy cutting conditions on a wide range of materials They are intended for rapid and heavy rates of stock removal where surface finish is of lesser importance Available in coarse and fine pitch knuckle form and flat cresttype Brooke 11 Cutting Tools Limited HINTS FOR SUCCESSFUL END MILL USAGE Itis assumed that the workpiece clamping and machine size and power are adequate for the intended operation Always select the most suitable tool for the job on hand a few minutes spent on selection can save hours of machining Use roughing end mills when removing large amounts of stock two or three flute end mills for deep slotting applications for edge cutting and espically when machining light alloys Use multi flute end mills for edge cutting as well as for light finishing cuts Use threaded shank or flatted shank cutters where heavy stock removal and high tooth loads are involved Plain shank cutters are particularly suitable for quick change CNC applications and for pre setting
27. ons Material hardness Material surface conditions Machining characteristics Cutter Holders Collets Chucks Draw bars Runout Damage 48 Brooke Cutting Tools Limited TOLERANCES Tolerances 277 1 micron 1 1000mm DIAMETER OR WIDTH Brooke 49 Cutting Tools Limited DIFFICULT TO MACHINE MATERIALS There are number of materials which are generally regarded as being difficult to machine In general terms the material being worked is considered to be difficult when it does not respond readily to normal machining techniques Among these difficult materials are aluminium alloys stainless steel and work hardening steels Aluminium Alloys require relatively high speeds and feeds They respond best to cutters with few teeth and correspondingly wide chip Spaces and can be worked very effectively by using two flute end mills which have the advantage of fewer teeth engaged in the cut In many cases coolant may not be needed to cool the cutter although it is of benefit in lubricating and particularly in removing chips Climb milling gives definite advantages and shows significant benefits where a good quality surface finish is needed These materials can be worked quite effectively with regular tooling although benefits would be obtained from custom tools in the event of large volume production being the norm Stainless Steels require lower speeds and higher feed r
28. pecifically to High Speed Steel Brooke 55 Cutting Tools Limited USEFUL FORMULAE Trigonometry Formulae for the solution of Formulae for the solution of RIGHT ANGLED OBLIQUE ANGLED TRIANGLES TRIANGLES A b A C B a Opposite c The Sine rule JE adjacent a a _ b _ _ SinA SinB SinC te Sin O Rypotenus6 The Cosine rule a b c 2bc Cos A Cos B adjacent b a c 2ac CosB os_ hypotenuse b c a b 2ab USEFUL VALUES IN TRIGNOMETRICAL RATIOS For right angled triangles 60 2 4 gt 4 45 gt 30 45 5 1 ANGLES 30 45 60 n Tan Cos I 30 1 1 13 0 577350 0 500000 gt 0 866025 3 2 2 45 1 1 1 2 0 707107 2 0 707107 60 1 3 1 732051 3 0 866025 2 0 500000 56 Brooke Cutting Tools Limited Useful formulae for Finding Dimensions of Circles Squares etc D is diameter of stock necessary to turn shape desired E is distance across flats or diameter of inscribed circle C is depth of cut into stock turned to correct diameter TRIANGLE 2 C E 7 side x 0 57735 D side x 1 1547 2E N Side D x 0 866 Ex0 5 Dx0 25 Mu ou SQUARE Aa lt side D x 0 7071 LN side x 1 4142 diagonal Side Dx0 7071 X D x 0 14645 PENTAGON side x 1 3764 D x 0 809 D side x 0 7013 E x 1 2361 Side D x 0 5878 C D x 0 0955 HEXAGON side x 1 7
29. s heat treated alloy Steels and non free machining grades of stainless steel for better tool life and to reduce work hardening It is not recommended on material having a hard scale such as cast or scaly forged surfaces because abrasion would quickly ruin the cutting edges Also some very soft steels do not lend themselves to climb milling because of their tendency to drag and tear Climb milling cannot be applied to every milling operation and should not be attempted ifthe material and the machine setup are not adapted to this type of milling 46 Brooke Cutting Tools Limited PROBLEM SOLVING Milling problems are often caused by one or more of the following factors which should be carefully checked in a systematic and logi cal manner Speeds and Feeds See page 30 for recommendations Coolants Seek advice from your supplier Cutter Selection Always select the correct type and quality of cutter to suit the appli cation Arbors Straightness runout size wear damage Bushing wear damage Re sharpening Clearance angles See page 51 Runout Burning overheating Surface finish Milling Machines Slides and gib strips Lead screws and nuts Backlash elimination Attachments Defective workheads Worn tailstocks Worn centres Brooke 47 Cutting Tools Limited Workholding Workdolder condition Workholder suitability Workholder alignment Workholder rigidity Workpiece Condition Machine suitability Material specificati
