Overview

This document provides comprehensive technical specifications, models, and usage guidelines for FULLCUT MILL cutting tools and related components, emphasizing the BIG-PLUS dual contact spindle system and compatibility with various taper shanks and machining centers.

1. Product Types and Components

• FULLCUT MILL Types: Includes FCR (Fullcut Mill Contact Grip) and FCM (Fullcut Mill Center Boy).
• Cutting Heads: FCR heads feature the CONTACT GRIP system with threaded coupling ensuring taper and face contact for enhanced cutting performance.
• Adapters: Available for BT50, BBT30/40/50, BDV50, SK50 taper shanks, and HSK-A standard and long nose types.
• Inserts: Specialized inserts for ramping, helical milling, shoulder milling, and peck drilling; ordered separately and must match cutter diameter.
• Shanks: BIG-PLUS tools compatible with conventional spindles including BBT, BDV, HSK-A, and CAPTO systems.

2. Specifications and Dimensions

• Models cover cutter diameters from ø16 to ø32 (standard) and ø17 to ø33 (oversize), with detailed parameters such as insert sizes, number of inserts, lengths (L, L1, L2, L3), axial depth of cut (ap), and weights.
• Compliance with standards: JIS B 6339, DIN 69871 A/B, ISO12164, DIN 69893-1, ISO26623-1.
• Long nose types recommended for medium-heavy or heavy slot milling with projections exceeding 120 mm (small diameters) or 135 mm (larger diameters).
• Coolant pipes and accessories are optional and ordered separately; manual clamping holes and wrench tools included with heads.

3. Cutting Conditions and Recommendations

• Use inserts matching cutter diameter; FCM type inserts are not compatible with FCR cutters.
• Recommended cutting parameters vary by application; lower parameters advised for long projections or 3-flute models.
• 2-flute models preferred for medium-heavy or heavy slot/pocket milling, especially when projection length exceeds 2.5 times cutter diameter.
• Maximum ramping angle is 10° with axial depth of cut up to 10 mm on vertical #40 taper machines.
• Anti-seizure lubricant and wrench included for insert clamping; standard wrench required for head clamping.

4. Features and Benefits

• BIG-PLUS Dual Contact System: Enhances rigidity and accuracy by ensuring taper and face contact between tool and spindle, reducing vibration and improving surface finish.
• CONTACT GRIP Heads: Provide superior cutting performance compared to conventional threaded coupling systems.
• Integral FULLCUT MILL Version: Offers increased rigidity due to reduced gage length, suitable for machines with small spindle tapers, and reduces costs by eliminating chucks.
• Compatibility: BIG-PLUS tools usable in machining centers with conventional spindles; CAPTO products are licensed and fully compatible with Sandvik Coromant standards.

5. Ordering and Maintenance

• Inserts supplied in packets of 10; specify insert type and grade when ordering (e.g., BRG160808ACZ350S).
• Regular replacement of clamping screws and wrenches recommended to maintain performance.
• Coolant pipes and other accessories ordered separately.

6. Summary of Critical Parameters

7. Visual and Functional Features

• Manual clamping holes and optional coolant pipes enhance usability and cooling efficiency.
• Wrenches and anti-seizure lubricants included to facilitate maintenance and assembly.
• Threaded coupling with taper and face contact reduces vibration and improves surface finish.

8. Insert Specifications and Grades

• Insert models include BRG160808, BRG200808, BRG250808, BRG321008, BRG321032 for cutter diameters ø16 to ø32 mm.
• Grades such as ACZ350S, ACZ310, DS20 recommended for steel, stainless steel, cast iron, and aluminum.
• Coatings include TiAlN, TiCN, DLC to enhance tool life and performance.

9. Recommended Cutting Conditions

• Cutting speeds range from 60 to 220 m/min depending on material and cutter size.
• Feed rates vary from 0.04 to 0.35 mm/rev or mm/tooth based on operation and material.
• Air or wet cutting fluids recommended; oil-based fluids prohibited due to fire risk.
• Safety enclosures advised to protect operators from chip scattering.

10. Milling Operations and Parameters

• Ramping and helical milling: Minimum traverse intervals and ramping angles specified to optimize tool life and machining quality.
• Plunge milling and shoulder/slot milling speeds and feeds detailed for various materials including stainless steel, cast iron, die steel, carbon steel, alloy steel, prehardened steel, and aluminum.
• Axial and radial depths of cut provided for different milling strategies.

11. Tool Holding Systems and Compatibility

• Compatible with HSK-A, HSK-E (ISO12164 & DIN 69893-1/5), BIG COROMANT CAPTO (ISO26623-1).
• HSK-E lacks drive key-ways; caution advised to avoid slippage under high cutting loads.

12. Best Practices and Maintenance

• Use included wrench and anti-seizure lubricant to maintain correct clamping force.
• 2-flute models recommended for medium to heavy slot milling, especially with long projections.
• Adjust cutting conditions based on machine and workpiece specifics.
• Do not use oil-based cutting fluids to avoid fire hazards.
• Ensure safety enclosures are in place.
• Regularly replace clamping screws and wrenches to maintain performance.

13. Chamfering and Specialized Tools

• Ultra-high feed chamfer mills, R-cutter chamfer mills, and bolt hole/tap starting hole tools detailed with dimensions, insert types, and recommended cutting parameters.
• Chamfer angles range from 5° to 85°, with front and back chamfering options.
• Sharp edge inserts reduce burr formation; TiAlN coated carbide inserts improve cutting efficiency significantly.
• Wet cutting generally recommended for better surface quality; soluble oil advised for aluminum and stainless steel.

14. Summary of Cutting Speeds and Feed Rates for Chamfering

15. Tool Presetters and Setup

• PL Presetters (BBT30, BBT40, BBT50, HSK63) enable quick cutting edge height adjustment within 15 seconds with micron-level precision.
• Support cutter diameters up to ø160 mm and max tool lengths accordingly.
• Dial gauges with 0.001 mm resolution included for precise setup.

16. Critical Notes and Safety

• Correct insert selection by cutter diameter is essential to avoid poor cutting results.
• FULLCUT MILL arbor type cutters should not be used for Z-axis feeding operations (ramping, plunging, boring).
• Dry cutting preferred for steel and stainless steel except finishing where coolant may be used.
• High-speed cutters require balancing above 12,000 min-1 spindle speed.
• Use safety enclosures to protect operators from chip scattering.

Conclusion

This document serves as a detailed technical guide for FULLCUT MILL and related cutting tools, inserts, adapters, and accessories. It highlights the advantages of the BIG-PLUS dual contact system and CONTACT GRIP heads for improved rigidity, accuracy, and cutting performance. Proper insert selection, adherence to recommended cutting parameters, and regular maintenance are critical for optimal machining results and tool longevity. The document also covers specialized tools such as chamfer mills and bolt hole cutters, providing comprehensive data to support efficient and safe machining operations across a wide range of materials and applications.