New Wear Resistant Solid Carbide Endmills for Machining Stainless Steel Efficiently
NPA 02/2019
Highlights
ISCAR has designed the CHATTERFREE ECY-S5 geometry with 5 flutes, sub-flutes and variable helix for a wide range of milling operations on stainless steel.
ISCAR is introducing the ECY-S5 – a family of new solid carbide endmills for milling austenitic, duplex, cast and precipitation hardening (PH) stainless steels (ISO M group of applications).
The new ECY-S5 endmills are suitable for a wide range of milling operations, from rough to finish machining and including trochoidal milling.
The new endmills feature a unique patent-pending design that delays wear and significantly improves tool life.
Features
- Unique core taper shaped sub-flute contributes to better chip evacuation, particularly on full depth machining ( 2XD)
- 5 flutes with variable angular pitch and different helix portions
- The combination of the new AlTiCrSiN PVD coating with a hard submicron grade IC08, creates a high wear resistant grade IC608
- Accuracy: e8 tolerance limits for the nominal endmill diameter (D) and h6 for the endmill shank diameter
- Edge wear transition mechanism
- Varying rake angles create softer cut while taking wide chips
Varying rake and relief angles
Sub-flutes with variable helix
Flutes with different helix
Bi-directional Wear Guidance Design
- Controlled wear transmission in diverging directions
- Provides uniform wear to increase overall tool life
Wear transmission mechanism
Advantages
- The sub-flute wear control mechanism combined with variable and different rake and relief angles considerably increases tool life
- Variable and different helix portions inhibit resonance and increase chip evacuation space proximate to the cutting end face
- Reinforced core taper improves structural strength
- Performance benefits are particularly notable when milling at depth of cut of approximately 2×D
Typical cutting data when milling ISO M materials:
|
Shoulder milling |
DC=8-10 mm |
DC=12-16 mm |
ECY-S5 |
Vc (m/min) |
Ap |
Ae, max |
Fz (mm/t) |
Fz (mm/t) |
100-150 |
~2×D |
0.4×D |
0.03-0.045 |
0.04-0.055 |
|
Shoulder milling |
DC=8-10 mm |
DC=12-16 mm |
ECY-S5 |
Vc (m/min) |
Ap |
Fz (mm/t) |
Ap max |
Fz (mm/t) |
Ap max |
70-90 |
D |
0.02-0.04 |
0.25×D |
0.03-0.04 |
0.25×D |
|
HSM / Trochoidal milling |
DC=8-10 mm |
DC=12-16 mm |
ECY-S5 |
Vc (m/min) |
Ap |
Ae, max |
Fz (mm/t) |
Fz (mm/t) |
180-250 |
~2×D |
0.1×D |
0.05-0.12 |
0.06-0.13 |
Application report:
Application: Shoulder milling
Material: AISI/SAE 304 (DIN X5CrNi 18 9, W.-Nr. 1.4301)
Coolant: Emulsion
Pressure: 8 bar
Machine type: Vertical machining center
Brand: HAAS
Spindle adaptation: BT40
Manufacturer |
ISCAR - Actual |
Other - Competitor |
Tool |
ECY-S5 16-32C16CFR.8-92 608 |
Competitor |
Diameter (mm) |
16 |
16 |
No. of Flutes |
5 |
5 |
Carbide Grade |
608 |
Coated |
Edge Preparation |
Standard |
Standard |
Tool Stability |
Fair |
Fair |
Overhang (mm) |
45 |
45 |
Cutting Speed (m/min) |
226 |
226 |
Cutting Speed (m/min) |
226 |
226 |
Spindle Speed (rpm) |
4,496 |
4,496 |
Depth of Cut (mm) |
28 |
28 |
Width of Cut (mm) |
0.6 |
0.6 |
Machining Length (mm) |
600 |
600 |
Feed per Tooth (mm/t) |
0.09 |
0.09 |
Table Feed (mm/min) |
2,023 |
2,023 |
Number of Passes |
10 |
10 |
Parts per Cutter |
44 |
17 |
Avg. Chip Thickness (mm) |
0.02 |
0.02 |
Surface Quality |
Good |
Good |
Chip Type |
Comma/Helical |
Comma/Helical |
Wear |
Crater Wear |
Crater Wear |
Reason for Stopping the Test |
Wear |
Wear |
Metal Removal Rate (cm3/min) |
33.98 |
33.98 |
The tool from a competitor showed excessive wear formation after 15 parts and couldn’t exceed 17 parts.
ECY-S5-CFR
5 Flute Endmills with Different Helix for Milling Austenitic, Duplex, Cast and Precipitation Hardening Stainless Steels
(1) Number of flutes
(2) Maximum ramping angle
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