30. site direction to the feed ofthe workpiece This is termed conventional milling In conventional milling the end mill engages the workpiece at the bottom of the cut The end mill teeth slide along until sufficient pres sure builds up to break through the surface of the work This sliding action under pressure tends to abrade the periphery of the end mill with resulting dulling Also in horizontal conventional milling the cut ting action has a tendency to lift the workpiece fixture and table from their bearings In recent years milling machines have been greatly improved through backlash elimination and greater rigidity so that climb milling is now possible Climb milling improves surface finish and increases tool life Conventional Milling Climb Milling Force Brooke 45 Cutting Tools Limited In climb milling the end mill rotates in the direction of the feed The tooth meets the work at the top of the cut at the thickest portion of the chip This provides instant engagement of the end mill with the workpiece producing a chip of definite thickness at the start of the cut without the rubbing action resulting from conventional milling It further permits the gradual disengagement of the teeth and work so that feed marks are largely eliminated Climb milling will often provide better product finish permit greater feed per tooth and prolong the cutter life per sharpening It is par ticularly desirable to climb mill such materials a
31. ting diameter see page 49 for tolerance tables Three Flute End Mill Tolerance e8 on cutting diameter see page 49 for tolerance tables Multi Flute End Mill Tolerance js14 on cutting diameter see page 49 for tolerance tables Roughing End Mill Tolerance js 16 on cutting diameter see page 49 for tolerance tables Brooke Cutting Tools Limited W END MILL APPLICATIONS Two and Three Flute End Mills Two and three flute end mills are shank type cutters with peripheral teeth and end teeth of the plunging type Intended for general purpose use they have right hand cutting right hand helical teeth they are used on keyway and closed slotting operations where the close minus tolerance ofthe cutting diameter allows slot widths to be produced in one pass These cutters are also extensively used when profiling and end milling aluminium alloys due to the greater chip space required by this material Ball Nose Two Flute End Mills Ball nosed two flute end mills are manufactured to the same tolerances as the normal two flute end mill and have a centre cutting ball end They are used extensively in die making for cutting fillets radiused slots pocketing etc These cutters have right hand cutting right hand helical teeth 10 Brooke Cutting Tools Limited Multi Flute End Mills Multi flute end mills are shank type cutters with peripheral teeth and end teeth of the both plunging and n
32. ts to form the T slots used extensively on machine tables They are produced in a range of diameters and widths to allow clearance ona standard range of bolt head sizes Woodruff Cutters t Shank type cutters with right hand cutting alternate helical peripheral teeth Available in a range of diameters and widths Designed to produce slots to suit standard woodruff keys HINTS FOR SHANK CUTTER USAGE See page 12 for hints on end mill usage Brooke 17 Cutting Tools Limited ARBOR MOUNTED CUTTERS SIDE AND FACE CUTTER NOMENCLATURE Side and Face Cutter Staggered Tooth shown SIDE TEETH HELIX ANGLE DIAMETER PERIPHERAL PERIPHERAL E CLEARANCE TEETH SIDE TEETH CONCAVITY Tolerance js16 on metric cutting diameter and k11 on width see page 49 for tolerance tables 18 Brooke Cutting Tools Limited Shell End Mills Plain Form RAKE ANGLE HELIX NU ANGLE mak INTERNAL DIAMETER OVERALL LENGTH DIAMETER See page 24 for application Roughing Form See page 24 for application Brooke 19 Cutting Tools Limited Side and Face Cutter Straight Tooth Tolerance js16 on metric fractional cutting diameter and k11 on metric fractional width see page 49 for tolerance tables Cylindrical Cutter MEM Tolerance js16 on cutting diameter and width see page 49 for tolerance tables 20 Brooke Cutting Tools Limited Single Angle Cutter
33. tter and the workpiece Always use correct lubricants Workpiece clamping should be rigid and able to withstand the forces acting upon it under the action of the cutter Select correct speeds and feeds for the cutter in use and the nature of the workpiece material and the size of the taken 28 Brooke Cutting Tools Limited Use recommended coolants and direct flow to the point of cutting Consult the coolant suppliers for specific recommendations Adequate cooling is essential to prevent overheating of the cutter and failures associated with overheating Always use drive keys between the cutter and the arbor friction between the cutter and the arbor bushes is seldom sufficient when cutters are under correct load Never force a cutter onto a arbor or over an ill fitted key Protect your hands by wrapping the cutter in a soft material when fitting or removing itfrom the arbor Due to the brittle nature of hardened tool steels it is not advisable to remove a cutter with a mallet once it has been tightened onto the arbor Maintain cutters in sharp condition Regrind as soon as wear becomes apparent Store cutters carefully when not in use using a light film of oil to prevent rusting Cleanliness of cutters and arbors is essential Use helically fluted cutters wherever possible to minimise shock as teeth contact the workpiece Brooke 29 Cutting Tools Limited TECHNICAL INFORMATION

Milling Cutter User Guide

Contents

Download Pdf Manuals

Related Search

Related Contents