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P Steel (14)
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P0Low-Carbon Steels, Long Chipping C < .25%; <125 HB; <530 N/mm^2 UTS(14)
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P1Low-Carbon Steels, Short Chipping C < .25%; <125 HB; <530 N/mm^2 UTS(14)
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P2Medium and High Carbon Steels C < .25%; <220 HB; <25 HRC; >530 N/mm^2 UTS(14)
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P3Alloy Steels & Tool Steels C > .25%; <330 HB; <35 HRC; 600-850 N/mm^2 UTS(14)
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P4Alloy Steels & Tool Steels C > .25%; 350-420 HB; 35-43 HRC; 850-1400 N/mm^2 UTS(14)
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P5Ferritic, Martensitic, and PH Stainless Steels <330 HB; <35 HRC; 600-900 N/mm^2 UTS(14)
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P6High Strength Ferritic, Martensitic, and PH Stainless Steels 350-450 HB; 35-43 HRC; 900-2400 N/mm^2 UTS(14)
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M Stainless Steel (14)
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M1Austenitic Stainless Steel 130-200 HB; <600 N/mm^2 UTS(14)
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M2High Strength Austenitic Stainless and Cast Stainless Steels 150-230 HB; <25 HRC; >600 N/mm^2 UTS(14)
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M3Duplex Stainless Steel 135-275 HB; <30 HRC; 500-1200 N/mm^2 UTS(14)
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K Cast Iron (14)
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K1Gray Cast Iron 120-290 HB; <32 HRC; 125-500 N/mm^2 UTS(14)
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K2Low and Medium Strength CGI and Ductile Irons 130-260 HB; <28 HRC; <600 N/mm^2 UTS(14)
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K3High Strength Ductile and Austempered Ductile Iron 180-350 HB; <43 HRC; >600 N/mm^2 UTS(14)
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S High-Temp Alloys (1)
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S1Iron-Based, Heat-Resistant Alloys 160-260 HB; 25-48 HRC; 500-1200 N/mm^2 UTS(1)
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S2Cobalt-Based, Heat-Resistant Alloys 250-450 HB; 25-48 HRC; 1000-1450 N/mm^2 UTS(1)
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S3Nickel-Based, Heat Resistant Alloys 160-450 HB; <48 HRC; 600-1700 N/mm^2 UTS(1)
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S4Titanium and Titanium Alloys 300-400 HB; 33-43 HRC; 900-1600 N/mm^2 UTS(1)
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H Hardened Materials (13)
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H1Hardened Materials 44-48 HRC(13)
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ID Thread Turning (13)
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OD Thread Turning (13)
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UN (14)
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2.0 (14)
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KC610M (1)
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KC635M (13)
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N (14)
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30.0 (14)
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TM-TRIANGLE THREAD MILL 60 (14)
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8.382 (1)
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8.89 (1)
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9.144 (1)
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9.652 (2)
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9.906 (2)
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10.16 (1)
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14.224 (2)
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14.478 (1)
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14.732 (2)
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14.986 (1)
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0.33 (1)
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0.35 (1)
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0.36 (1)
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0.38 (2)
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0.39 (2)
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0.4 (1)
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0.56 (2)
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0.57 (1)
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0.58 (2)
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0.59 (1)
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12.0 (1)
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14.0 (2)
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16.0 (2)
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18.0 (2)
