New Selection

System
for Milling

GMILLINGMILLIN
MILLINGMILLING
OOLINGTOOLING
THINK MILLING, THINK KENNAMETAL.
 WORLD’S MOST COMPREHENSIVE
MILLING SOLUTIONS FOR INDUSTRY
Our metalcutting tools are unsurpassed in quality, value,
and performance! No other single resource delivers such
a comprehensive combination of indexable and solid
Milling products – in one book!

We have the BEST tool – no matter what your Milling

application, workpiece, or equipment – to reduce your
machining time, while providing you superior surface
finishes!

Kennametal‘s newest easy selection

guide system guarantees you:
Ř 1st choice milling solution for your application.

Ř 1st choice cutting conditions for your application.

Ř Milling process optimization for improved productivity.

Ř Most importantly, the benefits of maintaining constant

mean chip thickness (hm), especially for applications
involving radial engagements (AE) less than 50% of the
cutter diameter (D1).

Ř Kennametal your proven productivity booster.

THINK MILLING, THINK KENNAMETAL.

Indexable Milling – New Product Highlights NEW!

TM

Dodeka
Best in class in face milling.
Boost your productivity with 12 cutting edges
per insert! Provides smooth cutting action!

TM

Mill 1
Boost your performance to the top.
One tool for face and shoulder milling,
circular and helical interpolation, ramping
and 3D-milling. Available in 14 mm, 18 mm
and 25 mm axial depth of cut!

TM

KSCM
Precise, easy & productive solution for
Aluminum milling.
Improved stability with consistent performance
and reliability. Excellent Tool Life and surface
finishes!

TM

KDMB
1st choice for Die & Mold.
Get consistent, measurable performance
at high speeds – and long tool life!

4
 Indexable Milling Highlights

TM

KenFEED
Reach feed rates of .118" per tooth!

TM

KSSM Slotting Cutters

Perform right-hand, left-hand, and full slotting with
one cutter!

TM

HexaCut
Achieve unbeatable efficiency and surface finish with
12 cutting edges - ideal for cast and ductile iron!

TM

KSSM Helical Cutter - Harvi style

Prevent chip packing, reduce harmonics, with unique
helical design!

TM

KSSR
Increased productivity and higher metal removal rates
due to optimum cutter density!

FIX - PERFECT Finisher

PERFECT surface for finishing and reduced cycle time!

5
Application Selection Steps – Choose the right cutter

1) Choose your application:

Ř Face Mills Ř 0° Square Shoulder Ř Die and mold
Ř Ceramics Ř Chamfer Mills Ř Slotting
Ř Thread milling

Face Mills

Ř k = 15° Ř k= 0°

FIX - PERFECT Finisher KSCM PCD Shell Mills

Cast Iron 4 cutting edges NEW! 1 cutting edges

AP1 = 0.04" AP1 = .118"

Page 246 Dia: 4.00" - 8.00" Page 268 Dia: 3.00" - 12.00"
Ř Ř Ř Ř Ř k = 43° Ř Ř Ř Ř k=45°

KSOM Mini Dodeka KSHR

NEW! 8 cutting edges NEW! 12 cutting edges

AP1 = .138" (8 cutting edges)

AP2 = .354" (4 cutting edges) AP1 = 0.178"
Page 218 Dia: 2.00" - 6.00" Page 214 Dia: 2.00" - 6.00"

6
 Application Selection Steps – Choose the right cutter

Ř Ř k = 6° Ř k=20°

KSSR FIX - PERFECT 70° IC 12

8 cutting edges Cast Iron 8 cutting edges

AP1 = .213" (8 cutting edges)

AP1 = .200" AP2 = .275" (4 cutting edges)
Page 264 Dia: 2.50" - 10.00" Page 238 Dia: 2.00" - 10.00"
Ř k = 45° Ř Ř Ř Ř Ř k=45°
HexaCut 45° - Cast Iron KSSM 45°
12 cutting edges 4 cutting edges

AP1 = .256" AP1 = .260"

Page 250 Dia: 3.15" - 12.00" Page 230 Dia: 1.26" - 7.87"
Ř Ř Ř Ř Ř k = 15°
P = Steel
KSSM 15°
4 cutting edges M = Stainless Steel
K = Cast Iron
N = Non-Ferrous Materials
S = High-Temp Alloys
H = Hardened Materials

Please find entire application

AP1 = .314" Consult selection guide in the new
Page 234 Dia: 3.15" - 6.30" milling book 6050 Inch on page 76-79.

