Tangential Shoulder Milling with Mill 4™-12KT

We’re going to be demonstrating some steel cutting with an indexable milling cutter with tangentially mounted inserts that is known as the Mill 4-12KT. 

Test #1

With a depth of cut range of up to 12 millimeters the versatile Mill 4-12KT covers many shorter milling applications which we're about to show you. With that we're using a shell mill adapter with a KM4X63™ connection running on this 25-horsepower machine. We're going to start with a light cut on the periphery of this 3 by 6 inch steel block.

We're doing two passes with an 80 millimeter diameter cutter with seven inserts. Each pass with the following cutting parameters: 3 millimeter axial depth of cut, 20 millimeter radial depth of cut, a feed rate of 0.25 millimeters per tooth and 215 meters per minute cutting speed.

Let's take a look at the surface finish we achieved with that 3 millimeter depth of cut. We're seeing that with these cutting parameters the spindle load is 42%. We should take a look at the metal removal rate that we achieved with this light cut with a 3 millimeter depth of cut, 20 millimeter radial depth of cut, and 1728 millimeters per minute feed rate we achieved a metal removal of 104 cubic centimeters. Next we're going to be doing a heavier cut on the periphery of this steel block with the Mill 4-12KT.

Test #2

This time we're adjusting the cutting parameters to stay within the capabilities of the machine. We're increasing the axial depth of cut to eight millimeters while we are reducing the radial depth of cut from 20 millimeters to 15 millimeters. We're cutting the feed rate in half from 0.25 millimeters per tooth to 0.125 millimeters per tooth. The cutting speed remains the same with 215 meters per minute. We should now take account of the surface finish we achieved with that 8 millimeter depth of cut.

With these adjusted cutting parameters, we're seeing the spindle load decreased 37%. Let's compare the metal removal rate with what we saw in the first cut. With an 8-millimeter depth of cut, 15-millimeter radial depth of cut, and 958 millimeters per minute feed rate we achieved a metal removal of 115 cubic centimeters. And finally, we're going to do the heaviest cut on the periphery of this steel block with the same Mill 4-12KT cutter again. 

Test #3

We're doing two passes and adjusting two parameters again. We're increasing the axial depth of cut to the maximum of 12 millimeters while we're decreasing the radial depth of cut to 10 millimeters feed and speed remain the same. Why don't we take another look at the surface finish again on the 12-millimeter cut. And a quick check on the spindle load we're at 46%. With the maximum depth of cut of 12 millimeters, 10-millimeter radial depth of cut, and 1131 millimeters per minute feed rate we achieved our highest metal removal rate of 136 cubic centimeters. Thanks for checking out the Mill 4-12KT with me here in the technology lab at Kennametal!

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