power milling with greenleaf ® power milling with greenleaf ®

Power Milling

With Greenleaf

®

Power Milling

With Greenleaf

®

Power MillingWith Greenleaf

®

Power MillingWith Greenleaf

®

Milling 101Heavy Milling Cutters– Powermill– Special Milling Cutters

• Heavy Milling• Rail Milling• Crankshaft Milling• Camshaft Milling

– Cutter Repair

Carbide Milling Grades CVD PVDGA-5023 G-910 G-9120GA-5036 G-915GA-5040 G-935GA-5125 G-955

Milling 101Milling 101

The basics of Milling with Greenleaf

® Milling cutters.The basics of Milling with Greenleaf

® Milling cutters.

Hand of Cutters

• Right Hand Cutters Rotate Clockwise

• Left Hand Cutters Rotate

Counter-Clockwise


Select Correct Cutter Diameter

• 1.5 Times Work Piece Width• WOC = 2/3 Cutter Diameter• Watch Machine Horsepower


Lead Angle

• Thins the Chip

• Uses Less Horsepower

• Improved Tool Life


Lead Angles and Cutting Forces

• Less Force Into Part

• More Force on Spindle

• Less Force on Spindle

• More Force Into Part


Lead Angle Effect on Chip Thickness

• At 0° B = A• At 45° B = 70% of A


Cutter PitchCoarse Pitch :• Better Chip Evacuation• Heavier IPT (MM/tooth)• Larger DOC

Fine Pitch :• More Teeth Engaged• Heavier IPM (MM/min)• Lighter DOC

A good guide is diameter (inches) + 2A good guide is diameter (inches) + 2


Cutter Geometry Radial Rake

• Impacts Edge strength• Affects Cutting Forces


Cutter Geometry Axial Rake

• Directs Chip Flow• Caution with Fixturing


Cutter GeometryNegative vs. Positive

• Strongest Geometry• Higher Feed Possible• Maximum Insert Usage• Higher Cutting Forces

• Lower Cutting Forces• Better Chip Evacuation• Lower HP Consumption• Weaker Geometry


Cutter GeometryDouble Negative

Advantages :• Strongest Shape• Cast Iron • Best Economy

Disadvantages :• Part/Machine Rigidity• Highest Forces• Chip Flow into Part

Negative Axial & Negative Radial


Cutter GeometryDouble Positive

Advantages :• Milling Aluminum• Work Hardening

Materials• Low HP

Disadvantages :• Fragile Cutting Edge• Pulling Forces• Not for Hardened

Materials

Positive Axial & Positive Radial


Cutter GeometryNegative / Positive

Advantages :• Best General Purpose• Most Materials• Excellent Chip Ejection• Balanced Cutting Forces

Disadvantages :• Fewer Cutting Edges

than Negative

Negative Radial & Positive Axial


Negative / PositiveBest of Both Worlds

• Capable of Heavy Duty Milling• Works Best With Lead Angle Cutters• Powermill & High Shear Cutters


Depth of Cut

Do Not Exceed 2/3 of Edge Length (L)


Milling TechniquesConventional (Up) Milling

• Counteract Table Feed Backlash• Poor Chip Formation – Creates Heat• Work Hardening• Poor Insert Life - Flank Wear


Milling TechniquesClimb (Down) Milling

• Good Tool Life• Inserts must Survive Shock of Entry• Good Chip Formation• Watch Table Backlash!


Milling TechniquesCutter Positioning

• Can Cause Vibration

Cutter On Center


• Helps Eliminate Vibration• Climb Mill If Possible• Keep 2 Teeth in Cut• 1/4 - 1/3 Cutter

Overhang

Slightly Off Center

Milling TechniquesCutter Positioning


Milling TechniquesAngle of Entry

Positive Angle of Entry

Contact at Weak Section of Insert

Poor Impact Resistance

E2 > 90°



Negative Angle of Entry

Contact at Strong Section of Insert

Best Impact Resistance

E1 < 90°


Milling Through Interruptions

• Use a Lead Angle Cutter• Use a Strong Carbide Grade• Use Medium to Fine Pitch Cutter• Use Lighter Feed Rate


• Radii Leave “Tracks”

• Radius Size Determines Finish

Milling TechniquesSurface Finish


• Milling Inserts Have Flats

• “Wiping Effect” Improves Finish

Milling TechniquesSurface Finish


Common Terms

Surface Feet Per Min.