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20.0 (2)
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24.0 (2)
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27.0 (1)
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28.0 (1)
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32.0 (1)
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12.0 (1)
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14.0 (2)
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16.0 (2)
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18.0 (2)
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20.0 (2)
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24.0 (2)
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27.0 (1)
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28.0 (1)
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32.0 (1)
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TM-TRIANGLE THREAD MILL 60 (14)
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0.2362 (2)
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0.25 (6)
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0.375 (6)
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6.0 (2)
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6.35 (6)
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9.525 (6)
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H W (14)
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KC610M (1)
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KC635M (13)
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TMS (13)
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I (14)
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M (14)
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N (14)
SAP Material Number | ISO Catalog Number | ANSI Catalog Number | Grade | TPI | [D] Insert IC Size | [D] Insert IC Size | [LI] Insert Length | [LI] Insert Length | [W] Cutting Width | [W] Cutting Width | Number of Teeth | |
---|---|---|---|---|---|---|---|---|---|---|---|---|
2384504 | STN1018UNI | STN1018UNI | KC635M | 18 | 6.0000 | .2362 | 10.4140 | .4100 | 8.3820 | .3300 | 6 |
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2384505 | STN1020UNI | STN1020UNI | KC635M | 20 | 6.0000 | .2362 | 10.4140 | .4100 | 8.8900 | .3500 | 7 |
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2384509 | STN1114UNI | STN1114UNI | KC635M | 14 | 6.3500 | .2500 | 10.9220 | .4300 | 9.1440 | .3600 | 5 |
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2384510 | STN1116UNI | STN1116UNI | KC635M | 16 | 6.3500 | .2500 | 10.9220 | .4300 | 9.6520 | .3800 | 6 |
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2384511 | STN1118UNI | STN1118UNI | KC635M | 18 | 6.3500 | .2500 | 10.9220 | .4300 | 9.9060 | .3900 | 7 |
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2384512 | STN1120UNI | STN1120UNI | KC635M | 20 | 6.3500 | .2500 | 10.9220 | .4300 | 10.1600 | .4000 | 8 |
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2384513 | STN1124UNI | STN1124UNI | KC635M | 24 | 6.3500 | .2500 | 10.9220 | .4300 | 9.6520 | .3800 | 9 |
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2384514 | STN1128UNI | STN1128UNI | KC635M | 28 | 6.3500 | .2500 | 10.9220 | .4300 | 9.9060 | .3900 | 1 |
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1912477 | STN1612UNI | STN1612UNI | KC635M | 12 | 9.5250 | .3750 | 16.0020 | .6300 | 14.7320 | .5800 | 7 |
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2384517 | STN1614UNI | STN1614UNI | KC635M | 14 | 9.5250 | .3750 | 16.0020 | .6300 | 14.4780 | .5700 | 8 |
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1288604 | STN1616UNI | STN1616UNI | KC610M | 16 | 9.5250 | .3750 | 16.0020 | .6300 | 14.2240 | .5600 | 9 |
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2384521 | STN1624UNI | STN1624UNI | KC635M | 24 | 9.5250 | .3750 | 16.0020 | .6300 | 14.7320 | .5800 | 14 |
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2384522 | STN1627UNI | STN1627UNI | KC635M | 27 | 9.5250 | .3750 | 16.0020 | .6300 | 14.2240 | .5600 | 15 |
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2384524 | STN1632UNI | STN1632UNI | KC635M | 32 | 9.5250 | .3750 | 16.0020 | .6300 | 14.9860 | .5900 | 9 |
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Replacement Product This item may be available through a distributor
Grades
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KC610M
A high-performance, TiN-TiCN-TiN-PVD-coated carbide grade characterised by good hardness and wear resistance for milling all types of material and is the first choice for steel. KC610M should be used with coolant or minimal lubrication.
PMKS -
KC635M
Universal carbide grade with PVD coating (TiAlN). KC635M is a high-performance grade for finishing operations. This grade is characterised by high hardness and wear resistance.
