KENNAMETAL HERTEL

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Alu 2.00 GB

Complete Solutions for a

Production with a Great Future

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IntroductionIntroduction

In all areas of industry, aluminium has become a basic material for workpieces of anyshape and load-bearing requirements. For a long time, this light-weight material hastaken over the functions of load-bearing components. New technologies in productionand machining of aluminium extend the limits of what is feasible further and further.

Consequently, the cutting of advanced aluminium alloys with geometrically determinedtips is gaining more and more importance - an area where KENNAMETAL HERTEL hasbeen carrying out development work and acquiring competence for many years. For along time, customers from all over the world have been relying on our products and ser-vices, for whatever targets, conditions and requirements aluminium workpieces aremachined.

Complete offer for Aluminium Machining

The high quality of our tools and the unique variety of our product range offer maximumflexibility and optimum choice. You can select from our Turning, Drilling, Countersinking,Reaming and Milling Tools at different price and performance levels - from uncoatedmicro fine-grain carbides through coated carbides especially developed for aluminiummachining to diamond cutting tools for the highest demands. Depending on your pro-duction, both the means and the strategies for these machining operations can be adap-ted to the requirements of your workpieces.

But KENNAMETAL HERTEL do not only offer carrier-tool systems especially adapted tothe requirements of aluminium cutting. Modern cutting materials and processing tech-nologies complete the offer - a sound basis for efficient tool application and economicproduction.

Service is a Matter of Course

Special solutions specifically developed to satisfy the customer's needs, supplement ourstandard programme. Ask for them! The specific application of these individual tools willfurther reduce machining times and increase your productivity.

It is not only high performance tools that matter. In addition, we give you advice andassistance in all questions of aluminium machining. The services we offer range fromdevelopment of tooling systems which conform to global standards and are permanent-ly available thanks to our global sales network through to simultaneous engineering atthe project planning phase.

The perfect coordination of all resources makes KENNAMETAL HERTEL a competentpartner for complex metal-cutting jobs - for our customers, for your projects, worldwide!

•• Milling Pages C3...C26

•• Turning Pages B2...B7

•• Drilling/Countersinking Pages A2...A27

•• Reaming Pages D2...D5

Overall contentsOverall contents

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Table of ContentsTable of ContentsDRILLINGDRILLING

• TF-Drill (B105) A2

• TX-Drill (B411) and TXD-Drill (B495) - PCD-tipped A6

• Special toolsSolid-carbide and PCD-tipped multi-stage drills A12

• Indexable-insert drill Drill-Fix DFR/DFT A15

COUNTERSINKINGCOUNTERSINKING

• Kendex Precision Lock boring toolsand face countersink S2S A18

• Multi-stage drilling and countersinking toolswith indexable inserts and PCD monobloc A24

Drilling and CountersinkingDrilling and Countersinking

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CD2 CS3

CS5

TF-DRILL (B105)Solid-carbide drill acc. to DIN 6537L for drilling Al alloys

The TF-Drill

The three symmetrical cutting edges of theTF-Drill not only achieve higher feed ratesthan conventional drills, they guaranteeoptimum centring and well balanced cuttingforces, from spot-drilling to drilling through.

The lands of the TF-Drill are extremely narrow.This reduces friction, eliminates cold weldsand any jamming of the drill in the workpiece.

The three spacious chip flutes with roundedheels provide for smooth chip evacuation,even at feed rates over 10 M/min.

The extremely slim back of the drill avoidschips becoming jammed or even welded on.Therefore, TF-Drills are ideally suited fordrilling with minimum-quantitylubrication.

Furthermore, the slim profile provides highdynamic rigidity with natural frequencies ofvibration far beyond those of the machine andworkpiece.

This makes the TF-Drill the optimum solutionto your high speed drilling requirements. Itremains unaffected by vibrations which mayoccur, for example, when spot drilling ordrilling through, and handles run-out and outof balance conditions far better than drillingtools with two cutting edges.

Special solutions? - No problem!

Please use pages A12 - A13 for your inquiriesfor special tools.

Note

TF-Drills are easily regrindable with theKENNAMETAL HERTEL regrinding fixture oron CNC grinding machines.

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Properties of carbide grades for drilling Hardness

Chemicalresistance

KF1K10

Thermalshockresistance

Heat resistance Toughness

A2

Note:As far as technical specifications are concerned, see DIN 6540.For intermediate dimensions, see note in current price list

Availability see current price listOrder example (for ø 3,0 version A – straight):1 piece B105 A 03000 K10

TF-DRILL (B105)®

Shank versions acc. to DIN 6535Form HA, straightVersion A:

Carbide grade: K10

CODE CODE Recommendations forø Version A Version F thread Helicoild1m7 (straight) (WHISTLE FLAT) tapping formers threads d2h6 I1 I2 I3 I4 I5 I3/d1

3,00 B 105 A 03000 B 105 F 03000 – – M2,5 6 66 28 23 36 0,7 7,73,10 A 03100 F 03100 – – – 7,43,20 A 03200 F 03200 M4 – M3 7,23,30 A 03300 F 03300 – – – 0,8 7,03,50 A 03500 F 03500 – – – 0,8 6,63,70 A 03700 F 03700 – M4 – 0,9 6,23,80 A 03800 F 03800 – – – 74 36 29 36 7,6

4,00 B 105 A 04000 B 105 F 04000 – – – 7,34,10 A 04100 F 04100 – – – 7,14,20 A 04200 F 04200 M5 – M4 1,0 6,94,50 A 04500 F 04500 – – – 1,0 6,44,65 A 04650 F 04650 – M5 – 1,1 6,24,70 A 04700 F 04700 – – – 6,24,80 A 04800 F 04800 – – – 82 44 35 36 7,3

5,00 B 105 A 05000 B 105 F 05000 M6 – – 1,2 7,05,10 A 05100 F 01500 – – – 1,2 6,95,20 A 05200 F 05200 – – M5 1,3 6,75,50 A 05500 F 05500 – – – 1,3 6,45,55 A 05550 F 05550 – M6 – 1,4 6,35,70 A 05700 F 05700 – – – 6,15,80 A 05800 F 05800 – – – 6,0

6,00 B 105 A 06000 B 105 F 06000 M7 – – 5,86,10 A 06100 F 06100 – – – 8 91 53 43 36 1,5 7,06,30 A 06300 F 06300 – – M6 6,86,40 A 06400 F 06400 – – – 6,76,50 A 06500 F 06500 – – – 6,66,60 A 06600 F 06600 – – – 6,56,70 A 06700 F 06700 – – – 6,46,80 A 06800 F 06800 M8 – – 1,6 6,3

7,00 B 105 A 07000 B 105 F 07000 – – – 1,7 6,17,10 A 07100 F 07100 – – – 6,17,40 A 07400 F 07400 – M8 – 5,87,50 A 07500 F 07500 – – – 5,77,60 A 07600 F 07600 – 5,77,80 A 07800 F 07800 M9 – – 1,8 5,5

8,00 B 105 A 08000 B 105 F 08000 – – – 1,9 5,48,10 A 08100 F 08100 – – – 10 103 61 49 40 2,0 6,08,30 A 08300 F 08300 – – – 5,98,40 A 08400 F 08400 – – M8 5,88,50 A 08500 F 08500 M10 – – 5,88,60 A 08600 F 08600 – – – 5,78,70 A 08700 F 08700 – – – 5,68,80 A 08800 F 08800 – – – 5,6

9,00 B 105 A 09000 B 105 F 09000 – – – 5,49,10 A 09100 F 09100 – – – 5,49,30 A 09300 F 09300 – M10 – 2,1 5,39,50 A 09500 F 09500 M11 – – 2,2 5,29,70 A 09700 F 09700 – – – 2,2 5,19,80 A 09800 F 09800 – – – 2,3 5,0

10,00 B 105 A 10000 B 105 F 10000 – – M10 2,3 4,9

Solid-carbide drill acc. to DIN 6537L for drilling Al alloys

Form HE 2° WHISTLE FLATVersion F:

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TF-DRILL (B105)

Shank versions acc. to DIN 6535Form HA, straightVersion A:

Carbide grade: K10

CODE CODE Recommendations forø Version A Version F thread Helicoild1m7 (straight) (WHISTLE FLAT) tapping formers threads d2h6 I1 I2 I3 I4 I5 I3/d1

10,10 B 105 A 10100 B 105 F 10100 – – – 12 118 71 56 45 2,4 5,610,20 A 10200 F 10200 M12 – – 5,510,30 A 10300 F 10300 – – – 5,410,50 A 10500 F 10500 – – – 5,310,70 A 10700 F 10700 – – – 5,210,80 A 10800 F 10800 – – – 5,2

11,00 B 105 A 11000 B 105 F 11000 – – – 2,6 5,111,10 A 11100 F 11100 – – – 5,011,20 A 11200 F 11200 – M12 – 5,011,50 A 11500 F 11500 – – – 2,7 4,911,70 A 11700 F 11700 – – – 2,7 4,811,80 A 11800 F 11800 – – – 2,8 4,7

12,00 B 105 A 12000 B 105 F 12000 M14 – – 2,8 4,7

12,10 B 105 A 12100 B 105 F 12100 – – – 14 124 77 60 45 2,9 5,012,50 B 105 A 12500 B 105 F 12500 – – M12 5,012,70 A 12700 F 12700 – – – 4,712,80 A 12800 F 12800 – – – 4,7

13,00 B 105 A 13000 B 105 F 13000 – – – 3,1 4,613,10 A 13100 F 13100 – M14 – 4,613,50 A 13500 F 13500 – – – 4,413,80 A 13800 F 13800 – – – 3,2 4,3

14,00 B 105 A 14000 B 105 F 14000 M16 – M12 3,3 4,3

14,20 B 105 A 14200 B 105 F 14200 – – – 16 133 83 63 48 3,3 4,414,50 B 105 A 14500 B 105 F 14500 – – M14 3,4 4,3

15,00 B 105 A 15000 B 105 F 15000 – – – 3,5 4,215,10 A 15100 F 15100 – M16 – 3,5 4,215,50 A 15500 F 15500 M18 – – 3,6 4,115,80 A 15800 F 15800 – – – 3,7 4,0

16,00 B 105 A 16000 B 105 F 16000 – – – 3,7 3,9

16,50 B 105 A 16500 B 105 F 16500 – – M16 18 143 93 71 48 3,8 4,316,90 B 105 A 16900 B 105 F 16900 – M18 – 3,9 4,2

17,00 B 105 A 17000 B 105 F 17000 – – – 4,0 4,217,50 A 17500 F 17500 M20 – – 4,1 4,117,70 A 17700 F 17700 – – – 4,0 4,0

18,00 B 105 A 18000 B 105 F 18000 – – – 4,2 3,9

18,50 B 105 A 18500 B 105 F 18500 – – – 20 153 101 77 50 4,3 4,218,75 A 18750 F 18750 – – M18 4,118,90 A 18900 F 18900 – M20 – 4,1

19,00 B 105 A 19000 B 105 F 19000 – – – 4,4 4,119,50 B 105 A 19500 B 105 F 19500 M22 – – 4,5 3,9

20,00 B 105 A 20000 B 105 F 20000 – – – 4,7 3,9

20,50 B 105 A 20500 B 105 F 20500 – – – 167 112 85 4,8 4,1

21,00 B 105 A 21000 B 105 F 21000 M22 – – 167 112 85 4,9 4,0

Solid-carbide drill acc. to DIN 6537L for drilling Al alloys

Note:As far as technical specifications are concerned, see DIN 6540.For intermediate dimensions, see note in current price list

Availability see current price listOrder example (for ø 10,10 version A – straight):1 piece B105 A 10100 K10

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Form HE 2° WHISTLE FLATVersion F:

A4

Cutting Data Guidelines and Application Examples

A

Application Instructions for the TF-DRILL (B105)®

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HSSETF-DRILL

F (mm/min)�

Vc(m/min)

Remarks:Assessment of the production processTF-DRILL B105:Even these extreme cutting values weremastered by the TF-DRILL without com-plaints, with optimum chip formation andgood drill-hole quality.

Note:vc [m/min] = Cutting speedn [rpm] = Rotational speedf [mm] = Feed per revolutionvf [mm/min] = Feed speedE = Emulsion

Parameters vc n f vf Coolant

TF-DRILL1st test run 267 10000 0,2 2000 E (external)2nd test run 377 15000 0,6 9000 E (external)3rd test run 603 24000 0,6 14400 E (external)4th test run 603 24000 0,8 19200 E (external)

K10

High-Speed Drilling

Oil channels in the gear lidMaterial: GK-AISi9Cu3Machine: Machining centre

Operation: through-holes Ø5,2mm

Before: HSSE drillNow: TF-Drill, K 10

Advantage: considerably reduced machining time,considerably longer tool life

Operation: hole, 8 mm dia. variation of vc and f

Drill depths: 20 mmDrilling tools: TF-DRILL

with 3 flutesWorkpiece: perforated plate

Material: GAISi 1Carbide grade: K10

Note:For the guidelines given, sufficient cooling lubricant and stability arenecessary. Feed values for drill hole diameters not given in the table,can be interpolated.