Revolutions Per Min.

Number Of Teeth

Feed Per Tooth

Feed Per Revolution

Feed Per Minute

= SFM= RPM= T= FPT (IPT)= FPR (IPR)= IPM= 3.1416

English Metric

Surface Meters Per Min.

Revolutions Per Minute

Number Of Teeth

Feed Per Tooth

Feed Per Revolution

Feed Per Minute

= M/Min= RPM= Z= FPT= (MM/Tooth)= FPR (MM/Rev)= MM/Min= 3.1416


•Select a cutter that is 1.5 times work piece width where possible.

•Select a cutter with Negative radial/Positive axial geometry in most cases.

•Select a cutter with a fairly course pitch for most materials.

•Use a cutter with a lead angle to reduce cutting forces.

•Climb (down) mill where possible.

•Position the cutter with a negative angle of entry with 1/4 th - 1/3rd overhang condition.

•Do not exceed 2/3rd cutting edge length on your depth of cut.


Questions?Questions?

Powermill®Powermill®

When should you consider a Powermill®?

• When removing forging scale in heavy-duty cutting with severe interruptions and uneven surfaces is required.

• When large DOC and high MRR are crucial for productivity.

• When versatility and durability is required.

• When cost is a consideration.

• When horsepower is a concern, the LNES sinusoidal insert can be used to reduce HP consumption by

approximately 30%.


M402LN-A: 2° Lead, Neg-NegDiameter range: 4” (100MM)-12” (315 MM)”

M400LNP-A: 0° Lead, Neg-PosDiameter range: 4” (100MM)-12” (315 MM)”

M430LNP-A: 30° Lead, Neg-PosC430LNP-H: 30° Lead, Neg-Pos (Heavy Duty)C430LNP-W: 30° Lead, Neg-Pos (Finishing)Diameter range: 4” (100MM)-12” (315 MM)”


M402LN-A: 2° Lead, Neg-NegNegative Radial, Negative Axial

Diameter Range: 4” (100MM) – 12” (315 MM)Max. DOC Range: .68” (17.3MM) - 1.06” (26.9MM)

Advantages :• Strongest Shape• Cast Iron • Best Economy• LNES insert for lower HP

machines.

Disadvantages :• Part/Machine Rigidity• Highest Forces• Chip Flow into Part

Note: Tune up kit available


M400LNP-A: 0° Lead, Neg-PosNegative Radial & Positive Axial

Diameter Range: 4” (100MM) - 12” (315 MM)Max. DOC Range: .68” (17.3MM) – 1.06” (26.9MM)

Advantages :• Best General Purpose• Most Materials• Excellent Chip Ejection• Balanced Cutting Forces


than Negative



Advantages :• Best General Purpose• Most Materials• Excellent Chip Ejection• Balanced Cutting Forces• Chip thinning


than Negative• Lower maximum depth of

cut than 0° lead cutter

M430LNP-A: 30° Lead, Neg-PosC430LNP-H: 30° Lead, Neg-Pos (Heavy Duty)C430LNP-W: 30° Lead, Neg-Pos (Finishing)

Diameter range: 4” (100MM)-12” (315 MM)Max. DOC Range: .50” (12.7MM) - .88” (22.3MM)



InsertsInserts

• Approximately equal width and thickness adds strength needed to handle large depths of cut and

heavy interrupted cuts.

•Insert design allows for high strength while using minimal carbide to reduce cost.

• Performance with high metal removal rates.

