double - duramill.com®.pdf · specifications and price list dia. of shank lenth of overall radius...
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DOUBLE YOUR TOOL LIFE!
WITH
®
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A family owned business now in its second generation,
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Dura-Mill, inc. • 16 Stonebreak roaD • Malta, nY 12020 • (800) 444-6455 or (518) 899-2255 • Fax: (518) 899-7869 • DuraMill.coM
Dura-Mill’s new WhisperKut Plus carbide end mills with Dura Shield provides customers with an enhanced version of our popular patented WhisperKut series end mills. By incorporating several new design features, WhisperKut Plus offers users substantial improvements in tool life and serves as a multi-functional tool. WhisperKut Plus’s design allows for roughing and finishing in both peripheral and slotting operations in all types of ferrous materials.
BENEFITS• Up to 100% tool life improvement
• Stronger and smoother cutting edges
• Leaves work piece surface exceptionally smooth
• New improved radius design offers maximum strength at the corner radii and axial cutting edges
• Increased cutter stability providing more predictable tool life
• New Nanocomposite coating specifically designed for the most extreme application
• Improved surface foundation for better adhesion of PVD coating
• A single tool will perform all of the multi functions of roughing, finishing and slotting up to 1 x D
Dura-Mill, inc. • 16 Stonebreak roaD • Malta, nY 12020 • (800) 444-6455 or (518) 899-2255 • Fax: (518) 899-7869 • DuraMill.coM
5 PASSES100X Mag
1 PASS100X Mag
WhisperKut Plus WKP-50500R-Ds2 No. of slots produced: 5 passes (10” long)Comments: Consistently predictable edge wear
Competitor “A” (Major tool mfg) No. of slots produced: 1 pass (10” long)Comments: Severe edge wear & heat retention
WhisperKut Plus WKP-50500R-Ds2 Application: Slotting of 17-4 PH Stainless Steel 37 Rc Radial DOC: .500” / Axial DOC: .500” SFM: 200 / IPM: 15.28 (under flood coolant conditions)
Note: Coolant turned off during start of 5th pass to facilitate illustration.
Edge Wear
slotting
Tool life
Coatings Coating Comparison
Tool life in Inconel 718 in a slot milling application
Tool life Comparison Number of parts produced in AISI 4140
Material (28-32 Rc) in a profile application
(1/2” Dia. 4-Flute Solid Carbide Variable Helix End Mill) (1/2” Dia. 5-Flute Solid Carbide Variable Helix End Mill)
22 22
29
28
54Cutting volume
at end of tool life
(cubic cm)
TiAIN AITiN WhisperKut
Number of parts
produced
WhisperKut Plus
PERFORMAncE EXAMPLES
Dura-Mill, inc. • 16 Stonebreak roaD • Malta, nY 12020 • (800) 444-6455 or (518) 899-2255 • Fax: (518) 899-7869 • DuraMill.coM
SPEcIFIcATIOnS AnD PRIcE LIST
Dia. of Shank Lenth of Overall Radius EDP No. with EDP No. with List Mill d1 Dia. d2 Cut I2 Length I1 Size Plain Shank Weldon Shank Price
