1. Product Series and Specifications

The document details multiple series of milling tools including the 20° Lead Face Mill Series (DM6G, DM5G), Multiple Geometry Cartridge Face Mill Series (4W2A), Top•On End Mill Series (1DP1G), End Mill Series (1DP1G), Face Mill Series (DP5G), and 20° Lead Face Mill Series (DM6Q, DM5Q). Each series is characterized by specific diameters, insert corner radii, cutting edge lengths, and other dimensional parameters.

• DM6G, DM5G Series: Diameters range from 1.5" to 8.0" with a cutting edge length of .230" and insert corner radius of .030"R.
• 4W2A Series: Diameters from 4.0" to 12.0", cutting edge length .230", insert corner radius .030"R, with facing coolant thru capability and 70° lead angle.
• 1DP1G Series (Top•On and End Mill): Diameters 1.25" to 1.5", insert corner radius .18", backdraft angle 92°, with detailed dimensions for neck adaption, length, and inserts number.
• DP5G Face Mill Series: Diameters 2.0" to 6.0", insert corner radius .18", coolant thru, backdraft angle 92°, and detailed bore and height dimensions.
• DM6Q, DM5Q Series: Larger diameters from 3.0" to 12.0", max depth of cut .480", insert corner radius .060"r, with coolant thru options and retention bolt specifications.

2. Inserts and Hardware

The document specifies various insert types with dimensions such as .20 x .45 IC, wiper edge options (.055 and .140), and corner radii. Inserts are identified by part numbers (e.g., PNCU0805GNTR, PNCU1708GNTR) and are categorized by application (multi-purpose, wiper, silicon nitride, sharp/polished for aluminum, flat top heavy duty, hi-temp/titanium).

Hardware includes insert screws, torque drivers, axial adjusting screwdrivers, and cartridge screwdrivers with specified torque values (e.g., 40 in. lbs. for insert screws, 150-180 in. lbs. for cartridge screws). Recommended torque driver bits and part numbers are provided for proper assembly.

3. Operating Guidelines and Recommendations

Detailed operating parameters are provided for different materials and hardness levels, including recommended surface footage (SFM), feed per revolution (IPR), insert grades, and coolant usage. Materials covered include aluminum alloys, gray and nodular cast iron, low and high carbon steels, alloyed steels, tool steels, stainless steels, nickel alloys, and titanium.

• Feed rates and surface footage vary by material hardness and type, with specific insert grades preferred for each application.
• Coolant usage is recommended or optional depending on material and operation.
• Wiper edge inserts have specific feed rate limits during finishing operations (.055" and .140" max feed per revolution).
• Torque specifications for insert screw tightening are emphasized to ensure proper assembly and performance.

4. Assembly and Mounting Instructions

Instructions for insert installation include proper seating with a gap, pushing the insert against clamping surfaces before tightening, and using a torque driver set to 40 in. lbs. The document highlights the importance of correct insert orientation, especially for wiper edges marked with "W".

Programming tips recommend using a corner radius of .18" in NC programs for 3D contour machining with a maximum allowance of up to .035".

5. Product Ordering and Contact Information

The document includes a product worksheet template for customers to specify design requirements such as diameters, tolerances, extension lengths, chamfer sizes, coolant preferences, and application types (rough, semi-finish, blind or through hole).

Contact details for Ingersoll Cutting Tools in the Americas, Canada, Mexico, and Europe are provided for sales and technical support.

6. Summary of Critical Parameters

• Insert Corner Radii: Typically .030"R for face mills, .18" for end mills.
• Cutting Edge Length: Commonly .230" for face mills.
• Torque Values: 40 in. lbs. for insert screws, 150-180 in. lbs. for cartridge screws.
• Feed Rates: Material-dependent, e.g., .005-.020 IPR for aluminum, .008-.020 for steels.
• Coolant: Through-spindle coolant recommended for many applications, optional for others.
• Insert Grades: Multiple grades tailored for material and operation type, including multi-purpose, heavy duty, hi-temp, and silicon nitride.

7. Tables and Data Interpretation

Tables provide detailed dimensional data for each tool series, including diameter ranges, insert numbers, cartridge numbers, bore diameters, bolt circle diameters, weights, and retention hardware specifications. Insert application tables correlate insert part numbers with material types and cutting edge configurations.

Operating guidelines tables link material hardness and type with recommended surface footage, feed rates, insert grades, and coolant usage to optimize tool life and machining performance.