• Productive Greenleaf carbide grades.


LNE-335 LNE-335F

LNE-34.57 LNE-34.57F

LNES-335

LNES-34.57

LNP-335R/L LNP-335-90R/L

LNP-34.57R/L LNP-34.57-90R/L

LNP-34.57 RW/LW

YCE-434-01

2° lead Neg-Neg

2° lead Neg-Neg

CutterInsert

0° lead Neg-Pos

30° lead Neg-Pos

30° lead Neg-Pos

Finishing


InsertsInserts

Test DataTest DataPowermill®Powermill®

Powermill

® Milling Cutter - M430LNP12AMaterial - 350 BHN Steel Forging

Cutter dia. - 12.0 (301.1 mm)Grade – G-955

Speed - 400 SFM (122 M/Min)Feed - .013 (0.33 mm) per Tooth

WOC - 8.0 (203.2 mm)DOC - .40 (10.2 mm)

MRR - 122 Cu In / Min (2000 cu cm/min)Required HP - 153

Resulted in an order for (4) 12” cutters and a blanket order for

23,000 inserts


Test DataTest Data

Powermill Milling Cutter - C430LNP10HMaterial – Alloy Steel unknown hardness

Cutter dia. - 10.0 (254 mm)Insert/Grade – LNP-44.57R GA-5036

Speed - 540 SFM (165 M/Min)Feed - .011 (0.28 mm) per Insert

WOC – 6.5 (165.1 mm)DOC - .60 (15.2 mm)


3X increase in speed and 2X increase in DOC with 225% increase in MRR resulted in order

Prior – Competitor Button CutterMaterial – Alloy Steel unknown hardness

Cutter dia. – 8.0 (203 mm)Insert/Grade – RNMA-84 SF30Speed - 367 SFM (112 M/Min)

Feed - .018 (0.45 mm) per Insert.0134 (.34 mm) ACT

WOC – 5.25 (134.1 mm)DOC - .30 (7.62 mm) Maximum



Test DataTest Data


Test DataTest Data

Beware of Required Horsepower

Powermill

® Milling Cutter - M430LNP04AMaterial – P20 350 BHN

Cutter dia. – 4.0” (102 mm)Speed – 400 SFM (122 M/Min)Feed - .020” (0.51 mm)/Insert

WOC – 3” (203.2 mm)DOC - .50” (12.7 mm)

MRR – 46.5 Cu In / Min (762 Cu Cm/Min)

Powermill

® Milling Cutter - M430LNP12AMaterial – P20 350 BHN

Cutter dia. – 12” (305 mm)Speed – 400 SFM (122 M/Min)Feed - .020” (0.51 mm)/Insert

WOC – 9” (203.2 mm)DOC - .50” (12.7 mm)

MRR – 140 Cu In / Min (2285 Cu Cm/Min)

Required HP - 93 Required HP - 279


•Powermill

® cutters have the versatility to get the job done.

•Powermill

® cutters are standard and most are in stock.

•Productive carbide grades available for many materials.

•Capable of very high metal removal rates.

•DOC range from .50 max to 1.06 max depending on cutter and hardware.

•Be sure to calculate horsepower and ensure the machine has the capability to run the cutter.

•Consider the Powermill

® before going to a special cutter.


Special Milling CuttersSpecial Milling Cutters

Advantages• Custom built milling cutters optimized for the application at

hand.

• If the application permits, most cutters can be designed for high speed milling and high metal removal rates.

• Most cutters are designed with replaceable hardened components.

• Productive carbide grades available for most applications.

• Tune up kits available

• In event of a major crash, we can re-work Greenleaf

®

special cutters to as new condition.


