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Face Mills

Face Mills
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Face Mills

Product catalog summary
Overview: The document provides comprehensive technical specifications and guidelines for various face milling tools in the Dodeka, MEGA, Beyond BLAST, Fix-Perfect, HexaCut, KSSR, KCMS, and Chamfer Mills series by Kennametal. It focuses on their performance, capabilities, and recommended usage across different machining scenarios.
Dodeka Series:
  • Dodeka Mini: Features up to 12 cutting edges per insert, suitable for light to heavy machining with a maximum axial depth of cut (Ap1 max) of 0.174".
  • Dodeka: Known for high metal removal rates and extended tool life in advanced face milling applications.
  • Dodeka MAX: Designed for heavy-duty applications with a larger insert size and Ap1 max of 0.315".
MEGA Series:
  • MEGA 45°, 15°, 60°, 90°: Tailored for heavy-duty machining with various lead angles to optimize cutting performance across different materials.
Beyond BLAST KSSM 45°: Recommended for machining titanium, offering superior performance in challenging materials with Precision Coolant Technology (PCT) for enhanced heat transfer and chip control.
Fix-Perfect Series:
  • Optimized for cast iron with different lead angles (20°, 0°) to enhance finishing and roughing capabilities.
HexaCut Series:
  • Designed for cast iron, offering 45° and 30° lead angles to improve cutting efficiency and surface finish.
KSSR and KCMS Systems:
  • Provide versatile solutions for roughing and finishing, with options for cartridge milling and aluminum-specific tools.
Chamfer Mills:
  • Available in 60°, 45°, and 30° configurations, ideal for creating precise chamfers in various materials.
Key Features:
  • High productivity with low cost per edge due to multiple cutting edges per insert.
  • Enhanced tool life and reduced cutting forces with Beyond™ premium milling grades.
  • Comprehensive insert selection guide for optimal performance across different material groups.
Recommendations:
  • Use the Dodeka Mini High-Feed for applications requiring long reach and light fixtures, benefiting from chip thinning effects and reduced cycle times.
  • Follow the recommended starting speeds and feeds for each material group to optimize tool performance and longevity.
Specifications: The document lists various face mill models with details such as diameter, maximum diameter, length, and maximum RPM. It also includes information on insert screws, wrench types, and spare parts for different models.
Procedures: Recommended starting speeds and feeds are provided for different material groups and machining types. The document emphasizes using "Light Machining" values as starting feed rates and adjusting speeds as chip thickness increases.
Insert Geometry and Feed Rates: The document outlines programmed feed per tooth (fz) as a percentage of radial depth of cut (ae) for various insert geometries, providing specific values for different machining conditions.
Material Group Recommendations: Materials are categorized into groups (P, M, K, N, S, H) with suitable insert geometries and grades for each group, highlighting first and alternate choices.
Applications: The document highlights the KM4X™ spindle interface for heavy-duty machining, suitable for aerospace and transportation industries, offering higher productivity and metal removal rates.
Conclusion: The document serves as a comprehensive guide for selecting and using Kennametal's cutting tools effectively, ensuring optimal performance and tool life in machining operations.
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Catalog excerpts

Face Mills-2

KM_Master12_O000_O001_MINCH_EN:Layout 1 3/23/12 1:36 PM Page O3 Face Mills Dodeka Series • Performance Booster (12 True Edges per Insert) . . . . . . . . . . . . . . . . . . . . . . . . . .O2–O26 Dodeka Mini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .O4–O15 Dodeka . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .O16–O22 Dodeka MAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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Face Mills-3

Dodeka™ Series • Leader in Advanced Face Milling Applications Primary Application Dodeka, Dodeka Mini, and Dodeka MAX™ are the most comprehensive face milling boosters on the market today. Twelve true cutting edges per insert mean low cost per edge and high productivity. With Beyond™ premium milling grades, you will see up to 30% higher Metal Removal Rates (MRR), 25% lower cutting forces due to real soft cutting action, and up to 35% better tool life in light to heavy machining. Dodeka Mini Series • Most comprehensive face milling booster in the market, up to Ap1 max = .174" All different cutter...

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Face Mills-4

KM_Master12_O002_O003_MINCH_EN:Layout 1 3/7/12 2:49 PM Page O3 Dodeka™ Mini Series insert size HN.J43 Ap1 max = .174" page O4–O15 Dodeka™ insert size HN.J535 Ap1 max = .178" page O16–O22 Dodeka MAX™ insert size HN.J75 Ap1 max = .315" page O24–O26 P M K N S Capable in all material groups • Excellent results in machining titanium www.kennametal.com O3

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Face Mills-5

Dodeka™ Mini High-Feed (HF) 75 1 Twelve cutting edges per insert. Dodeka Mini High-Feed 75° • Screw-On End Mills Spare Parts Dodeka Mini High-Feed 75° • Cylindrical End Mills Spare Parts

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Face Mills-6

Dodeka™ Mini High-Feed (HF) 75° Shell Mills 1 Twelve cutting edges per insert. Dodeka Mini High-Feed 75° • Shell Mills Spare Parts Dodeka Mini High-Feed First choice for long reach face milling applications Chip thinning effect due to lead angle 14.5°. Tremendous enlargement of feed rate and Metal Removal Rate (MRR). machining cycle time.