1) C.Gr. = Cutting Group2) E = Emulsion

Machining example for the TF-Drill

Tensile Cuttingstrength Brinell speed Drill dia. in mm

Structure Rm hardn. Coo- vc in Feed f per rev. [mm]C.Gr.1 Material Group Heattreatment (MPa) HB lant 2 [m/min] 3 5 8 12 16 22

21 Aluminium wrought alloys not ageable 60 E 100 - 300 0,09 - 0,15 0,14 - 0,24 0,21 - 0,36 0,31 - 0,51 0,40 - 0,67 0,54 - 0,9022 ageable / aged 100 E 100 - 250 0,11 - 0,18 0,15 - 0,25 0,21 - 0,35 0,31 - 0,52 0,42 - 0,70 0,60 - 1,0023 Aluminium cast alloys < 12% Si, not ageable 75 E 100 - 250 0,11 - 0,18 0,15 - 0,25 0,21 - 0,35 0,31 - 0,52 0,42 - 0,70 0,60 - 1,0024 < 12% Si, ageable / aged 90 E 100 - 200 0,10 - 0,16 0,14 - 0,23 0,20 - 0,34 0,29 - 0,49 0,38 - 0,65 0,53 - 0,8825 > 12% Si, not ageable 90 E 100 - 200 0,10 - 0,16 0,14 - 0,23 0,20 - 0,34 0,29 - 0,49 0,38 - 0,65 0,53 - 0,88

TX-DRILL (B411) and TXD-Drill (B495)for Precision-Drilling of Aluminium Alloys

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TX-Drills are a combination of high-performance drillwith coolant channels and reamer in one tool.In addition to the two main cutting edges,each TX-Drill possesses two precision cuttingedges for fine finishing. Run-outs and surfacestray, normally unavoidable when drilling intosolid, are considerably reduced by the TX-Drillthrough the roughing and finishing edgesarranged in the form of an X.

Cutting materialThe extremely wear-resistant cutting materialKF1 does not only enable very sharp cuttingedges, but also guarantees that they remainsharp for a long time. Furthermore, it posses-ses due to its very fine-grain microstructurethe toughness which allows even heavy cutsand unfavourable cutting conditions.

Internal coolingThe TX-Drill possesses cutting lands and thelargest coolant channels of its class. A highcoolant flow rate provides for quick chipevacuation. Friction and squeezing of thechips at the drill-hole wall are minimized,resulting in a high quality of the hole and longtool lives.

TXD-DrillsEconomy

The new diamond-tipped solid-carbide drills ofKENNAMETAL HERTEL offer you shortmachining times and the saving of valuableprocess time.

There is nothing harderA diamond is the hardest thing nature canoffer. Make use of its high wear resistance andthe absence of built-up edges in your machin-ing operations.

GeometryThe TXD-Drill is to a very great extent identicalwith the known TX-Drill. The high rigidity of thetool and the straight chip flute guaranteemaximum cutting rates. The cutting diameteris of tolerance class m7.

Advantages- Maximum wear resistance - long tool lives- Optimum surface qualities - as a rule, no

subsequent machining operation necessary- High economic efficiency - efficient

manufacture at low costs0

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Hardness of different materials

Diamond TiAIN

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TiCN TiN WC/C

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TX-Drill (B411)Solid-Carbide Drill Acc. to DIN 6537L for Drilling Al Alloys

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Carbide grade: KF1

CODE Recommendations for Overall dimensions to DIN 6537 Lø Version A thread Helicoild1k6 (straight) tapping formers threads d2h6 I1 I2 I3 I4 I5 I3/d1

4,00 B411 A 04000 – – – 6 74 36 29 36 0,9 7,34,20 B411 A 04200 M5 – M4 1,0 6,94,50 B411 A 04500 – – – 1,0 6,44,65 B411 A 04650 – M5 – 1,1 6,24,80 B411 A 04800 – – – 82 44 35 1,1 7,35,00 B411 A 05000 M6 – – 1,2 7,05,10 B411 A 05100 – – – 1,2 6,95,20 B411 A 05200 – – M5 1,2 6,75,50 B411 A 05500 – – – 1,3 6,45,55 B411 A 05550 – M6 – 1,3 6,35,80 B411 A 05800 – – – 1,4 6,06,00 B411 A 06000 M7 – – 1,4 5,86,30 B411 A 06300 – – M6 8 91 53 43 1,5 6,86,50 B411 A 06500 – – – 1,5 6,66,60 B411 A 06600 – – – 1,5 6,56,80 B411 A 06800 M8 – – 1,6 6,37,00 B411 A 07000 – – – 1,6 6,17,40 B411 A 07400 – M8 – 1,7 5,87,50 B411 A 07500 – – – 1,7 5,77,80 B411 A 07800 M9 – – 1,8 5,58,00 B411 A 08000 – – – 1,9 5,48,40 B411 A 08400 – – M8 10 103 61 49 40 2,0 5,88,50 B411 A 08500 M10 – – 2,0 5,89,00 B411 A 09000 – – – 2,1 5,49,30 B411 A 09300 – M10 – 2,2 5,39,50 B411 A 09500 M11 – – 2,2 5,29,80 B411 A 09800 – – – 2,3 5,0

10,00 B411 A 10000 – – – 2,3 4,910,20 B411 A 10200 M12 – – 12 118 71 56 45 2,4 5,510,50 B411 A 10500 – – M10 2,4 5,311,00 B411 A 11000 – – – 2,6 5,111,20 B411 A 11200 – M12 – 2,6 5,011,50 B411 A 11500 – – – 2,7 4,911,80 B411 A 11800 – – – 2,7 4,712,00 B411 A 12000 M14 – – 2,8 4,712,50 B411 A 12500 – – M12 14 124 77 60 2,9 4,813,00 B411 A 13000 – – – 3,0 4,613,50 B411 A 13500 – M14 – 3,1 4,413,80 B411 A 13800 – – – 3,2 4,314,00 B411 A 14000 M16 – – 3,3 4,314,20 B411 A 14200 – – – 16 133 83 63 48 3,3 4,414,50 B411 A 14500 – – M14 3,4 4,315,00 B411 A 15000 – – – 3,5 4,215,50 B411 A 15500 M18 M16 – 3,6 4,116,00 B411 A 16000 – – – 3,7 3,916,50 B411 A 16500 – – M16 18 143 93 71 3,8 4,317,00 B411 A 17000 – M18 – 4,0 4,217,50 B411 A 17500 M20 – – 4,1 4,118,00 B411 A 18000 – – – 4,2 3,919,00 B411 A 19000 – M20 – 20 153 101 77 50 4,4 4,119,50 B411 A 19500 M22 – – 4,5 3,920,00 B411 A 20000 – – – 4,7 3,921,00 B411 A 21000 M24 – – 167 112 85 4,9 4,022,00 B411 A 22000 – – – 167 112 85 5,1 3,923,00 B411 A 23000 – – – 25 184 125 98 56 5,4 4,324,00 B411 A 24000 M27 – – 5,6 4,125,00 B411 A 25000 – – – 5,8 3,9

Note:As far as technical specifications are concerned, see DIN 6540.For intermediate dimensions, see note in current price list.

Availability see current price listOrder example (for ø 4,0 version A – straight):1 piece B411 A 04000 KF1 A7

Shank forms to DIN 6535Form HA, straightVersion A:

Note:I5 = d1 / 7I3 = Effective flute length

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TXD-Drill (B495)PCD-Tipped Solid-Carbide Drill for Drilling Al Alloys

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Carbide grade: KD1415

CODE Recommendations for Overall dimensions to DIN 6537 Lø Version A thread Helicoild1m7 (straight) tapping formers threads d2h6 I1 I2 I3 I4 I5 I3/d1

5,00 B495 A 05000 M6 – – 6 82 44 35 36 1,2 7,05,55 B495 A 05550 – M6 – 1,3 6,36,00 B495 A 06000 M7 – – 1,4 5,86,80 B495 A 06800 M8 – – 8 91 53 43 1,6 6,37,00 B495 A 07000 – – – 1,6 6,17,50 B495 A 07500 – M8 – 1,7 5,78,00 B495 A 08000 – – – 1,9 5,48,50 B495 A 08500 M10 – – 10 103 61 49 40 2,0 5,89,00 B495 A 09000 – – – 2,1 5,49,30 B495 A 09300 – M10 – 2,2 5,3

10,00 B495 A 10000 – – – 2,3 4,910,20 B495 A 10200 M12 – – 12 118 71 56 45 2,4 5,510,50 B495 A 10500 – – M10 2,4 5,311,00 B495 A 11000 – – – 2,6 5,111,20 B495 A 11200 – – – 2,6 5,012,00 B495 A 12000 M14 – – 2,8 4,712,50 B495 A 12500 – – M12 14 124 77 60 2,9 4,813,00 B495 A 13000 – – – 3,0 4,613,50 B495 A 13500 – – – 3,1 4,414,00 B495 A 14000 M16 – – 3,3 4,3

Special solutions? - No problem!

We can also offer you special tools which weadapt exactly to your specific application. Todo so, we need in addition to the drill-holegeometry the following basic information:

Blind hole / through hole

This information determines the position of thecoolant channels.

Workpiece material

As a function of the material to be machined,we select for you the optimally suited diamondgrade for tipping your tools.

Please use pages A12 and A13for your inquiries for special tools.

Blind hole:

Coolant exit on thefront

Through hole /boring:

Coolant exit in thechip flute

Shank forms to DIN 6535Form HA, straightVersion A:

Note:I5 = d1 / 7I3 = Effective flute length

Note:As far as technical specifications are concerned, see DIN 6540.For intermediate dimensions, see note in current price list..

Availability see current price listOrder example (for ø 5,0 version A – straight):1 piece B495 A 05000 KD1415

A

Application Instructions for the TX-Drill and TXD-Drill

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Cutting Data Guidelines

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The coolant pressure as a function of the holediameter is shown in the opposite diagram.The higher the coolant pressure, the better thedrilling result. Tool life and hole quality improvewith increasing coolant flow rate.

Spot-drilling on inclined surfaces

When spot-drilling on inclined or curvedsurfaces, reduce the drilling feed as comparedwith the standard values. The necessary feedrate reduction depends on the angle ofinclination of the workpiece surface and thedesign of the drill (see table).

Inclination Max. spot-drilling feed a for B411 and B495

1° 80%2° 50%3° 30%

Surfaces with greater inclination have to bespot-faced e.g. with a milling cutter.

100% feed

Reduced feed

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Coolant pressure too low

Favourable values

Note:The feeds indicated are valid for high-capacity, stable machines withspindles of little play. In mounted condition, the tools should not exceed arun-out of 0.02 mm. Under unstable conditions, it is recommended to reducethe feed by 20%.

With optimum conditions as to machine and workpiece clamping, feedswhich are by 20 % higher than the standard values can be used.

1) C.Gr. = Cutting Group2) E = Emulsion

Note:For the guidelines given, sufficient cooling lubricant and stability arenecessary. Feed values for drill hole diameters not given in the table, can beinterpolated.

Tensile Cuttingstrength Brinell speed Drill dia. in mm

Structure Rm hardn. Coo- vc in Feed f per rev. [mm]C.Gr.1 Material Group Heattreatment (MPa) HB lant 2 [m/min] 4 6 8 12 16 22

21 Aluminium wrought alloys not ageable 60 E 100 - 300 0,12 - 0,20 0,16 - 0,28 0,21 - 0,36 0,31 - 0,51 0,40 - 0,67 0,54 - 0,9022 ageable / aged 100 E 100 - 250 0,12 - 0,21 0,16 - 0,27 0,21 - 0,35 0,30 - 0,51 0,41 - 0,69 0,58 - 0,9823 Aluminium cast alloys < 12% Si, not ageable 75 E 100 - 250 0,12 - 0,21 0,16 - 0,27 0,21 - 0,35 0,30 - 0,51 0,41 - 0,69 0,58 - 0,9824 < 12% Si, ageable / aged 90 E 100 - 200 0,11 - 0,19 0,16 - 0,26 0,20 - 0,33 0,29 - 0,48 0,38 - 0,63 0,51 - 0,8625 > 12% Si, not ageable 90 E 100 - 200 0,11 - 0,19 0,16 - 0,26 0,20 - 0,33 0,29 - 0,48 0,38 - 0,63 0,51 - 0,86

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Application Examples for the TX- and TXD-Drill

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Drilling of valve spring seats

Workpiece: cylinder head

Workpiece material: GK-AlSi9Cu

Diameter: 12 / 29,7 mm

Drill depth: 18 mm

Tool: TXD-Drill, special

Cutting speed vc: 1400 m/min

Feed f: 0,15 mm/rev.

Through-holes ø 7,4 into housing lid

Workpiece: housing lid

Workpiece material: G-AlSi12Cu

Diameter: 7,4 mm

Drill depth: 16 mm

Tool: B411A07400 KF1

Cutting speed vc: 140 m/min

Feed f: 0,2 mm/min

Surface finish Ra: 1,03 mm

Blind holes, dia 8.5, into Aluminium

Workpiece material: AlSi12

Diameter: 8,5 mm

Drill depth: 30 mm

Tool: B411A08500 KF1

Cutting speed vc: 160 m/min

Feed f: 0,23 mm/min

Number of holes

Drill hole diameter (mm)

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Taper hollow shankDIN 69893, part 1form C formanual toolchange

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Mounting Examples for TX- and TXD-Drills

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for Special Applications

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Steep taperDIN 69871form B/AD

Steep taperMAS 403 BTJIS B 6339

Steep taperCAT/ANSIwith inchpull studthread

FCM

Taper hollow shankDIN 69893, part 1form A forautomatic toolchange

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KM quick-changetooling

FCM

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40

50

63

50

40

63

40

50

63

50

63

100

Stage drill

Profile drilling tool

BF-Drill for drilling, chamfer-ing and face-countersinking

BF-Drill for drilling andform-countersinking

Chamfering ring for drillingand chamfering

SEFAS - drilling andchamfering

SEFAS - drilling andchamfering

KM

Special Tools - Solid-Carbide and PCD-Tipped Stage Drills ®

A12

Enquiry Order Workpiece drawing (also as enclosure)with tolerance indications.

Company

Customer order No.

Authorised signature

Order No. Customer No.

Internal

Note: Please photocopy and return this form to our address.Please use only one photocopy of this order form for each type oftool.

