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F1
ISCAR offers several plunger options which were designed for deep cavities and high shoulder milling. The tools are very effective and economical for deep machining of slots, straight and sloped walls which require very long tool overhang. The main feature of the plunger tools is that the loads on the machine, tool and workpiece are mainly axial, avoiding bending moments. It is recommended to use horizontal machines with an abundant coolant stream when machining deep cavities. Horizontal tool and cavity orientation allow gravity to enhance chip removal.
PH
Center cutting plunger that uses a very strong, double-ended insert with 4 cutting edges. The tools have a cylindrical or a CLICKFIT shank option. In case of vertical machining, the PH-A plunger (which has a spiral, drill-like flute) is recommended. This tool type evacuates chips effectively.
PLX
TANGPLUNGE HTP plungers carry tangentially clamped inserts on the frontal face of the tools, featuring high durability and excellent cutting performance. The tools are available with 3 insert size options: HTP LNHT 0604, HTP LNHT 1006 and HTP LNHT 1606. They all have coolant holes for efficient edge flushing and chip evacuation. The HTP LNHT tangentially clamped right-hand inserts feature four cutting edges, with a positive rake face for reduced forces during machining and high chip removal. The insert orientation on the tool results in excellent machined surface flatness. The integral shank tools are available as endmills with integral shank FLEXFIT and SHANKMASTER, which have a threaded connection modular shank option in a diameter range of 16-40 mm. They are also available as shell mills in in a diameter range of 40-100 mm. The shell mill plungers can also be used for general side milling applications.
HTP
Side plunger equipped with standard XCMT 120408TR inserts, featuring a maximum width of cut - ae = 11 mm for plunging and a maximum depth of cut - ap = 9 mm for tangential milling. Each insert has two cutting edges. The tool is multifunctional for rough plunging operations and light milling or semi-finishing. With the PLX cutter with an overhang of up to 3-3.5xD there is no need for angular retractions. (This is normally done in order to avoid insert breakage and scratching the walls of the workpiece during retract pass). The PLX cutter enables faster retraction from the workpiece and significantly reduces machining time and failure. There is no need to apply any special CNC programming for the retract pass. Operations with very long overhangs are performed by the PLX cutters with only 45 angular retractions. No other cutters will function under such long overhang conditions. The PLX cutters have a 17 angle built into the insert, which reduces the radial cutting forces and prevents insert breakage. The cutters also have high tooth density, which means that the PLX cutters can run very fast. All PLX cutters are manufactured with coolant holes for better chip evacuation.
P M K N S H 3 3 3 3
P M K N S H 3 3 3
P M K N S H 3 3 3 3
F2
ISCAR
TS HTP
Side Plungers with SHANK-MASTER Threaded Connection Carrying Tangentially Clamped Inserts with 4 Cutting Edges
T (1)
D ae
D2
ap
L5 Designation TS HTP D17/.67-2-T10-LN06 TS HTP D21/.83-3-T12-LN06
(1)
Tsi
D
17.00 21.00
Z
2 3
D2
15.20 19.20
L5
30.00 35.00
ae
4.5 5.0
ap
2.50 2.50
Tsi
T10 T12
T(1)
13.0 16.0
Kg
0.03 0.05
For inserts, see page: HTP LNHT 0604 (K103). For holders, see page: TS S-A (B72).
Spare Parts
Designation TS HTP Key
T-8/53
Screw
SR 14-560-HG
ae
L1
Cutter Diameter (mm)
16 20 25 9.80 13.56 16.25 18.33 20.00
The relationship between the maximal step L1max and the width of plunge ae is given by the following formula: L1max = 2x Dxae-ae2 D: cutter diameter
F3
HTP-LN06
D
16.00 20.00 25.00 25.00
d
16.00 20.00 25.00 25.00
ae
4.5 5.0 5.0 5.0
ap
2.50 2.50 2.50 2.50
L
120.00 150.00 150.00 130.00
H
32.00 40.00 50.00 50.00
Shank(1)
C C C C
Kg
0.17 0.33 0.51 0.44
Spare Parts
Designation HTP-LN06 Key
T-8/53
Screw
SR 14-560-HG
HTP-M-LN06
Side Plungers with FLEXFIT Threaded Connection Carrying Tangentially Clamped Inserts with 4 Cutting Edges
ap
T
Ts D3
ae
L5 Designation HTP D16/.62-2-M08-LN06 HTP D20-3-M10-LN06 HTP D25/1.00-3-M12-LN06
(1)
L6 Z
2 3 3
D
15.95 20.00 25.20
ae
4.5 5.0 5.0
ap
2.50 2.50 2.50
L6
47.50 50.00 57.00
L5
30.00 30.00 35.00
D3
13.00 18.00 21.00
Ts
M08 M10 M12
T(1)
10.0 15.0 17.0
Kg
0.03 0.06 0.10
For inserts, see page: HTP LNHT 0604 (K103). For holders, see pages: BT-ODP (FLEXFIT) (E47) C#-ODP (FLEXFIT) (E51) CAB M-M (FLEXFIT) (E43) DIN69871-ODP (E48) ER-ODP (E48) HSK A-ODP (FLEXFIT) (E49) HSK E-ODP (FLEXFIT) (E50) S M (E43) S M-CF (E45).