3/16 3/16 5/8 2 .015 30002 $27.65 1/4 1/4 3/4 2 1/2 .015 30009 $32.84 5/16 5/16 3/4 2 1/2 .015 30013 $40.75 3/8 3/8 1/2 2 .015 30017 $41.96 3/8 3/8 1 2 1/2 .015 30021 $50.38 1/2 1/2 5/8 2 1/2 .030 30028 30029 $68.40 1/2 1/2 1 3 .030 30040 30041 $77.74 1/2 1/2 1 1/4 3 .030 30052 30053 $84.00 1/2 1/2 2 4 .030 30062 30063 $127.48 5/8 5/8 1 1/4 3 1/2 .030 30072 30073 $144.58 3/4 3/4 7/8 3 .030 30080 30081 $189.00 3/4 3/4 1 1/2 4 .030 30090 30091 $212.20 3/4 3/4 2 1/4 5 .030 30098 30099 $273.78 1 1 2 1/2 5 .030 30106 30107 $422.70
5 Flute WhisperKut Plus End Mills Tools with Radius Corners
5 Flute WhisperKut Plus End Mills Tools with Square Corners
Dia. of Shank Lenth of Overall Radius EDP No. with EDP No. with List Mill d1 Dia. d2 Cut I2 Length I1 Size Plain Shank Weldon Shank Price
3/16 3/16 5/8 2 n/a 30001 $24.54 1/4 1/4 3/4 2 1/2 n/a 30008 $31.24 5/16 5/16 3/4 2 1/2 n/a 30012 $38.88 3/8 3/8 1/2 2 n/a 30016 $39.80 3/8 3/8 1 2 1/2 n/a 30020 $48.18 1/2 1/2 5/8 2 1/2 n/a 30024 30025 $64.98 1/2 1/2 1 3 n/a 30036 30037 $74.31 1/2 1/2 1 1/4 3 n/a 30048 30049 $79.38 5/8 5/8 1 1/4 3 1/2 n/a 30070 30071 $139.92 3/4 3/4 7/8 3 n/a 30078 30079 $179.55 3/4 3/4 1 1/2 4 n/a 30088 30089 $202.73
Dura-Mill, inc. • 16 Stonebreak roaD • Malta, nY 12020 • (800) 444-6455 or (518) 899-2255 • Fax: (518) 899-7869 • DuraMill.coM
d1
l2
l1
d2
r
T O L E R a N C E S d1 .0000” - .002” d2 -.0001” - .0004” r +.000” - -.002”
MATERIAL LISTIngS - AISI
Tensile Material Description Content Strength Hardness aISI Standards Group RM (Mpa) (HB)
P1 low-carbon Steels, c<.25% <530 <125 1008, 1010, 1108, 1020, 1213 long chipping
P2 low-carbon Steels, Free c<.25% <650 1045, 1050, 1545, 1572 Machining, Short chipping
P3 Medium, High Plain carbon c<.25% 600-850 1300, 2000, 3000 Steels, low-alloyed Sae: a, D, H, W1, W2, l2
P4 alloyed, tempered carbon c<.25% 800-1100 350-450 1300, 2000, 3000 Steels, tool Sae: a, D, H, W1, W2, l2
P5 Ferritic, Martensitic PH c=0.4% 600-850 410, 416, 15-5 PH, Stainless Steels 13-8 PH, 17-4 PH
P6 High-Strength Ferritic, c=.1-.6% 900-1350 410, 416, 15-5 PH, Martensitic, PH Stainless Steels 13-8 PH, 17-4 PH
M1 austenitic Stainless Steel 200, 201, 301, 302, 304, 304l
M2 High-Strength austenitic 310, 314, 316, 316l, Stainless, cast Stainless Steels aStM: xM-1, xM-5
M3 Duplex Steel 323, 329, F55, 2205
k1 Gray cast, low-Strength class 20, 25, 30, 35 Ductile irons Sae: J431: Grade G1800
k2 low-, Medium-Strength 60-14-18, 65-45-12 cGi Ductile irons M3210, M4504
k3 High-Strength Ductile, 32510, 40010, 50005, austempered Ductile iron 70003, 90001
S1 iron-based, Heat-resistant alloys a-286, incoloy 801, a608, a567
S2 nickel or cobalt-based, Haynes 188, Haynes 21, Heat-resistant alloys Hastelloy, inconel 901
S3 titanium Pure ti
S4 titanium alloys 6ai-4V, ti 6ai-2Sn4Zr-2Mo
