MillLine

Tungaloy Report No. 429-US

w w w. t u n g a l o y a m e r i c a . c o m

Exceptional productivity
for aluminum and non-ferrous
material machining!
w w w.t u n g a l o y a m e r i c a .c o m

MillLine

V-shaped bottom secures insert

on the cutter and supports high
speed machining as well as
helical ramping!
 Outstanding productivity in demanding applications, such
as high helical ramping, straight ramping and step milling!

Secure, stable insert clamping design with unique

V-shaped bottom
V shape provides counter force V-shaped clamping restricts insert
against the cutting force and movement even during high ramp
centrifugal force to stabilize the machining and reduces shear force
insert on the screw
V-shaped insert bottom FE analysis

Cutters General type

V-shaped design

Insert 3.0 µm 10.5 µm

Cutting movement
force Centrifugal (down cutting)
force
Cutting force Cutting force

Stress on
Counter force 100% 120%
the screw

Milling cutter : EPV16R125U0125W02 (ø1.25, z = 2)

Exceptional productivity is Insert : XVCT160508R-AJ TH10
achieved with high cutting Workpiece : Aluminum alloy
Cutting speed : Vc = 6600 sfm
speeds (Vc) of up to 16000 sfm. Feed per tooth : fz = 0.006 ipt
Depth of cut : ap = 0.2"
Width of cut : ae = 0.4"

Special features of the insert pocket

Simplified screw clamping

Coolant directed to the design for improved insert
cutting edge seating

2 face radial contact for Wide axial support for

precise 90° machining superior surface finish

V-shaped pocket enables

stable, high speed machining

4
 Excellent cutting edge geometry for aluminum and
non-ferrous materials
Helical cutting edge and high positive
rake angle
Polished rake face
rε: 0.016" - 0.197"

Wiper edge

High relief angle

Fully ground flank face

High positive, polished rake face prevents cutting edge built-up

High cutting edge clearance allows steep ramping
Comparison of maximum ramping angle
Tool diameter Competitor
øDc: ø1.500"

Max. ap
A B C
Max. ramping
angle θ 11.5° 11° 9° 9°
θ

Applicable for a wide range of machining

Target application
Profiling
· Where productivity needs to
be increased while maintaining
accurate machining and high
Pocket
milling Helical
surface quality
Slotting
ramping · Components that require high
Shouldering Face precision, such as aerospace
milling
frame parts
Straight
ramping

Excellent surface finish for both roughing and finishing

Comparison of surface roughness
ap = 0.059" ap = 0.314"
Surface Roughness: Ra (µm)

Surface Roughness: Ra (µm)

2.5 2.0
Competitor A Competitor A
2.0 1.6

1.5 1.2
Milling cutter : EPV16R125U0125W02
(ø1.25", z = 2)
1.0 Competitor B 0.8 Insert : XVCT160508R-AJ TH10
Competitor B Workpiece : Aluminum alloy
0.5 0.4 Cutting speed : Vc = 1970 sfm
Width of cut : ae = 1.00"
0 0
0.004 0.008 0.012 0.004 0.008 0.012
Feed per tooth: fz (ipt) Feed per tooth: fz (ipt)
5
 Cutter
Bore type
¡' E
¡G
D

E
Max. ap = 0.512" - 0.630"

R
Parts

/I
Parts Cat. No.
Descriptions
TPV16R…

DS
Clamping screw TS40093I/HG
Bit BT15S
¡' F Ý Wrench
Grip H-TBS

No. of Dimensions (in) Max. Weight Air

Center bolt
Cat. No. Stock inserts Inserts
øDc øDb ød r Lf (lb) hole RPM
b a (Option)
TPV16R150U0075A03 䊉 3 1.500 1.421 0.750 0.750 2.000 0.170 0.315 0.44 with 30,000 TCS9.525-35-I XVCT1605...
TPV16R200U0075A04 䊉 4 2.000 1.890 0.750 0.750 2.000 0.170 0.315 0.89 with 27,000 SD 06-46 XVCT1605...
TPV16R250U0100A05 䊉 5 2.500 2.165 1.000 0.750 2.000 0.197 0.375 1.34 with 24,000 SD 08-47 XVCT1605...
TPV16R300U0100A05 䊉 5 3.000 2.362 1.000 0.750 2.000 0.197 0.375 1.92 with 21,000 SD 08-47 XVCT1605...
TPV16R400U0150A06 䊉 6 4.000 3.150 1.500 1.059 2.500 0.319 0.625 4.28 with 19,000 SD 12-82 XVCT1605...
TPV16R500U0150A07 䊉 7 5.000 3.740 1.500 1.059 2.500 0.319 0.625 6.70 with 17,000 SD 12-82 XVCT1605...