Spare Parts
Designation HTP-M-LN06 Key
T-8/53
Screw
SR 14-560-HG
F4
ISCAR
HTP-LN10
ap
D ae H L Designation HTP D025-2-L200-C25-LN10 HTP D032-3-L190-C25-LN10 HTP D032-3-L210-C32-LN10 HTP D032-3-L210-W32-LN10 HTP D040-4-L250-C32-LN10
For user guide, see pages F11-17
(1)
D
25.00 32.00 32.00 32.00 40.00
d
25.00 25.00 32.00 32.00 32.00
Z
2 3 3 3 4
ae
7.0 8.0 8.0 8.0 8.0
ap
3.00 3.00 3.00 3.00 3.00
L
200.00 190.00 210.00 210.00 250.00
H
120.00 50.00 120.00 120.00 50.00
Shank(1)
C C C W C
Kg
0.64 0.68 1.1 1.1 1.5
C-Cylindrical, W-Weldon
Spare Parts
Designation HTP-LN10 Screw
SR 34-550
Torx Blade
BLD T10/S7
Handle
SW6-SD
HTP-M-LN10
Side Plungers with FLEXFIT Threaded Connection Carrying Tangentially Clamped Inserts with 4 Cutting Edges
ap
T
D ae L5 L6 Z
2 3 3 4
Ts D3
D
25.00 32.00 35.00 42.00
ae
7.0 8.0 8.0 8.0
ap
3.00 3.00 3.00 3.00
L6
57.00 60.00 68.00 68.00
L5
35.00 35.00 43.00 43.00
D3
21.00 29.00 29.00 29.00
Ts
M12 M16 M16 M16
T(1)
17.0 25.0 25.0 25.0
Kg
0.09 0.17 0.22 0.26
For inserts, see page: HTP LNHT 1006 (K104). For holders, see pages: BT-ODP (FLEXFIT) (E47) C#-ODP (FLEXFIT) (E51) CAB M-M (FLEXFIT) (E43) DIN69871-ODP (E48) ER-ODP (E48) HSK A-ODP (FLEXFIT) (E49) HSK E-ODP (FLEXFIT) (E50) S M (E43) S M-CF (E45).
Spare Parts
Designation HTP-M-LN10 Screw
SR 34-550
Torx Blade
BLD T10/S7
Handle
SW6-SD
F5
Shell Mill Plungers Carrying Tangentially Clamped Inserts with 4 Cutting Edges
D3 Da
HTP-R-LN10
L 3 ae Z
4 5 5
D
40.00 50.00 50.00
ae
8.0 8.0 8.0
D3
38.00 48.00 48.00
Da
16.00 22.00 22.00
L
40.00 40.00 40.00
Arbor(1)
A A A
Kg
0.20 0.31 0.34
Spare Parts
Designation HTP D040-4-16-R-LN10 HTP D050-5-22-R-LN10 HTP D052-5-22-R-LN10
(1)
Screw
SR 34-550 SR 34-550 SR 34-550
Torx Blade
BLD T10/S7 BLD T10/S7 BLD T10/S7
Handle
SW6-SD SW6-SD SW6-SD
Slot/Bore
Shoulder
Face Milling
Spot Face
F6
ISCAR
HTP-R-LN16
Shell Mill Plungers Carrying Tangentially Clamped Inserts with4 Cutting Edges
D3 Da A 0.5 L ap D Designation HTP D050-04-22-R-LN16 HTP D052-04-22-R-LN16 HTP D063-05-27-R-LN16 HTP D066-05-27-R-LN16 HTP D080-06-27-R-LN16 HTP D080-06-32-R-LN16 HTP D100-07-32-R-LN16
For user guide, see pages F11-17.