PMKH
TM25 Inserts
Materials | Brinell | surface speeds | indexable inserts | |
steel | HB | KC610M | KC635M | feed fz (IPT) |
P1 | 125 | 100–210 | 90–180 | 0,05–0,20 |
P2 | 180 | 100–170 | 90–160 | 0,05–0,20 |
P3 | 225 | 60–130 | 70–115 | 0,05–0,20 |
P4 | 250 | 80–150 | 80–160 | 0,05–0,20 |
P5 | 275 | 75–130 | 80–160 | 0,05–0,15 |
P6 | 325 | 70–110 | 60–100 | 0,05–0,10 |
stainless steel | ||||
M1 | 180 | 100–170 | 120–180 | 0,05–0,10 |
M2 | 250 | 70–140 | 100–140 | 0,05–0,10 |
M3 | 330 | 70–120 | 100–120 | 0,05–0,10 |
cast iron | ||||
K1 | 180 | 60–130 | 100–120 | 0,02–0,08 |
K2 | 220 | 60–125 | 80–100 | 0,05–0,15 |
K3 | 260 | 50–90 | 60–90 | 0,05–0,10 |
non-ferrous | ||||
N1 | 60–100 | 100–250 | – | 0,05–0,25 |
high-temp alloys | ||||
S1 | 200 | 20–45 | 20–40 | 0,05–0,10 |
S2 | 250 | 20–30 | 20–30 | 0,02–0,05 |
S3 | 280 | 15–20 | 15–20 | 0,02–0,05 |
S4 | 350 | 10–15 | 10–15 | 0,02–0,05 |
hardened steel | ||||
H1 | 55 HRC | 20–45 | 20–45 | 0,01–0,03 |
Methods of External Thread Milling
right-hand thread... conventional milling | left-hand thread... conventional milling |
right-hand thread... climb milling | left-hand thread... climb milling |
Methods of Internal Thread Milling
right-hand thread... conventional milling | left-hand thread... conventional milling |
right-hand thread... climb milling | left-hand thread... climb milling |
Minimum Bore Diameters
cutter | TPI | 48 | 32 | 24 | 20 | 16 | 12 | 10 | 8 | 7 | 6 | 5.5 | 5 | 4.5 | 4.5 | 4 | 4 |
pitch mm | 0,5 | 0,75 | 1,0 | 1,25 | 1,5 | 2,0 | 2,5 | 3,0 | 3,5 | 4,0 | 4,5 | 5,0 | 5,5 | – | 6,0 | – | |
cutter diameter (D1) | minimum bore diameter (D) (inches) | ||||||||||||||||
K035TM1RW050-STN10 | .35 | .374 | .394 | .421 | .449 | ||||||||||||
K045TM1RW050-STN11N | .45 | .472 | .492 | .520 | .547 | .571 | |||||||||||
K049TM1RW037LT11S | .49 | .512 | .531 | .559 | .587 | .610 | |||||||||||
K061TM1RW062-STN16T | .61 | .630 | .650 | .667 | .705 | .728 | .768 | ||||||||||
K067TM2RW075-STN11D | .67 | .693 | .717 | .748 | .772 | .787 | .827 | ||||||||||
K075TM1RW075-STN16T | .75 | .776 | .803 | .827 | .850 | .866 | .906 | ||||||||||
K079TM1RW075-STN16N | .79 | .815 | .843 | .866 | .890 | .906 | .945 | ||||||||||
K087TM1RW100-STN16L | .87 | .893 | .921 | .945 | .969 | .984 | 1.024 | ||||||||||
K102TM2RW100-STN16D | 1.02 | 1.051 | 1.079 | 1.102 | 1.130 | 1.154 | 1.193 | ||||||||||
K118TM1RW100-STN27N | 1.18 | 1.209 | 1.236 | 1.260 | 1.291 | 1.319 | 1.362 | 1.441 | 1.535 | 1.654 | 1.772 | 1.890 | |||||
K146TM1RW125-STN27N | 1.46 | 1.496 | 1.520 | 1.555 | 1.591 | 1.614 | 1.654 | 1.732 | 1.830 | 1.929 | 2.047 | 2.185 | |||||
K165TM2RW125-STN27D | 1.65 | 1.701 | 1.724 | 1.772 | 1.811 | 1.831 | 1.866 | 1.929 | 2.047 | 2.146 | 2.268 | 2.401 | |||||
– | 1.38 (UN) | – | – | – | – | – | – | – | – | – | 1.969 | – | 1.843 | – | 1.756 | – | 2.228 |
