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KMT Stellram expanded milling catalog

KMT Stellram expanded milling catalog
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KMT Stellram expanded milling catalog

Product catalog summary
Overview: The document outlines Kennametal's Stellram® high-performance milling solutions, emphasizing patented innovations for machining challenging materials like titanium, nickel alloys, and stainless steel. These tools aim to boost metal removal rates, enhancing capacity and profitability across various industries.
Key Sections:
  • Application Guide: Describes the patented X-Grade Insert Technology, utilizing Ruthenium and Cobalt to improve performance in machining tough materials.
  • 7792 High Feed Milling: Details the patented cutter and insert designs for maximizing metal removal rates, highlighting the 7792 series' operational security and performance.
  • Technical Specifications: Provides dimensions, configurations, and capabilities of the 7792 series, including modular, Weldon, cylindrical, and shell mill configurations.
  • Case Study - Ti Alpha Barrier: Demonstrates the 7792VXD12 with X-500 Grade inserts' effectiveness in machining titanium, showing improvements in energy consumption, material removal rate, and tool life.
  • Machining Techniques: Discusses high feed cutters' benefits, such as reduced cycle times, improved part quality, and extended tool life.
Critical Information:
  • Patented Technologies: Highlights unique patented technologies enhancing cutting tools' performance in challenging environments.
  • Industry Applications: Applicable in aerospace, defense, power generation, oil and gas, medical, transportation, and construction industries.
  • Performance Metrics: Tools offer up to 90% increase in metal removal rates and reduce hazardous chemical processes.
Specifications and Technical Information: Detailed specifications for Kennametal's 7792VX and 7700VR series cutters focus on high feed milling applications. Includes formulas for calculating average chip thickness based on radial engagement and depth of cut, emphasizing proper chip thickness for optimal tool life.
Case Histories: Case studies show significant cycle time reductions using 7792VX cutters, such as a 90% reduction in machining 4140 steel and a 75% reduction in machining 6-4 Titanium in aerospace components.
High Feed Geometries and Grades: Describes geometries and grades like GH2, X500, and SC6525, highlighting their coating types and applications for high metal removal rates and resistance.
The 77 Family of Cutters: Introduces the 77 family, including 7700VR08, 7710VRD20, and 7713VR series, emphasizing patented designs for roughing, semi-finishing, and finishing high-performance materials.
Technical Information and Formulas: Provides formulas for calculating program feed rate and average chip thickness, explaining the relationship between chip thickness, radial engagement, and depth of cut.
Recommended Speeds and Feeds: Includes tables with recommended speeds and feeds for various materials, offering guidance on selecting appropriate cutters and inserts.
Specifications and Features: Discusses cutting tools for roughing and semi-finishing in difficult materials, highlighting SP6519 X500 and MP91M grades with PVD and CVD coatings for high shock resistance and metal removal rates.
Geometry and Design: Tools feature strong positive geometry, smaller primary angles, and controlled hone to reduce cutting pressures, enhancing chip evacuation.
Applications: Suitable for roughing and semi-finishing profiles and complex contours in various materials, with a case history showing a 40% productivity increase in machining a turbine blade in stainless steel.
Technical Information: Includes detailed specifications for cutter dimensions, insert grades, and recommended feeds, with guidelines for machining different materials.
Recommendations: Suggests using specific grades and geometries based on material, with speed recommendations and coolant usage guidelines to enhance tool life and efficiency.
Additional Features: Highlights modular systems and cylindrical shank extensions for vibration absorption and machining stability, and the 5700 Series High-Speed Aluminum Cutters for extreme metal removal in aluminum machining.
Overview: Provides specifications and guidelines for Kennametal's high-speed aluminum cutters, specifically the 5720 Patented Series and 5700 Profile Pocket Milling tools, designed for high-speed machining of aluminum.
Specifications: Details the 5720 Series' capability of operating up to 51,000 RPM and the 5700 Series' design for thin-walled machining, with specific balancing and torque requirements.
Procedures: Outlines assembly and disassembly procedures, emphasizing correct torque settings and balance inspections.
Standards and Compliance: Tools are designed, manufactured, and tested according to EN ISO standard 15641:2001.
Recommendations: Provides specific maximum depth of cut recommendations for slotting applications and emphasizes correct torque values and balancing procedures.
Technical Data: Includes product dimensions, ramping angles, and recommended feeds and speeds for various materials and applications.
Material Guide: Offers chemical composition limits, typical applications, and machinability ratings for various aluminum alloys.
Specifications and Recommendations: Provides speed recommendations for various materials using the 5182VZ series milling inserts, with specific speed ranges and coolant recommendations.
Technical Information: Outlines maximum RPM and ramp angles for different models, with instructions for tightening fixing screws and formulas for calculating program feed rate and average chip thickness.
Safety Instructions: Highlights risks associated with metalcutting operations and emphasizes personal protective equipment and proper ventilation.
Contact Information: Lists contact details for Kennametal's headquarters and offers customer service support and technical assistance.
Additional Notes: Advises consulting Kennametal's Metalcutting Safety booklet for more detailed guidance.
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Catalog excerpts