(1)
ae Da
22.00 22.00 27.00 27.00 27.00 32.00 32.00
D
50.00 52.00 63.00 66.00 80.00 80.00 100.00
D3
48.00 48.00 59.00 62.00 65.00 72.00 78.00
Z
4 4 5 5 6 6 7
L
50.00 50.00 50.00 50.00 50.00 50.00 50.00
ae
13.0 13.0 14.0 14.0 14.0 14.0 14.0
ap
3.00 3.00 3.00 3.00 3.00 3.00 3.00
Arbor(1)
A A A A A A B
Kg
0.38 0.39 0.53 0.60 0.82 0.89 1.28
Spare Parts
Designation HTP D050-04-22-R-LN16 HTP D052-04-22-R-LN16 HTP D063-05-27-R-LN16 HTP D066-05-27-R-LN16 HTP D080-06-27-R-LN16 HTP D080-06-32-R-LN16 HTP D100-07-32-R-LN16
(1)
Screw
SR SR SR SR SR SR SR 34-535 34-535 34-535 34-535 34-535 34-535 34-535
Torx Blade
BLD BLD BLD BLD BLD BLD BLD T15/S7 T15/S7 T15/S7 T15/S7 T15/S7 T15/S7 T15/S7
T-Handle
SW6-T SW6-T SW6-T SW6-T SW6-T SW6-T SW6-T SHORT SHORT SHORT SHORT SHORT SHORT SHORT
SR SR SR SR
Slot / Bore
Shoulder
Spot Face
A
F7
PH
D
40.00 50.00
L1
90.0 100.0
L7
105.70 103.00
Z
2 4
d
32.00 32.00
D3
48.60 48.60
Shank(1)
W W
L5
113.70 111.00
L6
173.70 171.00
Kg
0.97 1.12
W-Weldon
Spare Parts
Designation PH Screw
SR 14-562XL
Key
T-10/51
PH-A
High Productivity Center Cutting Plungers with Spiral Flutes Carrying PLHT 1305-PDX Inserts
D D L1 L5 d
L6 Zeff
2 2
D
50.00 63.00
L1
140.0 140.0
Z
4 6
d
32.00 40.00
Shank(1)
W W
L5
160.00 160.00
L6
220.00 230.00
Kg
1.43 2.36
W-Weldon
Spare Parts
Designation PH-A Screw
SR 14-562XL
Key
T-10/51
F8
ISCAR
PLX-M
Side Plungers with FLEXFIT Threaded Adaptation Carrying XCMT 120408TR Inserts
Rd
D ae
Ts D3
ap
L5
L6 L5 L6
60.00 60.00
D
32.00 40.00
Z
3 4
ae(1)
11.0 11.0
D3
30.40 29.00
ap
9.00 9.00
Ts
M16 M16
Rd
8.6 6.8
Kg
0.16 0.29
35.00 35.00
No internal coolant For user guide, see pages F11-17. Maximum side plunge For inserts, see page: XCMT-TR (K102). For holders, see pages: BT-ODP (FLEXFIT) (E47) C#-ODP (FLEXFIT) (E51) CAB M-M (FLEXFIT) (E43) DIN69871-ODP (E48) HSK A-ODP (FLEXFIT) (E49) HSK E-ODP (FLEXFIT) (E50) S M (E43) S M-CF (E45).
Spare Parts
Designation PLX-M Screw
SR 34-510/L11.7
Torx Blade
BLD T15/S7
T-Handle
SW6-T
F9
PLX
Rd
ap
ae D Designation PLX D52-22-12 PLX D66-22-12 PLX D80-32-12
(1)
D
52.00 66.00 80.00
D3
50.00 64.00 68.00
Z
6 7 8
Da
22.00 22.00 32.00
L
40.00 40.00 50.00
ae(1)
11.0 11.0 11.0
ap
9.00 9.00 9.00
Rd
4.9 3.5 2.8
Arbor(2)
A A A
Kg
0.43 0.70 1.07
With holes for internal coolant For user guide, see pages F11-17. Maximum side plunge (2) For adaptation see page L13. For inserts, see pages: XCMT-TR (K102).
Spare Parts
Designation PLX D52-22-12 PLX D66-22-12 PLX D80-32-12 Screw
SR 34-510/L11.7 SR 34-510/L11.7 SR 34-510/L11.7
Torx Blade
BLD T15/S7 BLD T15/M7 BLD T15/M7
T-Handle
SW6-T SW6-T SW6-T
Plunging
Finishing Cut
F1
F2
F10
ISCAR
USER GUIDE
Recommended Cutting Conditions for Side Plunging
Plunging Cycle: Step 1- Plunge in (axially-Z direction). Step 2- Back stroke (rapid) at an angle b2. Step 3- Move to the next cycle.