– | 1.38 (ISO) | – | – | – | – | – | – | – | – | – | 1.969 | 2.102 | 1.673 | 1.969 | – | 2.264 | – |
– | 1.38 (BSW) | – | – | – | – | – | – | – | – | – | 1.961 | – | 1.831 | – | 1.866 | – | – |
UN-ISO-BSW
workpiece material | Cutting Speed vc SFM | feed rate per revolution (inch) |
KC635M | ||
carbon steels 187 HB | 300–700 | .004–.008 |
carbon steels 187–220 HB | 300–500 | .004–.006 |
alloy steel 200–250 HB | 200–425 | .004–.006 |
alloy steel 250–325 HB | 150–300 | .004–.006 |
stainless steel, austenitic 210 HB | 300–450 | .004–.006 |
stainless steel, martensitic 321 HB | 250–350 | .002–.006 |
stainless steel, ferritic 245 HB | 350–550 | .002–.004 |
cast steel 140 HB | 350–550 | .002–.006 |
cast steel 220302 HB | 225–425 | .002–.004 |
titanium alloys | 200–400 | .001–.003 |
high-temperature (nickel and iron base) | 75–150 | .001–.002 |
high-temperature (cobalt base) | 50–100 | .001–.002 |
cast iron | 250–350 | .002–.006 |
malleable iron | 250–400 | .001–.003 |
workpiece material | Cutting Speed vc m/min | feed rate per revolution (mm) |
KC635M | ||
carbon steels 187 HB | 90–210 | 0,10–0,20 |
carbon steels 187–220 HB | 90–150 | 0,10–0,15 |
alloy steel 200–250 HB | 60–130 | 0,10–0,15 |
alloy steel 250–325 HB | 50–90 | 0,10–0,15 |
stainless steel, austenitic 210 HB | 90–140 | 0,10–0,15 |
stainless steel, martensitic 321 HB | 80–110 | 0,05–0,15 |
stainless steel, ferritic 245 HB | 110–170 | 0,05–0,10 |
cast steel 140 HB | 110–170 | 0,05–0,15 |
cast steel 220302 HB | 70–130 | 0,05–0,10 |
titanium alloys | 60–120 | 0,03–0,08 |
high-temperature (nickel and iron base) | 20–45 | 0,03–0,05 |
high-temperature (cobalt base) | 15–30 | 0,03–0,05 |
cast iron | 80–110 | 0,05–0,15 |
malleable iron | 80–120 | 0,03–0,08 |
cutter | TPI | 48 | 32 | 24 | 20 | 16 | 12 | 10 | 8 | 7 | 6 | 5.5 | 5 | 4.5 | 4.5 | 4 | 4 |
pitch mm | 0,5 | 0,75 | 1,0 | 1,25 | 1,5 | 2,0 | 2,5 | 3,0 | 3,5 | 4,0 | 4,5 | 5,0 | 5,5 | – | 6,0 | – | |
cutter diameter (D1 mm) | minimum bore diameter (D) (mm) | ||||||||||||||||
K035TM1RW050-STN10 | 8,89 | 9,50 | 10,01 | 10,69 | 11,40 | ||||||||||||
K045TM1RW050-STN11N | 11,43 | 11,99 | 12,50 | 13,21 | 13,89 | 14,50 | |||||||||||
K049TM1RW037LT11S | 12,45 | 13,00 | 13,49 | 14,20 | 14,91 | 15,49 | |||||||||||
K061TM1RW062-STN16T | 15,49 | 16,00 | 16,51 | 16,94 | 17,91 | 18,49 | 19,51 | ||||||||||
K067TM2RW075-STN11D | 17,02 | 17,60 | 18,21 | 19,00 | 19,61 | 19,99 | 21,01 | ||||||||||
K075TM1RW075-STN16T | 19,05 | 19,71 | 20,40 | 21,01 | 21,59 | 22,00 | 23,01 | ||||||||||
K079TM1RW075-STN16N | 20,07 | 20,70 | 21,41 | 22,00 | 22,61 | 23,01 | 24,00 | ||||||||||
K087TM1RW100-STN16L | 22,10 | 22,68 | 23,39 | 24,00 | 24,61 | 24,99 | 26,01 | ||||||||||
K102TM2RW100-STN16D | 25,91 | 26,70 | 27,41 | 27,99 | 28,70 | 29,31 | 30,30 | ||||||||||
K118TM1RW100-STN27N | 29,97 | 30,71 | 31,39 | 32,00 | 32,79 | 33,50 | 34,59 | 36,60 | 38,99 | 42,01 | 45,01 | 48,01 | |||||