Shank type
¡'F

¡'V

DS
Ý /I RV Max. ap = 0.512" - 0.630"
/
Parts
Parts Cat. No.
Descriptions
EPV16R100… EPV16R125/150…
Clamping screw TS40085I/HG TS40093I/HG
Bit BT15S
Wrench
Grip H-TBS

No. of Dimensions (in) Weight Air

Cat. No. Stock inserts Max. RPM Inserts
øDc øDs rs Lf
(lb) L hole
EPV16R100U0100W02 䊉 2 1.000 1.000 3.000 2.000 5.000 0.82 with 38,000 XVCT1605...
EPV16R100U0100W02L 䊉 2 1.000 1.000 4.000 3.000 7.000 1.17 with 38,000 XVCT1605...
EPV16R125U0125W02 䊉 2 1.250 1.250 4.000 2.000 6.000 1.69 with 34,000 XVCT1605...
EPV16R125U0125W02L 䊉 2 1.250 1.250 5.000 3.000 8.000 2.28 with 34,000 XVCT1605...
EPV16R125U0125W03 䊉 3 1.250 1.250 4.000 2.000 6.000 1.68 with 34,000 XVCT1605...
EPV16R125U0125W03L 䊉 3 1.250 1.250 5.000 3.000 8.000 2.27 with 34,000 XVCT1605...
EPV16R150U0125W03 䊉 3 1.500 1.250 5.000 2.000 7.000 2.08 with 30,000 XVCT1605...
EPV16R150U0125W03L 䊉 3 1.500 1.250 8.000 2.000 10.000 3.14 with 30,000 XVCT1605...
* When using inserts with corner radius r ε ≥ 0.126", standard
cutter body has to be modified with "R". "R" = rε - 0.012"
6
●: Stocked items
 Inserts

$ Uў 7

Grades Dimensions (in)

Cat. No. Accuracy Honing Cutter
TH10 A B T rε Max. ap
XVCT160504R-AJ C without 䊉 0.876 0.442 0.232 0.016 0.630 E/TPV16R
XVCT160508R-AJ C without 䊉 0.876 0.442 0.232 0.031 0.630 E/TPV16R
XVCT160512R-AJ C without 䊉 0.856 0.442 0.228 0.047 0.610 E/TPV16R
XVCT160516R-AJ C without 䊉 0.835 0.442 0.226 0.063 0.591 E/TPV16R
XVCT160520R-AJ C without 䊉 0.818 0.442 0.226 0.079 0.571 E/TPV16R
XVCT160524R-AJ C without 䊉 0.800 0.442 0.224 0.094 0.551 E/TPV16R
XVCT160530R-AJ C without 䊉 0.767 0.442 0.220 0.118 0.551 E/TPV16R
XVCT160532R-AJ C without 䊉 0.757 0.442 0.220 0.126 0.551 E/TPV16R
XVCT160540R-AJ C without 䊉 0.724 0.442 0.217 0.157 0.512 E/TPV16R
XVCT160550R-AJ C without 䊉 0.722 0.442 0.213 0.197 0.512 E/TPV16R
●: Stocked items

7
 Standard cutting conditions

Feed per
Chip-
ISO Workpiece materials Hardness Grades
breaker Cutting speed tooth

HB Vc (sfm) fz (ipt)
900 - 1600 0.006 - 0.015
60 TH10 AJ
650 - 6600 0.004 - 0.010
Aluminum alloy
650 - 6600 0.006 - 0.012
100 TH10 AJ
650 - 5000 0.004 - 0.010
650 - 3200 0.003 - 0.006
75 TH10 AJ
650 - 2600 0.003 - 0.006
Cast aluminum alloy (Si ≤ 12%)
900 - 3200 0.004 - 0.006
90 TH10 AJ
900 - 2600 0.004 - 0.006
300 - 1600 0.004 - 0.006
Cast aluminum alloy (Si > 12%) 130 TH10 AJ
300 - 900 0.004 - 0.006
900 - 1600 0.006 - 0.015
Copper alloys (Pb > 1%) 110 TH10 AJ
650 - 6600 0.004 - 0.010
650 - 6600 0.006 - 0.012
90 TH10 AJ
650 - 5000 0.004 - 0.010
Copper alloys
650 - 3200 0.003 - 0.006
100 TH10 AJ
650 - 2600 0.003 - 0.006
900 - 3200 0.004 - 0.006
Duroplastics, fiber plastics - TH10 AJ
900 - 2600 0.004 - 0.006
300 - 1600 0.004 - 0.006
Hard rubber - TH10 AJ
300 - 900 0.004 - 0.006