A Tool

1. Shank form to DIN 6535:

2. Coolant:

3. Coolant notches in the shank:

4. Drill type:

B Workpiece

1. Material to DIN:

2. Strength or Hardness: [N/mm2/HB]

3. Drill hole tolerance required:

4. Additonal information:

C Machine

1. Type:

2. Power (kW):

3. No. of spindles:

4. max. rotational speed: [min–1]

D Machining

Machining problems(short description):

withoutclamping flat with clamping flat (2°)

Internal External

Yes No

Solid-carbide

PCD

Without

to bedetermined

by KMH

LathesMachining CentresSpecial

E How many pieces to be offered? 5 10 —

Date of order

Special Tools - Solid-Carbide and PCD-Tipped Stage Drills®

A13

Please tick the boxes which correspond to thetool you want and send the completed formtogether with the workpiece drawing to ouraddress.

Enquiry drawings

KENNAMETAL HERTEL will, where possible,assume any missing dimensions accordingto the application.

14

Indexable Insert Drills Drill-Fix DFR and DFT®

The New Drill-Fix DFR

is the optimum solution in the diameter rangefrom 12.5 to 24 mm. Its concept - designedentirely for economic and process-safemanufacture - offers the following advantages:

- rectangular basic shape of the two stableinserts for maximum feed rates

- the helical top surface of the inserts putsthe chips in the right shape

- the short helical chips are reliablyevacuated from the drill-hole

- the highly positive geometry LD, combinedwith the TiAlN coating applied in the PVDprocess, provides for an extremely highperformance and process safety whenmachining aluminium alloys

The Drill-Fix DFT

enables short manufacturing times, long toollives and good hole qualities for larger drill-holes. The optimum cutting-edge position,combined with the excellent centring of theKENNAMETAL HERTEL trigon-shaped index-able inserts, compensates the resultant cuttingforces and stabilizes the drill in its workingposition. Chip-flute profile and turning contourare designed in such a way that the chips oflong-chipping aluminium alloys are optimallyevacuated.

The newly developed HP geometry wasdesigned especially for ductile, long-chippingmaterials. The highly positive chip breaker isparticularly efficient with high feed rates andenables an economic cutting of nonferrousmetals.

Drilling with x-offset

All Drill-Fix DFR and DFT offer the possibility todrill holes directly into solid larger than thenominal diameter. Intermediate dimensions andfits are manufactured economically using the x-offset. On turning machines, this advantagecan be utilized immediately, while for rotatingapplications, adjustable chucks are available.

Notes on the step drilling tools:Please refer to pages A23 - A27.

du

d1

x

A15

Indexable Insert Drill DRILL-FIX DFR 2xd and DFT 2,5xdRight-hand Type WD20, WD32, WD40, WD50

®

d1

l

l

2

4

0,2d

lT

s

s

max

ø ø Clamping TORX-d1 range CODE CODE CODE CODE I2 I4 Tmax Insert screw screw driver

12,5 12,5 - 13,5 DFR125R2WD20M 47,4 46,8 25 DFR020204 193.281 170.02712,7 12,7 - 13,7 DFR127R2WD20M 47,8 47,2 25,4 (M2x4,5) (Tx 6)13 13,0 - 14,0 DFR130R2WD20M 48,4 47,8 2613,5 13,5 - 14,5 DFR135R2WD20M 49,4 48,8 2714 14,0 - 15,0 DFR140R2WD20M 50,4 49,8 2814,5 14,5 - 15,5 DFR145R2WD20M 53,4 52,8 2915 15,0 - 16,0 DFR150R2WD20M 54,4 53,8 3015,5 15,5 - 16,5 DFR155R2WD20M 55,4 54,8 3116 16,0 - 17,0 DFR160R2WD20M 56,4 55,8 3216,5 16,5 - 17,5 DFR165R2WD32M 62,0 61,6 33 DFR030204 92.416 170.02317,0 17,0 - 18,0 DFR170R2WD32M 63,0 62,6 34 (M2.2*5.2) (Tx 7)17,5 17,5 - 18,5 DFR175R2WD32M 64,0 63,6 3518,0 18,0 - 19,0 DFR180R2WD32M 65,0 64,6 3618,5 18,5 - 19,5 DFR185R2WD32M 66,0 65,6 3719,0 19,0 - 20,0 DFR190R2WD32M 67,0 66,6 3819,5 19,5 - 20,5 DFR195R2WD32M 68,0 67,6 3920,0 20,0 - 21,0 DFR200R2WD32M 72,0 71,6 4020,5 20,5 - 21,5 DFR205R2WD32M 73,0 72,5 41 DFR040304 192.432 170.02821,0 21,0 - 22,0 DFR210R2WD32M 74,0 73,5 42 (M2.5*5.9) (Tx 8)22,0 22,0 - 23,0 DFR220R2WD32M 76,0 75,5 4423,0 23,0 - 24,0 DFR230R2WD32M 78,0 77,5 4624,0 24,0 - 25,0 DFR240R2WD32M 80,0 79,5 48

25 25,0 - 27,0 DFT250R2WD32M DFT250R2WD40M 90 89,1 58 DFT05T308 191·924 170·024 (Tx 9)26 26 ,0- 27,0 DFT260R2WD32M DFT260R2WD40M 100 88,9 65 (M3 x 7,2)27 27,0 - 29,0 DFT270R2WD32M DFT270R2WD40M 98,928 28,0 - 29,0 DFT280R2WD32M DFT280R2WD40M 98,729 29,0 - 31,0 DFT290R2WD32M DFT290R2WD40M 98,730 30,0 - 31,0 DFT300R2WD32M DFT300R2WD40M 115 113,6 7531 31,0 - 33,0 DFT310R2WD32M DFT310R2WD40M 113,632 32,0 - 33,0 DFT320R2WD32M DFT320R2WD40M 113,5

33 33,0 - 35,0 DFT330R2WD32M DFT330R2WD40M 113,6 DFT06T308 191·848 170·025 (Tx 15)34 34,0 - 35,0 DFT340R2WD32M DFT340R2WD40M 113,5 (M3,5 x 8,7)35 35,0 - 38,0 DFT350R2WD32M DFT350R2WD40M 113,436 36,0 - 37,0 DFT360R2WD32M DFT360R2WD40M 113,237 37,0 - 38,0 DFT370R2WD32M DFT370R2WD40M 135 133,3 9538 38,0 - 41,0 DFT380R2WD32M DFT380R2WD40M 133,239 39,0 - 40,0 DFT390R2WD32M DFT390R2WD40M 133,140 40,0 - 41,0 DFT400R2WD32M DFT400R2WD40M 133,0

41 41,0 - 44,0 DFT410R2WD32M DFT410R2WD40M 133,1 DFT070408 191·698 170·025 (Tx 15)42 42,0 - 43,0 DFT420R2WD32M DFT420R2WD40M 133,1 (M3,5 x 12)43 43,0 - 44,0 DFT430R2WD32M DFT430R2WD40M 150 147,9 11044 44,0 - 47,0 DFT440R2WD32M DFT440R2WD40M 147,9

45 45,0 - 46,0 DFT450R2WD40M DFT450R2WD50M 147,846 46,0 - 47,0 DFT460R2WD40M DFT460R2WD50M 147,747 47,0 - 50,0 DFT470R2WD40M DFT470R2WD50M 147,648 48,0 - 49,0 DFT480R2WD40M DFT480R2WD50M 147,6

Note:For further standard drills, see Drilling Catalogue 202.00

Availability see current price list.Ordering example:1 piece DFR125R2WD20M

Shank type ø dsh6 ls

WD20M 20 45

WD32M 32 58

WD40M 40 68

WD50M 50 68

d d

lT

s

s

max

1

l

l

2

4

0,2

A16

CuttingBrinell speed

Structure hardn. Coo- vc in Feed f per rev. [mm] for indexable inserts*C.Gr.1 Material Group Heattreatment HB lant 2 [m/min] DFT05.. DFT06.. DFT07..

21 Aluminium wrought alloys not ageable 60 E 400 - 600 0,08 0,12 0,1422 ageable / aged 100 E 400 - 600 0,08 0,12 0,1423 Aluminium cast alloys < 12% Si, not ageable 75 E 400 - 600 0,12 0,14 0,1624 > 12% Si, ageable / aged 90 E 300 - 450 0,12 0,14 0,1625 > 12% Si, not ageable 90 E 300 - 450 0,12 0,14 0,16

CuttingBrinell speed

Structure hardn. Coo- vc in Feed f per rev. [mm] for indexable inserts*C.Gr.1 Material Group Heattreatment HB lant 2 [m/min] DFT02.. DDF03.. DFR04..

21 Aluminium wrought alloys not ageable 60 E 400 - 600 0,06 0,07 0,0822 ageable / aged 100 E 400 - 600 0,06 0,07 0,0823 Aluminium cast alloys < 12% Si, not ageable 75 E 400 - 600 0,08 0,10 0,1424 < 12% Si, ageable / aged 90 E 300 - 450 0,08 0,10 0,1425 > 12% Si, not ageable 90 E 300 - 450 0,08 0,10 0,14

Application Instructions for the Drill-Fix DFR and DFTIndexable Insert DFTIndexable Insert DFR

Note:*) The values indicated are standard values. For drill dephts over 2.5 x d,

they should not be exceeded.

Availability see current price listOrder example10 pieces DFR020204LD KC7225

®

Indexable inserts DFR

ørange CODE Carbide grade R s b d2 l

12,6 - 16,0 DFR020204LD KC7225 0,4 2,8 4,9 2,3 7,116,5 - 20,0 DFR030204LD KC7225 2,9 6,0 2,5 8,720,5 - 24,0 DFR040304LD KC7225 3,8 7,4 2,9 10,8

Indexable inserts DFT

ørange CODE Carbide grade a R s d1 d2 l1

25,0 - 32,0 DFT05T308HP KC7215 8° 0,8 3,8 8,0 3,5 5,333,0 - 40,0 DFT06T308HP KC7215 7° 3,8 10,0 4,4 6,641,0 - 48,0 DFT070408HP KC7215 7° 4,8 12,0 4,4 7,9

Recommended Cutting Data for the Drill-Fix DFR

Recommended Cutting Data for the Drill-Fix DFT

d

b R

2

10°

l

s

d

d

sl

24° α

1

1

2

R

A17

1) C.Gr. = Cutting Group2) E = Emulsion

Note:For the guidelines given, sufficient cooling lubricant and stability arenecessary.

Boring and Countersinking ToolsThe Suitable System for Every Application

®

Internal coolingis a matter of course for both S2S counter-sinks and Kendex Precision Lock.

Both systems are self-centring and do notneed additional guide strips. Therefore, theirhandling is simple and they can also easily beused with minimum-quantity lubrication.

Kendex Precision Lockis the name of boring and countersinking toolswhose indexable inserts can be adjusted withhigh precision to the required diameter tole-rance. The special BPGX indexable insertsare accurately guided in their V-shaped seatsduring the adjustment operation. The adjust-ment of the diameter influences neither theapproach angle nor the edge-height diffe-rence.

The inserts are ground on all surfaces andhave particularly sharp edges and a positivegeometry. This guarantees good chip forma-tion and drill-hole surfaces, in particular whenmachining aluminium alloys.

S2S countersinksare particularly robust tools for roughing andmedium finishing. They combine the high flexi-bility, favourably priced design and simplehandling of ISO tools with a cutting geometryespecially developed for boring and counter-sinking.

Rake angles of 20° to 25° and smooth sur-faces provide for low cutting forces and avoidthe formation of built-up edges. The secon-dary cutting edge, which is specifically adap-ted to face countersinking operations, dam-pens any arising vibrations or prevents themcompletely.

A18

Face Countersink S2S®

Basic Body with Coolant Supply Insert SPHX

Basic body with straight shank DIN 1835 form E

No. ofø Inserts Clamping TORX-d1 CODE d2 min d5 I1 I2 I3 max z Insert screw Screw driver

18 3·51180 R 120 8,4 20 86 35 25 3 SPHX 060204 R22 192·432 (M 2,5) 170·028 (Tx 8)20 3·51200 R 120 8,522 3·51220 R 120 10,424 3·51240 R 120 10,5 91 40 30 2 SPHX 090304 R22 191·924 (M 3) 170·024 (Tx 9)26 3·51260 R 120 13 96 45 35 228 3·51280 R 120 15 101 50 40 330 3·51300 R 120 1532 3·51320 R 120 1733 3·51330 R 120 1736 3·51360 R 132 19 32 116 5540 3·51400 R 132 21 121 60 50 SPHX 120404 R22 191·916 (M 3,5) 170·025 (Tx 15)42 3·51420 R 132 22 126 65 5546 3·51460 R 132 25 126 65 55

Insertsø d1- 2-edged Carbide range CODE new CODE old grade I = d1 s d2 r γ° α1° α2°

18 – 22 SPHX060204R22 3·61122R001 KM1 6,35 2,38 2,6 0,4 25 – 1124 – 36 SPHX090304R22 3·61222R001 KM1 9,52 3,18 3,5 –40 – 46 SPHX120404R22 3·61322R001 KM1 12,70 4,76 4,5 –

l=d R s

d

αα

γ

1

1

2

2

l

l

dd

1

1

2

2

H13

ds

l3

Availability see current price listOrder example1 piece 3·51180 R120

10 pieces SPHX060204R22 KM1

with 2 cutting edges for machining aluminium

A19

b11°

s

s

γ Rl

Basic body

ø ø Clamping Adjusment TORXd1 CODE dS l1 l2 l3 max Insert element screw screw driver

1-edged type5,8 - 6,2 KPL060R2SS12N1M 12 70 25 15 BPGX0301.. 551.052 570.052 170.099 (TX 5)6,8 - 7,2 KPL070R2SS12N1M 70 25 15 BPGX0301..7,8 - 8,2 KPL080R2SS12N1M 75 30 20 BPGX0301..8,8 - 9,2 KPL090R2SS12N1M 75 30 20 BPGX0301..9,7 - 10,3 KPL100R2SS16N1M 16 83 35 25 BPGX0502.. 551.053 570.053 170.027 (TX 6)

10,7 - 11,3 KPL110R2SS16N1M 83 35 25 BPGX0502..11,7 - 12,3 KPL120R2SS16N1M 88 40 30 BPGX0502..12,7 - 13,3 KPL130R2SS16N1M 88 40 30 BPGX0502..