K146TM1RW125-STN27N | 37,08 | 38,00 | 38,61 | 39,50 | 40,41 | 41,00 | 42,01 | 43,99 | 46,48 | 49,00 | 51,99 | 55,50 | |||||
K165TM2RW125-STN27D | 41,91 | 43,21 | 43,79 | 45,01 | 46,00 | 46,51 | 47,40 | 49,00 | 51,99 | 54,51 | 57,61 | 60,99 | |||||
– | 35,05 (UN) | – | – | – | – | – | – | – | – | – | 50,01 | – | 46,81 | – | 44,60 | – | 56,59 |
– | 35,05 (ISO) | – | – | – | – | – | – | – | – | – | 50,01 | 53,39 | 42,49 | 50,01 | – | 57,51 | – |
– | 35,05 (BSW) | – | – | – | – | – | – | – | – | – | 49,81 | – | 46,51 | – | 47,40 | – | – |
1–2: | rapid approach |
2–3: | tool entry along tangential arc with simultaneous feed along Z-axis |
3–4: | helical movement during one full orbit (360°) |
4–5: | tool exit along tangential arc with continuing feed along the Z-axis |
5–6: | rapid return |
1–2: | radial entry with simultaneous feed along the Z-axis |
2–3: | helical movement during one full orbit (360°) |
3–4: | radial exit |
figure A | figure B |
internal left hand thread threading tool workpiece | external thread workpiece threading tool | workpiece threading tool |
Calculation of Feed Rates at the Cutting Edge
1–2: | radial entry |
2–3: | helical movement during one full orbit (360°) |
3–4: | radial exit |
Radial Approach
internal thread | external thread |
F1 = fz x Z x n | RPM = | 12 x SFM | |
π x d1 | |||
F1=tool feed rate at the cutting edge (in/min) fz=inch per tooth (feed rate) Z=number of effective inserts in cutter n=rotational speed (spindle RPM) | SFM=cutting speed, surface feet per minute d1=cutter diameter, over insert π=3.1416 |
P1 = F1 + | (F1 x d1) | ||
D | external thread | internal thread | |
P1= program feed rate (in/min) D= major diameter (external thread) D= minor diameter (internal thread) d1= cutting diameter, over insert | tool workpiece |
Step-by-Step Thread Milling Example
pitch (TPI) | 24 | 20 | 16 | 12 |
pitch mm | 1,0 | 1,25 | 1,5 | 2,0 |
cutter dia. d1 | minimum bore diameter D | |||
.67 | .748 | .772 | .787 | .827 |
.75 | .827 | .850 | .866 | .906 |
.79 | .866 | .890 | .906 | .945 |
Choosing Insert Size
insert IC | a inch (mm) | pitch (TPI) | internal thread | b inch thread length (in) | number of teeth | grade | external thread | b inch thread length (in) | number of teeth | grade | cutter type | ||
catalog number | KC610M | KC620M | catalog number | KC610M | KC620M | ||||||||
32 | STN16 32UN-I | .59 | 19 | STN16 32UN-E | .59 | 19 | |||||||
28 | STN16 28UN-I | .57 | 16 | STN16 28UN-E | .57 | 16 | |||||||
27 | STN16 27UN-I | .56 | 15 | STN16 27UN-E | .56 | 15 | |||||||
24 | STN16 24UN-I | .55 | 14 | STN16 24UN-E | .58 | 14 | |||||||
3/8 | .63 (16) | 20 | STN16 20UN-I | .55 | 11 | STN16 20UN-E | .55 | 11 | STN16 | ||||
18 | STN16 18UN-I | .56 | 10 | STN16 18UN-E | .56 | 10 | |||||||
16 | STN16 16UN-I | .56 | 9 | STN16 16UN-E | .56 | 9 | |||||||
14 | STN16 14UN-I | .57 | 8 | STN16 14UN-E | .57 | 8 | |||||||
