Milling inserts and grades for steel
Find your CVD- and PVD-coated carbide grades and uncoated cermets optimized for steel.
Tool life, CoroMill® 345
Tool life increase
| Component: | Mounting plate |
| Material: | P1.1.Z.AN (S355 JOWP), 170 HB |
| Operation: | Face milling |
| Machine: | WBK (ISO 50) |
Result: By changing to grade GC1230, we achieved a 42% increase in the tool life. Additionally, the cutting data can be increased to reduce the energy consumption while maintaining the same tool life as GC1130.
Sustainability proposition: Decrease energy consumption and CO2 emissions by increasing vc by 37% (vc 313 m/min (1027 ft/min)) for the same tool life as GC1130.
| GC1130 | GC1230 | |
| Tool | 345-125Q40-13M | 345-125Q40-13M |
| Insert | 345-1305M-PM GC1130 | 345-1305M-PM GC1230 |
| DCX, mm (inch) / zn | 125 (5.0) / 8 | 125 (5.0) / 8 |
| vc, m/min (ft/min) | 228 (748) | 228 (748) |
| fz, mm/z (in/z) | 0.095 (.004) | 0.095 (.004) |
| ap, mm (inch) / ae | 2.0 (.078) / 80% | 2.0 (.078) / 80% |
| Coolant | Dry | Dry |
| Tool life, min | 93 | 132 |
| No. of components | 7 | 10 |
Tool life, CoroMill® 210
Tool life increase
| Component: | Billet, 130×108×70 mm (5.12×4.25×2.76 inch) |
| Material: | P1.2.Z.AN (C45) 207 HB |
| Operation: | Face milling |
| Machine: | DMG Mori – NHX 4000 (ISO 50) |
Result: By changing to grade GC1230, we achieved a remarkable 62% increase in the tool life. In addition, the cutting data can be increased to reduce energy consumption while maintaining the same tool life as GC1130 without compromising security.
Sustainability proposition: Decrease energy consumption and CO2 emissions by increasing vc by 29% (vc 313 m/min (1027 ft/min)) for the same tool life as GC1130 and advocate DRY milling.
| GC1130 | GC1230 | |
| Tool | R210-032A25-09H | R210-032A25-09H |
| Insert | R210-090414E-PM GC1130 | R210-090414E-PM GC1230 |
| DCX, mm (inch) / zn | 32 (1.25) / 3 | 32 (1.25) / 3 |
| vc, m/min (ft/min) | 242 (793) | 242 (793) |
| fz, mm/z (in/z) | 0.25 (.010) | 0.25 (.010) |
| ap, mm (inch) / ae | 1.0 (.043) / 100% | 1.0 (.043) / 100% |
| Coolant | Wet (emulsion) | Wet (emulsion) |
| Tool life, min | 22 | 35 |
| No. of components | 8 | 13 |
Performance
Customer case CoroMill® 490 with size 14 inserts
Tool life increase
| Component: | Fixture |
| Material: | Unalloyed steel P1.2.Z.AN (CMC 01.2) |
| Operation: | Face milling |
| Machine: | Mori Seiki NH4000DCG |
| GC4230 | GC4330 | |
| Tool | 490-080Q27-14M | 490-080Q27-14M |
| Insert | 490R-140408M-PM | 490R-140408M-PM |
| zn | 6 | 6 |
| n, rpm | 900 | 900 |
| vc, m/min (ft/min) | 226 (741) | 226 (741) |
| vf, mm/min (in/min) | 1000 (39.3) | 1000 (39.3) |
| fz, mm/z (in/z) | 0.19 (0.007) | 0.19 (0.007) |
| ap, mm (inch) | 2 (0.079) | 2 (0.079) |
| ae, mm (inch) | 70 (2.75) | 70 (2.75) |
| Tool life (components) | 32 | 45 |
| Surface roughness criteria reached |
Performance
Customer case CoroMill® 331
| Component: | Screw blank |
| Material: | High-alloy steel P3.0.Z.AN (CMC 03.11) |
| Operation: | Slitting/grooving |
| Machine: | Mori Seiki machining center |
| GC4230 | GC4330 | |
| Tool | R331.32-127R32EM0.394 | R331.32-127R32EM0.394 |
| Insert | N331.1A-08 45 08M-PM | N331.1A-08 45 08M-PM |
| zn | 10 | 10 |
| n, rpm | 246 | 246 |
| vc, m/min (ft/min) | 98 (322) | 98 (322) |
| vf, mm/min (in/min) | 156 (6.15) | 156 (6.15) |
| fz, mm/z (in/z) | 0.127 (0.005) | 0.127 (0.005) |
| ap, mm (inch) | 10 (0.394) | 10 (0.394) |
| ae, mm (inch) | 12.7 (0.5) | 12.7 (0.5) |
| Tool life (components) | 40 | 40 |
| Stopped at same number of components |
Performance
Customer case CoroMill® 345
Tool life increase
| Component: | Pipe plate |
| Material: | Low-alloy steel P2.2.Z.AN (CMC 02.1), flame cut |
| Operation: | Face milling |
| Machine: | BFW |
| GC4240 | GC4340 | |
| Tool | 345-100Q32-13M | 345-100Q32-13M |
| Insert | 345R-1305M-PM | 345R-1305M-PM |
| zn | 7 | 7 |
| n, rpm | 556 | 556 |
| vc, m/min (ft/min) | 188 (617) | 188 (617) |
| vf, mm/min (in/min) | 1944 (76.5) | 1944 (76.5) |
| fz, mm/z (in/z) | 0.5 (0.019) | 0.5 (0.019) |
| ap, mm (inch) | 4 (0.157) | 4 (0.157) |
| ae, mm (inch) | 70 (2.76) | 70 (2.76) |
| MRR cm3/min (in3/min) | 544 (33.2) | 544 (33.2) |
| Tool life (min) | 20 | 26 |
Performance
CoroMill® 390 with size 07 inserts
Tool life increase
| Component | Die and mould |
| Workpiece material | P2.5.Z.HT |
| Operation | Slot and pocket milling |
To achieve acceptable component quality, maximum cutting depth was restricted in this application. After switching to CoroMill® 390 cutter with size 07 inserts, the cutting depth could be increased, generating higher productivity. With GC1130 inserts the tool life was improved by 47%, significantly reducing cost per component.