Test DataTest Data


24” (610mm) Dia. 24” (610mm) Dia. 3030oo Lead High Shear Mill Lead High Shear Mill

High Speed Milling with gradesHigh Speed Milling with gradesGA-5125,GA-5125, G-9120G-9120


24” (610mm) Dia. 30o Lead High Shear Mill

Insert – 428522 GA-5125Speed - 415 SFM (127 M/Min)

Feed - .0075” (0.19 mm) per InsertWOC - 18” (203.2 mm)DOC - .50” (12.7 mm)

Special Milling CutterMaterial - 350 BHN Steel Forging

Cutter dia. - 24” (301.1 mm)

MRR–107 Cu In/Min (1180 Cu Cm/ MinRequired HP - 133


24” (610mm) Dia. 30o Lead High Shear Mill


Cutter dia. - 24” (301.1 mm)

Insert – 428522 G-9120Speed - 415 SFM (127 M/Min)

Feed - .0101” (0.26 mm) per InsertWOC - 18” (457.2 mm)DOC - .50” (12.7 mm)

35% increase in feed equated to a 35% increase in MRR 35% increase in feed equated to a 35% increase in MRR over GA-5125 with 30 minute time savings per block!over GA-5125 with 30 minute time savings per block!

MRR-144 Cu In/Min (2360 Cu Cm/Min)MRR-144 Cu In/Min (2360 Cu Cm/Min)Required HP - 180Required HP - 180


12” (305MM) Dia. 30o Lead High Shear Mill

High Speed Milling with grade G-955


12” (305MM) Dia. 30o Lead High Shear Mill


Cutter dia. - 12.0 (301.1 mm)Insert - 436034 G-955

Speed - 400 SFM (122 M/Min)Feed - .013 (0.33 mm) per Insert

WOC - 8.0 (203.2 mm)DOC - .40 (10.2 mm)


MRR - 122 Cu In / Min (2000 Cu Cm/Min)Required HP - 153


6” (152.4MM) Dia. 90o Lead High Shear Mill



6” (152.4MM) Dia. 90o Lead High Shear Mill

Special Milling Cutter Material - 4140 Steel 350 BHN

Cutter dia. - 6” (301.1 mm)Insert – TPEN-53P12R G-935Speed - 474 SFM (145 M/Min)

Feed - .004” (0.10 mm) per InsertWOC - 4.5” (114 mm)DOC - .50” (12.7 mm)


MRR - 29 Cu In / Min (475 Cu Cm/Min)Required HP - 36


High Speed Milling with grade GA-5125

9.0” (228 MM) Dia. Special Switch Point Rail Milling Cutter


9.0” (228 MM) Dia. Special Switch Point Rail Milling Cutter

High Speed Milling with grade GA-5125Special Milling Cutter

Material - Manganese Steel 400 BHNCutter dia. – 9.0” (229 mm)Insert – RPGN-84 GA-5125

SPGN-643 GA-5125Speed - 500 SFM (152.5 M/Min)

Feed - .0126” (0.32 mm) per InsertWOC – .75” (19 mm)

DOC - VariesLOC – 39 Feet (11.9 Meter)

See customer testimonial


Several grades of carbide from threedifferent manufacturers, Ingersoll, AGI / VR Wesson and Greenleaf

® havebeen run in these tools trying to improveperformance. The best performanceachieved was from Greenleaf with theirGA-5125 grade carbide inserts

In almost every case where a catastrophicInsert failure has occurred, we were able toreplace the wedges, wedge screws and or back-up plates, and have the tool backin service in less than a couple of hours.

A page from the customersjustification report


Another page from thecustomers justificationreport.


9.5” (241 MM) Dia. Special Rail Milling Cutter



9.5” (241 MM) Dia. Special Rail Milling Cutter

Special Milling Cutter Material - Manganese Steel 375 BHN

Cutter dia. – 9.5” (301.1 mm)Insert – SNGN-643 GA-5125

431884 GA-5125431885 GA-5125

Speed - 500 SFM (152.5 M/Min)Feed - .0298” (0.76 mm) per Insert

to obtain .018 (0.46 mm) ACTWOC – 3.5” (89 mm)DOC - .08” (2 mm)


Required HP - 48


25 degree Special Flair Rail Milling Cutter

Cutter uses 72 inserts!