2-edged type9,8 - 10,2 KPL100R2SS16N2M 83 35 25 BPGX0301.. 551.052 570.052 170.099 (TX 5)

10,8 - 11,2 KPL110R2SS16N2M 83 35 25 BPGX0301..11,8 - 12,2 KPL120R2SS16N2M 88 40 30 BPGX0301..12,8 - 13,2 KPL130R2SS16N2M 88 40 30 BPGX0301..13,8 - 14,2 KPL140R2SS16N2M 93 45 35 BPGX0301..14,7 - 15,3 KPL150R2SS20N2M 20 95 45 35 BPGX0502.. 551.053 570.053 170.027 (TX 6)15,7 - 16,3 KPL160R2SS20N2M 100 50 40 BPGX0502..16,7 - 17,3 KPL170R2SS20N2M 100 50 40 BPGX0502..17,7 - 18,3 KPL180R2SS20N2M 105 55 45 BPGX0502..18,7 - 19,3 KPL190R2SS20N2M 105 55 45 BPGX0502..

3-edged type14,8 - 15,2 KPL150R2SS20N3M 95 45 35 BPGX0301.. 551.052 570.052 170.099 (TX 5)15,8 - 16,2 KPL160R2SS20N3M 100 50 40 BPGX0301..16,8 - 17,2 KPL170R2SS20N3M 100 50 40 BPGX0301..17,7 - 18,3 KPL180R2SS20N3M 110 60 45 BPGX0502.. 551.053 570.053 170.027 (TX 6)18,7 - 19,3 KPL190R2SS20N3M 110 60 45 BPGX0502..19,7 - 20,3 KPL200R2SS20N3M 115 65 50 BPGX0502..20,7 - 21,3 KPL210R2SS20N3M 115 65 50 BPGX0502..21,7 - 22,3 KPL220R2SS20N3M 120 70 55 BPGX0502..22,7 - 23,3 KPL230R2SS20N3M 120 70 55 BPGX0502..23,7 - 24,3 KPL240R2SS20N3M 125 75 60 BPGX0502..24,7 - 25,3 KPL250R2SS20N3M 125 75 60 BPGX0502..

Availability see current price listOrder example

1 piece KPL060R2SS12N1M10 pieces BPGX030101LHP K313

Kendex Precision Lock Boring ToolsBasic Body Insert

®

A20

Insert CarbideCODE grade l r s b x γ°

BPGX030101LHP K313 3 0,05 1,7 0,8 x 16°BPGX030102LHP K313 3 0,2 1,7 0,8 x 16°BPGX050202LHP K313 5 0,2 2,7 1,4 x 16°BPGX050204LHP K313 5 0,4 2,7 1,4 x 16°

d d

l

s

1

1

l

l

2

3 max.

A

Application Instructions®

21

*) The feed in mm/rev and per cutting edge depends on the required surface quality. In general, however, the maximum feed per edge should not exceed 1/3 ofthe insert corner radius.For high surface qualities (less than Rz = 10), inserts with bevel grinding may be an advantage. They allow higher feed rates than indexable inserts with cornerradius.In principle, it is recommended to chose a cutting depth not less than 1.5 x corner radius. For multi-edged tools, the maximum cutting depth must not exceed3/4 of the cutting-edge length of the insert, and for single-edged tools, 1/3.

Selection of indexable inserts:

In addition to standard inserts with cornerradius, inserts with special bevel grindings areavailable for Kendex Precision Lock.

To achieve optimum surface qualities, theseinserts are adapted to the application in que-stion. For finishing operations, inserts in PCD,fullface version, are also available.

Adjustment of Kendex precision boringtools:The cutting-circle diameter should in generalonly be measured optically to avoid damage tothe cutting edges. The insert will be clampedand then the diameter can be enlarged to thedesired dimension.

Corrections are effected by turning the adjust-ment screw clockwise. An additional locking ofadjustment screw and clamping element is notnecessary. For resetting, the clamping elementmust first be released.

Recomm.edge inset / Cutting Countersink diameter [mm]

Material Structure Brinell- carbide speed Feed f per revolution [mm]C.Gr.1 sub-group heattreatment hardn. HB grade Vc in [m/min] 18 - 22 24 - 36 40 - 46

21 Aluminium not ageable 60 KM1/22 150 - 200 0,10 - 0,12 0,20 - 0,30 0,30 - 0,4022 wrought alloys ageable, aged 100 KM1/22 150 - 200 0,10 - 0,12 0,20 - 0,30 0,30 - 0,40

23 Aluminium < 12%Si,cast alloys not ageable 75 KM1/22 150 - 200 0,10 - 0,12 0,20 - 0,30 0,30 - 0,40

24 < 12%Si,ageable, aged 90 KM1/22 150 - 200 0,10 - 0,12 0,20 - 0,30 0,30 - 0,40

25 > 12%Si,not ageable 130 KM1/22 70 - 100 0,10 - 0,12 0,20 - 0,30 0,30 - 0,40

Application Instructions for S2S

Recomm.edge inset / Cutting Countersink diameter [mm]

Material Structure Brinell- carbide speed Feed f per revolution [mm]C.Gr.1 sub-group heattreatment hardn. HB grade Vc in [m/min] 5,8 - 13,3 13,4 - 19,3 19,4 - 25,3

21 Aluminium not ageable 60 K313 150 - 200 0,02 - 0,07 0,05 - 0,10 0,07 - 0,1222 wrought alloys ageable, aged 100 K313 150 - 200 0,02 - 0,07 0,05 - 0,10 0,07 - 0,12

23 Aluminium < 12%Si,cast alloys not ageable 75 K313 150 - 200 0,02 - 0,07 0,05 - 0,10 0,07 - 0,12

24 < 12%Si,ageable, aged 90 K313 150 - 200 0,02 - 0,07 0,05 - 0,10 0,07 - 0,12

25 > 12%Si,not ageable 130 K313 70 - 100 0,02 - 0,07 0,05 - 0,10 0,07 - 0,12

Application Instructions for Kendex Precision Lock

Machining of a caliper of Aluminium:Machine: machining centre

Specifications: Short machining time,few tool changes,sealing faces withRa < 1,6 µm,drill-hole tolerance +/- 0,03,high process security,CPK = 2,0

Workpiecematerial: AlSi8

1st operation:Pilot-drilling and boring and chamferingof the piston hole with S2S countersinkCutting depths: up to 10 mm

Cutting data: n = 6500 min-1

vc = 900 m/minf = 0,33 mmvf = 2145 mm/min

Cutting material: KM1

Result: Quiet running,secure chip evacuationtc = 1,5 sec.

Output: 3.000 holes

2nd Operation: Fine-drilling of the piston hole withKendex Precision LockCutting depths: ~ 0,3 mm

Cutting data: n = 8000 min-1

vc = 1130 m/minf = 0,3 mmvf = 2400 mm/min

Cutting material: KD100

Result: Quiet running, no built-upedges, very good surfaces,all dimensions in accor-dance with specificationstc = 1,3 sec.

Output: 45.000 holes

4544

,3

52

150

Application Examplefor S2S / Kendex Boring and Countersinking Tools

®

A22

Special Drilling and Countersinking Tools ø 16 – 85 ®

Enquiry Order Note: Please photocopy, complete and return this form to our address.Please use only one photocopy of this order form for each type of tool.

Company

Customer order No. Date of order

Authorised signature

Internal

Order No. Customer No.

Workpiece material:

Tool: Left-hand cutting

Sketch of the workpiece:

Note: Please indicate all relevant dimensions and tolerances!

Right-hand cutting

A24

Steep Taper (SK)DIN 69871 DIN 2080 MAS 403 BT

Form: A B C D

SK = 40 45 50 40 50 30 40 50

Straight Shank VDI 3425/DIN 69880(Direct clamping in turning machine turret)Toothing Yes Nods =

Special Drilling and Countersinking Tools ø 16 – 85®

Tool Shank TypeStraight Shank DIN 6535 HE(WHISTLE FLAT)ds = 20 25 32 40 50 60

16 20 30 40 50 60

Straight Shank DIN 6535 HB(WELDON)ds = 20 25 32 40 50 60

FCMSize 25 32 40 63 80 100

KMSize 32 40 50 63 80 100

HSK DIN 69893 Part 1 and 2Form AD Bds = 32 40 50 63 80 100

Other Shank TypesPlease enclose drawing or completedesignation

Function

Drilling into Solid

Drilling into Solid withNarrow Tolerances

Drilling of Stacked Plates

Multistage Drilling

Countersinking

Multistage Countersinking

Ø ds

Ø ds

Ø ds

Ø ds

Ø ds

Ø ds

Ø ds

Adjustable Countersinking

Adjustable Stage-Countersinking

Stage-Countersink with PCD monobloc

A25

3015

240

30

30°

30°

60°

R3,5

0,2

0,2

0,2

0,2

0,2

x 45°

3013

2

42,5

33,4

0,2

0,2

0,2

0,2

0,2

30

125 0,2

0,2

0,2

34

30

0,2

0,2

4050

0,1

0,2

30°

30°

30

5

0,5 x 45°

0,005

0,2

1,520 0,150,15

4030

0,1

0,1530°60°

5 0,2

30

17,5 30,1

0,2

25 0,15

25 0,1

0,5 x 45°

30°

How to Select Drilling and Chamfering Tools ®

K E N N A M E T A L H E R T E LTool Expert Software System

T E S S

Below are the types of tools, components and adaptors for KENNAMETAL HERTEL multistage drilling and countersinking tools:

Available Shank Types

Straight shank FCM KM Steep taper MORSE taper Stub taper HSK GRANLUND WOHLHAUPTER

Drillingø 12,5 – 82 mm

Countersinkingø 6 – 85 mm

Countersinkingø 35 – 160 mm

with indexable inserts ISO with cassettes

Insert GeometriesKENNAMETAL HERTEL

Standard InsertsKENNAMETAL HERTEL

Special InsertsKENNAMETAL HERTEL

ISO Special Insertsø adjustable

Cutting of variable Workpiece Geometries

SPHX.. CPEX.. WC../WO.. DFR.. SIS BP....

TC..SC.. CC..

A26

How to Select Drilling and Chamfering Tools®

K E N N A M E T A L H E R T E LTool Expert Software System

T E S S

This illustration shows some application examples for the multistage drilling and countersinking tool:

A B C

D

E

G

H

A27

F

Table of ContentsTable of Contents

• Cutting Materials and Chip Breaker Geometries B2for Machining Non-ferrous Metals

• KENNA PERFECT Negative ISO Indexable Inserts B4

• KENNA PERFECT Positive ISO Indexable Inserts B6

• Top-Notch Indexable Inserts B7

TurningTurning

®

B

Cutting Materials and Chip Breaker Geometries

2

for Machining Non-Ferrous Metals

KD100

Polycrystalline diamond. Extremely wear-resistantdiamond cutting material with a grain size of 25 µm forhigh-speed machining of nonferrous metals.

KC5410

PVD-TiB2-coated carbide with high wear-resistance formachining in the upper cutting-speed range. A cuttingmaterial for medium machining to roughing operations.The extremely hard TiB2-coating possesses a very lowaffinity to aluminium materials. In connection with apolished cutting face, this cutting material combines theexcellent properties of resistance against formation ofbuilt-up edges and wear resistance.

Negative ISO Indexable Inserts

The KENNA PERFECT selection system for nonferrousmetals offers three main chip-breaker geometries for theclamping systems P and M. For finishing operations andfor machining aluminium with a high silicon content,peripherally ground PCD edges are the first choice.

For aluminium alloys with a low silicon content, the chipbreaker GP with 10° rake angle and the chip breakerMS with 20° rake angle are suggested.

Negative ISO Indexable Inserts

For machining operations with positive, screw-clampedinserts, the chip breaker -HP with its polished, highlypositive geometry covers the main field of applicationfor the machining of non-ferrous materials.

The geometries offered are supplemented by the chipbreaker -LF and the high-performance PCD inserts.

The KENNAMETAL Top Notch programme is aclamping system for profiling operations of maximumrequirements, with convincing system solutions.

®

Wea

r re

sist

ance

Toughness

KD100

KC5410

B

Application Examples

3

®

Roughing a Cylinder Piece

Workpiece: Cylinder pieceWorkpiece material: 7075 T6 Aluminium

(0,5% Si)Machine: CNC lathe

Insert: CNMS 120408Cutting material: KC5410

Cutting data:Cutting speed: vc = 950 m/minFeed: f = 0,28 mmDepth of cut: ap = 1,5 mm

Tool life:KC5410 T = 545 minCarbide, PVD-coated: T = 55 minCarbide, uncoated: T = 27 min

Profiling a Tire Rim

Workpiece: Tire rimWorkpiece material: AlSi12Machine: CNC lathe

Insert: RCGT 1204M0-HPCutting material: KC5410

Cutting data:Cutting speed: vc = 2500 m/minFeed: f = 0,28 mmDepth of cut: ap = 1,0 - 2,5 mm

Tool life:KC5410 T = 60 pcs.Carbide, uncoated: T = 40 pcs.

