Power Milling With Greenleaf Power Milling With Greenleaf

Power Milling With Greenleaf ®

Power Milling With Greenleaf ® Milling 101 Heavy Milling Cutters – Powermill – Special Milling Cutters • • Heavy Milling Rail Milling Crankshaft Milling Camshaft Milling – Cutter Repair Carbide Milling Grades CVD GA-5023 GA-5036 GA-5040 GA-5125 PVD G-910 G-915 G-935 G-955 G-9120

Milling 101 The basics of Milling with Greenleaf Milling cutters. ®

Milling 101 Hand of Cutters • Right Hand Cutters Rotate Clockwise • Left Hand Cutters Rotate Counter-Clockwise

Milling 101 Select Correct Cutter Diameter • 1. 5 Times Work Piece Width • WOC = 2/3 Cutter Diameter • Watch Machine Horsepower

Milling 101 Lead Angle • Thins the Chip • Uses Less Horsepower • Improved Tool Life

Milling 101 Lead Angles and Cutting Forces • Less Force Into Part • More Force on Spindle • Less Force on Spindle • More Force Into Part

Milling 101 Lead Angle Effect on Chip Thickness • At 0° • At 45° B=A B = 70% of A

Milling 101 Cutter Pitch Coarse 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) + 2

Milling 101 Cutter Geometry Radial Rake • Impacts Edge strength • Affects Cutting Forces

Milling 101 Cutter Geometry Axial Rake • Directs Chip Flow • Caution with Fixturing

Milling 101 Cutter Geometry Negative vs. Positive • • Strongest Geometry Higher Feed Possible Maximum Insert Usage Higher Cutting Forces • • Lower Cutting Forces Better Chip Evacuation Lower HP Consumption Weaker Geometry

Milling 101 Cutter Geometry Double Negative Axial & Negative Radial Advantages : Disadvantages : • Strongest Shape • Cast Iron • Best Economy • Part/Machine Rigidity • Highest Forces • Chip Flow into Part

Milling 101 Cutter Geometry Double Positive Axial & Positive Radial Advantages : Disadvantages : • Milling Aluminum • Work Hardening Materials • Low HP • Fragile Cutting Edge • Pulling Forces • Not for Hardened Materials

Milling 101 Cutter Geometry Negative / Positive Negative Radial & Positive Axial Advantages : • • Disadvantages : Best General Purpose • Fewer Cutting Edges than Negative Most Materials Excellent Chip Ejection Balanced Cutting Forces

Milling 101 Negative / Positive Best of Both Worlds • Capable of Heavy Duty Milling • Works Best With Lead Angle Cutters • Powermill & High Shear Cutters

Milling 101 Depth of Cut Do Not Exceed 2/3 of Edge Length (L)

Milling 101 Milling Techniques Conventional (Up) Milling • • Counteract Table Feed Backlash Poor Chip Formation – Creates Heat Work Hardening Poor Insert Life - Flank Wear

Milling 101 Milling Techniques Climb (Down) Milling • • Good Tool Life Inserts must Survive Shock of Entry Good Chip Formation Watch Table Backlash!

Milling 101 Milling Techniques Cutter Positioning • Can Cause Vibration Cutter On Center

Milling 101 Milling Techniques Cutter Positioning Slightly Off Center • Helps Eliminate Vibration • Climb Mill If Possible • Keep 2 Teeth in Cut • 1/4 - 1/3 Cutter Overhang

Milling 101 Milling Techniques Angle of Entry Positive Angle of Entry Contact at Weak Section of Insert Poor Impact Resistance E 2 > 90°

Milling 101 Milling Techniques Angle of Entry Negative Angle of Entry Contact at Strong Section of Insert Best Impact Resistance E 1 < 90°

Milling 101 Milling Techniques Angle of Entry

Milling 101 Milling Through Interruptions • • Use a Lead Angle Cutter Use a Strong Carbide Grade Use Medium to Fine Pitch Cutter Use Lighter Feed Rate

Milling 101 Milling Techniques Surface Finish • Radii Leave “Tracks” • Radius Size Determines Finish

Milling 101 Milling Techniques Surface Finish • Milling Inserts Have Flats • “Wiping Effect” Improves Finish