7
Application Selection Steps – Choose the right cutter

2) Choose the depth of cut (AP1):

Ř Example .178"

3) Find the Appropriate Application and AP1:

Example: Face milling and .178" AP1. Any tool located after selected AP1
value in that application section is suitable for your operation. Tools that
become before the selected AP1 value in that Application section are not
applicable to your operation.

4) Choose the Material:

Each tool has a material grid marked with a solid dot for appropriate for that tool.

Material grid Approach angle

Ř Ř Ř Ř k = 45°

Dodeka KSHR
NEW!
12 cutting
edges

Max
depth AP1 = .178"
of cut

Page 214 Dia: 1.26" - 6.00"

Link to catalog 6050 Inch with all details Available Standard offering

8
 How to Determine Speeds and Feeds

STEP 1: Choose the Milling Cutter

NEW!

TM

Dodeka
Shell Mills - Right Hand - Coarse Pitch
D1 order number catalog number Z D D1max D6 L Ap1max lbs. Max RPM
2.000 3326850 KSHR200HN5345C3 4 .750 2.434 1.593 1.570 .178 .81 12500
2.500 3326852 KSHR250HN5345C3 6 .750 2.933 1.986 1.570 .178 1.32 10000
3.000 3326924 KSHR300HN5345C4 6 1.000 3.433 2.189 1.750 .178 1.79 8300
4.000 3326926 KSHR400HN5345C5 8 1.250 4.432 2.722 1.750 .178 2.93 6300
5.000 3326928 KSHR500HN5345C6 10 1.500 5.431 3.652 2.380 .178 5.94 5000
6.000 3326930 KSHR600HN5345C8 12 2.000 6.432 4.722 2.380 .178 9.10 4100

STEP 2: Choose the Inserts

1) Choose the insert style.

2) Find the (hm) value in the chart. This will help you in defining the feed rate
per to tooth.
3) Determine the workpiece material. See pages 516-520 of catalog 6050 Inch
for material descriptions.
4) Determine the insert grade. The black dot in the material grid indicates
first-choice grades of machining those materials.
H
S ŘŘ
3 N
K Ř Ř
M ŘŘ
P Ř Ř
KC520M
KC522M
KC725M
KC915M
KC935M

2 4
1 catalog number
HNGJ535ANENLD
cutting edges
12
D
.625"
S
.219"
L10
.338"
Rε
.047"
hm
.004" ŘŘŘŘŘ
HNGJ535ANSNGD 12 .625" .219" .338" .047" .006" ŘŘŘ

9
How to Determine Speeds and Feeds

STEP 3: Determine the Cutting Speed

1) Choose the material group.

2) Choose the grade.
3) To determine the sfm for the chosen grade, go to the bold-type center
column for that grade. These are first-choice recommended starting speeds.
4) Move down the bold-type column until you reach the value that is directly in
line with the appropriate material in the first column on the left. The bold-type
value that corresponds to the material on the left is your starting sfm value.

Recommended Starting Speeds (sfm)

45° approach angle

Material Group KC520M KC522M KC725M KC915M KC935M

P1 1030 900 840 1550 1360 1260
P2 640 580 520 960 960 780
P3 580 520 470 860 780 710
P4 380 360 320 430 400 360 650 600 540
P5 530 480 430 590 530 480 890 790 720
P6 320 280 360 310 540 470
M1 600 530 490 670 590 540 1010 890 820
M2 550 490 460 610 550 500 920 830 760
M3 410 370 460 410 680 610
K1 1060 960 850 650 590 530 1440 1310 1310 1010 910 820
K2 830 740 700 800 720 660 520 460 430 1140 1020 950 800 720 660
K3 700 620 560 670 600 550 430 380 350 960 850 780 670 600 550
N1
N2
S1 130 110 140 120
S2 110 110 120 120
S3 140 140 160 160
S4 180 170 200 180
H1

10
 How to Determine Speeds and Feeds

STEP 4: Determine the Feed Rate

1) Choose the (hm) value in the feed chart that matches the (hm) value in
the insert chart you selected in Step1.
2) Define the radial width of cut as a percentage. To determine this, divide
the radial width by the cutter diameter to achieve the percentage of the
engagement.