ISCAR mat. AISI/SAE/ group* ASTM 4 8 9 10 12 14 16 17 34 37 38 1060 4340 3135 H13 420 304L Class 40
Insert Hardness, HTP LN HB type 180-200 260-300 HRC 35-40* 200-220 200 ER 200 250 ER 200 350 ER HRC 34-36 HRC 45 max ETR ER
Feed Fz, m/min 0.12-0.15 0.1-0.15 0.08-0.15 0.08-0.12 0.08-0.12 0.08-0.1 0.12-0.2 0.1-0.17 0.07-0.1 0.07-0.1 0.08-0.1
Coolant
Air blow
Class 650.7050 (GGG50) 45-12 Inconel 718 Ti6Al4V (Grade 5) 4340 2.4668 3.7164 1.6582
IC810/ IC910
The table data refer to a cutter overhang up to 4D (D-the diameter of a cutter) * ISCAR material group in accordance with VDI 3323 standard ** Quenched and tempered
50
14.0 23.8 30.0 32.5 34.7 36.6 38.5 40.0 41.4 42.7 43.8 -
52
14.3 24.3 30.6 33.2 35.5 37.5 39.3 41.0 42.5 43.8 45.0 -
80
17.8 30.4 38.7 42.1 45.2 48.0 50.5 52.9 55.1 57.1 59.0 60.8
100
19.9 34.1 43.6 47.5 51.0 54.3 57.2 60.0 62.6 65.0 67.3 69.4
F11
USER GUIDE
Recommended Cutting Conditions for Slot Plunging
L- Width of Cut (mm)
L max
Description Non-alloy steel Low alloy steel Low alloy steel High alloy steel Martensitic s.s.
Feed Fz, m/min 0.1-0.15 0.1-0.12 0.08-0.12 0.08-0.1 0.08-0.1 0.08-0.1 0.12-0.18 0.1-0.15 0.07-0.09 0.07-0.09 0.08-0.09
Wet (emulsion)
Air blow
The table data refer to a cutter overhang up to 4D (D-the diameter of a cutter) * ISCAR material group in accordance with VDI 3323 standard ** Quenched and tempered
F12
ISCAR
USER GUIDE
Recommended Cutting Conditions for Face Milling
Ap
Ae
Coolant
IC830/ IC928
Air blow
Wet (emulsion)
Air blow
The table data refer to a cutter overhang up to 4xD and the maximal width of cut Ae=0.7xD (D-the diameter of a cutter) The maximal depth of cut Ap is 2.5 mm for hardened steel and 3 mm for other material groups * ISCAR material group in accordance with VDI 3323 standard ** Quenched and tempered
F13
USER GUIDE
Recommended pattern for the use of PH...- type plunger tools First hole - drilling mode, see Sketch 1. 2) Second and following overlapping by a pitch of 0.5d < A < 0.8d, see Sketch 1. 3) For overlap between pass 1 and 2, see Sketch 2.
1)
Cutting conditions For alloy steel SAE 4340, P20, using carbide grade IC328 Vc = 150 m/min fz = 0.05 - 0.07 mm/flute
Sketch 1
#9 #2
#8 #3
#7 #4
#6 #5
Sketch 2
Hmin = 1 mm
F14
ISCAR
USER GUIDE
Recommended pattern for the PLX...- type plungers Maximum width ae for each pass should not excede 11 mm, see Sketches #1 through #3. 2) Total width of penetration should not exceed A<0.7D, see Sketch #3. 3) ae for additional lateral side steps have an 11 mm maximum, see Sketch #4.
1)
Cutting Conditions: For alloy steel SAE 4340, P20. 30 to 32 Rc, using carbide grade IC328 Vc = 150 m/min fz = 0.12 - 0.15 mm/tooth
Sketch 1
Sketch 2
ae max1 = 11 mm
ae max2 = 11 mm
Sketch 3
Sketch 4
Dt Di
ae max = 11 mm
A max = 0.7D
F15
USER GUIDE
When plunging starts from a pre-drilled hole, the initial diameter of the hole Di should be larger than the plunger diameter Dt.
Sketch 5
Di > Dt
Dt Di
ae max = 11 mm
Note: After each axial plunge stroke, move 45 from the horizontal a distance of at least 0.5 mm. Only after this move can you move up and away for a rapid exit. See Sketch 6.
0.5 mm
mi
Sketch 6
45
F16
ISCAR
USER GUIDE
The PLH...- type (trepanning) plungers have a hollow center. This requires a specific pattern so the column that remains after each plunge is removed completely and smoothly. The coordinates in Table 1 produce the pattern shown in Sketch 7. This provides the optimal results for the PLH D75-27-13 type plunger (outer diameter of 75 mm, inner diameter of 24 mm).
Sketch 7
C F
C H B F
Y
A
Y X
A
Y
A
X
D
G D
Table 1 Hole A B C D E F G H
F17