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
Bi-directional Wear Guidance Design
Controlled wear transmission in diverging directions
Provides uniform wear to increase overall tool life
Wear transmission mechanism
Advantages
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
Performance benefits are particularly notable when milling at depth of cut of approximately 2×D
Typical cutting data when milling ISO M materials:
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
The tool from a competitor showed excessive wear formation after 15 parts and couldn’t exceed 17 parts. 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