Recommended Starting Feeds

Programmed Feed Rate fz (Inch)

45° Approach Angel Feed-Per-Tooth Compensation

(Radial Width-of-Cut Dependent)

Percentage of the Cutter Diameter in Cut

11
Influence of radial cutter engagement (0° lead angle – Mill 1-14)

Radial Width of Cut Ae Constant feed rate fz Average chip

thickness hm
100%
fz
Full =
Slot hm

Milling

50%

fz

hm1

20%

fz

hm2

10%

fz
hm3

Radial cutter engagement fz = constant

less then 50%.
Tool life hm > hm1> hm2 > hm3
Surface quality
Chip forming
Productivity

12
 Influence of radial cutter engagement (0° lead angle – Mill 1-14)

Radial Width of Cut Ae Constant average chip Feed rate fz

thickness hm
100%
fz
Full =
Slot hm

Milling

50%

fz1

hm

20%

fz2

hm

10%

fz3
hm

hm = constant

BEST fz < fz1 < fz2 < fz3

SOLUTION
Assume that the chip thickness value is .006"
+ Tool life
fz compensation for 20% radial engagement (Ae)
+ Surface quality Increase fz to fz2 = .006" to .013" = 215%
+ Productivity booster
fz compensation for 10% radial engagement (Ae)
Increase fz to fz3 = .006" to .019" = 315%

13
Insert edge preps

Finishing Semi-roughing Roughing

F – edge prep E – edge prep S – edge prep

Small
Sharp Hone „T“land +
Hone

E – edge prep T – edge prep

Small Small
Hone „T“land

S – edge prep

Small
„T“land +
Hone

Periphery ground inserts

1) 1st choice for finishing, high precision applications and machining

of non ferrous materials.
2) Inserts with tolerance class G,K,C,H are periphery ground.
3) For example: Insert catalog number OFKT53AFEN4GB, KC725M.

Pressed and sintered to size inserts (PSTS)

1) 1st choice for semi-roughing and roughing applications.

2) Inserts with tolerance class P are pressed and sintered to size
(PSTS or molded).
3) For example: Insert catalog number EP1408EHD, KC935M.

14
 Recommended starting hm-values

Finishing Semi-roughing Roughing

Page Milling Platform hm hm hm

215 Dodeka HNGJ53..ENLD .004" HNGJ53..SNGD .006" HNGJ53..SNHD .008"

OFKT53..SN6LB .008"
OFKT53..AFFN4LNJ .002" OFKT53.. EN4GB .004"
219 KSOM Mini OFKT53..SN4HB .008"
OFKT53..EN6LB .002" OFPT53..EN4GB .004"
OFPT53..SN4HB .008"

265 KSSR SNXF43..ENLD .002" SNXF43..SNGP .004" SNXF43..SNHE .004"

KSCMCA75UN .003" KSCMCA75HR .003"

269 KSCM AluMill KSCMCA75QF .003"
KSCMCA90UN .003" KSCMCA75UN

EC1408FLDJ .002" EC1408EGD .002" EP1408SGD .005"

285 Mill 1-14
EC1408ELD .003" EP1408EHD .003"

EC18..E .005"
EC18..FJ .002"
291 Mill 1-18 EP18..E .005" EP18..S .005"
EC18..E .005"
EP18..EHD .004"

SDET43...ER8GB2 .003"
SDCT43...FR8LE .002" SDET43...SR8GB2 .004"
318 KSSM 90° SDPT43...ER8GB2 .003"
SDCT43...ENLD2 .002" SDPT43...SR8GB2 .005"
SDCW43...SR8GN .003"