Safety guidelines
1. Use only the original inserts, cutters and spare 5. Maximum RPM values are determined based
parts. on the burst test. Using RPM beyond maximum
2. Insert pocket must be cleaned before clamping values may cause insert breakage, machine
the insert. damage or personal injury.
3. Clamp torque of screw should be 4.5 N·m. 6. XVCT insert has sharp cutting edges. Always
4. For safety reasons, use a new screw when wear gloves for protection from injury when
changing the insert. handling.

8
 Tool dia.: øDc (in), Number of revolutions: n (rpm), Feed rate: Vf (ipm), Depth of cut: ap = 0.630", No. of inserts: z
ø1.000" ø1.250" ø1.500" ø2.000" ø2.500" ø3.000" ø4.000" ø5.000"
z=2 z=2 z=3 z=3 z=4 z=5 z=5 z=6 z=7
n Vf n Vf n Vf n Vf n Vf n Vf n Vf n Vf n Vf
19,100 380 14,900 290 14,900 440 11,900 350 9,500 370 7,600 370 6,000 300 4,800 280 3,800 260
Vc = 5,000 sfm, fz = 0.010 ipt
12,700 200 9,900 160 9,900 230 8,000 190 6,400 200 5,100 200 4,000 160 3,200 150 2,500 140
Vc = 3,300 sfm, fz = 0.008 ipt
12,700 200 9,900 160 9,900 230 8,000 190 6,400 200 5,100 200 4,000 160 3,200 150 2,500 140
Vc = 3,300 sfm, fz = 0.008 ipt
10,200 120 8,000 90 8,000 140 6,400 110 5,100 120 4,000 120 3,200 90 2,500 90 2,000 80
Vc = 2,600 sfm, fz = 0.006 ipt
7,600 60 6,000 50 6,000 70 4,800 60 3,800 60 3,000 60 2,400 50 1,900 40 1,500 40
Vc = 2,000 sfm, fz = 0.004ipt
6,400 50 5,000 40 5,000 60 4,000 50 3,200 50 2,500 50 2,000 40 1,600 40 1,300 40
Vc = 1,600 sfm, fz = 0.004 ipt
7,600 70 6,000 60 6,000 90 4,800 70 3,800 70 3,000 70 2,400 60 1,900 50 1,500 50
Vc = 2,000 sfm, fz = 0.005 ipt
6,400 60 5,000 50 5,000 70 4,000 60 3,200 60 2,500 60 2,000 50 1,600 50 1,300 40
Vc = 1,600 sfm, fz = 0.005 ipt
3,800 40 3,000 30 3,000 40 2,400 30 1,900 40 1,500 40 1,200 30 1,000 30 800 30
Vc =1,000sfm, fz = 0.005 ipt
2,500 20 2,000 20 2,000 30 1,600 20 1,300 20 1,000 20 800 20 600 20 500 20
Vc = 660 sfm, fz = 0.005 ipt

