A New Star is Born - Dura-Mill Irons SAE: J431: Grade G1800 K2 Low-, Medium-Strength CGI -- -...
5
A New Star is Born ® Achieve up to double your tool life! with ™ ®
Transcript of A New Star is Born - Dura-Mill Irons SAE: J431: Grade G1800 K2 Low-, Medium-Strength CGI -- -...
A New Star is Born
®
Achieve up to double your tool life!
with™
®
Dura-Mill's WhisperKut Plus end mills include all of the features of our original patented end mill design plus the addition of a controlled surfacetreatment process, "DURA-SHIELD". This unique process improves PVDcoating adhesion and strengthens the cutting edges thereby avoiding premature chipping and cutter failure.
• Up to 100% tool life improvement
• Enhanced version of our proven patented variable helix design (US Patent No. 6,899,494)
• Stronger and smoother cutting edges
• Leaves work piece surface exceptionally smooth
• Improved mechanical strength & reduced friction during machining
• Improved surface foundation for PVD coating forbetter adhesion
• More stable cutting edges
• New nanocomposite coating specifically designedfor the most extreme applications
"DURA-SHIELD" Benefits:
The best, just got better!
"I have been using WhisperKut end mills for over two years and I thought that Dura-Mill could not improve on their design. I was wrong. WhisperKut Plus has doubled my tool life while improving my part finish."
BEFORE
AFTER
BEFORE
AFTER
Dedicated to providing innovative cutting toolsolutions serving the following industries:
aerospace
power generation
medical
mold & die
machine tool
defense
www. d u r am i l l . c om
defense
machine tool
mold & die
medical
power generation
aerospace
®
5 Flute WhisperKutPlus End Mills Tools with Radius Corners
d1 d2
l2
Tools with Square Corners
ZrNM
N
92399 N
92389 N
N
N
l1
Dia. of Shank Length Overall Radius EDP No. EDP No. ListMill Dia. of Cut Length Size with with Price d1 d2 l2 l1 Welded Shank Plain Shank
3/16 3/16 5/8 2-1/2 .015 - 30002 -
1/4 1/4 3/4 2-1/2 .015 - 30004 -
5/16 5/16 3/4 2-1/2 .015 - 30008 -
3/8 3/8 7/8 2-1/2 .015 - 30012 -
1/2 1/2 1 3 .030 30051 30020 -
1/2 1/2 1-1/4 3 .030 30052 30021 -
5/8 5/8 1-1/4 3-1/2 .030 30057 30026 -
3/4 3/4 1-1/2 4 .030 30062 30031 -
1 1 2-1/2 5 .030 30069 30038 -
Dia. of Shank Length Overall Radius EDP No. EDP No. ListMill Dia. of Cut Length Size with with Price d1 d2 l2 l1 Welded Shank Plain Shank
3/16 3/16 5/8 2-1/2 - - 30001 -
1/4 1/4 3/4 2-1/2 - - 30003 -
5/16 5/16 3/4 2-1/2 - - 30007 -
3/8 3/8 7/8 2-1/2 - - 30011 -
1/2 1/2 1 3 - 30049 30018 -
1/2 1/2 1-1/4 3 - 30050 30019 -
5/8 5/8 1-1/4 3-1/2 - 30056 30025 -
3/4 3/4 1-1/2 4 - 30061 30030 -
1 1 2-1/2 5 - 30068 30037 -
with Material Description Content Tensile Hardness Hardness AISIGroup Strength (HB) (HRC) Standards
RM (Mpa)
P1 Low-Carbon Steels, Long Chipping C<.25% <530 <125 - 1008, 1010, 1108, 1020, 1213
P2 Low-Carbon Steels, C<.25% <650 - - 1045, 1050, 1545, 1572Free Machining, Short Chipping
P3 Medium, High Plain Carbon C>.25% 600-850 - - 1300, 2000, 3000 SAE: A, D, H,Steels, Low-Alloyed W1, W2, L2
P4 Alloyed, Tempered Carbon C>.25% 800-1100 350-450 - 1300, 2000, 3000 SAE: A, D, H,Steels, Tool W1, W2, L2
P5 Ferritic, Martensitic C=0-.4% 600-850 - - 410, 416, 15-5 PH, 13-8 PH, PH Stainless Steels 17-4 PH
P6 High-Strength Ferritic, C=.1-.6% 900-1350 - - 410, 416, 15-5 PH, 13-8 PH, Martensitic, PH Stainless Steels 17-4 PH
M1 Austenitic Stainless Steel - - - - 200, 201, 301, 302 304, 304L
M2 High-Strength Austenitic 310, 314, 316, 316L, Stainless, Cast Stainless Steels - - - - ASTM: XM-1, XM-5
M3 Duplex Steel - - - - 323, 329, F55, 2205
K1 Gray Cast, Low-Strength - - - - Class 20, 25, 30, 35Ductile Irons SAE: J431: Grade G1800
K2 Low-, Medium-Strength CGI - - - - 60-14-18, 65-45-12Ductile Irons M3210, M4504
K3 High-Strength Ductile, - - - - 32510, 40010, 50005, Austempered Ductile Iron 70003, 90001
S1 Iron-Based, Heat Resistant Alloys - - - - A-286, Incoloy 801, A608, A567
S2 Nickel or Cobalt-Based, - - - - Haynes 188, Haynes 21, Heat-Resistant Alloys Hastelloy, Inconel 901
S3 Titanium - - - - Pure Ti
S4 Titanium Alloys - - - - 6AI-4V, Ti 6AI-2SN4ZR-2Mo
H1 Hardened Steels, Irons - - - - Tool Steel H10, H11, D2, D3, 4340, P20
H2 Hardened Steels, Irons - - - - Tool Steel H10, H11, D2, D3, 4340, P20
H3 Hardened Steels, Irons - - - - Tool Steel H10, H11, D2, D3, 4340, P20
H4 Hardened Steels, Irons - - - - Tool Steel H10, H11, D2, D3, 4340, P20
MATERIAL LISTINGS • AISI
Material Group
P1, P2 General Purpose
P3 Low Alloyed Carbon Steels
P4 Tempered Carbon Steels, Tool Steel
P5, P6 Ferritic Martensitic, PH Stainless Steeel
M1, M2, M3 Austenitic Stainless Steel
K1, K2, K3 Cast Materials
S1, S2, S3 Heat-Resistant Alloys Nickel Based
H1, H2, H3, H4 Hardened Steel
RECOMMENDED MATERIAL USE
www. d u r am i l l . c om
™
rd1 .0000” -.002”d2 -.0001” -.0004”r +.000” -.002”
TOLERANCES
ZrNM of Cut Length C
N
N N N
N
92399 N
N
N 92389 N
Shallow0.25 - 0.5 XD
Max.