25 degree Special Flair Rail Milling Cutter

50% increase in speed, 90% increase in feed. Resulted in order of more geometries!

Required HP - 143


Examples of Tools for the Rail industry


Camshaft and Crankshaft Milling


OD Segments

Design

64” (1625 MM) diameter cutter

Special Milling CuttersSpecial Milling CuttersCamshaft and Crankshaft Milling

(48) Inserts RNGN-84

(120) Inserts SNGN-643

12 segments per cutter168 total inserts/load


Design

• Locomotive and Marine Diesel Engines • Power Generation• Automotive (48) Inserts RNGN-84

(120) Inserts SNGN-643

Crankshaft Milling Cutter supplied by Greenleaf

®


Customers' existingCutter


Segments allow inexpensive repairs

Qualified mounting allows you to replace

one segment or all

22.44” (570 MM) I.D.

3.425 (87 MM) Width of Cut


®


ID SegmentsID SegmentsDesignDesign

8 Segments per cutter64 inserts total/cutter load


Cam Shaft MillCutter Dia: 16.0”

(406.4 mm)Cutting width: .81”

(20.6 mm)72 Total Inserts, (24)

Effective


®


Cam Shaft, 4140 Steel Forging

Insert Grade GA-5036

Original Tool Life:Slotting Cutter:

18 parts per index

New Tool Life:Slotting Cutter:

85 parts per index


We refurbish and repair damaged Greenleaf

® special Tooling.

Cutter RepairCutter Repair

Advantages• Custom built milling cutters optimized for the application at hand.

• If the application permits, most cutters can be designed for high speed milling and high metal removal rates.

• Most cutters are designed with replaceable hardened components.

• Productive carbide grades available for most applications.

• Tune up kits available

• In event of a major crash, we can re-work Greenleaf

® special cutters to as new condition.


Greenleaf

® Corporation is an industry pioneer in coated carbide technology.

Selecting the best carbide grade for the application is critical to the success and productivity of any milling

operation.

Greenleaf

® Carbide Grades for Milling

Greenleaf


G-60

G-53UNCOATED

G-53 General Purpose MillingSteel and Steel AlloysGood Toughness and Wear Resistance

High Shear, Powermill

G-60 Finish Milling Grade for SteelsFinish Wiper Inserts

Powermill

Greenleaf


Greenleaf


MT-CVD COATED

GA-5036 High Performance Steel MillingHeavy or Light Duty at High Speed

Hushcut, High Shear, Powermill, Screw-on, Excelerator

GA-5125 High Performance Manganese Steel Milling GradeHigh Speeds and Moderate Feeds

Special Applications

Greenleaf


Greenleaf


MT-CVD COATED

GA-5023 High Performance Cast Iron Milling


GA-5040 Tough Grade for Milling most MaterialsSevere Applications, Low Speeds

Hushcut, High Shear, Powermill, Screw-on, Excelerator

Greenleaf


Greenleaf


G-910 High Temp Alloys, Primarily Titanium at Moderate Speeds

High Shear

PVD COATED

G-915 High Temps, Stainless & Carbon Steelsat Moderate SpeedsTough, Abrasion Resistant

Hushcut, High Shear, Screw-on, Excelerator

G-935 Tough, Higher Speed Steel Milling

Screw-on

Greenleaf


Greenleaf


PVD COATED

G-955 Rough Steel Forgings, tool steels.Tough, High speed steel Milling


G-9120 Tough, Higher Speed Steel MillingRough Steel Forgings, tool steelsImprovement over G955 in most apps


Greenleaf


Greenleaf


Thank You!Thank You!

power milling with greenleaf ® power milling with greenleaf ®

Documents

milling inserts

basics of milling

greenleaf milling cutters

greenleaf power milling

counterclockwise milling

powermill slide

greenleaf slide

lighter feed rate milling