Kennametal is expanding its game-changing Mill 4 family with a new cutting tool, the Mill 4-11. Designed for smaller machining centers, the Mill 4-11 accommodates 40-taper CAT and BT, HSK50, and similarly sized spindles. Due to its free-cutting capabilities, it is ideal for successful metal removal in less-than-rigid setups and on light-duty machine tools, multi-taskers and live-tool lathes.
The Mill 4-11 enjoys the same strong insert design as its larger cousin, the Mill 4-15, but is 24% shorter and 34% narrower. With an 11mm maximum cut length, this addresses the needs of those job shops and manufacturers producing smaller parts and part features while still offering high metal removal rates and excellent tool life.
Because of the insert design and precision, there’s very little mismatch between passes. For example, using a 63mm diameter tool and SGE geometry you can achieve less than 8µm deviation between successive 6mm deep passes. One of Kennametal’s largest automotive customers completely eliminated a finishing operation on a steel alloy housing because of it, saving them many thousands of dollars annually.
The Mill 4-11 platform offers a full complement of grades and geometries including KCPM40 for most steel applications and KCSM40 for aerospace and medical machining. Kennametal have cast iron and aluminium grades and a variety of edge preps and corner radii up to 1.6 mm as well.
The Mill 4-11 is also easy to use. Each insert is securely locked in place with a single M3 screw, and marked with a series of dimples to indicate geometry and insert style. Keeping the tool clean and the screws lubricated with a small amount of grease and mounting all of the inserts with the dimples or markings facing the same direction improves accuracy during indexing, says Kennametal.
The cutter has uneven pocket spacing designed to break up machine harmonics and reduce chatter. Because of its complex insert geometry and positive placement in the pocket, it has an effective radial rake angle between 1° to 11°, depending on the cutter diameter, and an axial rake angle of 3°, this despite the Mill 4-11’s double-sided design.
When taking cuts up to approximately 6.5mm axial engagement, the cutter is essentially “stepless”, although cuts up to 11mm deep are possible while still maintaining square, smooth walls. Best of all, it removes material quickly.
For more information contact Kennametal South Africa on TEL: 011 748 9300 or visit www.kennametal.com