Walter Placute

Product handbook
Milling
_ SILVER, BLACK, STRONG
The new force

in machining.
THE MACHINING AGE IS OVER.
IT’S TIME TO TIGER.
Cutting tool materials with the Tiger·tec® technology

brand are setting the standard in machining again and
again, in terms of productivity and process stability.
With the new cutting tool material Tiger·tec®Silver, the
engineers at Walter have moved another great step
closer to the ideal cutting tool material. Tiger·tec®Silver
is ideal for dry and wet machining of steel and cast iron
materials, and is at home in important key sectors: the
automotive industry and rail vehicle manufacturing,
power engineering, the aerospace industry, mechanical
engineering and in mould and die making.
CONTENTS
Milling
2 Tiger·tec®Silver
2 The new technology

6 Applications and examples
12 Application chart
14 Extract from the milling cutter range
16 Walter Select milling cutters
34 Technical information
34 Cutting data for milling

38 Feed rate specification
54 Application-specific data
68 Description of indexable insert geometry
76 Calculation Formulae
78 Problem solving
Tiger·tec®Silver
The new technology
New Tiger,
new benchmark:
100 %
Up
to
increase
in output
Extremely
stable cutting
edges for
high level Extremely
of process smooth rake
reliability face for Silver coloured
excellent flank face for
tribochemical extremely
wear resistance easy wear
detection
during use
2
unique throughout the world
With its globally unique CVD coating Other features of Tiger·tec®Silver:
technology, the cutting tool material –– Enormous toughness and minimal
Tiger·tec®Silver is forging ahead into formation of hairline cracks thanks
new dimensions. In day-to-day manu- to optimum residual strength
facturing, this means that increases in –– Greatly reduced tribochemical
output of up to 100 % are possible in wear thanks to perfect, smooth
machining. rake faces
–– Not susceptible to thermal stress
variations during wet and dry
machining
Completely new CVD coating

technology:
–– Combines wear resistance and
toughness
–– for steel and cast iron workpieces
Optimum friction
behaviour
-Al2O3 Resistant to
tribochemical wear
MT-Ti(C, N) Greater resistance to

flank face wear
Substrate
Excellent hardness to
toughness ratio
Tiger·tec®Silver 3
Tiger·tec®Silver
The new technology
High level of wear resistance
A close-up view of the cutting edges indexable inserts. In the example shown,
shows it clearly: the new cutting tool heat treatable steel 42CrMo4 was
material Tiger·tec®Silver can easily milled twice, with the existing insert and
handle even the most difficult machin- with the new Tiger·tec®Silver. With the
ing conditions thanks to its new, Tiger·tec®Silver indexable insert, the
revolutionary coating. Hairline cracks, high level of wear resistance, the tough-
such as those that occur at high cutting ness and resistance to temperature
speeds, with interrupted cuts and diffi- reduce negative hairline crack forma-
cult cutting conditions in particular, are tions and chipping, and therefore costly
decisively reduced with Tiger·tec®Silver reductions in service life.
existing
4
Outstanding properties
PRODUCT PROPERTIES: Benefits for you:
Performance increase of up Low production costs

to 100 % –– higher cutting speeds thanks to
–– thanks to excellent wear behaviour heat-resistant coating
combined with extreme toughness
High level of process reliability
Excellent cutting and swarf –– high level of toughness thanks to
evacuation behaviour Tiger·tec®Silver technology
–– thanks to extremely smooth rake –– improved chip flow thanks to
faces extremely smooth rake faces
Resistant to deformation and Low cutting material costs

oxidation wear –– excellent wear detection thanks
–– thanks to the new type of aluminium to indicator coating
oxide coating –– unused cutting edges not wasted
High level of resistance to flank

face wear
–– thanks to fine-grained, columnar,
average temperature titanium
carbonitride
New dimension in the toughness

to wear resistance ratio
–– thanks to the new type of coating
technology
Tiger·tec®Silver
Applications and examples
THE APPLICATION
With the new Tiger·tec®Silver technolo- tool material increases exponentially.

gy, there is also completely new surface It is this combination of a high level of
treatment in addition to the special wear resistance and toughness that
coating combination. Due to the optimal gives Tiger·tec®Silver superior machining
residual stresses, the toughness of the performance.
wear-resistant Tiger·tec®Silver cutting
Temperature resistance
Tiger·tec®Silver
CVD
-Al2O3 Tiger·tec®
PVD-Al2O3
PVD
Toughness
WALTER GRADE DESIGNATION
W K P 35 S
Tiger·tec®Silver
Application range
Primary application ISO P
Walter Primary application ISO K
6
Material: steel (ISO P)
WKP 25
WKP 35 S
Tiger·tec®Silver
WSP 45
Toughness
Material: CAST IRON (ISO K)
WAK 15 WKK 25
WKP 25
WKP 35 S
Tiger·tec®Silver
Toughness
WKP 35 S
Primary application: all steel materi- Primary application: spheroidal graphite

als at medium to high cutting speeds cast iron or ADI materials at low to
and medium to high feeds per tooth. medium cutting speeds and medium
For unfavourable conditions, e.g. wet to high feeds per tooth. For unfavour-
machining, fluctuating material removal able conditions, e.g. wet machining,
or long projection length. fluctuating material removal or aggressive
interrupted cuts.
Tiger·tec®Silver
Example 1: machine frame (shoulder milling)
Workpiece material: St37 (1.0037), ISO P

(BS879M39,
EN40 Structural Steel)
Tool: F4042 / Z6 / dia. 63
Indexable insert: ADMT160608R-F56
Cutting tool material: WKP35S
Cutting data:
Competitor Tiger·tec®Silver
vc [m/min] 400 400
fz [mm] 0.2 0.2
vf [mm/min] 2425 2425
ap [mm] 1.5 – 3 1.5 – 3
ae [mm] 60 60
with coolant with coolant
Tool life quantity 1 inner surface 2 inner surfaces
Benefits for you:

–– high level of process stability despite
unstable weld design; holes and weld
seams are also milled in some areas
–– lower tool costs
Comparison in tool life of inner surfaces [pieces]
+ 100 %
Competition
Tiger·tec®Silver
0 0.5 1 1.5 2 2.5
8
Example 2: guide tracks (face milling)
Workpiece material: St52-2 (1.0570), ISO P

(Unalloyed Structural Steel)
Tool: F4080 / Z8 / dia. 125
Indexable insert: ODHT0605ZZN-F57
Cutting data:
existing Tiger·tec®Silver
vc [m/min] 236 283
fz [mm] 0.33 0.33
vf [mm/min] 1584 2000
ap [mm] 4 4
ae [mm] 100 100
Tool life [m] 18 36
Benefits for you:

–– reduced tool costs thanks to doubled
service life
–– machine capacity increased thanks to
26 % higher feed rate
Feed rate comparison [mm/min]
+ 26 %
existing
Tiger·tec®Silver
0 600 1200 1800 2400
Tiger·tec®Silver
Example 3: form insert (pocket milling)
Workpiece material: 40CrMnMo7 (1.2311),

ISO P (Mould Steel)
Tensile strength: 1200 N/mm2
Tool: F4042 / Z6 / dia. 63
Indexable insert: ADMT160608R-F56
Cutting data:
existing Tiger·tec®Silver
vc [m/min] 105 105
fz [mm] 0.3 0.3
vf [mm/min] 955 955
ap [mm] 3 3
ae [mm] 35 – 63 35 – 63
Tool life [m] 105 143
Benefits for you:

–– a complete component can be
reliably machined
–– lower tool costs
Tool life comparison [m]
+ 36 %
existing
Tiger·tec®Silver
0 50 100 150
10
Example 4: brake caliper (circular face milling)
Workpiece material: GGG50 (0.7050),

ISO K (Nodular Iron)
Tool: F4042R / Z7 / dia. 50
Indexable insert: ADMT10T308R-F56
Cutting data:
Competitor Tiger·tec®Silver
vc [m/min] 160 160
fz [mm] 0.215 0.215
vf [mm/min] 1533 1533
ap [mm] 1.5 1.5
ae [mm] 25 25
without coolant without coolant
Tool life quantity [pieces] 800 1400
Benefits for you:

–– reduction in CPP (cost per part)
–– low tool costs thanks to longer tool life
–– high level of process reliability
Tool life quantity comparison [pieces]
+ 75 %
Competition
Tiger·tec®Silver
0 400 800 1200 1600
Tiger·tec®Silver
Application chart
Workpiece material group