Recommended Milling Applications
Material Group ap ae ap Slot Profile .188 .250 .313 .375 .500 .625 .750 1.000
P1 1.25 x D 0.5 x D 0.25 - 0.5 x D 440 600 0.0014 0.0018 0.0023 0.0027 0.0035 0.0039 0.0043 0.0050
P2 1.25 x D 0.5 x D 0.25 - 0.5 x D 440 600 0.0014 0.0018 0.0023 0.0027 0.0035 0.0039 0.0043 0.0050
P3 1.25 x D 0.5 x D 0.25 - 0.5 x D 350 470 0.0011 0.0015 0.0020 0.0023 0.0029 0.0034 0.0038 0.0046
P4 1.25 x D 0.5 x D 0.25 x D MAX 270 440 0.001 0.0014 0.0018 0.0020 0.0026 0.0030 0.0033 0.0039
P5 1.25 x D 0.5 x D 0.25 - 0.5 x D 180 300 0.0009 0.0012 0.0016 0.0018 0.0023 0.0027 0.0030 0.0036
P6 1.25 x D 0.5 x D 0.25 x D MAX 150 225 0.0008 0.0010 0.0013 0.0015 0.0019 0.0022 0.0024 0.0028
M1 1.25 x D 0.5 x D 0.25 - 0.5 x D 235 300 0.0011 0.0015 0.0020 0.0023 0.0029 0.0034 0.0038 0.0046
M2 1.25 x D 0.5 x D 0.25 - 0.5 x D 180 235 0.0009 0.0012 0.0016 0.0018 0.0023 0.0027 0.0030 0.0036
M3 1.25 x D 0.5 x D 0.25 - 0.5 x D 180 235 0.0008 0.0010 0.0013 0.0015 0.0019 0.0022 0.0024 0.0028
K1 1.25 x D 0.5 x D 0.25 - 0.5 x D 350 470 0.0014 0.0018 0.0023 0.0027 0.0035 0.0039 0.0043 0.0050
K2 1.25 x D 0.5 x D 0.25 - 0.5 x D 325 415 0.0011 0.0015 0.0020 0.0023 0.0029 0.0034 0.0038 0.0046
K3 1.25 x D 0.5 x D 0.25 - 0.5 x D 300 390 0.0009 0.0012 0.0016 0.0018 0.0023 0.0027 0.0030 0.0036
S1 1.0 x D 0.3 x D 0.25 x D MAX 150 270 0.0011 0.0015 0.0020 0.0023 0.0029 0.0034 0.0038 0.0046
S2 1.25 x D 0.5 x D 0.25 - 0.5 x D 150 235 0.0009 0.0012 0.0016 0.0018 0.0023 0.0027 0.0030 0.0036
S3 1.0 x D 0.3 x D 0.25 x D MAX 65 120 0.0006 0.0008 0.0010 0.0012 0.0016 0.0018 0.0020 0.0025
S4 1.25 x D 0.5 x D 0.25 - 0.5 x D 135 190 0.0008 0.0011 0.0014 0.0017 0.0022 0.0025 0.0028 0.0033
H1 1.25 x D 0.5 x D 0.25 x D MAX 235 415 0.0010 0.0014 0.0018 0.0020 0.0026 0.0030 0.0033 0.0039
SFM SFM 3/16” 1/4” 5/16” 3/8” 1/2” 5/8” 3/4” 1”
SPEED & FEED RECOMMENDATIONS
Cutting Speed vc Recommended Feed Per Tooth is for side milling.For Slotting, reduce IPT by 10%
To Determine Formula:
Spindle Speed (RPM) RPM = SFM x 3.82 ÷ Tool Dir
Feed Rate (IPM) IPM = IPT x No. Teeth x PPM
SLOTTINGSIDE MILLING
ap ap
ae
Material Group
P1, P2 General Purpose
P3 Low Alloyed Carbon Steels
P4 Tempered Carbon Steels, Tool Steel
P5, P6 Ferritic Martensitic, PH Stainless Steeel
M1, M2, M3 Austenitic Stainless Steel
K1, K2, K3 Cast Materials
S1, S2, S3 Heat-Resistant Alloys Nickel Based
H1, H2, H3, H4 Hardened Steel
®
Dura-Mill, Inc.16 Stonebreak Road • Malta New York 12020
(800) 444-6455 or (518) 899-2255 • Fax: (518) 899-7869 www.duramill.com
®