Milling 101 Common Terms English Surface Feet Per Min. = Revolutions Per Min. = Number Of Teeth = Feed Per Tooth = Feed Per Revolution = Feed Per Minute = = Metric SFM Surface Meters Per Min. = M/Min RPM Revolutions Per Minute = RPM T Number Of Teeth = Z FPT (IPT) Feed Per Tooth = FPT FPR (IPR) Feed Per Revolution = (MM/Tooth) IPM Feed Per Minute = FPR (MM/Rev) 3. 1416 = MM/Min = 3. 1416

Milling 101 • 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 1/3 rd overhang condition. • Do not exceed 2/3 rd cutting edge length on your depth of cut.

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%.

Powermill ® M 402 LN-A: 2° Lead, Neg-Neg Diameter range: 4” (100 MM)-12” (315 MM)” M 400 LNP-A: 0° Lead, Neg-Pos Diameter range: 4” (100 MM)-12” (315 MM)” M 430 LNP-A: 30° Lead, Neg-Pos C 430 LNP-H: 30° Lead, Neg-Pos (Heavy Duty) C 430 LNP-W: 30° Lead, Neg-Pos (Finishing) Diameter range: 4” (100 MM)-12” (315 MM)”

Powermill ® M 402 LN-A: 2° Lead, Neg-Neg Negative Radial, Negative Axial Diameter Range: 4” (100 MM) – 12” (315 MM) Max. DOC Range: . 68” (17. 3 MM) - 1. 06” (26. 9 MM) Advantages : • • Strongest Shape Cast Iron Best Economy LNES insert for lower HP machines. Note: Tune up kit available Disadvantages : • Part/Machine Rigidity • Highest Forces • Chip Flow into Part

Powermill ® M 400 LNP-A: 0° Lead, Neg-Pos Negative Radial & Positive Axial Diameter Range: 4” (100 MM) - 12” (315 MM) Max. DOC Range: . 68” (17. 3 MM) – 1. 06” (26. 9 MM) Advantages : • • Best General Purpose Most Materials Excellent Chip Ejection Balanced Cutting Forces Note: Tune up kit available Disadvantages : • Fewer Cutting Edges than Negative

Powermill ® M 430 LNP-A: 30° Lead, Neg-Pos C 430 LNP-H: 30° Lead, Neg-Pos (Heavy Duty) C 430 LNP-W: 30° Lead, Neg-Pos (Finishing) Diameter range: 4” (100 MM)-12” (315 MM) Max. DOC Range: . 50” (12. 7 MM) -. 88” (22. 3 MM) Advantages : • • • Best General Purpose Most Materials Excellent Chip Ejection Balanced Cutting Forces Chip thinning Note: Tune up kit available Disadvantages : • Fewer Cutting Edges than Negative • Lower maximum depth of cut than 0° lead cutter

Powermill ® Hardened Anvils and Back-up Plates • Protect Cutter Body • Maintain Accuracy 58 -60 R/C Front Wedge Design • Maximum Security & Insert Rigidity • Hard Faced for Durability Interchangeable Components • Multiple Applications • 2 o & 30 o Anvils fit Left and Right Hand Cutters

Powermill ®

Powermill Inserts ® • 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.

Powermill Inserts Insert LNE-335 F LNE-34. 57 F LNES-335 ® Cutter 2° lead Neg 2° lead Neg-Neg LNES-34. 57 LNP-335 R/L LNP-335 -90 R/L LNP-34. 57 -90 R/L LNP-34. 57 RW/LW YCE-43401 30° lead Neg-Pos Finishing 0° lead Neg-Pos 30° lead Neg-Pos

Powermill Test Data ®

Powermill Test Data Powermill ® Milling Cutter - M 430 LNP 12 A Material - 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 ®

Powermill ® Test Data Prior – Competitor Button Cutter Material – Alloy Steel unknown hardness Cutter dia. – 8. 0 (203 mm) Insert/Grade – RNMA-84 SF 30 Speed - 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 MRR - 40 Cu In / Min (655 cu cm/min) Required HP - 50 Powermill Milling Cutter - C 430 LNP 10 H Material – Alloy Steel unknown hardness Cutter dia. - 10. 0 (254 mm) Insert/Grade – LNP-44. 57 R 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) MRR - 90 Cu In / Min (1475 cu cm/min) Required HP - 112 3 X increase in speed and 2 X increase in DOC with 225% increase in MRR resulted in order