P M K N S H
difficult cutting
Stainless steel
Hard materials
Materials with
Non-ferrous
properties
Cast iron
metals
Walter grade Standard
Steel
designation designation
HC – P 35 CC
WKP 35 S
HC – K 35 CC
HC – P 25 CC
WKP 25
HC – K 25 CC
WAK 15 HC – K 15 CC
HC – S 45 CC
WSP 45 HC – P 45 CC
HC – M 45 C C
WKK 25 HC – K 25 CC
HC = coated carbide C C Primary application
12
Indexable insert example
Application range
01 10 20 30 40
Coating composition
05 15 25 35 45
Coating process
TiCN + Al2O3
CVD
(+TiCN)
TiCN + Al2O3
CVD
(+TiN)
TiCN + Al2O3
CVD
(+TiN)
TiAlN + Al2O3
PVD
(ZrCN)
TiAlN + Al2O3
PVD
(ZrCN)
Extract from the milling cutter range
Trimming:
F 4238
Slot milling:
F 4042R
Pocket
milling:
F 4042
Circular inter-
polation milling:
F 4081
Shoulder milling:
F 4042
Plunging:
F 4030
Slot milling:
F 4253
14
Face milling:
F 4033
Copy milling:
F 4030
Shoulder milling:
F 4041
Face milling:
F 4045
Walter Select milling cutters
Face milling
Machining
Lead angle κ 45°
Face mill F 4033
Xtra·tec®
Dia. range [mm] 40 – 200
Ordering information* E. page 194
P Steel CC
K Cast iron CC
Basic shape of
indexable insert
SN . X 1205 . .
Indexable insert types
SN . X 1606 . .
Max. cut depths [mm] 6.5 + 9
Number of cutting edges

8
per indexable insert
* G. = Complete catalogue 2007

E. = Catalogue supplement 2009
F. = Innovation flyer 2010
16
75° 88° 45°
F 4047 F 4048 F 4045
Xtra·tec® Xtra·tec® Xtra·tec®

40 – 200 40 – 200 63 – 200
E. page 198 E. page 200 F. Page 153
CC CC
CC CC CC
XNHF 0705 . .
SN . X 1205 . . SN . X 1205 . .
XNHF 0906 . .
8 10 4+6
8 8 14
CC
plication
Primary ap
C
Additional
application
Face milling
Machining
Lead angle κ 43°
Face mill F 4080
Xtra·tec®
Ordering information* F. Page 155, G. page 510
P Steel CC
K Cast iron CC
Basic shape of
indexable insert
OD . . 0504 . .
OD . . 0605 . .
Max. cut depths [mm] 3 / 8 + 4 / 10

8

18
0–15° 0–21°
F 2330 F 4030
Xtra·tec®
20 – 85 25 – 63
E. page 192 F. Page 152
CC CC
CC CC
P 2633 .
P 23696 – 1.0
P 26379
1 + 1.5 + 2 1
3 6
CC
plication
Primary ap
C
Additional
application
Face milling
Machining
Roughing ▲
Finish milling ▲
Shoulder milling
Shoulder milling (finishing)
Plunging
Circular interpolation milling
Pocket milling
Lead angle κ 45° / 75° / 88°
Face mill F 2010

Ordering information* E. page 186, F. Page 159
P Steel CC
K Cast iron CC
Basic shape of
indexable insert
SN . X 1205 . .
SN . X 1606 . .
Max. cut depths [mm] 6.5 + 8 + 9 + 10
8

20
▲ ▲ ▲
▲
▲ ▲
▲ ▲
▲ ▲ ▲
▲ ▲ ▲
▲ ▲ ▲
90° 90° 0 – 15° 43° / 45° –
F 2010
80 – 315 80 – 315 70 – 305 80 – 315 74 – 309

G. page 472 G. page 468 G. page 452 G. page 454 G. page 474
CC CC CC CC CC
CC CC CC CC CC
AD . . 1204 . . P 2633 . – R25

LNGX 1307 . . OD . . 0605 . . RO . X 1605 . .
AD . . 1606 . . P 26379 – R25
13 11.7 + 15 2 4 / 10 8
4 2 3 8 6
CC
plication
Primary ap
C
Additional
application
Shoulder milling
Machining
Lead angle κ 90°
Shoulder milling cutter F 4041
Xtra·tec®
Ordering information* G. page 520
P Steel CC
K Cast iron CC
Basic shape of
indexable insert
Indexable insert types LNGX 1307 . .
Max. cut depths [mm] 13

4

22
90° 90°
F 4042R F 4042
Xtra·tec® Xtra·tec®
16 – 63 10 – 160
E. page 204, F. Page 158 E. page 202
CC CC
CC CC
AD . T 0803 . . AD . T 1204 . .
AD . T 10T3 . .
AD . T 1606 . . AD . T 1807 . .
10 8 + 11.7 + 15 + 16
2 2
CC
plication
Primary ap
C
Additional
application
Shoulder milling
Machining
Lead angle κ 90° 90°
Shoulder milling cutter F 4038 F 4138
Dia. range [mm] 20 – 32 32 – 80
G. page 556,
Ordering information* E. page 216
F. Page 156
P Steel CC CC
K Cast iron CC CC
Basic shape of
indexable insert
Indexable insert types AD . T 0803 . . AD . T 1204 . .
Max. cut depths [mm] 37 76

per indexable insert 2 2

24
90° 90°
F 4238 F 4338
40 – 80 63 – 125
G. page 558, F. Page 156 F. Page 156
CC CC
CC CC
AD . T 1606 . . AD . T 1807 . .
112 124
2 2
CC
plication
Primary ap
C
Additional
application
Slot milling
Machining
Lead angle κ 90°
Slot mill F 4053
Xtra·tec®
Ordering information* E. page 218, F. Page 157
P Steel CC
K Cast iron CC
Basic shape of
indexable insert
Indexable insert types LN.X 070204 . .
Max. cutting width

4
across teeth [mm]
2+2

26
90° 90°
F 4153 F 4253
80 – 200 100 – 315
E. page 220, F. Page 157 E. page 222, F. Page 157
CC CC
CC CC
LN . . 0803 . . LN . . 0804 . . LN . . 0804 . . LN . . 1005 . .

LN . . 1005 . . LN . . 1206 . . LN . . 1608 . .
6 + 8 + 10 12 + 14 + 16 + 20 + 25
2+2 2+2
CC
plication
Primary ap
C
Additional
application
Copy milling
Machining
Copy mill F 2334
P Steel CC
K Cast iron CC
Basic shape of
indexable insert
Indexable insert types RO . X . .
Max. cut depths [mm] 4 – 10

4–8

28
Machining
Lead angle κ 45° / 90°
Circular interpolation mill F 4081
Xtra·tec®
Ordering information* F. Page 155
P Steel CC
K Cast iron CC
Basic shape of
indexable insert
OD . . 0504 . .
OD . . 0605 . .
Max. cut depths [mm] 3+4

2–4
CC
plication
Primary ap
C
Additional
application
Machining
Lead angle κ 43°
Xtra·tec®
Ordering information* F. Page 155, G. page 510
P Steel CC
K Cast iron CC
Basic shape of
indexable insert
OD . . 0504 . .
OD . . 0605 . .
Max. cut depths [mm] 3 / 8 + 4 / 10

2–4

30
0–15° 0–21°
F 2330 F 4030
Xtra·tec®
20 – 85 25 – 63
E. page 192 F. Page 152
CC CC
CC CC
P 2633 .
P 23696 – 1.0
P 26379
1 + 1.5 + 2 1
3 6
CC
plication
Primary ap
C
Additional
application
Machining
Lead angle κ
P Steel CC
K Cast iron CC
Basic shape of
indexable insert
Indexable insert types RO . X . .
Max. cut depths [mm] 4 – 10

2–4

32
90° 90°
F 4042R F 4042
16 – 63 10 – 160
E. page 204, F. Page 158 E. page 202
CC CC
CC CC
AD . T 0803 . . AD . T 1204 . .
AD . T 10T3 . .
AD . T 1606 . . AD . T 1807 . .
10 8 + 11.7 + 15 + 16
2 2
CC
plication
Primary ap
C
Additional
application
Technical Information
Cutting data for milling
Brinell hardness HB
Material group
Workpiece material
approx. 0.15 % C annealed 125