SPHX12...ERGPB .004"
329 Fix Perfect 90° SPHX12...TRGPB .004" SPHX12...SRGPB .006"
SPHX12...TRGPBK .004"

SDET43...ER8GB2 .006"
SDCT43...FR8LE .002" SDET43...SR8GB2 .004"
368 KSSM Slotters SDPT43...ER8GB2 .003"
SDCT43...ER8LD2 .003" SDPT43...SR8GB2 .004"
SDCW43...SR8GN .005"

Ensure always that the feedrate (fz) is higher than the edge prep.

15
Milling Strategy

Full width cutting with 100% radial engagement (0° lead angle)

Ae = 100% of D1
 Ř Material 1045 (P2) Ř
ŘMID300E14085100L175 (Mill 1-14)
ŘEP1408SGD KC935M
ŘDiameter (D1) = 3.00"
ŘNumber of teeth (Z) = 8
ŘAverage Chip Thickness (hm)= .006"
ŘCutting Speed (Vc) = 720 sfm
ŘSpindle Speed (n) = 920 rpm
ŘAxial Depth of cut (Ap1) = .390"
ŘRadial Width of Cut (Ae) = 2.00"

fz = hm

Řfz = .006" (according feed chart for 100% radial engagement (Ae) and
lead angle compensation for 90°)

ŘFeedrate (Vf) = Feed Per Tooth (fz) x Number of Teeth (Z) x Spindle Speed (n)
Vf = .006 x 8 x 920 = 44.16"/min

Refer to Catalog 6050 for lead angle compensation on Feed Per Tooth (fz)
Page 289 of the Inch milling catalog.

16
 Milling Strategy

Partial width cutting with 10% radial engagement (0° lead angle)

Ae = 10% of D1
 Ř Material 1045 (P2) Ř
ŘMID300E14085100L175 (Mill 1-14)
ŘEDPT1EDPT1408SGD KC935M
ŘDiameter (D1) = 3.00"
ŘNumber of teeth (Z) = 8
ŘAverage Chip Thickness (hm)= .006"
ŘCutting Speed (Vc) = 720 sfm
ŘSpindle Speed (n) = 920 rpm
ŘAxial
OPTIMUM
Depth of cut (Ap1) = .390" SOLUTION
ŘRadial Depth of Cut (Ae) = .315"

Without feedrate (fz) compensation With feedrate (fz) compensation

ŘSince no compensation is considered, the feed per ŘAccording to the feed chart for 10% radial engage-
tooth (fz) does not vary with the radial engagement ment (Ae) and a lead angle compensation for 90°
(Ae). (refer 6050 catalog).

fz = Constant hm = Constant

fz fz
hm hm
Řfz= .006" Řhm = .006"
ŘVf = fz x Z x n fz = .019"
Vf = .006 x 8 x 920 ŘVf = fz x Z x n
= 44.16"/min Vf = .019" x 8 x 920
= 139.84"/min
Example: 13% radial width of cut in contact with
the workpiece. For calculation purposes use 15% 316% Time savings
to get the new feed rate per tooth.

17
Milling Strategy

Cutting with 80% radial engagement (45° lead angle)

TM

Dodeka Ae = 80% of D1
 Ř Material Class 35 Cast Iron (K1) Ř
ŘKSHR400HN5345C5 (Dodeka)
ŘHNGJ535ANSNGD KC915M
ŘDiameter (D1) = 4"
 ŘNumber of teeth (Z) = 8
ŘAverage Chip Thickness (hm) = .006"
ŘCutting Speed (Vc) = 1310 sfm
ŘSpindle Speed (n) = 1250 rpm
ŘAxial Depth of cut (Ap1) = .170"
ŘRadial Depth of Cut (Ae)= 3.120"

fz

hm

Řfz = .008" (according feed chart for 80% radial engagement (Ae) and lead
angle compensation for 45°)

Anything above 50% radial engagement, always use the 100% engagement
value.