13 | STN16 13UN-I | .54 | 7 | STN16 13UN-E | .54 | 7 | |||||||
12 | STN16 12UN-I | .58 | 7 | STN16 12UN-E | .58 | 7 |
pitch (TPI) | 24 | 20 | 16 | 12 |
pitch mm | 1,0 | 1,25 | 1,5 | 2,0 |
cutter dia. d1 | minimum bore diameter D | |||
17,02 | 19,00 | 19,61 | 19,99 | 21,01 |
19,05 | 21,01 | 21,59 | 22,00 | 23,01 |
20,07 | 22,00 | 22,61 | 23,01 | 24,00 |
insert IC | a (mm) | pitch (TPI) | internal thread | b thread length (mm) | number of teeth | grade | external thread | b thread length (mm) | number of teeth | grade | cutter type | ||
catalog number | KC610M | KC620M | catalog number | KC610M | KC620M | ||||||||
32 | STN16 32UN-I | 14,99 | 19 | STN16 32UN-E | 14,99 | 19 | |||||||
28 | STN16 28UN-I | 14,48 | 16 | STN16 28UN-E | 14,48 | 16 | |||||||
27 | STN16 27UN-I | 14,22 | 15 | STN16 27UN-E | 14,22 | 15 | |||||||
24 | STN16 24UN-I | 13,97 | 14 | STN16 24UN-E | 14,73 | 14 | |||||||
9,53 | 16 | 20 | STN16 20UN-I | 13,97 | 11 | STN16 20UN-E | 13,97 | 11 | STN16 | ||||
18 | STN16 18UN-I | 14,22 | 10 | STN16 18UN-E | 14,22 | 10 | |||||||
16 | STN16 16UN-I | 14,22 | 9 | STN16 16UN-E | 14,22 | 9 | |||||||
14 | STN16 14UN-I | 14,48 | 8 | STN16 14UN-E | 14,48 | 8 | |||||||
13 | STN16 13UN-I | 13,72 | 7 | STN16 13UN-E | 13,72 | 7 | |||||||
12 | STN16 12UN-I | 14,73 | 7 | STN16 12UN-E | 14,73 | 7 |
Step-by-Step Thread Milling Example
Calculate the feed rates: | |||||
First, find the RPM. | |||||
RPM = | 12 x SFM | = | 12 x 500 | = | 2418 RPM |
π x d1 | 3.14 x .79 | ||||
Next, calculate the feed rate at the insert cutting edge (F1): | |||||
(using the chosen feed per tooth of .004.) | |||||
F1 = | IPT x nt x RPM | = | .004 X 1 X 2418 | = | 9.67 in/min |
Finally, calculate the feed rate at the cutter centerline (F2): | |||||
F2 = | F1 x (D - d1) | = | 9.67 x (1.182 - .79) | = | 3.207 in/min |
D | 1.182 | ||||
Select the thread milling method. | |||||
Climb milling (preferred) see page . | |||||
Calculate the radius of the tangential arc Re: | |||||
Re = | (Ri - CL)2 + R02 | = | (.591 - .02)2 + .6252 | ||
2Ro | 2 x .625 | ||||
Re = | .573333 in. | ||||
Calculate the angle (β): | |||||
β = | 90° + arc sin | Ro - Re | |||
Re | |||||
β = | 90° + arc sin | .625 - .573333 | |||
.57333 | |||||
β = | 90° + 5.17° | = | 95.17° | = | 95° 10' |
Calculate the movement along the Z-axis during the entry approach from point “A” to point “B” (Zα). (NOTE: P = pitch) | |||||
Zα = P (in) x | α° | = | .0625 | = | .0156 in, because α = 90° |
360° | 4 | ||||
Calculate the “X” and “Y” values at the start of the entry approach. | |||||
X = 0Y = -Ri + CL = -.591 + .02 = - .571 in. | |||||
Define Z-axis location at the start of the entry approach. (NOTE: L = length of thread) | |||||
Z = - (L + Zα) = - (.50 + .0156) = - .5156 in. | |||||
Define the starting point. | |||||
Xa = 0 | |||||
Ya = 0 |
CNC Program (Fanuc 11M) | |||
% | |||
N10G90G00G57X0.000Y0.000 | |||
N20G43H10Z0.M3S2417 | |||
