Overview

This document provides detailed technical specifications, application guidelines, and machining parameters for a range of high feed milling cutters, specifically the UD90 series. These cutters are designed for powerful milling on live tooling lathes and machining centers with moderate rigidity and drive power.

Product Range and Specifications

The UD90 milling cutters are available in diameters ranging from 16 mm to 160 mm, optimized for high metal removal rates (Q) even with extreme overhangs. They come in two main types:

• Screw-in Milling Cutters: Diameters from 16 mm to 50 mm, with detailed dimensions such as cutting diameter (D), shank diameter (d), cutting edge length (H), number of teeth (z), feed per tooth (fz), and other parameters.
• Plug-in Milling Cutters: Larger diameters from 50 mm to 160 mm, with similar detailed dimensional and performance data.

All cutters use DIN tool holders with standard adaptation shanks and spindle connections compatible with HSK, Capto, and SK systems.

Cutting Inserts and Compatibility

The cutters utilize UDGT indexable inserts, available in various shapes and grades (e.g., SKY77, AV1044, AV1055, AV1077), tailored for different materials such as high alloy steels, cast iron, stainless steels, and titanium. Insert designations include UD.0602, UD.0803, UD.10T3, UD.1204, and UD.1606, each with specific cutting parameters.

Machining Parameters and Recommendations

Machining parameters are provided for different material groups, including steel, cast iron, stainless steels, and titanium. Key parameters include:

• Feed per tooth (fz): Ranges vary by insert type and material grade, typically from 0.45 mm to 2.10 mm.
• Cutting speed (vc): Specified ranges from 20 m/min up to 340 m/min depending on material and insert grade.

These parameters are matched to AV material groups (A22 to A16 for steels, D21 to D16 for cast iron, C12 to S08 for stainless steels and titanium), ensuring optimal cutting performance and surface quality.

Design Features and Benefits

• "Soft" cutting action enables maximum metal removal rates even with long tool overhangs, ideal for pocket milling.
• High feed milling cutters provide excellent surface finish and high feed rates.
• Ramp cutting capability is confirmed for all models.
• Insert screw length varies depending on the insert used, which should be considered during tool setup.

Critical Parameters and Limitations

• Feed rates and cutting speeds must be adjusted according to the specific insert grade and material to avoid tool wear or damage.
• Tool dimensions such as cutting diameter, shank diameter, and cutting edge length must be matched to machine tool capabilities and workpiece requirements.
• Some larger diameter tools (e.g., 160 mm) are available on request only.

Summary Tables and Data Highlights

The document includes comprehensive tables listing:

• Tool articles with dimensions and cutting parameters.
• Insert types with corresponding feed per tooth and cutting speed recommendations for various materials.
• Matching of machining parameters to AV material groups for steels, cast iron, stainless steels, and titanium.

These tables serve as a quick reference for selecting the appropriate cutter and insert combination for specific machining tasks.

Best Practices

• Use the recommended feed per tooth and cutting speed values for the specific material and insert grade to maximize tool life and machining efficiency.
• Ensure correct screw length is used for inserts to maintain tool integrity.
• Consider machine rigidity and drive power when selecting cutter diameter and type.
• Utilize the ramp cutting feature where applicable to improve machining flexibility.

Conclusion

The UD90 high feed milling cutters offer a versatile and efficient solution for high-performance milling operations on various materials. Proper selection of cutter size, insert type, and machining parameters is essential to achieve optimal metal removal rates, surface quality, and tool longevity.