Finishing a Torque Converter

Workpiece: Torque converterWorkpiece material: G-AlSi11Mg (11% Si)Machine: CNC lathe

Insert: TPGW 110208 FCutting material: KD100

Cutting data:Cutting speed: vc =1200 m/minFeed: f = 0,08 - 0,2 mmDepth of cut: ap = 0,5 mm

Tool life: T = approx. 60 min

B

Non-FerrousMetals

KENNA PERFECT - Non-Ferrous Metals

4

Insert Geometries for Non-Ferrous Metals

®

..MS Roughing

Negative Inserts

..GP Medium machining

..MS-F Finishing

Recommended Cutting Materials (Grade)

Cutting condition

Cipbreaker

Heavily interrupted cut

Slightly interrupted cut

Varying Depth of CutCasting or Forging skin

Smooth cut,Pre-turned Surface

KD100

KD100

KD100

KC5410

KC5410

KC5410

KC5410

KC5410

KC5410

KC5410

KC5410

KD100

KC5410

250 500 750 1000 1250 1500 1750 2000 2250Cutting Speed vc (m/min)

Recommended Cutting Speed

..MS..GP..MS-F (PCD)

(PCD)

Feed f (mm)

Depth of cutap (mm)

B

Medium machining KC

CODE ..GP / ..MP 5410

CNGP 120401* •CNGP 120402* •CNGP 120404* •CNGP 120408* •CNGP 120412* •CNGP 120416* •CNMP 160612 •CNMP 190612 •DNGP 150401* •DNGP 150402* •DNGP 150404* •DNGP 150408* •DNGP 150604* •DNGP 150608* •SNGP 120404* •SNGP 120408* •

TNGP 160402* •TNGP 160404* •TNGP 160408* •TNMP 220408 •TNMP 220412 •

VNGP 160401* •VNGP 160402* •

FinishingKD

CODE ..MS-F 100

CNMS 120408F •

DNMS 150408F •

SNMS 120408F •SNMS 120412F •

TNMS 160404F •TNMS 160408F •TNMS 220404F •TNMS 220408F •TNMS 220412F •

VNMS 160404F •VNMS 160408F •

RoughingKC

CODE ..MS 5410

CNMS 120408 •CNMS 160608 •CNMS 190608 •

DNMS 150408 •DNMS 190608 •

SNMS 120408 •SNMS 120412 •SNMS 190612 •

TNMS 160404 •TNMS 160408 •TNMS 220404 •TNMS 220408 •TNMS 220412 •TNMS 270608 •TNMS 270612 •TNMS 270616 •VNMS 160404 •VNMS 160408 •

ISO Indexable Inserts for Clamping Systems P and M

5

®

Order example:10 pieces CNMS120408 KC5410

We reserve the right of technical modifications of our products and deliveryprogramme.

B

KENNA PERFECT - Non-Ferrous Metals

6

Insert Geometries for Non-Ferrous Metals

®

Non-FerrousMetals

Positive Inserts-HP

Mediummachining

..GW-F Fine-finishing

-LF Finishing

Recommended Cutting Materials (Grade)

Cutting condition

Chipbreaker

Heavily interrupted cut

Slightly interrupted cut

Varying Depth of CutCasting or Forging skin

Smooth cut,Pre-turned Surface

KD100

KD100

KD100

KC5410

KC5410

KC5410

KC5410

KC5410

KC5410

KC5410

KD100

KC5410

250 500 750 1000 1250 1500 1750 2000 2250Cutting Speed vc (m/min)

Recommended Cutting Speed

-HP-LF..GW-F (PCD)

Feed f (mm)

Depth of cutap (mm)

(PCD)

B

ISO Indexable Inserts for Clamping System S, Top Notch Indexable Inserts

7

®

Mediummachining KC

CODE ..GT-HP 5410

CCGT 060202 HP •CCGT 060204 HP •CCGT 060208 HP •CCGT 09T302 HP •CCGT 09T304 HP •CCGT 09T308 HP •CCGT 120401 HP •CCGT 120402 HP •CCGT 120404 HP •CCGT 120408 HP •CPGT 060202 HP* •CPGT 060204 HP* •CPGT 060208 HP* •CPGT 09T302 HP •CPGT 09T304 HP •CPGT 09T308 HP* •DCGT 070202 HP •DCGT 070204 HP •DCGT 070208 HP* •DCGT 11T302 HP •DCGT 11T304 HP •DCGT 11T308 HP •DPGT 070202 HP •DPGT 070204 HP •DPGT 070208 HP* •DPGT 11T304 HP •DPGT 11T308 HP •

RCGT 0803M0 HP •RCGT 10T3M0 HP •RCGT 1204M0 HP •

TCGT 110202 HP •TCGT 110204 HP •TCGT 110208 HP •TCGT 16T304 HP •TCGT 16T308 HP •

TPGT 110202 HP •TPGT 110204 HP •TPGT 110208 HP •TPGT 16T304 HP •TPGT 16T308 HP •

VBGT 160404 HP •VBGT 160408 HP •

Fine-finishing KC KDCODE ..GW-F 5410 100

CPGW 060202 F •CPGW 060204 F •CPGW 060208 F •CPGW 09T304 F •CPGW 09T308 F •

DPGW 11T304 F •DPGW 11T308 F •

TPGW 110202 F •TPGW 110204 F •TPGW 110208 F •

VBGW 160404 F •

Top NotchProfiling KC KD

CODE 5410 100

KCGR 110304 R08 •KCGR 110304 L08 •KCGR 110308 R08 •KCGR 110308 L08 •

KCGX 110301 R15 •KCGX 110301 L15 •KCGX 110304 R15 •KCGX 110304 L15 •

VCGR 160402 •VCGR 160404 •VCGR 160408 •VCGR 160412 •VCGR 160416 •

VCGN 160404 •VCGN 160408 •VCGN 160412 •

Finishing KCCODE ..GT-LF 5410

CPGT 060204 LF •CPGT 09T304 LF •

DPGT 070202 LF •

Order example:10 pieces CCGT060202HP KC5410

We reserve the right of technical modifications of our products and deliveryprogramme.

Table of ContentsTable of Contents

• Milling Programme FIX-PERFECT C2

• Milling Programme KendexMiniMill C16

• Milling Programme RPF C18

• Milling Programme Solid-carbide C22

MillingMilling®

FIX-PERFECT Programme

PM

HPM

HSM

®

C

FIX-PERFECT Programme

3

No. of teethAchievable Available and adjustable Carbide Carbide PCD-

surface diameters insert seats Balance quality uncoated coated tipped

Ø of which(mm) Ztotal Zadjustable

50 3 3 G6,3 at KC510M KD1410Rz = 2 µm 63 4 4 10.000 rpm KD1415Ra = 0,2 µm 80 5 5 high-precision

100 6 6 balancing

Ø of which(mm) Ztotal Zadjustable

Rz = 3 µm 50 3 3 G6,3 at K110M KC510M KD1410Ra = 0,3 µm 63 4 4 10.000 rpm KD1415

80 5 5100 6 6125 8 8160 10 10

Ø (mm)coarse of whichpitch Ztotal Zadjustable

40 2 – G6,3 at K110M KC510M50 3 – 10.000 rpm63 4 180 5 1100 6 2125 8 2

Rz = 5 µm 160 10 2Ra = 0,55 µm 200 12 3

250 16 4

Ø (mm)fine of whichpitch Ztotal Zadjustable

80 6 2 G6,3 at K110M KC510M100 8 2 10.000 rpm125 10 2160 12 3200 16 4250 10 4

PerformanceMilling

PM

HighPerformance

Milling

HPM

HighSpeed Milling

HSM

®

C

FIX-PERFECT Programme - The Insert

4

Our Solution

• one insert for shoulder and face milling• reduced stock inventories• simple handling

• suitable for different technologies• optimum cutting material for all to all kinds of workpiece

materials• fitting into all basic bodies• optimum adaptation of technological parameters• combined cutting materials possible

• ideal cutting geometry for Aluminium• smooth cut• low cutting forces• high feed rates possible• reduced edge built-up• ideal for thin-walled component parts• increased tool life due to polished cutting face• short and quick-crumbling chips

• improved surface quality• cost reduction• long tool lives• reduced number of production steps

• reduced stock inventories• high availability• top supply service

One sizefor all basic bodies

Carbide, uncoatedCarbide, coatedPCD-tipped

34˚ positive rake angle on the indexable insert

Roughing and finishingat one operation

Competentrecycling service

Your Benefit

®

+ 34°

t

t

C

FIX-PERFECT Programme - The Basic Body

5

• exact milling angle of 90°• high edge stability

• for every application the proper selection provided• optimum utilization of the machine tool´s output

• high-resistant, surface-hardened Aluminium basic body(HPM series)

• useful weight reduction• rigid steel type with HSM (High-Speed Milling)

• high adjustment accuracy (0.002 mm)• high running accuracy• high functional security at high-speed level

(up to vc 4000m/min)

• central coolant supply• optimum chip evacuation from the cutting-edge zone• improved surface quality

• optimum tool balancing• longer tool lives• reduced load on the machine spindle

Cutting edge positionat periphery

Medium and fine pitch

Steel / Aluminium basic body

Adjustment ofPCD-tipped finisher

Coolant supply lock screw(option)

Balancing

Our Solution Your Benefit

®

Steel Aluminium

C

FIX-PERFECT Programme

6

Roughing - Finishing

Uncoated carbideK110M

Coated carbide

KC510M

PCD-tippedKD1410/KD1415

▼▼ ▼

Roughing:

Carbide:apmax = 10 mm

PCD: apmax = 4 mm

Finishing:apmax = 0,5 mm

Off-set:0,04

▼ ▼

®

C

FIX-PERFECT Programme

7

What surface Qualities Can Be Achieved

Combined inserts Adjustableinsert seat

yes,but only Wiper

insert

yes, for all Rz = 3 µm Rz = 5 µm notpossible

no notrecommended

notrecommended

Rz = 10 µm

Rz = 2 µm Rz = 3 µm Rz = 5 µm

HSM HPM PM

Achievable surface quality

Maximum adjustmentpath: 0,10 mm

▼

▼

®

▼▼

▼ ▼

▼

▼ ▼

▼▼

0,04

▼▼

±0,002

C

FIX-PERFECT Programme

8

Speed and Balancing Qualities

HSM

HPM

PM

Material basic body Balancing qualitySpeed limit,

Cutting speed range

ex factory:G6,3at 10.000 rpm

On site: balancable to thefinest degree bybalancing screws /rings

ex factory:G6,3at 10.000 rpm

Solid steelmonoblock

vcmax = 4000 m/min

vcmax = 4000 m/min

vcmax = 4000 m/min

Steel

Diameter from 50 up to 80 mm: Steel

Diameter from 100 up to 160 mm: Aluminium

ex factory:G6,3at 10.000 rpm

Ø (mm)

100806350

Ø (mm)

160125100806350

nmax ( rpm)

12.73215.91520.21025.464

nmax ( rpm)

7.95710.18512.73215.91520.21025.464

Ø (mm)

25020016012510080635040

nmax ( rpm)

5.0926.3667.957

10.18512.73215.91520.21025.46431.830

®

FIX-PERFECT Programme - BlueBox Recycling Service®

Der intelligente Kundenservic

eBoxBlue Our intelligent customer service for your valuable

tools.

With the new PCD indexable inserts, you receive high-quality KENNAMETAL HERTEL milling tools:The scope of delivery includes a corresponding BlueBox;we offer you to profit from our recycling service: Onceyour PCD inserts are worn out, return them in theBlueBox to your subsidiary.

This return is a comfortable way to order new PCDinserts. You will receive the replacement inserts at a lowerprice. Simply complete the form enclosed in the BlueBoxand return it together with your worn indexable inserts.The new inserts at a more favourable price will arrivewithin few days.

