New Wear Resistant Solid Carbide Endmills for Machining Stainless Steel Efficiently
NPA 02/2019
Highlights
ISCAR has designed the CHATTERFREE ECY-S5 geometry with 5 flutes, sub-flutes and variable helix for a wide range of milling operations on stainless steel.
ISCAR is introducing the ECY-S5 – a family of new solid carbide endmills for milling austenitic, duplex, cast and precipitation hardening (PH) stainless steels (ISO M group of applications).
The new ECY-S5 endmills are suitable for a wide range of milling operations, from rough to finish machining and including trochoidal milling.
The new endmills feature a unique patent-pending design that delays wear and significantly improves tool life.
Features
- Unique core taper shaped sub-flute contributes to better chip evacuation, particularly on full depth machining ( 2XD)
- 5 flutes with variable angular pitch and different helix portions
- The combination of the new AlTiCrSiN PVD coating with a hard submicron grade IC08, creates a high wear resistant grade IC608
- Accuracy: e8 tolerance limits for the nominal endmill diameter (D) and h6 for the endmill shank diameter
- Edge wear transition mechanism
- Varying rake angles create softer cut while taking wide chips
Varying rake and relief angles
Sub-flutes with variable helix
Flutes with different helix
- Controlled wear transmission in diverging directions
- Provides uniform wear to increase overall tool life
Wear transmission mechanism
- The sub-flute wear control mechanism combined with variable and different rake and relief angles considerably increases tool life
- Variable and different helix portions inhibit resonance and increase chip evacuation space proximate to the cutting end face
- Reinforced core taper improves structural strength
- Performance benefits are particularly notable when milling at depth of cut of approximately 2×D
Shoulder milling | DC=8-10 mm | DC=12-16 mm | |||
---|---|---|---|---|---|
ECY-S5 | Vc (m/min) | Ap | Ae, max | Fz (mm/t) | Fz (mm/t) |
100-150 | ~2×D | 0.4×D | 0.03-0.045 | 0.04-0.055 |
Shoulder milling | DC=8-10 mm | DC=12-16 mm | ||||
---|---|---|---|---|---|---|
ECY-S5 | Vc (m/min) | Ap | Fz (mm/t) | Ap max | Fz (mm/t) | Ap max |
70-90 | D | 0.02-0.04 | 0.25×D | 0.03-0.04 | 0.25×D |
HSM / Trochoidal milling | DC=8-10 mm | DC=12-16 mm | |||
---|---|---|---|---|---|
ECY-S5 | Vc (m/min) | Ap | Ae, max | Fz (mm/t) | Fz (mm/t) |
180-250 | ~2×D | 0.1×D | 0.05-0.12 | 0.06-0.13 |
Application report:
Application: Shoulder milling
Material: AISI/SAE 304 (DIN X5CrNi 18 9, W.-Nr. 1.4301)
Coolant: Emulsion
Pressure: 8 bar
Machine type: Vertical machining center
Brand: HAAS
Spindle adaptation: BT40
Manufacturer | ISCAR - Actual | Other - Competitor |
---|---|---|
Tool | ECY-S5 16-32C16CFR.8-92 608 | Competitor |
Diameter (mm) | 16 | 16 |
No. of Flutes | 5 | 5 |
Carbide Grade | 608 | Coated |
Edge Preparation | Standard | Standard |
Tool Stability | Fair | Fair |
Overhang (mm) | 45 | 45 |
Cutting Speed (m/min) | 226 | 226 |
Cutting Speed (m/min) | 226 | 226 |
Spindle Speed (rpm) | 4,496 | 4,496 |
Depth of Cut (mm) | 28 | 28 |
Width of Cut (mm) | 0.6 | 0.6 |
Machining Length (mm) | 600 | 600 |
Feed per Tooth (mm/t) | 0.09 | 0.09 |
Table Feed (mm/min) | 2,023 | 2,023 |
Number of Passes | 10 | 10 |
Parts per Cutter | 44 | 17 |
Avg. Chip Thickness (mm) | 0.02 | 0.02 |
Surface Quality | Good | Good |
Chip Type | Comma/Helical | Comma/Helical |
Wear | Crater Wear | Crater Wear |
Reason for Stopping the Test | Wear | Wear |
Metal Removal Rate (cm3/min) | 33.98 | 33.98 |
ECY-S5-CFR
5 Flute Endmills with Different Helix for Milling Austenitic, Duplex, Cast and Precipitation Hardening Stainless Steels (1) Number of flutes
(2) Maximum ramping angle
The NPA02-2019's pdf file: View (PDF) or Download (ZIP)