N30G91G00X0.Y0.Z–0.5156 | |||
N40G41D60X0.000Y–0.5710Z0. | |||
N50G03X0.6250Y0.5710Z0.0156R0.5733F3.206 | |||
N60G03X0.Y0.Z0.0625I–0.625J0. | |||
N70G03X–0.625Y0.5710Z0.0156R0.5733 | |||
N80G00G40X0.Y–0.5710Z0. | |||
N90G49G57G00Z8.0M5 | |||
N100M30 | |||
% | |||
Ri = | D | Ro = | Do |
2 | 2 | ||
D = minor diameter | Do = nominal diameter | ||
α 90° | |||
Calculate the feed rates: | |||||
First, find the RPM. | |||||
RPM = | 1000 x Vc | = | 1000 x 150 | = | 2387 RPM |
π x d1 | π x 20 | ||||
Next, calculate the feed rate at the insert cutting edge (F1): | |||||
(using the chosen feed per tooth of 0,1mm.) | |||||
F1 = | Fz x Z x N | = | 0,1 X 1 X 2387 | = | 238,7 mm/min |
Finally, calculate the feed rate at the cutter centerline (F2): | |||||
F2 = | F1 x (D - d1) | = | 238,7 x (3020) | = | 79,57 mm/min |
D | 30 | ||||
Select the thread milling method. | |||||
Climb milling (preferred) see page . | |||||
Calculate the radius of the tangential arc Re: | |||||
Re = | (Ri - CL)2 + RO2 | = | (150,5)2 + 15,8752 | ||
2 x RO | 2 x 15,875 | ||||
Re = | 14,55mm | ||||
Calculate the angle (β): | |||||
β = | 90° + arc sin | Ro - Re | |||
Re | |||||
β = | 90° + arc sin | 15,875 - 14,55 | |||
14,55 | |||||
β = | 90° + 5.17° | = | 95,2° | = | 95° 12' |
Calculate the movement along the Z-axis during the entry approach from point “A” to point “B” (Zα). (NOTE: P = pitch) | |||||
Zα = P (mm) x | α° | = | 1,578 | = | 0,394mm because α = 90° |
360° | 4 | ||||
Calculate the “X” and “Y” values at the start of the entry approach. | |||||
X = 0Y = Ri + CL = 15 + 0,5 = 15,5mm | |||||
Define Z-axis location at the start of the entry approach. (NOTE: L = length of thread) | |||||
Z = (L + Zα) = 12,7 + 0,3945 = 13,0945mm | |||||
Define the starting point. | |||||
Xa = 0 | |||||
Ya = 0 |
Step-by-Step Thread Milling Example
Appendix A | |
Derivation of Formulas for Internal Thread Milling | |
Re, β, and X can be found by a geometric analysis of the entry path. | |
This entry path is defined by the tool traveling along a circular path, with a radius of Re about the point C. | |
Re = | (Ri - CL)2 + Ro2 |
2Ro | |
Triangle OAC enables us to simply solve for Re.Note that OAC is a right angle triangle, and that: | |
OA = Ri – CL CA = Re OC = Ro – Re | |
Pythagoras’ law states: OA2 + OC2 = AC2 | |
Replacing actual values, we get: | |
(Ri - CL)2 + (Ro - Re)2 = Re2 | |
Simplifying, we get: | |
Re = | (Ri - CL)2 + Ro2 |
2R0 | |
Find the angle β. | ||||
sin | ||||
= arc sin | ( | Ro - Re | ) | |
Re | ||||
Therefore, β = 90° + arc sin | ( | Ro - Re | ) | |
Re | ||||
Appendix B | |
Derivation of Formulas for External Thread Milling | |
Re, β, and X can be found by a geometric analysis of the entry path. | |
This entry path is defined by the tool traveling along a circular path, with a radius of Re about the point C. | |
Re = | (Ro - CL)2 + Ri2 |
2Ri | |