If you do not want to make use of our recycling service,you will get a credit note for the inserts returned in theBlueBox. You save money and valuable resources canflow back into the material circulation of KENNAMETALHERTEL.

apmaxcutting edges z z weight

d1 CODE d2h6 l1 l3 d3H7 d4 d6 h 2 1 total adjust. kg nmax (min-1)

50 50A03R049A32PBG15S3WHPM 32 110 49 - - - - 10 4 3 3 0,83 25.46463 63A04R049A32PBG15S4WHPM 32 110 49 - - - - 4 4 0,97 20.21063 63A04RP90BG15C4WHPM - - - 22 - 50 40 4 4 0,51 20.21080 80A05RP90BG15C5WHPM - - 27 - 60 50 5 5 1,08 15.915

100 100B06RP90BG15C6WHPM - - 32 - 80 50 6 6 0,65 12.732125 125B08RP90BG15C8WHPM - - 40 - 90 63 8 8 1,20 10.185160 160C10RP90BG15C10WHPM - - 40 66,7 110 63 10 10 1,75 7.957

C

L1

ap

d1

90°

L2

h

ap

d1

90°

d6

d2

d3

FIX-PERFECT Programme - HSM Mills

FIX-PERFECT Programme - HPM Mills

10

apmaxCuttingedges z z weight

d1 CODE HSK l1 l2 2 1 total adjust. kg nmax (min-1)

50 50A03R060S63PBG15S3WHSM 63 60 34 10 4 3 3 1,00 25.46463 63A04R070S63PBG15S4WHSM 70 44 4 4 1,30 20.21080 80A05R090S63PBG15S5WHSM 90 64 5 5 2,12 15.915

100 100A06R090S63PBG15S6WHSM 90 64 6 6 2,97 12.732

®

ap

d1

90°

d2

L1

L3

Ordering example:1 piece 50A03R060S63PBG15S3WHSM

Component parts HPM

Clamping- Clamping- Screwdriver for Adjustment Screwdriver for SW Lock- Showerd1 stud screw clamping screw SW MAn* screw adjustment screw TX screw cover

50 410.083 420.060 170.003 3 5 193.326 DT15 15 - -63 420.100 -63 420.100 -80 420.120 -

100 420.160 -125 420.200** 470.232160 420.200** 470.233

Inserts for roughing

Cutting K KC KD KDCODE l s edges bf e bγ 110M 510M 1410 1415

BGHX15L5PCERGGT 10,5 5 1 0,9 0,6 - ● ●BGHX15L5PCFRGG 2 1,2 0,2 - ● ●BGHX15L5PCTRGG 2 1,2 0,2 0,1 ● ●

Inserts for finishing / Wiper inserts

Cutting K KC KDCODE l s edges bf e bγ 110M 510M 1415

BGHX15L5PCERGGT1W 10,5 5 1 - 0,8 - ●BGHX15L5PCFRGG1W - 0,5 - ● ●BGHX15L5PCTRGG1W - 0,5 0,1 ● ●

C

FIX-PERFECT Programme - Inserts for HSM and HPM

11

®

34°

90° l

s ebf

Component parts HSM

Clamping- Clamping- Screwdriver for Adjustment Screwdriver for SW Lock- Balancingd1 stud screw clamping screw SW MAn* screw adjustment screw TX screw rings

50 410.083 420.060 170.003 3 5 193.326 DT15 15 - -63 420.100 -80 420.120 SHVBR0635M

100 420.160 SHVBR0635M

34°

90° l

s ebf

34°

bγ

34°

90° l

s e

34°

90° l

s e

bγ

*) MAn = Tightening torque of clamping screw Nm**) only necessary when clamping with shell mill arbour

Ordering example:10 pieces BGHX15L5PCERGGT K110M

h

ap

d1

90°

d6

d2

d3

C12

FIX-PERFECT Programme - PM Mills

PM Mills, coarse pitch

apmaxcutting edges z z

d1 CODE d3h7 d4 d6 h 2 1 total adjust. kg nmax (min-1)

40 40A02RP90BG15CPM 16 - 35 40 10 4 2 - 0,21 31.83050 50A03RP90BG15CPM 22 - 41 40 3 - 0,35 25.46463 63A04RP90BG15C1WPM 22 - 50 40 4 1 0,52 20.21080 80A05RP90BG15C1WPM 27 - 60 50 5 1 1,12 15.915

100 100B06RP90BG15C2WPM 32 - 80 50 6 2 1,68 12.732125 125B08RP90BG15C2WPM 40 - 90 63 8 2 2,80 10.185160 160C10RP90BG15C2WPM 40 66,7 110 10 2 4,64 7.957200 200C12RP90BG15C3WPM 60 101,6 130 12 3 6,00 6.366250 250C16RP90BG15C4WPM 60 101,6 130 16 4 9,40 5.092

PM Mills, fine pitch

apmaxcutting edges z z

d1 CODE d3h7 d4 d6 h 2 1 total adjust. kg nmax (min-1)

80 80A06RP90BG15C2WPM 27 - 60 50 10 4 6 2 1,12 15.915100 100B08RP90BG15C2WPM 32 - 80 50 8 2 1,75 12.732125 125B10RP90BG15C2WPM 40 - 90 63 10 2 3,00 10.185160 160C12RP90BG15C3WPM 40 66,7 110 12 3 4,80 7.957200 200C16RP90BG15C4WPM 60 101,6 130 16 4 6,50 6.366250 250C20RP90BG15C4WPM 60 101,6 130 20 4 9,80 5.092

®

Inserts for roughing

Cutting K KCCODE l s edges bf e bγ 110M 510M

BGHX15L5PCFRGG 10,5 5 2 1,2 0,2 - ● ●BGHX15L5PCTRGG 10,5 5 2 1,2 0,2 0,1 ● ●

Inserts for finishing / Wiper inserts

Cutting K KC KDCODE l s edges bf e bγ 110M 510M 1415

BGHX15L5PCERGGT1W 10,5 5 1 - 0,8 - ●BGHX15L5PCFRGG1W - 0,5 - ● ●BGHX15L5PCTRGG1W - 0,5 0,1 ● ●

C13

FIX-PERFECT Programme - Inserts for PM®

34°

90° l

s ebf

34°

bγ

34°

90° l

s e

bγ

34°

90° l

s e

bγ

Component parts PM

Clamping- Clamping- Screwdriver for Adjustment Screwdriver for Lock Showerd1 stud screw clamping screw SW MAn* screw adjustment screw TX screw cover

40 410.083 420.060 170.003 - - - - - - -50 3 5 193.326 DT15 15 - -63 420.100 -80 420.120 -

100 420.160 -125 420.200** 470.232160 420.200** 470.233200 - 470.234250 - 470.235

*) MAn = Tightening torque of clamping screw Nm**) only necessary when clamping with shell mill arbour

Ordering example:10 pieces BGHX15L5PCFRGG K110M

C14

4·2 15

01 R 667

FIX-PERFECT Programme - KENNA PERFECT Identification Code KeyInserts

Basic body

®

Cutting materials

CoatingCutting grade Composition and recommended application

KD1415(KD108)

Diamond cutting grade with 10µm grain size

for general machining conditions with Aluminium at low Si-content, non-ferrous metals andplastics at high cutting speeds, also with interrupted cut and high demands at the surfacequality.

KD1410(KD100)

Diamond cutting grade with 25µm grain sizefor machining Aluminium with high Si-content, abrasive non-ferrous metals and fibre-reinforcedplastics at very high cutting speeds and high demands at the surface quality.

KC510M(KC705M)

Coated carbide grade with TiAIN coating (PVD)KC510 is a tough carbide grade. Due to TiAIN coating a very good wear resistance at highcutting edge stability is achieved. Main application range is milling Aluminium and high-temperature alloys.

K110M(KM1)

Uncoated carbide gradeUniversal grade for machining non-ferrous metals. Application range is the light and generalmachining range with coolant or dry machining.

80 A 05 R P 90 B G 15 C 1W PM

Adjustment angleClamping type

Cutting directionNo of teeth

Type and/or size of the adaptorCutter diameter

B G H X 15 L5 PC F R GG KC510M

Insert thicknessSize of indexable inserts

Insert featuresTolerance class

Clearance angle related to rake or point angleInserts shape: 2 cutting edges

Carbide gradeType of cutting edge

Cutting directionCutting edge

Cutting corner

Cutter seriesNo of adjustable insert seats

Normal clearance of the wiper edgeInsert cutting edge length

Normal clearance angle of the insertInsert shape (e.g. rhomboid and 2 cutting edges)

Mounting the Inserts and/or Wipers

C15

FIX-PERFECT Programme - Instruction of Adjustment®

Standard inserts Finishing inserts/ Wipers

▼ ▼▼

PM HPM / HSM PM / HPM / HSM

➀ ➀ ➀

Move the adjustment element backward Move the adjustment element backward Move the adjustment element backward

➁ ➁ ➁

Mount the insert and pre-clamp the insert seat

Adjust all inserts at the face milling position of 0 µm.Caution: Backlash of every insert must be 20 µm! Adjust the wiper(s) above the other inserts.

➂ ➂ ➂

Tighten the adjustment element slightly

Adjust all inserts at the face milling position of 0 µm.Caution: Backlash of every insert must be 20 µm! Adjust the wiper(s) above the other inserts.

➃ ➃ ➃

Tighten the mounted inserts seats Tighten the adjustable insert seat Tighten the adjustable insert seat(s)

Check for even face milling results!

Caution:When mounting a new insert this operation must be repeatedFor clamping the inserts only the intended original components must be used

min. 0,01 mm

5 Nm 1,5 Nm 1,5 Nm

040 µm

5 Nm 5 Nm 5 Nm

0

min. 0,01 mm min. 0,01 mm

C

FIX-PERFECT Programme - KENNA PERFECT Selection System®

15a

for Insert and Cutting Grade

KD100 3600

K110M 300

K110M 300

K110M 500

K110M 500

K110M 500

K110M 400

300

K110M 300

K110M 300

KD1415 3600

KD100 3000

KD1415 1500

KD1415 3600KC510M 900

KC510M 600KD1415 3000

KC510M 900

KC510M 500

KD1415 3500

KC510M 350KD1410 3600

KD1415 3000

KD1415 3000

KC510M 450

KC510M 550

KC510M 600KD1415 3600

K110M 300

KC510M 600KD1415 3600

KC510M 600

free cutting alloys,Pb > 1%

CuZn, CuSnZn

Cu, unleaded andelectrolytic copper

25

Feed per tooth (mm)

Dep

th o

f cut

(mm

)

Non-ferrous metals

Aluminium alloys

Aluminium cast alloys

Workpiece materialStructure,heat treatment HB

21

22

23

24

not ageable

ageable

≤ 12% Si, not ageable

≤ 12% Si, ageable / aged

> 12% Si, not ageable

0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3

Correction factor Fvc for vc

Vc1)ToughnessGr.

Cutting grade

Copper and alloys(bronze, brass)

30

26

27

28

29Plastics,composites

Duroplastics,fibre-reinforced plastics

Hard rubber, wood etc.

60

100

75

90

100

130

110

90

90

100

Aluminium (Si ≤ 12%)Group 21-24, 26-30

K110MKD1415 K110M

K110M KC510M

K110M KC510M

K110M

KC510M

ight eneral eavy

Aluminium (Si >12%)Group 25

KD1410KD1410 K110M

KD1410 KC510M

K110M KC510M

K110M

KC510M

ight eneral eavy

Guidelines for Cutting Speeds

Wear resistance

1 2

12

1

1

1 2

Notch wear1. Select a more wear-resisctance

grade2. Same grade, stabler cutting edge

Crater wear1. Select a more wear-resisctance grade2. More wear-resistance grade,

sharper cutting- edge3. Reduce cutting speed

Flank wear1. Select a more wear-resisctance

grade2. Reduce cutting speed

Breakage, chipping1. Select a tougher grade2. Same grade, stabler cutting edge3. Reduce feed per tooth

Built-up edge1. Same grade, sharper cutting edge2. Increase cutting speed

What if...

1,0

2,0

3,0

4,0

5,0

10,0

0,08 0,1250,1 0,16 0,2 0,25 0,32 0,4 0,5

BGHX15L5PC.R-GG

BGHX15L5

PCER-GGT

6,0

7,0

8,0

9,0

ight eneral eavy

C

FIX-PERFECT Programme - Application Examples®

16a

Pump housingMilling tool: 63A04RP90BG15C1WPMDiameter d1: 63 mmNo. of teeth z: 4

Insert: BGHX15L5PCERGGTCutting material: KD1415

Cutting data:Cutting speed vc: 1385 m/minFeed rate vf: 6721 mm/minFeed per tooth fz: 0,24 mmDepth of cut ap: 3 mm

Material: AlSi9Cu3Cooling: with coolant

Tool life: 400 min.

Transmission housingMilling tool: 125B08RP90BG15C8WHPMDiameter d1: 125 mmNo. of teeth z: 8

Insert: BGHX15L5PCERGGTCutting material: KD1415

Cutting data:Cutting speed vc: 1400 m/minFeed rate vf: 6704 mm/minFeed per tooth fz: 0,20 mmDepth of a cut ap: 2 mm

Material: AlSi9Cu3Cooling: with coolant

Oil pump housingMilling tool: 80A05RP90BG15C1WPMDiameter d1: 80 mmNo. of teeth z: 5

Insert: BGHX15L5PCTRGGCutting material: K110M

Cutting data:Cutting speed vc 1000 m/minFeed rate vf: 2387 mm/minFeed per tooth fz: 0,12 mmDepth of a cut ap: 2 mm

Material: Aluminium sand-mould casting with8% Silicium, with sand pockets andshrink holes

Cooling: with coolant

KendexMiniMill spare parts for end mill

Ø d1 Clamping Adjustment MAn*range set element Tx Nm

12 - 32 551.050 570.050 5 0,5

ap

l

l

d2h6

3

1

d1

90°ap

h

d6

d1

90°

d3H11

KendexMiniMillEnd Mill for Indexable Inserts BDHX...PPFRL... Face Mill for Indexable Inserts BPHX...PDFRL...

®

Note:*) MAn= Tightening torque of clamping screw in Nm

For availability, see current price list.Order example:1piece 12A2R026A16CBD082W

KendexMiniMill end mill

Ø RIGHT-HAND Weight d1 CODE d2h6 l1 l3 z apmax kg

12 12A2R026A16CBD082W 16 75 26 2 7 0,0916 16A3R026A16CBD083W 16 75 26 3 0,1020 20A4R033A25CBD084W 25 90 33 4 0,2825 25A5R033A25CBD085W 25 90 33 5 0,3232 32A6R039A32CBD086W 32 100 39 6 0,45

KendexMiniMill face mill

Ø RIGHT-HAND Weight d1 CODE d3H11 d6 h z apmax kg

40 40A07RC90BP12D7W 16 32 40 7 11 0,250 50A08RC90BP12D8W 22 40 8 0,363 63A09RC90BP12D9W 22 40 9 0,4

KendexMiniMill spare parts for face mill

Ø d1 Clamping Adjustment MAn*range set element Tx Nm

40 - 63 551.051 570.051 6 1

C16

Shank versions to DIN 6535Form HA, straightVersion A:

bf

s

R

l

C17

KendexMiniMill

B.HX...P.FRL...

Inserts B.HX...P.FRL... for End and Face Mills

®

For availability, see current price list.Order example:10 pieces BDHX08T1PPFRLD1S K110M

Dep

th o

f cut

ap

Feedper tooth fz

K KC KDCODE l s R bf 110M 510M 1415

BDHX08T1PPFRLD1S 8 1,75 0,4 0,8 • •BDHX08T1PPFRLND1S 8 1,75 •BPHX1202PDFRLD1S 12 2,30 • •BPHX1202PDFRLNC1S 12 2,30 •

0,8

1,0

2,0

3,2

4,0

5,5

7,0

0,08 0,16 0,2 0,25 0,32 0,4 0,630,1 0,125

11,0

BD

HX

08T

1PP

FRL.