Powermill Test Data ®

Powermill ® Beware of Required Horsepower Powermill ® Milling Cutter - M 430 LNP 04 A Material – P 20 350 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) Required HP - 93 Powermill ® Milling Cutter - M 430 LNP 12 A Material – P 20 350 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 - 279

Powermill ® • 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.

Questions?

Special Milling Cutters

Special 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. ®

Special Milling Cutters Test Data

Special Milling Cutters 24” (610 mm) Dia. 30 o Lead High Shear Mill High Speed Milling with grades GA-5125, G-9120

Special Milling Cutters 24” (610 mm) Dia. 30 o Lead High Shear Mill Special Milling Cutter Material - 350 BHN Steel Forging Cutter dia. - 24” (301. 1 mm) Insert – 428522 GA-5125 Speed - 415 SFM (127 M/Min) Feed -. 0075” (0. 19 mm) per Insert WOC - 18” (203. 2 mm) DOC -. 50” (12. 7 mm) MRR– 107 Cu In/Min (1180 Cu Cm/ Min Required HP - 133

Special Milling Cutters 24” (610 mm) Dia. 30 o Lead High Shear Mill Special Milling Cutter Material - 350 BHN Steel Forging Cutter dia. - 24” (301. 1 mm) Insert – 428522 G-9120 Speed - 415 SFM (127 M/Min) Feed -. 0101” (0. 26 mm) per Insert WOC - 18” (457. 2 mm) DOC -. 50” (12. 7 mm) MRR-144 Cu In/Min (2360 Cu Cm/Min) Required HP - 180 35% increase in feed equated to a 35% increase in MRR over GA-5125 with 30 minute time savings per block!

Special Milling Cutters 12” (305 MM) Dia. 30 o Lead High Shear Mill High Speed Milling with grade G-955

Special Milling Cutters 12” (305 MM) Dia. 30 o Lead High Shear Mill High Speed Milling with grade G-955 Special Milling Cutter Material - 350 BHN Steel Forging 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

Special Milling Cutters 6” (152. 4 MM) Dia. 90 o Lead High Shear Mill High Speed Milling with grade G-935

Special Milling Cutters 6” (152. 4 MM) Dia. 90 o Lead High Shear Mill High Speed Milling with grade G-935 Special Milling Cutter Material - 4140 Steel 350 BHN Cutter dia. - 6” (301. 1 mm) Insert – TPEN-53 P 12 R G-935 Speed - 474 SFM (145 M/Min) Feed -. 004” (0. 10 mm) per Insert WOC - 4. 5” (114 mm) DOC -. 50” (12. 7 mm) MRR - 29 Cu In / Min (475 Cu Cm/Min) Required HP - 36

Special Milling Cutters 9. 0” (228 MM) Dia. Special Switch Point Rail Milling Cutter High Speed Milling with grade GA-5125

Special Milling Cutters 9. 0” (228 MM) Dia. Special Switch Point Rail Milling Cutter High Speed Milling with grade GA-5125 Special Milling Cutter Material - Manganese Steel 400 BHN Cutter dia. – 9. 0” (229 mm) Insert – RPGN-84 GA-5125 SPGN-643 GA-5125 Speed - 500 SFM (152. 5 M/Min) Feed -. 0126” (0. 32 mm) per Insert WOC –. 75” (19 mm) DOC - Varies LOC – 39 Feet (11. 9 Meter) See customer testimonial

Special Milling Cutters A page from the customers justification report Several grades of carbide from three different manufacturers, Ingersoll, AGI / VR Wesson and Greenleaf ® have been run in these tools trying to improve performance. The best performance achieved was from Greenleaf with their GA-5125 grade carbide inserts In almost every case where a catastrophic Insert failure has occurred, we were able to replace the wedges, wedge screws and or back-up plates, and have the tool back in service in less than a couple of hours.