KMT Stellram expanded milling catalog-1

CUTTING TOOLS Stellram® Cutting Tools HIGH PERFORMANCE MILLING SOLUTIONS

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KMT Stellram expanded milling catalog-2

Patented Breakthroughs for Difficult to Machine Materials: Cut Faster. Cut Longer. Cut More Profitably. These Kennametal Milling Systems are specifically designed and manufactured for machining high performance, difficult-to-machine materials. This capability was developed after years of advanced R&D in materials science and machining Titanium and Titanium Alloys, Nickel Alloys and Superalloys, Stainless Steel and Specialty Alloys, and Hard Materials. The result: These proven “Best in Class” machining solutions presented in this brochure. Our strategy is to bring “game changing” cutting tool...

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KMT Stellram expanded milling catalog-3

5700 Profile Pocket Milling: Aluminum

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KMT Stellram expanded milling catalog-4

Application Guide Application Guide Chamfer Helical Interpolation Helical Interpolation with Bore Hole Shoulder/ Profile Shoulder/ Profile/Slot Slot/ Shoulder Spiral/ Circular Patented X-Grade Insert Technology 3-TIMES THE METAL REMOVAL RATE Titanium and Nickel Based Alloys are some of the toughest machining jobs on earth. And it is a rare element, a member of the platinum family, called Ruthenium, that is one of the key ingredients used in our patented X-Grade™ Technology cutting tools. We combine Ruthenium with Cobalt to form an exclusive binder that cements our engineered carbide formulas...

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KMT Stellram expanded milling catalog-5

7792 High Feed Milling • Patented Cutter Designs • Patented Insert Designs • Patented Grades To remove the highest volume of metal in the shortest possible time

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KMT Stellram expanded milling catalog-6

7792 Patented High Feed Milling 7792: Increase Metal Removal Rate up to 90% or More! Modular 0.625" – 1.500" • Cutting diameters from 0.625" to 6.300" • Modular, Weldon, Cylindrical and Shell Mill configurations • Modular Tungsten Extensions maintain stability in deep pocket applications • All inserts feature 4 cutting edges The Patented 7792 Insert The unique 7792 insert design provides outstanding operational security and performance, with enhanced metal removal capability. Cylindrical 0.625" – 1.500" • Maximize tool life, versatility and performance • Face, Pocket, Shoulder, Profile, Helical...

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KMT Stellram expanded milling catalog-7

7792 Patented High Feed Milling How High Feed Cutters Work The patented design of High Feed Cutters and Inserts combine to drive the cutting forces axially into the spindle. This allows even less rigid machines to outperform newer machines with conventional cutters by taking high feed, shallow cuts. • 5 times the feed rate of conventional face mills • High feed, shallow cuts • Dramatically reduced cycle times • Reduced vibration • Better quality parts in less than half the time • Twice the tool life or more Hard Case: The Ti Alpha Barrier The Alpha Casing, which forms during the cooling of the...