Unalloyed steel 1 approx. 0.45 % C heat treated 250
approx. 0.75 % C heat treated 300
annealed 180
P heat treated 275

Low-alloy steel 1
heat treated 300
heat treated 350
High-alloyed steel and annealed 200

high-alloyed tool steel 1 hardened and tempered 325
ferritic / martensitic, annealed 200
Stainless steel 1
martensitic, heat treated 240
pearlitic/ferritic 180
Grey cast iron
pearlitic (martensitic) 260
Grey cast iron with ferritic 160

K spheroidal graphite pearlitic 250
ferritic 130
Malleable cast iron
pearlitic 230
34
Roughing with surface/ Roughing with Roughing with
shoulder milling cutters porcupine cutters side and face mills
Machining group 2
WKP 35 S WKP 35 S WKP 35 S
ae / DC3 ae / DC3 ae / DC
1/1 1/1
1/5 1/5 central 1/5 1/10
1/2 1/2
1 250 300 195 250 195 250 275
2 220 260 170 215 170 215 230
3 195 220 150 185 150 185 285
4 180 200 140 170 140 170 170
5 160 180 130 145 130 145 150
6 220 270 170 215 170 215 235
7 180 210 135 155 130 165 165
8 170 190 130 145 125 145 150
9 130 150 90 105 90 100 105
10 130 160 100 120 100 120 130
11 80 90 60 70 60 75 75
12 140 160 105 120 105 130 130
13 100 120 70 95 70 95 105
15 300 330 160 180 160 180 190
16 170 200 120 140 120 140 150
17 200 220 140 150 140 150 160
18 140 160 110 120 110 120 130
19 210 240 150 170 150 170 180
20 150 180 130 140 130 140 150
1
and cast steel
2
The arrangement of the machining group can be found in the complete catalogue 2007,
from page 791
3
ae / DC = 1/10, vC = 10 % higher than 1/5
Cutting data for milling
Brinell hardness HB
Material group
Workpiece material

Unalloyed steel 1 approx. 0.45 % C heat treated 250
approx. 0.75 % C heat treated 300
annealed 180
P heat treated 275

Low-alloy steel 1
heat treated 300
heat treated 350
High-alloyed steel and annealed 200

high-alloyed tool steel 1 hardened and tempered 325
ferritic / martensitic, annealed 200
Stainless steel 1
martensitic, heat treated 240
pearlitic/ferritic 180
Grey cast iron
pearlitic (martensitic) 260
Grey cast iron with ferritic 160

K spheroidal graphite pearlitic 250
ferritic 130
Malleable cast iron
pearlitic 230
36
Roughing with copy milling cutters Circular interpolation milling
Machining group 2
WKP 35 S WKP 35 S
ae / DC ae / DC3
1/1 1/5 1/10 1/1 1/5
1 240 300 300 220 270

2 200 255 275 200 230
3 185 240 240 180 200
4 155 195 210 160 180
5 145 180 185 140 160
6 165 210 230 200 240
7 155 195 215 160 190
8 145 180 200 150 170
9 120 155 170 110 130
10 110 145 160 120 140
11 75 100 100 80 90
12 120 155 170 120 140
13 110 145 155 90 100
15 240 280 300 270 297
16 190 230 250 153 180
17 240 280 300 180 198
18 190 230 250 126 144
19 250 290 310 189 216
20 200 240 260 135 162
1
and cast steel
2
The arrangement of the machining group can be found in the complete catalogue 2007,
from page 791
3
ae / DC = 1/10, vC = 10 % higher than 1/5
Determining the feed
Cutter types F 2010 / F 2330

Face milling
Feed per tooth fzo

for
ae = Dc Dc ap max
ap = ap max = Lc
Lead angle κ 0 – 15°

fzo = [mm]
Tool dia. or dia. range [mm] 20 – 25 32 – 85 52 – 315
max. depths of cut ap max = Lc [mm] ap max = 1 ap max = 1.5 ap max = 2
Unalloyed steel* 1.2 1.6 2.0
Low-alloyed steel* 1.0 1.4 1.8
P
High-alloyed steel and tool steel* 0.7 1.0 1.2
Stainless steel*, martensitic 0.5 0.6 0.8
Grey cast iron 1.2 1.6 2.0
K Cast iron with spheroidal graphite 1.0 1.4 1.8
Malleable cast iron 1.0 1.4 1.8
P 2633 . – P 2633 . – P 2633 . –

Indexable insert types R 10 R 14 R 25
ae / Dc = 1/1–1/2 1.0 1.0 1.0

Correction factor Kae
1/5 1.4 1.4 1.3
for the feed per tooth
1/10 1.8 1.8 1.8
dependent on the ratio
cut width ae to 1/20
cutter diameter Dc
1/50
ap = 0.5 1.3 1.4 1.5
Correction factor Kap
1.0 1.0 1.2 1.4
for the feed per tooth dependent 1.5 1.0 1.2
on the depth of cut ap
2.0 1.0
Correction 1<(L : D c)≤2 1.4 1.4 1.4

factor K Dc
2<(L : D c)≤4 1.0 1.0 1.0
L
4<(L : D c)≤6 0.7 0.7 0.7
fz = fzo · Kae · Kap · K
* and cast steel
38
Face mill: F 2010, F 2330, F4030
F 2330 F 4030 F 4030

Plunging Face milling Plunging
0 – 15° 0 – 21° 0 – 21°
fzo = [mm] fzo = [mm] fzo = [mm]
20 – 25 32 – 85 52–315 25 – 63 25 – 63
ae max = 7 ae max = 10 ae max = 15 apmax = 1 aemax = 10
0.18 0.25 0.30 1.2 0.18
0.16 0.22 0.25 1.0 0.16
0.12 0.16 0.22 0.7 0.12
0.10 0.12 0.15 0.5 0.10
0.18 0.25 0.30 1.2 0.18
0.16 0.22 0.28 1.0 0.16
0.16 0.22 0.28 1.0 0.16
P 2633 . – P 2633 . – P 2633 . – P 23696 – P 23696 –
P 26379 – P 26379 – P 26379 –
R 10 R 14 R 25 R 14 R 14
1.0
1.4
1.8
1.3
1.0
1.0 1.0 1.0 1.0

0.7 0.7 0.7 0.7
0.5 0.5 0.5 0.5
Cutter types
F 2010 / F 4080
Feed per tooth fzo

for
ae = Dc
ap = ap max = Lc Dc ap max
Xtra·tec®
Lead angle κ 43°

fzo = [mm]
Tool dia. or dia. range [mm] 32–125 50–315
max. depths of cut ap max = Lc [mm] 3 /8 4 / 10
Unalloyed steel* 0.45 0.50
Low-alloyed steel* 0.40 0.45
P
High-alloyed steel and tool steel* 0.30 0.35
Stainless steel,* martensitic 0.20 0.25
Grey cast iron 0.45 0.50
K Cast iron with spheroidal graphite 0.35 0.40
Malleable cast iron 0.35 0.40
OD . . OD . .
0504 . . 0605
ae / Dc = 1/1–1/2 1.0 1.0

1/5 1.1 1.1
1/10 1.2 1.2
cut width ae to 1/20 1.3 1.3
cutting diameter Dc
1/50
ap = 1 1.0 1.0
2 1.0 1.0
Correction factor Kap 3 1.0 1.0
for the feed per tooth 4 0.6 1.0

dependent on the 6 0.6 0.6
depth of cut ap
8 0.6 0.6
ap max = Lc 0.6 0.6
* and cast steel
40
Face mill: F 2010, F 4080, F 4081, F 4033, F 4045
F 4081 F 2010 / F 4033 F 4045
45° 45° 45°