Special Milling Cutters Another page from the customers justification report.

Special Milling Cutters 9. 5” (241 MM) Dia. Special Rail Milling Cutter High Speed Milling with grade GA-5125

Special Milling Cutters 9. 5” (241 MM) Dia. Special Rail Milling Cutter High Speed Milling with grade GA-5125 Special Milling Cutter Material - Manganese Steel 375 BHN Cutter dia. – 9. 5” (301. 1 mm) Insert – SNGN-643 GA-5125 431884 GA-5125 431885 GA-5125 Speed - 500 SFM (152. 5 M/Min) Feed -. 0298” (0. 76 mm) per Insert to obtain. 018 (0. 46 mm) ACT WOC – 3. 5” (89 mm) DOC -. 08” (2 mm) Required HP - 48

Special Milling Cutters 25 degree Special Flair Rail Milling Cutter uses 72 inserts!

Special Milling Cutters 25 degree Special Flair Rail Milling Cutter 50% increase in speed, 90% increase in feed. Resulted in order of more geometries! Required HP - 143

Special Milling Cutters Examples of Tools for the Rail industry

Special Milling Cutters Camshaft and Crankshaft Milling

Special Milling Cutters Camshaft and Crankshaft Milling Design OD Segments 64” (1625 MM) diameter cutter

Special Milling Cutters Camshaft and Crankshaft Milling Design (120) Inserts SNGN-643 (48) Inserts RNGN-84 12 segments per cutter 168 total inserts/load

Special Milling Cutters Crankshaft Milling Cutter supplied by Greenleaf ® • Locomotive and Marine Diesel Engines • Power Generation (120) Inserts SNGN-643 • Automotive (48) Inserts RNGN-84

Special Milling Cutters Camshaft and Crankshaft Milling Customers' existing Cutter

Special Milling Cutters Crankshaft Milling Cutter supplied by Greenleaf ® Segments allow inexpensive repairs Qualified mounting allows you to replace one segment or all 3. 425 (87 MM) Width of Cut 22. 44” (570 MM) I. D.

Special Milling Cutters Camshaft and Crankshaft Milling Design ID Segments 8 Segments per cutter 64 inserts total/cutter load

Special Milling Cutters Crankshaft Milling Cutter supplied by Greenleaf ® Cam Shaft Mill Cutter Dia: 16. 0” (406. 4 mm) Cutting width: . 81” (20. 6 mm) 72 Total Inserts, (24) Effective

Special Milling Cutters 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

Cutter Repair We refurbish and repair damaged Greenleaf ® special Tooling.

Special 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.

Questions?

Greenleaf Carbide Grades for Milling ® 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 ® UNCOATED G-53 General Purpose Milling Steel and Steel Alloys Good Toughness and Wear Resistance High Shear, Powermill G-60 Finish Milling Grade for Steels Finish Wiper Inserts Powermill

Greenleaf Carbide Grades for Milling ® MT-CVD COATED GA-5036 High Performance Steel Milling Heavy or Light Duty at High Speed Hushcut, High Shear, Powermill, Screw-on, Excelerator GA-5125 High Performance Manganese Steel Milling Grade High Speeds and Moderate Feeds Special Applications

Greenleaf Carbide Grades for Milling ® MT-CVD COATED GA-5040 Tough Grade for Milling most Materials Severe Applications, Low Speeds Hushcut, High Shear, Powermill, Screw-on, Excelerator GA-5023 High Performance Cast Iron Milling Special Applications

Greenleaf Carbide Grades for Milling ® PVD COATED G-910 G-915 G-935 High Temp Alloys, Primarily Titanium at Moderate Speeds High Shear High Temps, Stainless & Carbon Steels at Moderate Speeds Tough, Abrasion Resistant Hushcut, High Shear, Screw-on, Excelerator Tough, Higher Speed Steel Milling Screw-on

Greenleaf Carbide Grades for Milling ® PVD COATED G-955 Rough Steel Forgings, tool steels. Tough, High speed steel Milling Special Applications G-9120 Tough, Higher Speed Steel Milling Rough Steel Forgings, tool steels Improvement over G 955 in most apps Special Applications

Questions?

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