ŘFeedrate (Vf) = Feed Per Tooth (fz) x Number of Teeth (Z) x Spindle Speed (n)
Vf = .008 x 8 x 1250 = 80"/min

18
 Milling Strategy

Partial width cutting with 30% radial cutter engagement (45° lead angle)

TM

Dodeka Ae = 30% of D1
 Ř Material Class 35 Cast Iron (K1) Ř
ŘKSHR400HN5345C5 (Dodeka)
ŘHNGJ535ANSNGD KC915M
ŘDiameter (D1) = 4"
ŘNumber of teeth (Z) = 8
ŘAverage Chip Thickness (hm) = .006"
ŘCutting Speed (Vc) = 1310 sfm
ŘSpindle Speed (n) = 1250 rpm
ŘAxial Depth of cut (Ap1) = .170" OPTIMUM
SOLUTION
ŘRadial Depth of Cut (Ae) = 1.2"

Without feedrate (fz) compensation With feedrate (fz) compensation

ŘSince only lead angle (k) compensation is consi- Ř According to the feed chart for 30% radial engage-
dered, the feed per tooth (fz) does not vary with ment (Ae) and a lead angle compensation for 45°
the radial engagement (Ae). (refer 6050 catalog).

fz = Constant hm = Constant

fz fz
hm hm

Řfz = .008" Řhm = .006"

ŘVf = fz x Z x n fz = .015"
Vf = .008 x 8 x 1250 ŘVf = fz x Z x n
= 80"/min Vf = .015 x 8 x 1250
= 150"/min

187% Time savings

19
 TM

HARVI Solid Carbide Endmills

ŘUnequal flute spacing delivers smooth,

chatter-free machining!
ŘYields
superior surface finishes,
even at high speed!
ŘRougher and finisher in one tool!
ŘEasy to regrind!
ŘMaximize performance in steel,
stainless steel, cast iron, and high-
temp alloys!

THINK MILLING,
THINK KENNAMETAL.
 Solid Carbide / End Mills Highlights

HARVI Square End Finishers

HPHV... P M K N S H
Features ŘŘŘ Ř
1/8" to 1" ∅
Ř Plain and weldon shank.
Ř Sharp and Corner chamfer -

center cutting.
Catalog 6050 Inch: Product Page 28
Application Data 44
Operations
Ř Side cutting, slotting and ramping.
Ř For aerospace, general engineering,

medical, and automotive applications.

HPHVT – HARVI FOR TITANIUM P M K N S H
Features Ř
1/2" to 1" ∅
Ř Factory standard.
Ř Weldon shannk.
Ř Sharp and Corner chamfer -
Catalog 6050 Inch: Product Page 30
center cutting. Application Data 44

Operations
Ř Side cutting, slotting and ramping.
Ř For aerospace and medical.

HARVI Long Reach Finishers P M K N S H

ŘŘŘ Ř
HPRSHV... 1/2" to 1" ∅
Features
Ř Factory standard.
Ř Plain and weldon shank. Catalog 6050 Inch: Product Page 29
Application Data 44
Ř Sharp and Corner chamfer -

center cutting.

Operations
Ř Side cutting, slotting and ramping.
Ř For aerospace and automotive applications.

21
Solid Carbide / End Mills Highlights

HARVI Ball Nose Finishers

HPHUBN... P M K N S H
Features ŘŘŘ Ř
1/8" to 1" ∅
Ř Factory standard.
Ř Plain and weldon shank.
Ř Ball nose.
Catalog 6050 Inch: Product Page 64
Application Data 70
Operations
Ř Side cutting, slotting, and 3-dimensional milling.
Ř For general engineering, aerospace applications and medical.