36–85 52–85 40–315 50–315 63–200 80–200

3 /8 4 / 10 6 9 4 6
0.40 0.45 0.25 0.40

0.36 0.40 0.20 0.35
0.27 0.32 0.20 0.30
0.18 0.22 0.15 0.20
0.40 0.45 0.30 0.50 0.30 0.50
0.32 0.36 0.25 0.40 0.25 0.40
0.32 0.36 0.25 0.30 0.25 0.30
OD . . 0504 . . OD . . 0605. . SN . X 120512

with with SN . X 120520 SN . X 1606 XNHF 0705 XNHF 0906
corner radius corner radius SN . X 1205 ANN
1.0 1.0 1.0 1.0 1.0 1.0
1.1 1.1 1.1 1.1 1.1 1.1
1.2 1.2 1.2 1.2 1.2 1.2
1.3 1.3 1.3 1.3 1.3 1.3
1.0 1.0
1.0 1.0
1.0 1.0
1.0 1.0
0.6 1.0
0.6 0.6
0.6 0.6
Cutter types
F 2010 / F 4047 F 2010 / F 4048
Feed per tooth fzo

for
ae = Dc
ap = ap max = Lc Dc ap max
Lead angle κ 75° 88°

fzo = [mm] fzo = [mm]
Tool dia. or dia. range [mm] 63 – 315 63 – 315
max. depths of cut ap max = Lc [mm] 8 10
P
SN . X 120512 SN . X 120512
Indexable insert types SN . X 120520 SN . X 120520
SN . X 1205 ENN SN . X 1205 ZNN
ae / Dc = 1/1–1/2 1.0 1.0
1/5 1.1 1.1
1/10 1.2 1.2
cutter diameter Dc
1/50
fz = fzo · Kae
* and cast steel
42
Face and shoulder mill:
F 2010, F 4047, F 4048, F 4041, F 4042, F 4042R
F 2010 / F 4041 F 2010 / F 4042 / F 4042R
90° 90°
40 – 315 10 – 50 16 – 32 25 – 315 40 –315 50 – 160
13 8 10 11.7 15 16.7
0.20 0.15 0.18 0.20 0.25 0.30
0.15 0.10 0.12 0.15 0.18 0.22
0.15 0.10 0.12 0.15 0.18 0.22
0.12 0.08 0.10 0.12 0.15 0.18
0.25 0.15 0.20 0.25 0.30 0.40
0.20 0.12 0.15 0.20 0.25 0.30
0.20 0.12 0.15 0.20 0.25 0.30
AD . . AD . . AD . . AD . . AD . .
LNGX 1307
0803 10T3 1204 1606 1807
1.0 1.0 1.0 1.0 1.0 1.0
1.1 1.1 1.1 1.1 1.1 1.1
1.2 1.2 1.2 1.2 1.2 1.2
1.3 1.3 1.3 1.3 1.3 1.3
Cutter types
F 2010 / F 4038
Feed per tooth fzo

for Lc
ae = Dc
ap = ap max = Lc Dc
Xtra·tec®
Lead angle κ 90°

fzo = [mm]
Tool dia. or dia. range [mm] 20 – 32
max. depths of cut ap max = Lc [mm] 15 – 37
Unalloyed steel* 0.15
Low-alloyed steel* 0.10
P
High-alloyed steel and tool steel* 0.10
Stainless steel,* martensitic 0.08
Grey cast iron 0.15
K Cast iron with spheroidal graphite 0.12
Malleable cast iron 0.12
Indexable insert types AD . . 0803
ae / Dc = 1/1–1/2 1.0 1
1/5 1.1
1/10 1.2
cut width ae to 1/20 1.3
cutter diameter Dc
1/50 1.5
ap = 1 1.0
2 1.0
Correction factor Kap 3 1.0
for the feed per tooth 4 1.0

dependent 6 0.8
on the depth of cut ap
8 0.7
ap max = Lc 0.5 2
* and cast steel
44
Shoulder mill: F 4038, F 4138, F 4238, F 4338
F 4138 F 4238 F 4338
90° 90° 90°

32 – 80 40 – 80 63 – 125
33 – 76 29 – 112 31 – 124
0.20 0.25 0.25
0.15 0.20 0.20
0.15 0.18 0.18
0.12 0.12 0.12
0.25 0.28 0.28
0.20 0.22 0.22
0.20 0.22 0.22
AD . . 1204 AD . . 1606 AD . . 1807
1.0 1 1.0 1 1.0 1

1.1 1.1 1.1
1.2 1.2 1.2
1.3 1.3 1.3
1.5 1.5 1.5
1.0 1.0 1.0
1.0 1.0 1.0
1.0 1.0 1.0
1.0 1.0 1.0
0.8 0.8 0.8
0.7 0.7 0.7
0.5 2 0.5 2 0.5 2
1
only possible if ap < 0.5 x DC · 2 only possible if ae/DC < 1/5
Cutter types
F 4053
Feed per tooth fzo

for
plunging
central positioning
Xtra·tec®
Lead angle κ 90°

fzo = [mm]
Tool dia. or dia. range [mm] 80–160
max. depths of cut ap max = Lc [mm] 4
Unalloyed steel* 0.11
Low-alloyed steel* 0.09
P
High-alloyed steel and tool steel* 0.09
Stainless steel,* martensitic 0.05
Grey cast iron 0.12
K Cast iron with spheroidal graphite 0.11
Malleable cast iron 0.11
Indexable insert types LN . X0702
central 1.0
Correction factor Kae ae / Dc = 1/3 1.5
for the feed per tooth 1/5 1.8

dependent on the ratio 1/10 2.5
cut width ae to
cutter diameter Dc 1/20 3.3
1/50 5.8
fz = fzo · Kae
* and cast steel
46
Side and face mills: F 4053, F 4153, F 4253
F 4153 F 4253
90° 90°
80 – 200 80 – 200 80 – 200 100 – 200 100 – 200 125 – 200 160 – 250 160 – 315
6 8 10 12 14 16 20 25
0.12 0.13 0.14 0.15 0.15 0.20 0.20 0.23
0.10 0.12 0.12 0.13 0.13 0.17 0.17 0.20
0.10 0.12 0.12 0.13 0.13 0.17 0.17 0.20
0.05 0.07 0.07 0.08 0.08 0.10 0.10 0.13
0.13 0.15 0.15 0.18 0.18 0.23 0.23 0.23
0.12 0.13 0.13 0.15 0.15 0.20 0.20 0.20
0.12 0.13 0.13 0.15 0.15 0.20 0.20 0.20
LN . . 0803 LN . . 0804 LN . . 1005 LN . . 0804 LN . . 0804 LN . . 1005 LN . . 1206 LN . . 1608
1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8
2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
5.8 5.8 5.8 5.8 5.8 5.8 5.8 5.8
Please note: The feed per tooth fz should not exceed 0.6 mm.
Determining the feed of copy mills: F 2010, F 2334
Cutter types
F 2010 / F 2334
Feed per tooth fzo

for Lc
ae = Dc
ap = ap max = Lc Dc
Tool dia. or dia. range [mm] 25 / 32 32 / 66 40–80 52–250 63–160

max. depths of cut ap max = Lc [mm] 4 5 6 8 10
Unalloyed steel* 0.11 0.17 0.22 0.28 0.33
Low-alloyed steel* 0.09 0.13 0.15 0.22 0.28
P
High-alloyed steel and tool steel* 0.09 0.13 0.15 0.22 0.28
Stainless steel,* martensitic 0.07 0.09 0.11 0.13 0.17
Grey cast iron 0.13 0.22 0.28 0.33 0.39
K Cast iron with spheroidal graphite 0.11 0.17 0.22 0.28 0.33
Malleable cast iron 0.11 0.17 0.22 0.28 0.33
RO . X RO . X RO . X RO . X RO . X
0803 10T3 1204 1605 2006
ae / Dc = 1/1–1/2 1.0 1.0 1.2 1.2 1.2

1/5 1.2 1.2 1.4 1.4 1.4
1/10 1.5 1.5 1.6 1.6 1.6
cut width ae to 1/20 1.8 1.8 1.8 1.8 1.8
cutter diameter Dc
1/50 2.0 2.0 2.0 2.0 2.0
ap = 1 1.4 1.5 1.6 1.8 2.0
2 1.1 1.2 1.3 1.4 1.5
Correction factor Kap 4 1.0 1.0 1.1 1.2 1.5
for the feed per tooth 5 1.0 1.0 1.1 1.2

dependent on the 6 1.0 1.1
depth of cut ap
8 1.1
10 1.0
* and cast steel
48
Circular interpolation mill: F 4081
Cutter types
F 4081
Feed per tooth fzo

for Lc
ae = Da Da
ap = ap max = Lc
Xtra·tec®
Lead angle κ 45°

fzo = [mm]
Tool dia. or dia. range [mm] 36 - 85 52 - 85
P
Indexable insert types OD . . 0504 . . OD . . 0605 . .
ae / Dc = 1/1–1/2 1.0 1.0