BP

HX

1202

PD

FRL.

eneralight eavy

7,4mm 3,4mm 7,4mm 11mm

ShoulderMilling

Milling Programme RPFTorus Mills

®

Ramping Plunge andFeed

Helicalinterpolation

Facing

Ramp angle

R P F

Ramping Plunging Feed (Face Mill)

Description

The RPF Mill – R = ramping, P = plunging, F = feed (facemilling) – is a high productivity cutter design for millingaerospace components and cavities. This cutter series isespecially effective for milling large die cavities in a widevariety of die materials.

The RPF cutter design incorporates the latest high shearcutting insert geometry, giving you greater productivitythrough freer cutting action and lower horsepowerconsumption. The rigidly designed cutter body also hasgenerous chip spaces and no clamping componentsabove the insert. This gives better chip formation andclear chip flow from the cut.

These features are particularly valuable when millingtitanium, titanium alloys and aluminium alloys.

Ramping

The RPF insert and cutter design permits highlyproductive ramp milling of aircraft and die cavities on awide range of aerospace and die materials. Our design isequally effective for helical interpolation of small and largediameters from solid material.This can provide atremendous time and cost savings over conventionalmilling or boring methods.

Plunging

Z-axis plunging can be performed with our RPF cutterbefore starting to mill in the ”Y” or ”X” direction. Thisprocess allows rapid milling of cavity depths up to200 mm – a real productivity bonus.

The process only requires simple CNC programming andproduces maximum metal removal results.

Feed (Face Milling)

Once ramping or plunging to the cutter’s maximumcapacity, a simple face milling operation can begin ineither the ”Y” of ”X” direction using high productionmilling feed rates. The reliability of the RPF cutter designprovides excellent face milling capabilities on the outsidesurface or at the bottom of a cavity, while producingsuperior finishes on a wide variety of materials.

C18

KCCODE l d1 d2 s R 510M

LFEW220480FNLN 22,2 15,88 5,5 4,76 8 •

Dep

th o

f cut

(mm

)

RPF spare parts

Clamping Screw- MAn*screw driver Tx Nm

MS1129 DT15 15 3

h

ap

dd

d2

3

6

d1R dd

l s

R

1 2

25°

Milling Programme RPF

LFEW220480FNLN

Torus Mills for Inserts LFEW220480FNLN

®

Note*) MAn= Tightening torque of clamping screw in Nm

For availability, see current price list.Order example:

1 piece 35A03RS90LF2210 pieces LFEW220480FNLN

RPF Torus Mills for Inserts LFEW220480FNLN

Maximum RampØ RIGHT-HAND Weight plunging angled1 CODE d2 d3

H7 d6 h R z apmax nmax(rpm) kg depth <) *

35 35A03RS90LF22 50,8 16 48,0 40 7,9 3 11 12.090 0,5 7,4 16,0°47 47A04RS90LF22 62,8 22 51,5 50 4 10.770 0,7 11,0°64 64B05RS90LF22 79,8 27 49,5 5 9.560 0,9 7,5°84 84B06RS90LF22 99,8 32 59,5 6 8.550 1,0 5,5°

109 109B06RS90LF22 124,8 40 71,5 63 6 7.650 3,0 4,0°

Feed per tooth (mm)

ight eneral eavy

1,0

1,6

2,5

4,0

6,3

10,0

16,0

0,08 0,16 0,2 0,25 0,32 0,4 0,5

LFEW220480FNLN

0,1 0,125

C19

RPF End Mill for Inserts LF.W1503

Ramp MaximumØ RIGHT-HAND Weight angle plungingd1 CODE d2h6 l1 l3 z apmax kg nmax (rpm) <) * depth

32 32A3R043A25SLF10 25 100 43 3 10 0,3 15.400 17° 532 32A3R063A25SLF10 25 120 63 0,4532 32A3R079A32SLF10 32 140 79 0,740 40A3R049A32SLF10 32 110 49 0,7 13.800 11°40 40A3R079A40SLF10 40 150 79 1,2 13.800 11°50 50A4R059A40SLF10 130 60 4 1,3 12.350 8°50 50A4R099A40SLF10 170 100 4 1,9 12.350 8°

RPF spare parts

Clamping Screw- MAn*screw driver Tx Nm

MS1589 DT15 15 1,5

h

ap

dd

3

6

d1

*ap

l

l

d2h6

3

1

d1

Milling Programme RPF - Radiused MillsFace Mill for Inserts LF.W1503... End Mill for Inserts LF.W1503...

®

Note*) MAn= Tightening torque of clamping screw in Nm

For availability, see current price list.Order example:

1 piece 40A03RS90LF10

RPF Face Mill for Inserts LF.W1503

Ramp MaximumØ RIGHT-HAND Weight angle plungingd1 CODE d3

H7 d6 h z apmax kg nmax (rpm) <) * depth

40 40A03RS90LF10 16 38,7 50 3 10 0,25 13.800 11° 550 50A04RS90LF10 22 41,5 50 4 10 0,3 12.350 8° 5

C20

Shank versions to DIN 6535Form HA, straightVersion A 1:

Note:1) for Version A : Available

Dec. 2000

1,0

1,6

2,5

4,0

6,3

10,0

16,0

0,08 0,16 0,2 0,25 0,32 0,4 0,5

LF.W1503....

0,1 0,125

ight eneral eavy

C21

Milling Programme RPF - Radiused Mills

LFHW...R

Inserts LF.W1503... for Radiused Mills

®

For availability, see current price list.Order example:10 pieces LFEW150304R K313

Dep

th o

f cut

ap

Feed per tooth fz

KCCODE l d1 d2 s R K313 510M

LFEW150304FRLN 15,44 9,52 4,4 3,3 0,4 •LFEW150308FRLN 0,8 •LFEW150312FRLN 1,2 •LFEW150316FRLN 1,6 •LFEW150320FRLN 2,0 •LFEW150324FRLN 2,4 •LFEW150332FRLN 3,2 •LFEW150340FRLN 4,0 •LFHW150304R 0,4 •LFHW150308R 0,8 •LFHW150312R 1,2 •LFHW150316R 1,6 •LFHW150320R 2,0 •LFHW150324R 2,4 •LFHW150332R 3,2 •LFHW150340R 4,0 •

3°

dd

sl

1 2

R

25°

KENNAMETAL HERTEL Milling Programme - Solid Carbide ®

Recommended Application for End Mills when Aluminium Machining in Special Processes

Recommended Cutting Speeds – End MillsGuidelines for cutting speeds vc acc. to material groups

C22

FIRST CHOICE not recommended

Side millingFinishing

Fine finishing

End mill CODE No.: F3BA….W.45 Page C25

Factory standard3 teeth; 45° helixK600

End mill CODE No.: F3BA….BW.30 Page C23End mill CODE No.: F3BA….BW.30-C...Page C23Factory standard3 teeth; 45° helixK600

End mill CODE No.: F2AA…..DL45 Page C25

DIN 6527 long edge2 teeth; 45° helixK600; KC631M

Slotting +Key slot cutting

Type of process Key slot cutting Roughing

E = Emulsion, MMS = Minimum quantity lubrication, S = Cutting oil, SA = Dust exhaust

Gr. MaterialStructureHeat treatment

TensilestrengthRm(MPa)

Coolingmethod

Brinellhard-nessHB

21 not ageable E/MMS 150 - 500 250 - 75060

Aluminium millsK600 K631

22 ageable aged E/MMS 150 - 300 250 - 450100

24

23 ≤12% Si, not ageable E/MMS 150 - 350 200 - 60075

≤12% Si, ageable, aged E/MMS 150 - 200 200 - 30090

26

25 >12% Si, not ageable E/MMS 150 - 250 200 - 350130

free cutting alloys, PB > 1% E/MMS 150 - 250 -110

28

27 CuZn, CuSnZn E/MMS 150 - 350 -90

Cu, unleaded and electrolytic copper E/MMS 150 - 350 -100

29Non-ferrous metals

composites, fibre-reinforced plastics E/MMS/SA 120 - 200 -

30 hard rubber, wood etc. E/MMS/SA 150 - 300 -

Copper and alloys(Bronze, brass)

Aluminiumcast alloy

Aluminium malleablealloy

C23

Milling Programme - Solid Carbide End Mills ®

Roughing Mills to Factory Standard, 30° Helix Angle, Shank B to DIN 6535

d

d

l

l

l

1

1

2

2

3

Roughing Mills to Factory Standard with Internal Coolant Supply, 30° Helix Angle, Shank B to DIN 6535

d

d

l

l

l

1

1

2

2

3

Shanktype B3 teeth

ø Carbide grade: K600d1h10 CODE d2h6 l1 l2 l3

6 F3BA0600BWS30 6 57 13 398 F3BA0800BWM30 8 63 16 41

10 F3BA1000BWM30 10 72 22 4212 F3BA1200BWL30 12 83 26 4716 F3BA1600BWL30 16 92 32 5520 F3BA2000BWX30 20 104 38 5325 F3BA2500BWX30 25 121 45 60

Shanktype B3 teeth

ø Carbide grade: K600d1h10 CODE d2h6 l1 l2 l3

8 F3BA0800BWM30C160 8 63 16 4110 F3BA1000BWM30C220 10 72 22 4212 F3BA1200BWL30C260 12 83 26 4716 F3BA1600BWL30C320 16 92 32 5520 F3BA2000BWX30C380 20 104 38 5325 F3BA2500BWX30C450 25 121 45 60

3 teethShank DIN 6535, centre-cuttingType B (Weldon)

3 teethShank DIN 6535, centre-cuttingType B (Weldon)

Note:For recommended applications and cutting speeds see page C22For recommended feeds see page C24Shank selection: Type B (Weldon) corresponds to DIN 6535 form HB

For availability see current price list.Ordering example: for Aluminium roughing mills 3 teeth, ø 6 mm,

shank type B, factory standard, 30° helix angle1 piece F3BA0600BWS30 K600

0,2 x d

0,4 x d

0,6 x d

0,8 x d

1,0 x d

1,2 x d

0,16

0,08

0,06

0,05

0,03

0,01

1614128 1065

1,4 x d

1,6 x d

1,8 x d

2,0 x d

0,02

0,0

K600

0,05 x d

0,1 x d

0,2 x d

0,4 x d

1,0 x d

0,14

0,12

0,10

0,04

252018

0,75 x d

f = 0,074z

a =adp rel.

p

1

a =ade rel.

e

1

a

d1

e

ap

Milling Programme - Solid Carbide End Mills Recommended Feeds

®

Main application range: The Allround-Mill for machining almost all kinds of materialMachinability Classification (see page C22)

Aluminium mills, 30° helix angle:

Machining ExampleFull Slot Milling

Material ............................................: AlMgSi1Tensile strength ................................: 410 N/mm

2

Milling Tool ......................................: F3BA1600BWL30 K600Mill. dia. ............................................: 16 mmCarbide grade ..................................: K600Qty. of teeth z ..................................: 3 teethCutting speed vc ..............................: 300 m/minDepth of cut ap ................................: 10 mmWidth of cut ae ................................: 16 mm

Result: Feed per tooth fz Feed rate vf Rotational speed n

Slotting ............................................: 0,074 mm 441 mm/min 5968 rpmFull slot milling..................................: 0,074 mm 1324 mm/min 5968 rpm

rel.

dept

h of

cut

ap

Feed

per

toot

h f z

rel. width of cut ae

[mm] Mill dia.

limit for full slot milling

Warning: With slotting (sinking) only one tooth is in contact over centre,i.e. for calculating feed rate vf 1 x fz should be used!