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Face Mills-7

Dodeka ™ Mini High-Feed (HF) 75° Insert Selection Guide Indexable Inserts • first choice catalog number catalog number catalog number catalog number

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Face Mills-8

Dodeka ™ Mini High-Feed (HF) 75° Recommended Starting Speeds and Feeds Recommended Starting Speeds [SFM] NOTE: FIRST choice starting speeds are in bold type. As the average chip thickness increases, the speed should be decreased. Recommended Starting Feeds [IPTJ NOTE: Use "Light Machining" values as starting feed rate.

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Face Mills-9

• Twelve cutting edges per insert. • Maximum number of teeth per diameter. • Productivity booster in all materials. Dodeka Mini 45° • Screw-On End Mills Spare Parts Dodeka Mini 45° • Weldon® End Mills order number catalog number Spare Parts

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Face Mills-10

1 Twelve cutting edges per insert. 1 Maximum number of teeth per diameter. 1 Productivity booster in all materials. Dodeka Mini 45° • Cylindrical End Mills Spare Parts

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Face Mills-11

Shell Mills • Twelve cutting edges per insert. • Maximum number of teeth per diameter. • Productivity booster in all materials. ■ Dodeka Mini 45° • Shell Mills Spare Parts coolant lock screw assembly

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Face Mills-12

Insert Selection Guide HNGJ-LDJ Wiper HNGJ-LD HNPJ-GD HNPJ-HD Indexable Inserts catalog number • first choice ' For Wiper insert XNGJ, 3 left-hand (LH) and 3 right-hand (RH) wiper edges per insert. catalog number ' For Wiper insert XNGJ, 3 left-hand (LH) and 3 right-hand (RH) wiper edges per Insert. catalog number catalog number

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Face Mills-13

Recommended Starting Speeds and Feeds Recommended Starting Speeds [SFM] NOTE: FIRST choice starting speeds are in bold type. As the average chip thickness increases, the speed should be decreased. Recommended Starting Feeds [IPTJ NOTE: Use "Light Machining" values as starting feed rate.

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Face Mills-14

Twelve cutting edges per insert. Higher Ap1 max with standard inserts. Productivity booster in all materials. Shell Mills Dodeka Mini 30° • Shell Mills Spare Parts insert socket-head coolant lock D1 screw in. lbs. wrench cap screw screw assembly

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Face Mills-15

Insert Selection Guide Indexable Inserts

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Face Mills-16

Recommended Starting Speeds and Feeds Recommended Starting Speeds [SFM] NOTE: FIRST choice starting speeds are in bold type. As the average chip thickness increases, the speed should be decreased. Recommended Starting Feeds [IPTJ NOTE: Use "Light Machining" values as starting feed rate.

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Face Mills-17

Shell Mills Dodeka High-Feed 75° • Shell Mills Spare Parts with coolant groove coolant coolant coolant lock screw lock screw shower plate

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Face Mills-18

Insert Selection Guide Indexable Inserts

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Face Mills-19

Recommended Starting Speeds and Feeds Recommended Starting Speeds [SFM] NOTE: FIRST choice starting speeds are in bold type. As the average chip thickness increases, the speed should be decreased. Recommended Starting Feeds [IPTJ NOTE: Use "Light Machining" values as starting feed rate.

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Face Mills-20

Shell Mills 1 Twelve cutting edges per insert. 1 Through-coolant on cutters <4" diameter. 5" diameter cutters and above do not have through-coolant. 1 Soft cutting action. Dodeka 45° • Shell Mills Spare Parts with coolant groove coolant lock screw assembly coolant coolant lock screw shower plate NOTE: Please order all spare parts separately.

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Face Mills-21

Insert Selection Guide Indexable Inserts • Dodeka • XNGJ • Finishing • first choice catalog number ' 3 left-hand (LH) and 3 right-hand (RH) wiper edges per insert.

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Face Mills-23

Recommended Starting Speeds and Feeds • 45° Approach Angle Recommended Starting Speeds [SFM] NOTE: FIRST choice starting speeds are in bold type. As the average chip thickness increases, the speed should be decreased. Recommended Starting Feeds [IPTJ NOTE: Use "Light Machining" values as starting feed rate.

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.