1/5 1.1 1.1
1/10 1.2 1.2
cutter diameter Dc
1/50
fz = fzo · Kae
* and cast steel
Cutter types
F 4080
Feed per tooth fzo

for Lc
ae = Da Da
ap = ap max = Lc
Xtra·tec®
Lead angle κ 43°

fzo = [mm]
Tool dia. or dia. range [mm] 32 - 125 50 - 170
P
Indexable insert types OD . . 0504 . . OD . . 0605 . .
ae / Dc = 1/1–1/2 1.0 1.0

1/5 1.1 1.1
1/10 1.2 1.2
dependent on the
ratio cut width ae to 1/20 1.3 1.3
cutter diameter Dc
1/50
fz = fzo · Kae
* and cast steel
50
Circular interpolation mills: F 4080, F 2330, F 4030
F 2330 F 4030
Xtra·tec®
0 – 15° 0 – 21°
20 - 25 32 - 85 52 - 85 25 - 63
1 1.5 2 1
1.00 1.40 1.80 1.40
0.90 1.25 1.60 1.30
0.60 0.90 1.00 1.00
0.45 0.50 0.70 0.50
0.90 1.25 1.60 1.30
0.90 1.25 1.60 1.30
1.00 1.40 1.80 1.40
P2633.-R10 P2633.-R14 P2633.-R25

P23696-1.0
P26379–R10 P26379–R14 P26379–R25
1.0 1.0 1.0 1.0

1.4 1.4 1.4 1.4
1.8 1.8 1.8 1.8
Cutter types
F 2334
Feed per tooth fzo

for Lc
ae = Da Da
ap = ap max = Lc
Lead angle κ
fzo = [mm]
Tool dia. or dia. range [mm] 25 - 32 32 - 66 40 - 80
max. depths of cut ap max = Lc [mm] 4 5 6
Unalloyed steel* 0.11 0.17 0.22
Low-alloyed steel* 0.09 0.13 0.15
P
High-alloyed steel and tool steel* 0.09 0.13 0.15
Stainless steel,* martensitic 0.07 0.09 0.11
Grey cast iron 0.13 0.22 0.28
K Cast iron with spheroidal graphite 0.11 0.17 0.22
Malleable cast iron 0.11 0.17 0.22
Indexable insert types RO . X0803 . . RO . X10T3 . . RO . X1204 . .
ae / Dc = 1/1–1/2 1.0 1.0 1.0

1/5 1.1 1.1 1.1
1/10 1.2 1.2 1.2
dependent on the
ratio cut width ae to 1/20 1.3 1.3 1.3
cutter diameter Dc
1/50
fz = fzo · Kae
* and cast steel
52
Circular interpolation mills: F 2334, F 4042
F 4042
Xtra·tec®
90°
fzo = [mm]
52 - 141 63 - 160 10 - 50 16 - 63 25 - 80 40 - 160 50 - 160
8 10 8 10 11.7 15 16.7
0.28 0.33 0.13 0.16 0.18 0.22 0.27
0.22 0.28 0.09 0.10 0.13 0.16 0.20
0.22 0.28 0.09 0.10 0.13 0.16 0.20
0.13 0.17 0.07 0.09 0.10 0.13 0.16
0.33 0.39 0.13 0.18 0.22 0.27 0.36
0.28 0.33 0.10 0.13 0.18 0.22 0.27
0.28 0.33 0.10 0.13 0.18 0.22 0.27
RO . X1605 . . RO . X2006 . . AD . . T0803 . . AD . . T10T3 . . AD . . 1204 . . AD.T1606 . . AD.T1807 . .
1.0 1.0 1.0 1.0 1.0 1.0 1.0

1.1 1.1 1.1 1.1 1.1 1.1 1.1
1.2 1.2 1.2 1.2 1.2 1.2 1.2
1.3 1.3 1.3 1.3 1.3 1.3 1.3
Application-specific data
Face milling (F 4080 only)

Maximum cut depth ap [mm]
OD . . 0504 . . OD . . 0605 . . a p1 a p2
ap1 3 4
ap2 8 10
F 4080 F 4081
f/2 f/2
f f
Da Da
D0 D0
Circular interpolation into solid material

Range of diameters for milling of bore in one pass [mm]
Indexable insert
Da OD . . 050408 OD . . 060508
[mm] D0 min D0 max fmax D0 min D0 max fmax
[mm] [mm] [mm] [mm] [mm] [mm]
32 40.4 64 4.5
40 56.4 80 4.5
50 76.4 100 4.5 69.5 100 5.8
52 80.4 104 4.5 73.5 104 5.8
58 92.4 116 4.5
60 89.5 120 5.8
63 102.4 126 4.5 95.5 126 5.8
66 108.4 132 4.5 101.5 132 5.8
71 118.4 142 4.5
73 115.5 146 5.8
80 136.4 160 4.5 129.5 160 5.8
88 152.4 176 4.5
90 149.5 180 5.8
100 176.4 200 4.5 169.5 200 5.8
108 192.4 216 4.5
110 189.5 220 5.8
125 226.4 250 4.5 219.5 250 5.8
133 242.4 266 4.5
135 239.5 270 5.8
160 289.5 320 5.8
170 309.5 340 5.8
54
Octagon cutters F 4080 / F 4081
E°
Da
Inclined plunging
Max. feed angle E [°]
Da [mm] OD . . 0504 . . OD . . 0605 . . Da [mm] OD . . 0504 . . OD . . 0605 . .
32 14.0 88 2.4
40 8.3 90 4.0
50 5.5 9.6 100 2.0 3.1
52 5.1 8.9 108 2.0
58 4.6 110 3.1
60 7.7 125 1.5 2.3
63 3.8 6.2 133 1.5
66 3.5 5.8 135 2.3
71 3.2 160 1.7
73 5.4 170 1.7
80 2.7 4.3
VERTICAL plunging
Max. plunging depth Tmax [mm]
OD . . 0504 . . OD . . 0605 . . Tmax
Tmax 2.8 4.0

Da
Note:
Please use the F 4081 with indexable inserts with corner radii only, e.g. ODHT060508...
ap
Face milling
P 2633 . – R 10 P 2633 . – R 14 P 2633 . – R 25
P 26379 – R10 P 26379 – R14 P 26379 – R25
ap max 1 1.5 2
E°
Da
Inclined plunging
Maximum feed angle E [°]
P 2633 . – R 10 P 2633 . – R 14 P 2633 . – R 25
Da [mm]
P 26379 – R10 P 26379 – R14 P 26379 – R25
20 4.0
25 2.3
32 2.5
35 2.0
40 1.5
42 1.4
52 1.2 2.3
66 0.9 1.4
85 0.6 1.0
Plunging
Maximum milling depth ae [mm]
P 2633 . – R 10 P 2633 . – R 14 P 2633 . – R 25
P 26379 – R10 P 26379 – R14 P 26379 – R25
ap max 7 10.3 15 ae max
56
High-performance mill F 2330
ap max
2
ap max
(f)
Da
D0

Range of diameters for milling of a hole in one pass [mm]
Indexable insert
P 2633 . – R 10 P 2633 . – R 14 P 2633 . – R 25
Da
P 26379 – R10* P 26379 – R14* P 26379 – R25*
[mm]
D0 min D0 max D0 min D0 max D0 min D0 max
[mm] [mm] [mm] [mm] [mm] [mm]
20 24.2 40
25 34.2 50
32 41.8 64
35 47.8 70
40 57.8 80
42 61.8 84
52 81.8 104 70.4 102.6
66 109.8 132 98.4 130.6
85 147.8 170 136.4 168.6
*Special geometry for circular interpolation milling (see Description of geometry, page 68)
rt
R X
kr
Programming information
r
Indexable insert R r rt k kr X
P 2633 . – R 10 10.0 0.8 2.0 4.0 1.8 0.5