| GC1130 | Existing solution | |
| Tool | R390-012A12-07M | |
| Insert | 390R-070204M-PM 1130 | |
| zn | 3 | 3 |
| n rpm | 4005 | 3979 |
| vc m/min (ft/min) | 151 (495) | 150 (492) |
| vf mm/min (in/min) | 853 (33.583) | 900 (35.433) |
| fz mm (inch) | 0.07 (0.003) | 0.075 (0.003) |
| ap mm (inch) | 1.5 (0.059) | 1 (0.039) |
| ae mm (inch) | 12 (0.472) | 12 (0.472) |
| Result | Tool life 44 minutes | Tool life 30 minutes |
Performance
Slot and shoulder milling with long overhang
Tool life increase
| Component | Rear spindle |
| Workpiece material | P2.5.Z.HT |
| Operation | Slot and shoulder milling |
Unstable conditions with long overhang, combined with a forged surface and coolant, were causing some challenges for the insert tool life in this application. Surface quality issues, caused by flaking of the coating, set the limitation on insert tool life. By exchanging the existing solution with GC1130 inserts, flaking was significantly reduced and 57% more components could be machined.
| GC1130 | Existing solution | |
| Tool | R390-020A20-11M | |
| Insert | R390-11 T3 08M-PM 1130 | |
| zn | 3 | 3 |
| n rpm | 2400 | 2400 |
| vc m/min (ft/min) | 151 (495) | 151 (495) |
| vf mm/min (in/min) | 864 (34.016) | 864 (34.016) |
| fz mm (inch) | 0.12 (0.005) | 0.12 (0.005) |
| ap mm (inch) | 3.5 (0.138) | 3.5 (0.138) |
| ae mm (inch) | 20 (0.787) | 20 (0.787) |
| Result | Tool life 440 components | Tool life 280 components |
Performance
Shoulder milling in unalloyed steel
| Component | Plate, General Engineering |
| Workpiece material | P1.1.Z.AN |
| Operation | Shoulder milling |
Thermal cracks and flaking were causing short insert tool life. Inserts in grade GC1130 were introduced to tackle the problem. Conducted tests have shown that these inserts lasted much longer with a lot less wear than the existing solution, resulting in reduced costs and improved security.
| GC1130 | Existing solution | |
| Tool | 490-044C4-08H | |
| Insert | 490R-08T308M-PM 1130 | |
| zn | 6 | 6 |
| n rpm | 1912 | 1912 |
| vc m/min (ft/min) | 264 (866) | 264 (866) |
| vf mm/min (in/min) | 1722 (67.795) | 1722 (67.795) |
| fz mm (inch) | 0.15 (0.006) | 0.15 (0.006) |
| ap mm (inch) | 1.5 (0.059) | 1.5 (0.059) |
| ae mm (inch) | 22 (0.866) | 22 (0.866) |
| Result | Not worn out after 42 minutes | Tool life 42 minutes |
Performance
Face milling of connecting rod
Tool life increase
In this application the currently used insert was worn out after 27 minutes. Thermal cracks and chipping of the insert caused bad surface quality and could result in potential insert breakage. In order to tackle the challenge, GC1130 inserts were tested, reaching 100% longer tool life and improved production economy.
| GC1130 | Existing solution | |
| Tool | R390-032A32-17L | |
| Insert | R390-17 04 31M-PM 1130 | |
| zn | 2 | 2 |
| n rpm | 2636 | 2636 |
| vc m/min (ft/min) | 265 (869) | 265 (869) |
| vf mm/min (in/min) | 791 (31.142) | 791 (31.142) |
| fz mm (inch) | 0.15 (0.006) | 0.15 (0.006) |
| ap mm (inch) | 5 (0.197) | 5 (0.197) |
| ae mm (inch) | 26 (1.024) | 26 (1.024) |
| Result | Worn out after 54 minutes | Worn out after 27 minutes |
Join us. Stay updated.
Sign up for our newsletter today