22
 Tool selection guide

3 4 5 2 Ř...first
choice

See Page
...alternative
Range of choice
Diameter
Type Tool (inch) No. of Helix Special Type of Workpiece
of Tool Style Min-Max Flutes Angle Features Application Material

R-Radius
CH-Chamfer
N-Neck
C-Coolant
KW-Keyway 1
Mic-Micro
TR-Toriodal
SQ-Square End P M K N S H

Side
HPHV .125-1.000 4 38 CH, SQ
milling
Slotting ŘŘŘ Ř [3733]

Side
HPRSHV .500-1.000 4 38 CH, SQ
milling ŘŘŘ Ř [3751]

Side
HPHVT .500-1.000 4 38 CH, SQ
milling
Slotting Ř [7473]

1) Workpiece Material (S)

2) Type of Application (Slotting)

3) Diameter (Ø 10)

4) No. of Flutes and Helix Angel (4 and 38°)

5) Special Features (Radius)

23
Tool selection guide

HPHV – Unequal Flute Spacing

Features
Ř Kennametal standard.
Ř Plain and Weldon shanks.
Ř Sharp and chamfered corner -
center cutting.
Application
Ř Side cutting and slotting.
Ř For aerospace, general engineering,
die and mold, medical, and automotive
applications.

D1 BCH KCH D1 D1 Tolerance D Tolerance

≤ 5/16" .015" 45° < 1/4" +.000" to – .002" +.0000" to – .0005"
≥ 3/8" .020" 45° 1/4" and larger +.000" to –.003" +.0000" to –.0005"

Ř 4-Flute, 38° Helix H

Ř Chamfer Table
S Ř
N
Ř End Mill Tolerances
Ř...first choice K Ř
M Ř
...alternative choice P Ř

KC633M
D1 D Ap1 max L Rε mounting style catalog number
1 1 1 1/2 4 .0 WELDON HPHV1000S4150 Ř
1 1 1 1/2 4 — WELDON HPHV1000S4150CH Ř
1/8 1/8 1/2 2 .0 PLAIN HPHV125S4050 Ř
1/8 1/8 1/2 2 — PLAIN HPHV125S4050CH Ř
3/16 3/16 5/8 2 1/4 .0 PLAIN HPHV188S4063 Ř
3/16 3/16 5/8 2 1/4 — PLAIN HPHV188S4063CH Ř
1/4 1/4 3/8 2 .0 PLAIN HPHV250S4038CH Ř
1/4 1/4 3/4 2 1/2 — PLAIN HPHV250S4075 Ř
1/4 1/4 3/4 2 1/2 .0 PLAIN HPHV250S4075CH Ř
5/16 5/16 3/4 2 1/2 — PLAIN HPHV312S4075 Ř
5/16 5/16 3/4 2 1/2 .0 PLAIN HPHV312S4075CH Ř
3/8 3/8 7/8 2 1/2 — PLAIN HPHV375S4088 Ř
3/8 3/8 7/8 2 1/2 .0 PLAIN HPHV375S4088CH Ř
1/2 1/2 5/8 2 1/2 — WELDON HPHV500S4063 Ř
1/2 1/2 5/8 2 1/2 .0 WELDON HPHV500S4063CH Ř
1/2 1/2 1 3 — WELDON HPHV500S4100CH Ř
1/2 1/2 1 1/4 3 .0 WELDON HPHV500S4125 Ř
1/2 1/2 1 1/4 3 — WELDON HPHV500S4125CH Ř
5/8 5/8 3/4 3 .0 WELDON HPHV625S4075 Ř
5/8 5/8 3/4 3 — WELDON HPHV625S4075CH Ř
5/8 5/8 1 1/4 3 1/2 .0 WELDON HPHV625S4125 Ř
5/8 5/8 1 1/4 3 1/2 — WELDON HPHV625S4125CH Ř
3/4 3/4 7/8 3 1/2 .0 WELDON HPHV750S4088 Ř
3/4 3/4 7/8 3 1/2 — WELDON HPHV750S4088CH Ř
3/4 3/4 1 1/2 4 .0 WELDON HPHV750S4150 Ř
3/4 3/4 1 1/2 4 — WELDON HPHV750S4150CH Ř

24
 Tool selection guide

Application data

HPHV...