P 2633 . – R 14 14.0 1.2 2.5 5.5 2.6 0.8
P 2633 . – R 25 25.0 2.0 3.0 8.0 3.4 0.9
Programming the theoretical tool radius “rt” results in a maximum deviation from the final contour
as shown. The minimal difference (only in the corners) is corrected by the subsequent tools during
the remaining machining operations.
Face milling
P 23696 – 1.0 ap
ap1 1.0
Inclined plunging
Max. feed angle E [°]
Da [mm] P 23696 – 1.0 E°
25 10.5 Da
32 8.0
35 7.0
40 5.5
42 5.0
50 3.8
52 3.5
63 2.5
plunging
Maximum milling depth ae [mm]
Da [mm] P 23696 – 1.0
25 8.5
ae max
32 10
35 10
40 10
42 10
50 10
52 10
63 10
58
High-performance mill F 4030
ap max
2
ap max
(f)
Da
D0

Range of diameters for milling of bore in one pass [mm]
Da P 23696 – 1.0
[mm] D0 min[mm] D0 max[mm]
25 33 50
32 44 64
35 50 70
40 59 80
42 63 84
50 78 100
52 82 104
63 104 126
rt
R X
kr
Programming information
r
Indexable insert R r rt k kr X
P 23696–1.0 14.0 1.2 2.0 5.8 2.1 0.6
Programming the theoretical tool radius “rt” results in a maximum deviation from the final contour
as shown. The minimal difference (only in the corners) is corrected by the subsequent tools during
the remaining machining operations.
Inclined plunging and circular interpolation milling into solid material

Plunging with shoulder mill F 4042 / F 4042R
AD . . 080304 AD . . 10T308
a max = 8 mm a max = 10 mm
Mill dia. Plunging Plunging

DC angle D0 min D0 max a0 angle D0 min D0 max a0
[mm] Emax [ ° ] [mm] [mm] [mm] Emax [ ° ] [mm] [mm] [mm]
10 12.1 15 20 0.75
12 9.9 17 24 0.8
16 13.7 21 32 2.0 6.6 20 32 0.9
20 8.9 29 40 1.9 2.9 28 40 0.6
25 5.6 39 50 1.7 2 38 50 0.6
32 3.8 53 64 1.6 1.4 52 64 0.6
40 2.8 69 80 1.6 1.1 68 80 0.6
50 2.2 89 100 1.6 0.8 88 100 0.6
63 0.6 114 126 0.6
Inclined plunging and circular interpolation milling into solid material

Plunging with shoulder milling cutter F 4042
AD . . 120408 AD . . 160608
a max = 11 mm a max = 15 mm
Mill dia. Plunging Plunging

DC angle D0 min D0 max a0 angle D0 min D0 max a0
[mm] Emax [ ° ] [mm] [mm] [mm] Emax [ ° ] [mm] [mm] [mm]
25 8.5 36 50 2.3
32 5.6 50 64 2.2
40 3.9 66 80 2.1 5.9 62 80 2.9
50 2.7 86 100 1.9 3.9 82 100 2.6
63 2.0 112 126 1.9 2.6 108 126 2.3
80 1.5 146 160 1.9 1.9 142 160 2.3
100 1.5 182 200 2.3
120 1.2 232 250 2.3
160 0.9 302 320 2.3
60
Shoulder mills F 4042, F 4042R
Inclined plunging and circular inter-

polation milling into solid material
E
a1
Plunging with shoulder milling cutter F 4042
AD . . 180712
a max = 16 mm
Mill dia. Plunging

DC angle D0 min D0 max a0
a1
a2 ≤ amax E
a0
[mm] Emax [ ° ] [mm] [mm] [mm]
50 2.9 74 100 1.7

63 2.1 100 126 1.7
80 1.5 134 160 1.7
a0 E
100 1.2 174 200 1.7
an
120 0.9 224 250 1.7

L
160 0.7 294 320 1.7
an
Explanation of letter symbols
a0 [mm] amount by which the tool is to Groove depth after 2 plunging operations:
be lifted off at the end of
plunging before starting the
a2 = 2 · L · tan E – a0
next plunging operation
an [mm] cut depth
amax [mm] max. tool cut depth
E [°] feed angle Groove depth after plunging:
L [mm] groove length without radius
n Number of inclined plunging an = n · L · tan E – (n–1) · a0
operations
Feed angle: Number of inclined plunging operations:
[an + (n–1) · a0] (an – a0)

tan E = n=
(n · L) (L · tan Emax – a0)
Circular face milling

Max. axial feed per tool revolution
(“thread pitch”) f [mm]
machined AD . . 080304
hole dia. DC [mm]
D0 [mm] 10 12 16 20 25 32 40 50
15 3.4
20 6.7 4.4
30 8.0 8.0 8.0 4.9
40 8.0 8.0 8.0 8.0 4.7
50 8.0 8.0 8.0 8.0 7.8
60 8.0 8.0 8.0 8.0 8.0 5.8
80 8.0 8.0 8.0 8.0 8.0 8.0 6.2
100 8.0 8.0 8.0 8.0 8.0 8.0 8.0 6.0
120 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0
150 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0
180 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0
200 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0
250 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0
Circular face milling

(“thread pitch”) f [mm]
machined AD . . 10T308
hole dia. DC [mm]
D0 [mm] 16 20 25 32 40 50 63
15
20 1.5
30 5.1 1.6
40 8.7 3.2 1.6
50 10.0 4.8 2.7
60 10.0 6.4 3.8 2.1
80 10.0 9.5 6.0 3.7 2.4
100 10.0 10.0 8.2 5.2 3.6 2.2
120 10.0 10.0 10.0 6.8 4.8 3.1 1.9
150 10.0 10.0 10.0 9.1 6.6 4.4 2.9
180 10.0 10.0 10.0 10.0 8.4 5.7 3.8
200 10.0 10.0 10.0 10.0 9.7 6.6 4.5
250 10.0 10.0 10.0 10.0 10.0 8.8 6.2
62
Shoulder mills F 4042, F 4042R (continued)
Circular INTERPOLATION MILLING

Max. axial feed per tool revolution (“thread pitch”) f [mm]
machined AD . . 120408 AD . . 160608

hole dia. DC [mm] DC [mm]
D0 [mm] 25 32 40 50 63 80 40 50 63 80 100 125 160
40 7.0
50 11.0 5.5
60 11.0 8.6
80 11.0 11.0 8.7 13.1
100 11.0 11.0 11.0 7.4 15.0 10.8
120 11.0 11.0 11.0 10.3 6.4 15.0 15.0 8.1
150 11.0 11.0 11.0 11.0 9.7 3.4 15.0 15.0 12.4 7.5
180 11.0 11.0 11.0 11.0 11.0 5.9 15.0 15.0 15.0 10.7
200 11.0 11.0 11.0 11.0 11.0 8.5 15.0 15.0 15.0 12.8 8.2
250 11.0 11.0 11.0 11.0 11.0 10.2 15.0 15.0 15.0 15.0 12.3 8.0
300 11.0 11.0 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0 11.2
350 11.0 11.0 11.0 11.0 11.0 11.0 15.0 15.0 15.0 15.0 15.0 14.4 9.3
400 15.0 15.0 15.0 15.0 15.0 15.0 11.7
450 15.0 15.0 15.0 15.0 15.0 15.0 14.2
500 15.0 15.0 15.0 15.0 15.0 15.0 15.0
Circular INTERPOLATION MILLING

f/2
f (“thread pitch”) f [mm]
machined AD . . 180712
hole dia. DC [mm]
DC
D0 [mm] 50 63 80 100 125 160
D0
80 4.8
100 7.9 4.2
120 11.1 6.5
150 15.9 10.0 5.9
180 16.0 13.4 8.4 5.1
200 16.0 15.7 10.1 6.4
250 16.0 16.0 14.3 9.6 6.1
300 16.0 16.0 16.0 12.8 8.6 5.2
350 16.0 16.0 16.0 16.0 11.1 7.1
400 16.0 16.0 16.0 16.0 13.5 8.9
450 16.0 16.0 16.0 16.0 16.0 10.8
500 16.0 16.0 16.0 16.0 16.0 12.6
apmax
Face milling
Insert diameter d [mm]
d=8 d = 10 d = 12 d = 16 d = 20
apmax [mm] 4.0 5.0 6.0 8.0 10.0
tR
ar
f/2
d
Da
D0

