Kennametal’s Mill 16 face mill is designed to tackle tough cast iron applications. The Mill 16 has a fine-pitch and medium-pitch cutter body equipped with a single-screw, wedge-style clamping system. This reduces setting time in the tool crib and ensures rigid, no-fail tool placement, the company says. Each pocket on the cutter body is numbered, as are each of the insert’s cutting edges, promoting accuracy and ease of use when indexing to a new cutting edge.

The Mill 16 split case design is truly a clever concept. The largest split case cutter body weighs only 20.4kg

The heart of the Mill 16 is an octagonal, double-sided insert with 16 effective cutting edges. The face of each cutting edge contains an aggressive chip-breaker for positive cutting action and increased chip flow. The wedge clamp on either side of the insert’s top face is likewise chamfered to improve chip evacuation.

The tool is available in diameters ranging from 50 to 250mm. Kennametal has rated the maximum axial depth of cut (Ap1) at 5.5mm, although depths to 9mm or greater are possible. According to the company, low cutting forces facilitate machining at 100 per cent radial engagement. All cutters have internal coolant supply capability.

The carbide itself is Kennametal’s KCK20 grade, which comprises a PVD AlTiN/AlTiCrN multilayer coating bonded to a wear-resistant substrate that’s said to prolong tool life.

Wedge style and screw-on style cutters in fine, medium and coarse pitch cover all cast iron roughing and semi finishing applications

An assortment of insert edge preps, geometries and corner radii as well as several complementary grades are available to ensure performance in a variety of machining conditions, from heavy roughing to semi-finishing and fine finishing to Ra 3.2 microns or better.

Making a change
Kennametal is pleased to announce that it is building on that success by expanding the Mill 16 platform by introducing new cutter body styles, new insert geometries and grades, and a split case design for large diameter bodies that reduces spindle bearing loads.

Wedge style and screw-on style cutters in fine, medium and coarse pitch cover all cast iron roughing and semi finishing applications

With these new additions the portfolio will fit any of your cast iron face milling applications. From fine pitch wedge style cutters for highest productivity and very powerful machines to medium and coarse pitch cutters with screw-on inserts when horsepower is limited. From machining of small components to very large components.

The Mill 16’s new split case design meets truly massive machining needs, with wedge-style cutter bodies ranging from 300 to 500mm in diameter. And for those worried about hanging such humungous cutters off their machine spindles, there’s good news: the largest split case Mill 16 cutter body weighs only 20.4kg, roughly one-third that of competing designs, but still able to rotate at up to 2 800 RPM.

And there is even more good news. All cutters use the same innovative, multi edged design insert. An insert with 16 cutting edges that provides lowest cost per cutting edge. The Mill 16 product line is covering all heavy roughing and semi finishing applications.

Finishing up consistently with KCFM
To an engine manufacturer, flatness and finish is everything. Without it, leaks are sure to occur, leading to expensive warranty claims and unhappy customers. The same can be said for those making transmissions, hydraulic manifolds, pump bodies, and anywhere a smooth sealing surface is needed. Unfortunately, the material used to make many of these components – cast iron – can be challenging to machine.

The double sided, 16 edged insert provides lowest cost per edge

The deterioration of the finishing occurs as soon as the inserts show slight wear. That causes an increase in cutter pressure, resulting in vibration, and feeding marks are observed. The result is down time due to frequent insert exchange.

The super positive KCFM – Kennametal Cast Iron Finishing Milling – with the new KBK50 full top PCBN (polycrystalline cubic boron nitride) grade was developed to address these issues.
Now customers can produce much more parts per edge in a reliable and consistent manner, so the cost per component will decrease.

And keep in mind machining time reduces drastically since PCBN can be applied with 3 times higher cutting speeds compared to carbide inserts.

But there are more options with KCFM available than just PCBN
Combining the semi finishing KY3500 silicon nitrate ceramic with KBK50 finishing wiper inserts is also a very productive, and cost effective solution for customers that don’t want to have a full load PCBN inserts in the cutter.

KCFM consistently achieves surface finishes of Ra 0.8μm with peak to peak wave heights of 10μm or less

PCBN and ceramic grades are perfect for mass production and stable conditions. But in many cases there is also the need for fine finishing on rather unstable conditions, such as weak workpiece clamping, limited spindle speed, or long overhang.

The answer to that the carbide grade KC514M. A TiAlN PVD coating that is both tough and wear resistant. Designed for light to medium machining. KC514M can be applied with or without cutting fluids.

For more information contact Kennametal South Africa on TEL: 011 748 9300 or visit www.kennametal.com