Cutting Reduce
conditions speed by
for: 20% for
HPHV slotting
applica-
tions
Recommended fz - Feed Per Tooth (Inch/th)
Application
Vc for side cutting operations.
KC633M For slotting operations, reduce fz by 20%.
Side Milling Slotting
D1 - Diameter (Inch)
Group Material ap ae ap SFM 1/8" 3/16" 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 1"
Medium and high
P2 1xD 0.5XD 1xD 500~600 .0012 .0014 .0016 .0021 .0026 .0031 .0034 .0036 .0040
carbon steels > 0.3%
Alloy steels and Tool
P3 1xD 0.5XD 1xD 400~500 .0012 .0014 .0016 .0021 .0026 .0031 .0034 .0036 .0040
steels <330HB, <35HRC
Alloy steels and Tool steels
P4 1xD 0.5XD 1xD 300~400 .0008 .0010 .0012 .0016 .0021 .0026 .0031 .0034 .0036
340- 450HB, 36-48HRC
Ferritic, Martensitic
P5 and PH Stainless steels 1xD 0.5XD 1xD 225~275 .0012 .0014 .0016 .0021 .0026 .0031 .0034 .0036 .0040
<330HB, <35HRC
Austenitic stainless steel
M1 1xD 0.5XD 1xD 275~375 .0008 .0010 .0012 .0016 .0021 .0026 .0031 .0034 .0036
(302, 303, 304)
Austenitic stainless steel
M2 1xD 0.5XD 1xD 200~275 .0004 .0008 .0012 .0014 .0016 .0020 .0022 .0026 .0031
(316, 316L)
Austenitic stainless steel:
M3 Duplex (Ferritic and 1xD 0.5XD 1xD 125~200 .0004 .0008 .0012 .0014 .0016 .0020 .0022 .0026 .0031
Austenitic Mixture)

K1 Grey Cast Iron (GG) 1xD 0.5XD 1xD 425~525 .0014 .0015 .0017 .0022 .0028 .0034 .0036 .0039 .0050

Iron based heat

S1 1xD 0.2XD 0.3XD 65~90 .0004 .0008 .0010 .0012 .0014 .0016 .0018 .0020 .0022
resistant alloys
Cobalt based heat
S2 1xD 0.2XD 0.3XD 65~90 .0004 .0008 .0010 .0012 .0014 .0016 .0018 .0020 .0022
resistant alloys
Nickel based heat
S3 1xD 0.2XD 0.3XD 65~90 .0004 .0008 .0010 .0012 .0014 .0016 .0018 .0020 .0022
resistant alloys
Alpha-Beta
S4 1xD 0.3XD 0.5XD 135~175 .0008 .0010 .0014 .0016 .0020 .0022 .0026 .0029 .0034
Titanium alloys

For Material Group Selection see Material Grade Table Page 546-551
(Catalog 6050 Inch).

25
Technical Notes

Number of Cutting Edges

Main Application Comment

Plunging (drilling) Very suitable for full slot milling,

greater dimensional accuracy in
feather key slot milling (F2AU …
DK30, F3AU … DK30)

Full slot (Feather key slot) Better for fill slot milling and helical
end milling; combined
machining more efficient

Face milling Smaller chip chambers

Roughing/finishing With two cutting edges in the center
Helical end milling Plunging possible, but small plunge
depth max. (0,1 x d) Steps

Contouring Helical end High form and positioning

milling Finishing tolerance, Surface quality, feed
rates (efficiency)

(small ae with increasing Higher ae

number of teeth) Poor chip evacuation
Chip cahmbers become
clogged

26
 Technical Notes

Ball Nose – Effective Cutting Diameter Calculation

When the axial depth of cut is less than half of the cutting diamter (ap < .5D1),
the end mill diameter used to determine speed and feed rate is smaller than the
cutting diameter (D1). This smaller end mill diameter is known as the effective
cutting diameter (Deff). This effective cutting diameter can be calculated using
a simple 4-step process.