H1 Hardened Steels, irons tool Steel H10, H11, D2, D3, 4340, P20
Material Group
Hardness (HB)
Dura-Mill, inc. • 16 Stonebreak roaD • Malta, nY 12020 • (800) 444-6455 or (518) 899-2255 • Fax: (518) 899-7869 • DuraMill.coM
WhisperKut PLUS Solid carbide End Mills - WKP Series SPEED & FEED REcOMMEnDATIOnS
SFM 3/16” 1/4” 5/16” 3/8” 1/2” 5/8” 3/4” 1”
ap ae ap Min Max .188 .250 .313 .375 .500 .625 .750 1.000
P1 1.25 x D 0.5 x D 1 x D 485 650 0.0014 0.0018 0.0023 0.0027 0.0035 0.0039 0.0043 0.0050
P2 1.25 x D 0.5 x D 1 x D 455 610 0.0014 0.0018 0.0023 0.0027 0.0035 0.0039 0.0043 0.0050
P3 1.25 x D 0.5 x D 1 x D 385 515 0.0011 0.0015 0.0020 0.0023 0.0029 0.0034 0.0038 0.0046
P4 1.25 x D 0.5 x D 0.75 x D 295 485 0.0010 0.0014 0.0018 0.0020 0.0026 0.0030 0.0033 0.0039
P5 1.25 x D 0.5 x D 1 x D 200 325 0.0009 0.0012 0.0016 0.0018 0.0023 0.0027 0.0030 0.0036
P6 1.25 x D 0.5 x D 0.75 x D 160 245 0.0008 0.0010 0.0013 0.0015 0.0019 0.0022 0.0024 0.0028
M1 1.25 x D 0.5 x D 1 x D 255 325 0.0011 0.0015 0.0020 0.0023 0.0029 0.0034 0.0038 0.0046
M2 1.25 x D 0.5 x D 1 x D 200 255 0.0009 0.0012 0.0016 0.0018 0.0023 0.0027 0.0030 0.0036
M3 1.25 x D 0.5 x D 1 x D 200 255 0.0008 0.0010 0.0013 0.0015 0.0019 0.0022 0.0024 0.0028
k1 1.25 x D 0.5 x D 1 x D 385 515 0.0014 0.0018 0.0023 0.0027 0.0035 0.0039 0.0043 0.0050
k2 1.25 x D 0.5 x D 1 x D 355 455 0.0011 0.0015 0.0020 0.0023 0.0029 0.0034 0.0038 0.0046
k3 1.25 x D 0.5 x D 1 x D 325 425 0.0009 0.0012 0.0016 0.0018 0.0023 0.0027 0.0030 0.0036
S1 1.0 x D 0.3 x D 0.3 x D 160 295 0.0011 0.0015 0.0020 0.0023 0.0029 0.0034 0.0038 0.0046
S2 1.25 x D 0.5 x D 1 x D 160 255 0.0009 0.0012 0.0016 0.0018 0.0023 0.0027 0.0030 0.0036
S3 1.0 x D 0.3 x D 0.3 x D 70 130 0.0006 0.0008 0.0010 0.0012 0.0016 0.0018 0.0020 0.0025
S4 1.25 x D 0.5 x D 1 x D 150 205 0.0008 0.0011 0.0014 0.0017 0.0022 0.0025 0.0028 0.0033
H1 1.25 x D 0.5 x D 0.75 x D 255 455 0.0010 0.0014 0.0018 0.0020 0.0026 0.0030 0.0033 0.0039
Cutting Speeds
Recommended Feed Per Tooth is for side milling For slotting, reduce IPT by 10%
Mat
eria
l
Recommended Milling application
apae
ap
Variation to the above may be required to achieve optimum results.
Lower value of cutting speed is used for high stock removal applications and for higher material hardness applications.
Higher value of cutting speed is used for finishing applications or lower material hardness applications.
All parameters are based on ideal machining conditions and adequate machine tool capability.
Lower value of cutting speed should be selected when using smaller machines with spindles less than 50 taper.
Dura-Mill, inc. • 16 Stonebreak roaD • Malta, nY 12020 • (800) 444-6455 or (518) 899-2255 • Fax: (518) 899-7869 • DuraMill.coM
Profile Slot
®
Dura-Mill, Inc.16 Stonebreak Road • Malta, NY 12020
(800) 444-6455 or (518) 899-2255 Fax: (518) 899-7869
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