Range of diameters for milling of a hole in one pass [mm]
Insert diameter d [mm]
Da d=8 d = 10 d = 12 d = 16 d = 20
[mm]
D0 min D0 max D0 min D0 max D0 min D0 max D0 min D0 max D0 min D0 max
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
25 34.6 50
32 48.4 64 45 64
40 61 80 57.4 80
50 81.4 100 77.2 100
52 85 104 81.2 104 75.4 104
63 102.4 126 103.2 126 97.6 126
66 113 132 109.4 132 103.4 132 97 132
80 137.8 160 131.4 160 124.8 160
96 163.4 192
100 171.4 200 164.8 200
116 203.4 232
125 221.4 250 214.8 250
141 253.4 282
160 284.8 320
64
Round insert cutter F 2334
tR
ar
f/2
d
Da
D0

Groove depth on the hole wall tR [mm]
axial feed rate per Insert diameter d [mm]
revolution
f [mm] d=8 d = 10 d = 12 d = 16 d = 20
1 0.031 0.025 0.02 0.015 0.01
2 0.127 0.010 0.08 0.06 0.05
3 0.292 0.230 0.19 0.14 0.11
4 0.536 0.417 0.34 0.25 0.20
5 0.878 0.670 0.54 0.40 0.32
6 (1.000) 0.80 0.58 0.46
7 (1.429) (1.12) 0.81 0.63
8 (1.53) (1.07) 0.84
ar max 1.25 1.5 2.0 3.0 4.5
apmax
E°
d
Da
Inclined plunging
Maximum feed angle E [°]
Da Indexable insert diameter d [mm]

[mm] d=8 d = 10 d = 12 d = 16 d = 20
25 10.5
32 6.8 8.6
40 5.8 7.9
50 4.0 5.4
52 3.9 5.3 6.1
63 3.0 3.4 4.4
66 2.8 3.4 4.1 5.3
80 2.6 3.1 3.9
96 2.4
100 2.3 2.8
116 1.9
125 1.7 2.1
141 1.5
160 1.5
ap max [mm] 6.9 8.8 10.5 1.9
Tmax
Vertical plunging
Maximum plunging depth Tmax [mm]
Indexable insert diameter d [mm]
d=8 d = 10 d = 12 d = 16 d = 20
Tmax [mm] 2.4 2.6 3.1 1.2 1.6
66
Round insert cutter F 2334 (continued)
apz
vf
E z°
d
Da
UP MILLING OF STEEP SURFACES

F 2334: Maximum plunging depth Tmax [mm]
18
17
d=20
16
15
14
d=16
13
12
11
10 d=12
9
8
d=10
7
6
d=8
5
4
3
2
1
0
0 15 30 45 60 70 90
Description of indexable insert geometry
suitable tool
Workpiece
Geometry
material group
example
Cut
families
Remarks on Main cutting
application area edge P M K N S H
P 26335 – 10° F 2010
The easy-cutting one F 2330
‡‡for good machining
conditions
CC CC CC CC
‡‡low cutting forces
‡‡medium feed rates
P 26337 –
The stable one 0°
‡‡for unfavourable
machining conditions
CC C CC C
‡‡maximum cutting edge
stability
‡‡high feed rates
P 26339 – Cutting edge

The universal one
0°
‡‡for medium machining
conditions
‡‡universal application for
most materials CC CC CC CC
Main cutting edge
10°
P 26379 – Cutting edge

The special one
0°
‡‡for circular interpolation
milling
‡‡universal application for
most materials CC CC CC CC
‡‡trailing edge version Main cutting edge

10°
P = Steel
M = Stainless steel
K = Cast iron
N = Non-ferrous metals
S = Materials with difficult cutting properties C C Primary application
H = Hard materials C Additional application
68
Face mills and circular interpolation mills
suitable tool
Workpiece
Geometry
material group
example
Cut
families
P 23696-1 – F 4030
The universal one 20°
‡‡ for medium to
unfavourable machining CC CC CC CC
conditions
‡‡ universal application for
most materials
A27 – The stable one F 2010

‡‡ for unfavourable 0° F 4080
machining conditions F 4081
‡‡ maximum cutting edge CC CC
stability
OD . . ‡‡ high feed rates
A57 – The special one

‡‡ for medium machining 0°
conditions
‡‡ predominantly for cast C CC
iron machining
D57 – The universal one

‡‡ for medium machining 10°
conditions
‡‡ universal application for CC CC CC CC
most materials
F57 –
The easy-cutting one 16°
‡‡ for good machining
conditions CC CC CC CC
‡‡ low cutting forces

‡‡ medium feed rates
G88 – The sharp one

‡‡ for machining aluminium 20°
‡‡ sharp cutting edges CC
C C Primary application
C Additional application
Description of indexable insert geometry
Workpiece
suitable tool
material group
Geometry
example
Cut
families
D27 – The special one F 2010
‡‡ for machining cast iron F 4033
10°
materials F 4047
‡‡ for sand inclusions or C CC F 4048
casting skin
‡‡ maximum process
SN . X . . reliability
F27 – The stable one

‡‡ for unfavourable
16°
‡‡ maximum cutting edge CC C CC C
stability
‡‡ high feed rates
F57 – The universal one

‡‡ for medium machining
16°
conditions
most materials
F67 –
The easy-cutting one
16°
K88 – The sharp one

‡‡ for machining aluminium
22°
P = Steel
M = Stainless steel
K = Cast iron
70
Face and shoulder mills
Workpiece
suitable tool
material group
Geometry
example
Cut
families
D27 – The stable one 10°
F 4045
‡‡ maximum cutting edge C CC
stability
XNHF . .
D57 – The universal one 10°
conditions
‡‡ universal application C CC
D67 – 10°
conditions C CC
L55 – The universal one F 2010

‡‡ for medium machining 20° F 4041
conditions
most materials
LNGX . .
L88 – The sharp one
C C Primary application
C Additional application
Description of indexable insert geometry – shoulder mills
Workpiece
suitable tool
material group
Geometry
example
Cut
families
D51 – The quiet one 10°
F2010
‡‡ antivibration geometry F 4042
‡‡ for tools with longer CC C CC C F 4042R
projection lengths F 4038
F 4138
D56 – The stable one F 4238
AD . T . . ‡‡ for unfavourable machin-
10° F 4338
ing conditions
‡‡ maximum cutting edge CC C CC C
stability
D67 – The powerful one 10°

‡‡ high cutting edge stability
‡‡ for machining high-alloy
and high-tensile steels
and Ni-based alloys CC CC C CC
‡‡ high level of accuracy
F56 – The universal one 16°

conditions
most materials
G56 –
20°
G77 – The special one

20°
‡‡ for machining titanium
materials
‡‡ low cutting forces C CC CC
G88 – The sharp one

‡‡ sharp cutting edges
CC
72
Copy mill
Workpiece
suitable tool
material group
Geometry
example
Cut
families
A27 – The stable one F 2010
0°
‡‡ for unfavourable F 2334
stability
RO . X . .
D57 – The universal one 10°
conditions
most materials
D67 – The powerful one 10°

‡‡ high cutting edge stability
‡‡ for machining high-alloy
and high-tensile steels
and Ni-based alloys, e.g. CC CC C CC
Inconel
G77 – The special one 20°

‡‡ for machining titanium
materials
‡‡ low cutting forces C CC CC
P = Steel
M = Stainless steel
K = Cast iron
Description of side and face mill geometry
Workpiece
suitable tool
material group
Geometry
example
Cut
families
D57T – The stable one F 4053
machining conditions 12°
LN . X . . stability
F57T – The universal one

conditions 18°
most materials
B57T – The stable one F 4153

‡‡ for unfavourable F 4253
machining conditions 6°
stability
LN . U . . ‡‡ high feed rates
F57T – The universal one

16°
conditions
most materials
P = Steel
M = Stainless steel
K = Cast iron
74
Workpiece material groups
Rm kc 1.1
Steel mc
(N/mm2) (N/mm2)
Low-carbon soft steels

<450 1350 0.21
Low tensile ferritic steels
Low-carbon free cutting steels 400 <700 1500 0.22
Normal structural steels, low to medium content

450 <550 1500 0.25
of carbon (< 0.5 % C)
Normal, low-alloy steels and cast steel;

P tempering steel; carbon steel (> 0.5 % C); 550 <700 1700 0.24
ferritic and martensitic, stainless steels
Normal tool steels; harder tempering steels;

700 <900 1900 0.24
martensitic, stainless steels
Hard-to-machine tool steels, hard, high-alloyed