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KMT Stellram expanded milling catalog-8

7792VXP06 High Feed Milling Cutter Item Description Cylindrical Shank Dimensions (inch) 7792VXP06 Modular Head - Medium and Fine Pitch Note: For cylindrical shank extensions in high density alloy with through coolant refer to page 45. Modular Head 7792VXP06 Technical Information (inch) Product Item Description Facing Pitch Helical Interpolation Facing Pitch Ramp angle A uses one outside cutting edge only. Ramp angle B uses two cutting edges (one outside and one inside edge). A A = max ramp angle utilizing full face contact B = max ramp angle utilizing full contact + internal corner radius

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KMT Stellram expanded milling catalog-9

7792VXP06 Milling Inserts & Recommended Feeds Application & Material Facing Item Description Dimensions (inch) Plunging d (IC) Machining Choice: 3rd Choice | Material Guide Key descriptions found on page 19. Chilled Cast Iron >1400 N/mm2 >400 HBN HTA Titanium Based Alloys HTA Nickel Based Alloys HTA Cobalt Based Alloys HTA Iron Based Alloys Malleable Iron Facing Slotting Plunging SpheroidalDuctile Iron Gray Iron Stainless Steel Refractory PH Facing Slotting Plunging Stainless Steel Alloyed Steel Unalloyed Steel Facing Slotting Plunging Facing Slotting Plunging Note: HTA = High Temperature Alloys...

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KMT Stellram expanded milling catalog-10

7792VXD09 High Feed Milling Cutter Product Item Description 7792VXD09 Shell Mill Fixation - Coarse, Medium and Fine Pitch C7792VXD09-A1.50Z3R C7792VXD09-A1.50Z4R C7792VXD09-A1.50Z5R C7792VXD09-A2.00Z5R C7792VXD09-A2.00Z6R Cylindrical Shank Item Description Note: For cylindrical shank extensions in high density alloy with through coolant refer to page 45. D Shell Mill Fixation 7792VXD09 Technical Information (inch) Product Item Description Facing Pitch Modular Head Helical Interpolation Flat Facing Pitch Ramp angle A uses one outside cutting edge only. Ramp angle B uses two cutting edges (one...

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KMT Stellram expanded milling catalog-11

7792VXD09 Milling Inserts & Recommended Feeds Application & Material Facing Item Description Dimensions (inch) Plunging d (IC) Machining Choice: 3 Choice | Material Guide Key descriptions found on page 19. XDLW090408SR-D X500 should be used for Alloy Steel and Stainless Steel with heavy scale. XDLT090412ER-D411 is a more positive geometry than the -D-41 with a larger radius which increases performance during smaller radial engagements or where chipping may occur when using the -D-41 geometry. XDLT090412ER-D411 uses less power than the -D-41 geometry. Facing Slotting Plunging Chilled Cast Iron...

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KMT Stellram expanded milling catalog-12

7792VXD12 High Feed Milling Cutter Item Description D Shell Mill Fixation Item Description 7792VXD12 Shell Mill Fixation - Coarse, Medium and Fine Pitch Note: For cylindrical shank extensions in high density alloy with through coolant refer to page 45. 7792VXD12 Technical Information (inch) Modular Head Item Description Facing Pitch Helical Interpolation Flat Facing Pitch Ramp angle A uses one outside cutting edge only. Ramp angle B uses two cutting edges (one outside and one inside edge). A A = max ramp angle utilizing full face contact B = max ramp angle utilizing full contact + internal corner...

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KMT Stellram expanded milling catalog-13

7792VXD12 Milling Inserts & Recommended Feeds Application & Material Facing Item Description Slotting Depth of Cut (inch) ap max. 0.079 Dimensions (inch) Plunging d (IC) Machining Choice: 3 Choice | Material Guide Key descriptions found on page 19. XDLW120508SR-D X500 should be used for Alloy Steel and Stainless Steel with heavy scale. XDLT120512ER-D411 is a more positive geometry than the -D-41 with a larger radius which increases performance during smaller radial engagements or where chipping may occur when using the -D-41 geometry. XDLT120512ER-D411 uses less power than the -D-41 geometry....

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