9
 Machining applications
Helical interpolation Hole enlarging
Plunging and
Shoulder Ramping traversing
milling Slotting

Feed

$
3
/ ¡' DH
DS

DS

Straight ramp down Step down Helical ramp down Hole

Tool ø Corner Max. depth enlarging
øDc radius of cut Max. Min. Max. Min. Min. Max. Max.
Cat. No. ramping length plunging machining pitch/rev machining pitch/rev Max.
(in) rε (in) ap (in) angle width
θ L (in) A (in) øD1 (in) P (in) øD2 (in) P (in) a e (in)
EPV16R100… 1.000 0.016, 0.031 0.630 22º 1.570 0.166 1.150 0.173 1.970 0.535 0.886
EPV16R100… 1.000 0.047 0.610 22º 1.570 0.166 1.150 0.173 1.970 0.535 0.886
EPV16R100… 1.000 0.063 0.591 22º 1.500 0.146 1.150 0.173 1.970 0.520 0.886
EPV16R100… 1.000 0.079 0.571 22º 1.500 0.146 1.150 0.173 1.970 0.520 0.886
EPV16R100… 1.000 0.118, 0.126 0.551 21º 1.500 0.098 1.150 0.165 1.970 0.484 0.886
EPV16R100… 1.000 0.157, 0.197 0.512 18.5º 1.570 0.090 1.150 0.146 1.970 0.484 0.886
EPV16R125… 1.250 0.016, 0.031 0.630 16.5º 2.130 0.158 1.690 0.346 2.520 0.535 1.134
EPV16R125… 1.250 0.047 0.610 16.5º 2.130 0.158 1.690 0.346 2.520 0.535 1.134
EPV16R125… 1.250 0.063 0.591 16º 2.130 0.138 1.690 0.335 2.520 0.520 1.134
EPV16R125… 1.250 0.079 0.571 16º 2.130 0.138 1.690 0.335 2.520 0.520 1.134
EPV16R125… 1.250 0.118, 0.126 0.551 15º 2.130 0.118 1.700 0.311 2.520 0.484 1.134
EPV16R125… 1.250 0.157, 0.197 0.512 13.5º 2.200 0.098 1.700 0.280 2.520 0.484 1.134
T/EPV16R150… 1.500 0.016, 0.031 0.630 11.5º 3.110 0.158 2.330 0.409 3.150 0.535 1.417
T/EPV16R150… 1.500 0.047 0.610 11.5º 3.110 0.158 2.330 0.409 3.150 0.535 1.417
T/EPV16R150… 1.500 0.063 0.591 11º 3.150 0.138 2.330 0.390 3.150 0.520 1.417
T/EPV16R150… 1.500 0.079 0.571 11º 3.150 0.138 2.330 0.390 3.150 0.520 1.417
T/EPV16R150… 1.500 0.118, 0.126 0.551 10º 3.230 0.118 2.330 0.354 3.150 0.484 1.417
T/EPV16R150… 1.500 0.157, 0.197 0.512 8.5º 3.540 0.098 2.330 0.299 3.150 0.484 1.417
TPV16R200… 2.000 0.016, 0.031 0.630 9.5º 3.780 0.158 3.110 0.512 3.940 0.535 1.772
TPV16R200… 2.000 0.047 0.610 9.5º 3.780 0.158 3.110 0.512 3.940 0.535 1.772
TPV16R200… 2.000 0.063 0.591 9º 3.860 0.138 3.110 0.484 3.940 0.520 1.772
TPV16R200… 2.000 0.079 0.571 9º 3.860 0.138 3.110 0.484 3.940 0.520 1.772
TPV16R200… 2.000 0.118, 0.126 0.551 8º 4.060 0.118 3.110 0.429 3.940 0.484 1.772
TPV16R200… 2.000 0.157, 0.197 0.512 7º 4.330 0.098 3.110 0.374 3.940 0.484 1.772
TPV16R250… 2.500 0.016, 0.031 0.630 7º 5.120 0.158 4.130 0.535 4.960 0.535 2.232
TPV16R250… 2.500 0.047 0.610 7º 5.120 0.158 4.130 0.535 4.960 0.535 2.232
TPV16R250… 2.500 0.063 0.591 6.5º 5.350 0.138 4.130 0.504 4.960 0.520 2.232
TPV16R250… 2.500 0.079 0.571 6.5º 5.350 0.138 4.130 0.504 4.960 0.520 2.232
TPV16R250… 2.500 0.118, 0.126 0.551 6º 5.350 0.118 4.140 0.465 4.960 0.484 2.232
TPV16R250… 2.500 0.157, 0.197 0.512 5.5º 5.510 0.098 4.140 0.425 4.960 0.484 2.232
TPV16R300… 3.000 0.016, 0.031 0.630 5º 7.200 0.158 5.470 0.535 6.300 0.535 2.835
TPV16R300… 3.000 0.047 0.610 5º 7.200 0.158 5.470 0.535 6.300 0.535 2.835
TPV16R300… 3.000 0.063 0.591 4.5º 7.760 0.138 5.470 0.488 6.300 0.520 2.835
TPV16R300… 3.000 0.079 0.571 4.5º 7.760 0.138 5.470 0.488 6.300 0.520 2.835
TPV16R300… 3.000 0.118, 0.126 0.551 4º 8.150 0.118 5.480 0.433 6.300 0.484 2.835
TPV16R300… 3.000 0.157, 0.197 0.512 3.5º 8.700 0.098 5.480 0.378 6.300 0.484 2.835
TPV16R400… 4.000 0.016, 0.031 0.630 3.5º 10.310 0.158 7.040 0.508 7.870 0.535 3.543
TPV16R400… 4.000 0.047 0.610 3.5º 10.310 0.158 7.040 0.508 7.870 0.535 3.543
TPV16R400… 4.000 0.063 0.591 3º 11.650 0.138 7.040 0.437 7.870 0.520 3.543
TPV16R400… 4.000 0.079 0.571 3º 11.650 0.138 7.040 0.437 7.870 0.520 3.543
TPV16R400… 4.000 0.118, 0.126 0.551 2.5º 13.070 0.118 7.050 0.362 7.870 0.484 3.543
TPV16R400… 4.000 0.157, 0.197 0.512 2.5º 12.170 0.098 7.050 0.362 7.870 0.457 3.543
TPV16R500… 5.000 0.016, 0.031 0.630 2.5º 14.450 0.158 9.020 0.476 9.840 0.535 4.429
TPV16R500… 5.000 0.047 0.610 2.5º 14.450 0.158 9.020 0.476 9.840 0.535 4.429
TPV16R500… 5.000 0.063 0.591 2º 17.480 0.138 9.020 0.382 9.840 0.520 4.429
TPV16R500… 5.000 0.079 0.571 2º 17.480 0.138 9.020 0.382 9.840 0.520 4.429
TPV16R500… 5.000 0.118, 0.126 0.551 1.5º 21.810 0.118 9.020 0.287 9.840 0.343 4.429
10 TPV16R500… 5.000 0.157, 0.197 0.512 1.5º 20.310 0.098 9.020 0.287 9.840 0.343 4.429
 Practical examples
Workpiece type Airplane part Airplane part
Cutter TPV16R200U0075A04 (ø2.00", z = 4) EPV16R125U0125W03 (ø1.25", z = 3)
Insert XVCT160504R-AJ XVCT160530R-AJ
Grade TH10 TH10
7050 7050
28"