900 <1200 2000 0.24
steels and cast steel, martensitic stainless steels
High tensile steels with difficult cutting properties;

hardened steels of groups 3 – 6; martensitic, >1200 2900 0.22
stainless steels
Rm kc 1.1
Cast iron mc
(N/mm2) (N/mm2)
Cast iron of medium hardness, grey cast iron 1150 0.22
Low-alloyed cast iron, malleable cast iron,

1225 0.25
nodular cast iron
K
Cast iron alloy of medium hardness, malleable cast
1350 0.28
iron, GGG, average cutting properties
Hard-to-machine, high-alloyed cast iron, malleable

1470 0.30
cast iron, GGG, hard to machine
Calculation formulae
Speed Feed per tooth
Cutting speed Metal removal rate
Feed rate Power requirement
n Speed rpm hm Medium chip

thickness mm
DC Drill
diameter mm kc Specific
cutting force N/mm2
ap Depth of cut mm
h Machine’s level
ae Width of cut mm
of efficiency (0.7–0.95)
z Number of teeth
k Lead angle °
vc Cutting speed m/min
js Engagement angle °
vf Feed rate mm/min
kc1.1* Specific
fz Feed per tooth mm cutting force
for 1 mm2
Q Metal removal rate cm3/min
Chip cross section N/mm2
Pmot Drive power kW
mc* Increase in the kc curve
Rake angle °
* mc and kc1.1 see table on page 75
76
Medium chip thickness Engagement angle
where cutter is positioned centrally
or where cutter is positioned eccentrically
as an approximation for ae/Dc < 30 %
Specific cutting force
fz Dc
φ2
φs ae
φ1
hm Vf
φm
φ2 = 90°
φs
Dc
ae
φ1
y = ae–Dc/2
Problem solving
Formation of hairline cracks Flank face wear
Feature Feature
In relation to the cutting edge, vertical The most frequently occurring type of
small cracks that can result in chipping wear, affecting the flank face.
along the edge and fractures in the
indexable insert. Cause
–– caused by abrasion between the
Cause flank face and workpiece
Formation of hairline cracks resulting –– during roughing, this often leads to
from stresses caused by changes in vibrations and increased capacity
temperature requirements. During finishing, it can
–– due to an interrupted cut (brief lead to poor surfaces
contact time between cutting edge
and workpiece, long cooling phase) Remedy / measure(s)
–– use of coolant (thermal shock) –– use a wear-resistant cutting material
–– Reduce the cutting speed
Remedy / measure(s) –– increase the feed
–– try working without coolant
–– use a tougher cutting material
–– reduce the cutting speed
78
Chips along the edge Plastic deformation
Feature Feature
Chipping along the edges of small Cutting edge deformed in some other,
sections of the cutting material in the undefined manner.
cutting edge.
Cause
Cause –– occurs at high machining tempera-
–– mechanical overload leads to small tures in conjunction with a high
sections of the cutting material in the mechanical load, because of
cutting edge breaking off “softening” and “yielding” of the
–– may be a result of hairline cracks cutting tool material
–– leads to a sudden and sharp increase
Remedy / measure(s) in the machining temperature and
–– select a more stable geometry (longer cutting force, fluctuations in dimen-
removal phase) sions and poor surfaces on the
–– ensure a stable machining process component, and sometimes frac-
–– use a tougher cutting material tures in the cutting edge
Remedy / measure(s)
–– use a wear-resistant cutting material
–– reduce the cutting speed
–– reduce feed
Problem solving
Remedy / measure(s)
Carbide wear resistance

Feed rate per tooth (fz)
Cutting edge stability

Carbide toughness
Cutting speed (vc)
Lead angle (κ)
Rake angle
Problem
Built-up cutting edge + + ~ + –

Formation of hairline cracks – +
Chips on contact with the workpiece – –
Machine overload – – +
Rattling, vibration ~ ~ ~ ~
Poor workpiece surface + – –
Chipping along the cutting edge – + ~ +
Deformation of the cutting edge – – +~
Chip formation, accumulation of chips ~ ~
Excessive crater wear – – +
Excessive flank face wear – +
Indexable insert fracture – + ~
+ increase
– decrease, reduce
~ check, optimise
80
Notes
Walter AG
Derendinger Str. 53, 72072 Tübingen

Postfach 2049, 72010 Tübingen
Germany
www.walter-tools.com
Walter GB LTD. Walter Malaysia Sdn. Bhd.

Bromsgrove, England Selangor D.E., Malaysia
+44 (1527) 839 450 +60 (3) 8023 7748
service.uk@walter-tools.com service.my@walter-tools.com
Walter Kesici Takimlar Sanayi ve Ticaret Walter Australia Pty. Ltd.

Limited Sirketi Victoria, Australia
Istanbul, Turkey +61 (3) 8793 1000
+90 (216) 528 1900 Pbx service.au@walter-tools.com
service.tr@walter-tools.com
Walter Tooling Japan K.K.
Walter Wuxi Co. Ltd. Nagoya, Japan
Wuxi, Jiangsu, P.R. China +81 (52) 723 5800
+86 (510) 8241 9399 service.jp@walter-tools.com
service.cn@walter-tools.com
Walter USA, LLC
Walter AG Singapore Pte. Ltd. Waukesha (WI), USA
+65 6773 6180, service.sg@walter-tools.com +1 800-945-5554
Printed in Germany 595 1372 (10/2010) EN
service.us@walter-tools.com
Walter Korea Ltd.
Ansan, Kyungki-do, Korea TDM Systems Inc.
+82 (31) 3646 100 Schaumburg (IL), USA
service.kr@walter-tools.com +1 (847) 605 1269, info@tdmsystems.com
Walter Tools India Pvt. Ltd. Walter Tools S.A. de C.V.

Pune, India Saltillo Coahuila, Mexico
+91 (20) 2714 5028 +52 (55) 5365-6895
service.in@walter-tools.com service.mx@walter-tools.com
Walter (Thailand) Co., Ltd. Walter Canada

Bangkok, Thailand Mississauga, Canada
+66 (2) 687 0388, service.th@walter-tools.com service.ca@walter-tools.com

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Product handbook

_ SILVER, BLACK, STRONG

The new force

Cutting tool materials with the Tiger·tec® technology

2 The new technology

14 Extract from the milling cutter range

16 Walter Select milling cutters

34 Cutting data for milling

The new technology

Completely new CVD coating

MT-Ti(C, N) Greater resistance to

The new technology

High level of wear resistance

PRODUCT PROPERTIES: Benefits for you:

Performance increase of up Low production costs

Resistant to deformation and Low cutting material costs

High level of resistance to flank

New dimension in the toughness

Applications and examples

With the new Tiger·tec®Silver technolo- tool material increases exponentially.

WALTER GRADE DESIGNATION

Primary application ISO P

Walter Primary application ISO K

Material: CAST IRON (ISO K)

Primary application: all steel materi- Primary application: spheroidal graphite

Example 1: machine frame (shoulder milling)

Workpiece material: St37 (1.0037), ISO P

Benefits for you:

Comparison in tool life of inner surfaces [pieces]

Workpiece material: St52-2 (1.0570), ISO P

Benefits for you:

Feed rate comparison [mm/min]

Example 3: form insert (pocket milling)

Workpiece material: 40CrMnMo7 (1.2311),

Benefits for you:

Tool life comparison [m]

Workpiece material: GGG50 (0.7050),

Benefits for you:

Tool life quantity comparison [pieces]

Workpiece material group

HC = coated carbide C C Primary application

Lead angle κ 45°

Face mill F 4033

Ordering information* E. page 194

Max. cut depths [mm] 6.5 + 9

Number of cutting edges

* G. = Complete catalogue 2007

F 4047 F 4048 F 4045

Xtra·tec® Xtra·tec® Xtra·tec®

E. page 198 E. page 200 F. Page 153

Lead angle κ 43°

Face mill F 4080

Ordering information* F. Page 155, G. page 510

Max. cut depths [mm] 3 / 8 + 4 / 10

Number of cutting edges

* G. = Complete catalogue 2007

E. page 192 F. Page 152

Face mill F 2010

Dia. range [mm] 80 – 315

* G. = Complete catalogue 2007

80 – 315 80 – 315 70 – 305 80 – 315 74 – 309

AD . . 1204 . . P 2633 . – R25

Lead angle κ 90°

Feed rate comparison [mm/min]