Step 1: Determine the following values from your application:

D1 = end mill cutting diameter, ap = axial depth of cut
Step 2: Determine the depth of cut ratio: depth of cut ratio = ap/D1
Step 3: Determine the diameter factor from the table below using the
depth of cut ratio from Step 2:
Step 4: Calculate the effective cutting diameter (Deff):
Deff = D1 multiplied by the diameter factor

Example: What is the effective cutting diameter for a 1/2"-diameter

ball nose end mill running at a .05“ axial depth of cut?
Step 1: D = 1/2" ap = .05"
Step 2: Depth-of-cut ratio = .05/.5 = .1
Step 3: Diameter factor = .6
Step 4: Effective cutting diameter = .5 x .6 = .3"

Depth of cut ratio

Diameter factor
= ap/D1
0.40 0.98
0.30 0.917
0.25 0.87
0.20 0.8
0.15 0.71
0.10 0.6
0.08 0.54
0.05 0.44
0.04 0.39
0.03 0.34
d eff
0.02 0.28
0.01 0.19

27
Technical Notes

Square End – Radial Width of Cut Factor

If the radial width of cut (ae) is less than .5 x D1, the actual chipload at the cutting
edge is less than the programmed chipload. To obtain the correct chipload at the
cutting edge, follow the simple 4-step process.

Step 1: Determine the following values from your application:

D1 = end mill cutting diameter, ae = radial width of cut
fz = desired chipload per tooth at the cutting edge
Step 2: Determine the radial width engagement ratio:
radial width engagement ratio = ae/D1
Step 3: Determine the chipload factor from the table below using
the radial width engagement ratio from Step 2:
Step 4: Calculate what the programmed chipload should be to get
the desired chipload at the cutting edge: fz programed = fz * chipload factor

Example: What is the programmed chipload to achieve a desired chipload of

.002"/tooth using a 1/2"-diameter end mill with a radial width of cut of .05"?

Step 1: D1 = .500" ae = .05" fz = .002"

Step 2: Radial width engagement ratio = ae/D1 = .05"/.500" = .1
Step 3: Chipload factor for a .1 radial width engagement ratio = 1.73
Step 4: The programmed chipload = fz x chipload factor = .002" x 1.73 = .0034"

Radial Width
Chip Load Factor
Engagement Ratio = ae/D1
0.3 1.1
0.25 1.15
0.2 1.25
0.15 1.41
0.1 1.73
0.07 2.0
0.05 2.33
0.03 2.93
0.02 3.6
0.01 5.0

28
 Technical Notes

Application hints Suggested solutions

in solid carbide milling

Splintering of the cutting edge Ř Decrease feed per tooth

(thermal load) Ř Increase cutting speed

Crumbling of the cutting edge Ř Check rigidity of machine,

(mechanical load) workpiece, workpiece clamping
Ř Reduce feed per tooth
Ř Shorten protrude length
Ř Climb milling
Ř Check tool clamping
Ř Check spindle movement

Mill breakage Ř Ensure free cutting process

Ř Increase cutting speed
Ř Reduce feed rate and cutting depth
Ř Check tool clamping
Ř Shorten protrude length
Ř Reduce cutting depth
Ř Improve chip evacuation

Heavy crater wear Ř Reduce cutting speed

Ř Use more wear-resistant carbide
grade

Heavy flank wear Ř Increase feed per tooth

Ř Reduce cutting speed
Ř Use coated version
Ř Use more wear-resistant carbide

grade

29
Technical Notes

Application hints Suggested solutions

in solid carbide milling

Edge build-up Ř Increase cutting speed and/or

feed rate
Ř Improve cooling

Vibrations (chatter) Ř Check damping and machine

stability
Ř Select a different cutting geometry
Ř Check alignment of milling cutter and

workpiece
Ř Climb milling

Inadequate surface on Ř Reduce feed per tooth

the on the workpiece Ř Check clamping and machine
stability
Ř Increase cutting speed
Ř Select a different cutting geometry

with larger twist angel

Ř Use milling cutter with more of teeth

Splintering on the workpiece Ř Reduce feed per tooth

Ř Use milling cutter with more teeth

Chip buildup Ř Use tool with larger chip chambers

(less teeth)
Ř Modify cutting geometry
Ř Modify cutting values
Ř Reduce cutting depth
Ř Use milling cutter with less teeth

30
31
KENNAMETAL CUSTOMER
APPLICATION SUPPORT

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