8"

5 9"
Workpiece material

6"
36"

3.15"
Cutting speed: Vc (sfm)
Cutting conditions

7,200 3,000
Feed per tooth: fz (ipt) 0.007 0.012
Depth of cut: ap (in) 0.2 0.1
Width of cut: ae (in) 1.4 1
Method of machining Pocket milling Pocket milling
Coolant Wet Wet
Machine Vertical M/C, CAT50 Vertical M/C, CAT50
Number of workpiece

10 400

8
1.1
1.1
(pcs/corner)

Doubled 300 times

Feed rate
Vf (ipm)
6
tool life! 200 productivity !
productivity!
Results 4
100
2
0 0
Competitor Competitor
Excellent sharpness drastically reduces cutting Lower cutting force allows higher feed
force, achieving longer tool life. machining, providing higher productivity.

Workpiece type Robot component Robot component

Cutter EPV16R100U0100W02 (ø1.00", z = 2) TPV16R200U0075A04 (ø2.00", z = 4)
Insert XVCT160504R-AJ XVCT160504R-AJ
Grade TH10 TH10
6061 Aluminum alloy
"
20
5 0"

Workpiece material
3.1

7.85"
1.181"

4"

20"

Cutting speed: Vc (sfm) 2,600 3,300

Cutting conditions

Feed per tooth: fz (ipt) 0.006 0.008

Depth of cut: ap (in) 0.4 0.24
Width of cut: ae (in) 1 1.8
Method of machining Pocket milling Slot milling
Coolant Wet Wet
Machine Vertical M/C, CAT40 Vertical M/C, CAT50
140 140
120 120
1.25
1.2 5 times 1.3
1. 3 times
Feed rate

100 100
Vf (ipm)
Feed rate
Vf (ipm)

80 productivity!!
productivity 80 productivity !
productivity!
60 60
Results
40 40
20 20
0 0
Competitor Competitor
Due to rigid clamping, excellent surface finish Sharp cutting edge reduces cutting force. This feature allows
can be achieved even with higher feed rates. the feed to be incrcased and achieves high productivity. 11
Tungaloy America, Inc.
3726 N Ventura Drive, Arlington Heights, IL 60004, U.S.A.
Inside Sales: +1-888-554-8394
Technical Support: +1-888-554-8391
Fax: +1-888-554-8392
www.tungaloyamerica.com

Tungaloy Canada
432 Elgin St. Unit 3, Brantford, Ontario N3S 7P7, Canada
Phone: +1-519-758-5779 Fax: +1-519-758-5791
www.tungaloy.co.jp/ca

Tungaloy de Mexico S.A.

C Los Arellano 113, Parque Industrial Siglo XXI
Aguascalientes, AGS, Mexico 20290
Phone:+52-449-929-5410 Fax:+52-449-929-5411
www.tungaloy.co.jp/mx

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