C24

C25

®

Shanktype A3 teeth

ø Carbide grade: K600d1h10 CODE d2h6 l1 l2 l3

3 F3AA0300AWS45 3 38 12 244 F3AA0400AWS45 4 50 12 355 F3AA0500AWS45 6 50 14 336 F3AA0600AWS45 6 50 16 308 F3AA0800AWM45 8 63 20 38

10 F3AA1000AWL45 10 76 22 4612 F3AA1200AWL45 12 76 25 4214 F3AA1400AWL45 14 89 32 4616 F3AA1600AWL45 16 89 32 4518 F3AA1800AWL45 18 100 38 4820 F3AA2000AWX45 20 104 38 54

Shank Shanktype A type B2 teeth 2 teeth

Ø Carbide grade: K600/KC631M Carbide grade: K600/KC631Md1h10 CODE CODE d2h6 l1 l2 l3

4 F2AA0400ADL45 F2AA0400BDL45 6 57 8 365 F2AA0500ADL45 F2AA0500BDL45 106 F2AA0600ADL45 F2AA0600BDL45 108 F2AA0800ADL45 F2AA0800BDL45 8 63 16

10 F2AA1000ADL45 F2AA1000BDL45 10 72 19 4012 F2AA1200ADL45 F2AA1200BDL45 12 83 22 4514 F2AA1400ADL45 F2AA1400BDL45 14 83 22 4516 F2AA1600ADL45 F2AA1600BDL45 16 92 26 4818 F2AA1800ADL45 F2AA1800BDL45 18 92 26 4820 F2AA2000ADL45 F2AA2000BDL45 20 104 32 50

(Type old: F208A) (Type old: F208B)

d

d

l

l

l

1

1

2

2

3

d

d

l

l

l

1

1

2

2

3

Milling Programme - Solid Carbide End Mills End Mills to DIN6527L, 45° Helix Angle, Shank A and B to DIN 6535

End Mills to Factory Standard, 45° Helix Angle, Shank A to DIN 6535

d

d

l

l

l

1

1

2

2

3

3 teethShank DIN 6535, centre-cuttingType A (Weldon)

For recommended applications and cutting speeds see page C24For recommended feeds see page C26Shank selection: Type A (straight) corresponds to DIN 6535 form HA

Type B (Weldon) corresponds to DIN 6535 form HB

For availability see current price list.Ordering example: for Aluminium mills 2 teeth, ø 4 mm,

shank type A, DIN 6527L, 45° helix angle1 piece F2AA0400ADL45 K600

2 teethcentre-cuttingShank DIN 6535Type B (Weldon)

2 teethcentre-cuttingShank DIN 6535Type A (straight)

Milling Programme - Solid Carbide End Mills ®

Recommended Feeds

Main application range: Mills for non-ferrous metals and plasticsMachinability Classification (see page C22)

Long edge, 45° helix angle:

Machining ExampleFull Slot Milling

Material ............................................: AlMgSi1Tensile strength ................................: 320 N/mm2

Milling Tool ......................................: F2AA1600ADL45Mill. dia. ............................................: 16 mmCarbide grade ..................................: KC631MQty. of teeth z ..................................: 2 teethCutting speed vc ..............................: 300 m/minDepth of cut ap ................................: 14,5 mmWidth of cut ae ................................: 16 mm

Result: Feed per tooth fz Feed rate vf Rotational speed n

Slotting ............................................: 0,13 mm 776 mm/min 2984 rpmFull slot milling..................................: 0,13 mm 1552 mm/min 5968 rpm

d a

a

1 p

e

0,2 x d

0,4 x d

0,6 x d

0,8 x d

1,0 x d

1,2 x d

1,4 x d

1,6 x d

1,8 x d

2,0 x d

0,350

0,270

0,230

0,190

0,150

0,100

0,040

0,020

201816141210864

KC631M

0,9 x d

a =adp rel.

p

1

a =ade rel.

e

1

f = 0,130z

0,05 x d 0,1 x d

0,2 x d

0,4 x d

1,0 x d

rel.

dept

h of

cut

ap

Feed

per

toot

h f z

rel. width of cut ae

[mm] Mill dia.

Warning: With slotting (sinking) only one tooth is in contact over centre,i.e. for calculating feed rate vf 1 x fz should be used!

C26

limit for full slot milling

• Reaming Programme for Aluminium Machining D2

• Application Examples D5

ReamingReaming

Table of ContentsTable of Contents

®

Reaming Tools ®

Multi-Edge Technology

Using multi-edged tools, you will achieve a very highprocess safety and, at the same time, maximumproductivity. Due to the fixed cutting edges, no time-consuming preadjustment is required. Therefore,handling is simple and no expensive measuringinstruments are needed.

Dimensions and geometries of the starting cut areoptimally designed for the specific workpiece andmaterial, guaranteeing dimensional accuracy and highprocess safety from the first operation. The reamers,some of which are of modular design and readjustable,are ground to the required dimension. Once the lowertolerance limit is reached, you can readjust the diameteron the tool while it is chucked. Precision fits of qualitiesup to IT5 can be reamed with high process safety.

Thanks to the multiple edges of the tools, incombination with optimum cutting materials and cuttinggeometries, productive times can greatly be reduced.

Solid-Carbide and PCD Reamers with InternalCoolant Supply (ICS)

Solid-carbide high-performance reamers in multi-edgedversion in the diameter range from 1.5 mm to 12 mm.The tools are available with straight or spiral flutes. Boththe fine-grain carbide and the cutting material PCD, incombination with the special point grinding, enable veryhigh metal removal rates. From 5 mm diameteronwards, some series are available with internalcoolant supply (ICS), which additionally enhances theperformance.

Modular Throw-Away Heads

In the diameter range 9.6 mm - 60 mm, differenttoolholder variants are available for the application ofthese tools, on the one hand toolholders with straightshanks for use in hydraulic expansion chucks and on theother hand toolholders for connection with compensationadaptors, both systems in short or long version. Thanksto the selection possibilities in terms of cutting material,form of starting cut and edge position (e.g. straight,inclined to the left or right), the throw-away heads canoptimally be adapted to each application.

Internal coolant supply (ICS) is a matter of course forthis system. When the tool is worn off, only the reaminghead will be exchanged. This increases the economy ofthe tools. Thanks to the high-precision interface, tool-changing accuracies are extremely high, enhancing theproductivity of your machine.

D2

Reaming Tools

Monobloc Reamers (Readjustable)

This product line offers the possibility of adjusting theedge diameter through simple readjustment via a boltwith deep cone head, in order to achieve close tolerancesup to IT5 and to compensate wear. The system is avail-able in the diameter range from 5.6 mm to 32.6 mm inconnection with straight shanks form A and internalcoolant supply (ICS).

We recommend to use the tools in combination with ourhydraulic expansion chucks or with shrink-on chucks.

Cutting-Ring Reamers (Readjustable)

Modular design, a multitude of cutting materials as wellas the possibility of compensating wear through a veryaccurate diameter adjustment are the features of thisseries. Thanks to the adjustability of the cutting rings,the tools can be adjusted with high precision to therequired diameter. Thus, it is also possible to reamcloser tolerances.

For the cutting rings in the diameter range from17.6 mm to 100.6 mm, basic adaptors with straightshanks form A and compensating adaptors in long orshort version are available. Both systems are providedwith internal coolant supply (ICS) channels. Byselecting different forms of starting cuts, the cuttingrings can optimally be adapted to the specificapplication.

Customized Special Solutions

The use of tools specifically developed for the applicationof our customers enables the latter to reduce the numberof machining operations and to achieve maximumcoaxiality of the holes.

Depending on the hole pattern, it is possible to combinevarious steps of premachining and finishing in one tool.Especially in case of large housings, holes lying besideone another are often machined with combination tools.

The exclusion of unnecessary nonproductive times hastop priority when designing a combination tool, withoutlosing sight, however, of the machining result and theprice/performance ratio.

®

D3

Reaming Tools

Aluminium Machining with PCD-Tipped Tools

Due to their high hardness and high abrasion resistance,polycrystalline diamond PCD cutting materials havegained particular importance for cutting workpieces madeof aluminium alloys. As in particular workpiece materialswith a high silicon content possess hard and softconstituents, thus stressing the cutting edge dynamically,conditions are comparable to those of machiningoperations with interrupted cuts. Tough and relatively lesswear-resistant cutting materials are subjected, due to thestrong abrasive effect of the hard dispersions in thematerials used, to a very high abrasive wear.

Therefore, contrary to the use of e.g. carbide, the use ofPCD-tipped tools often results in longer tool lives, withhigh cutting speeds and, therefore, in practice, in greateconomic advantages over conventional cutting materials.

For good diecast parts, a preparatory operation is in manycases unnecessary. Finish-machining is effected in oneoperation. As the requirements imposed on PCD-tippedtools are usually far higher than those for tools withconventional cutting materials, we design these toolsexclusively user-specifically.

Tool Adaptors

The axial running accuracy of fine-machining tools is ofdecisive importance for the result of the operation andfor attaining high process safety. We, therefore, alwaysrecommend to use our hydraulic expansion chucks(HDEC). For machines with larger axial run-outs on thespindle, we recommend to use shanks withcompensating flange or to combine our compensationtoolholders with the HDEC.

Very easily and very quickly, the axial run-out on themachine can be eliminated completely. As a rule, thisadjustment is done only once. The combination ofcompensating toolholder and expansion chuckingbushing makes this possible for tools with straightshanks. In this way, you will achieve excellent tool-changing accuracies, so that even holes with very tighttolerances can be produced with high process safety.The optimum axial running accuracy provides for longertool lives.

The improvement of the machining results achieved bymeans of the compensating toolholder and expansionchucking bushing is enormous and constitutes a furtherstep towards higher process safety of automaticproduction.

®

D4

Machining of compressor housings,hole: dia. 31,99 ±0,01

Machine: Vertical machining centreMaterial: GD-AlSi5Ni5

Cutting Data:Cutting speed: vc = 452 m/minRotational speed: n = 4500 rpmFeed rate: vf = 1710 mm/minFeed: f = 0,38 rpm

Tool: PCD monobloc reamer,readjustable, and hydraulicexpansion chuck HSK63A,ICS (internal coolant supply)

Result: Concentricity ≤ 0,002 mm

Application Examples®

for Multi-Edged Reamers

Machining of gear housings,reaming: dia. 62 H6 without preparation

Machine: Transfer lineMaterial: GD-AlSi1

Cutting Data:Cutting speed: vc = 300 m/minRotational speed: n = 1540 rpmFeed rate: vf = 600 mm/minFeed: f = 0,4 rpm

Tool: PCD cutting-ring reamer,readjustable, withcompensation toolholder,ICS (internal coolant supply)

Result: surface finish:Ra = 0,2 - 0,3 µm

Machining of brake cylinders,reaming: dia. 25,44with chamfering andspot facing

Machine: Machining centreMaterial: AlSiCu4

Cutting Data:Cutting speed: vc = 480 m/minRotational speed: n = 6000 rpmFeed rate: vf = 4800 mm/minFeed: f = 0,8 rpm

Tool: PCD monobloc multi-stagereamer and hydraulicexpansion chuckHSK63A - shank,ICS (internal coolant supply)

Result: surface finish: Ra = 0,2 µm

D5

KENNAMETAL HERTEL

®

EUROPEAN HEADQUARTERSKENNAMETAL HERTEL AGWerkzeuge + Hartstoffe

Postfach/P.O. Box 1751D-90707 FürthTel. (+49) (911) 9735-0Fax: (+49) (911) 9735-388

KENNAMETAL HERTEL Vertriebs-Adressen

AUSTRIA Kennametal Hertel G. Beisteiner Vertriebsges.m.b.H. Hauptplatz 3/12320 SchwechatE-Mail: office@kennametal-hertel.atPhone +43/1/7078471/72Fax +43/1/7071918

BELGIUM/LUXEMBOURGKennametal Hertel Belgium SA Parc Industriel des Hauts-SartsRue de Hermee 177A B-4040 Herstal Phone +32/42/482734Fax +32/42/482814

CZECH REPUBLICJan Havelka, spol. s. r. o.Bratri Capku 18101 10 Praha 10E-Mail: VHSM@mbox.vol.czPhone +42/02/71737347Fax +42/02/67313014

DENMARKGranaths Hardmetal A/S Hvidkjaersvej 24 7000 Fredericia E-Mail: Granath@Granath.dkPhone +45/75942122Fax +45/75941975

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FINLAND Hertek Oy Lukkokat 805840 HyvinkääE-Mail: hertek@hertek.fiInternet: http://www.hertek.fiPhone +358/19/483050Fax +358/19/483053

FRANCE Kennametal Hertel France S.A. P.O. Box 201F-91007 Evry Cedex Phone +33/1/69778383Fax +33/1/69778390

GERMANY European HeadquartersKennametal Hertel AGWerkzeuge + Hartstoffe Postfach/P.O. Box 1751D-90707 Fürth E-mail: info@kennametal-hertel.comPhone +49/911/9735-0Fax +49/911/9735-388

Sales OfficeKennametal Hertel GmbH Postfach/P.O. Box 1347 D-61364 Friedrichsdorf E-Mail frd-verkauf@kennametal-hertel.com Phone +49/6172/737-0 Fax +49/6172/78490

GREECE ToolMan Ltd.62, Doridos StreetPeristeri GR 121 31E-Mail: toolman@otenet.gr Phone +30/1/53 17 605Fax +30/1/53 17 608

HUNGARYHardt KFT. Csaba U.14.SZH-9023 GyörE-Mail: hardtkft@matavnet.huPhone +36/96/518186Fax +36/96/518181

ISRAEL Arnold Trading CompanyLtd. 6 Hamaachtesh St.Ind. Area Holon 58810Phone +97/2/35581313Fax +97/2/35581317

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NETHERLANDS Kennametal Hertel Nederland BV Postbus 159Nieuwe Havenweg 29NL-6800 AD ArnheimPhone +31/26/3699611Fax +31/26/3615309

NORWAY Verktoy Senteret Per Kulvik A/S Nedre lla 39N-7018 Trondheim Phone +47/73502650Fax +47/73502670

POLANDAvanti Spolka z o.oul. Kmieca 3PL-61-654 Poznan E-Mail: avanti@wlkp.top.plPhone +48/61/8202911Fax +48/61/8232631

PORTUGAL Kenci Lda. AV. do Aeroporto 1312-14470 MaiaPortugalE-Mail: portugal@kenci.comPhone +351/2/9417739/40Fax +351/2/9417716

SPAIN Kenci S.A. Poligono Ind. Rubi SurAvda. Antonio Gaudi, s/n08191 Rubi (Barcelona)E-Mail: kenci@kenci.com Phone +34/93/5860350Fax +34/93/6974600

SWEDENAB Sigfrid Stenberg Jonkopingsvagen 1 57134 NassjoBox 91457129 NassjoE-Mail: absigfrid@stenbergs.sePhone +46/380/77100Fax +46/380/18222

SWITZERLAND Walter Meier AGBahnstrasse 248603 Schwerzenbach E-Mail: wm@wmh.netInternet: http://www.waltermeier.chPhone +41/1/8064646Fax +41/1/8064692

TURKEYKennametal Hertel TurkeyHalyolu No: 11 K:5Icerenkoy - Istanbul E-Mail: kennametal@hertel.com.trPhone +90/216/4645164Fax +90/216/4645163

UNITED KINGDOM Kennametal Hertel UK PO Box 29KingswinfordGB-West Midlands DY6 7NPE-Mail: kmthtl@hotmail.com Phone +44/1384/401000Fax +44/1384/408015

Complete Solutions for a

Production with a Great Future

miniumAlu-