Triangle OAC enables us to simply solve for Re.Note that OAC is a right angle triangle, and that: | |
OA = Ro – CL CA = Re OC = Re – Ri | |
Pythagoras’ law states: OA2 + OC2 = AC2 | |
Replacing actual values, we get: | |
(Ro - CL)2 + (Re - Ri)2 = Re2 | |
Simplifying, we get: | |
Re = | (Ro - CL)2 + Ri2 |
2Ri | |
Find the angle β. | |||
β can be easily found using the same triangle: | |||
sin β = | AO | = | (Ro + CL) |
AC | Re | ||
β = arc sin | ( | Ro + CL | ) |
Re | |||
problem | possible cause | solution | |
excessive insert flank wear | • Cutting speed too high. | • Reduce cutting speed. | |
• Chip is too thin. | • Increase feed rate. | ||
• Insufficient coolant. | • Increase coolant quantity/pressure. | ||
chipping of cutting edge | • Chip is too thick. | • Reduce feed rate. • Use the tangential arc method of entrance. • Increase RPM. | |
• Vibration. | • Check rigidity. | ||
material build-up on the cutting edge | • Cutting speed too slow. | • Increase cutting speed. | |
• Chip thickness too small. | • Increase feed rate. | ||
chatter/vibration | • Feed rate is too high. | • Reduce the feed. | |
• Profile is too deep (coarse pitch threads). | • Execute two passes, each with increased cutting depth. • Execute two passes, each cutting only half the thread length. | ||
• Thread length is too long. | • Execute two passes, each cutting only half of the thread length. | ||
insufficient thread accuracy | • Tool deflection. | • Reduce feed rate. • Execute a zero cut. |
thread designation | standard designation | tolerance class |
UN | ANSI B 1.174 | 2A/2B |
UNJ | MIL-S-8879A | 3A/3B |
ISO | R262 (DIN 13) | 6g/6H |
NPT | USAS B2.1 : 1968 | standard NPT |
NPTF | ANSI B 1.20.3-1976 | standard |
BSW | B.S. 84 : 1956, DIN 259, ISO 228/1 : 1982 | medium class A |
BSPT | B.S. 21 : 1985 | standard BSPT |
ACME | ANSI B1/5 : 1988 | 3G |
PG | DIN 40430 | standard |
TR | DIN 103 | 7e/7H |
STN Series
Materials | Brinell | surface speeds | indexable inserts | |
steel | HB | KC610M | KC635M | feed fz (IPT) |
P1 | 125 | 325–675 | 290–590 | .002–.008 |
P2 | 180 | 290–550 | 290–520 | .002–.008 |
P3 | 225 | 200–425 | 225–375 | .002–.008 |
P4 | 250 | 250–490 | 250–500 | .002–.008 |
P5 | 275 | 250–425 | 250–500 | .002–.006 |
P6 | 325 | 225–350 | 200–325 | .002–.004 |
stainless steel | ||||
M1 | 180 | 325–550 | 375–590 | .002–.004 |
M2 | 250 | 225–450 | 325–450 | .002–.004 |
M3 | 330 | 225–375 | 325–375 | .002–.004 |
cast iron | ||||
K1 | 180 | 200–425 | 325–450 | .001–.003 |
K2 | 220 | 200–390 | 250–325 | .002–.006 |
K3 | 260 | 160–290 | 200–275 | .002–.004 |
non-ferrous | ||||
N1 | 60–100 | 325–820 | – | .002–.010 |
high-temp alloys | ||||
S1 | 200 | 65–140 | 65–130 | .002–.004 |
S2 | 250 | 65–90 | 65–90 | .001–.002 |
S3 | 280 | 50–65 | 50–65 | .001–.002 |
S4 | 350 | 30–50 | 30–50 | .001–.002 |
hardened steel | ||||
H1 | 55HRc | 65–140 | 65–140 | .0004–.001 |