CoroMill® 390
Versatile shoulder milling cutters with ramping capability for mixed production
Performance: Lightweight CoroMill® 390 produced with additive manufacturing
A small reduction in distance and mass between the cutting edges and the Silent Tools™ damper enables an increased depth of cut, and in doing so, a significant productivity increase when working with long overhangs.
+200%
INCREASED PRODUCTIVITY
| Workpiece material | P2.5.Z.HT, hardness 290 HB | |
| Operation | Face milling with large radial cutter engagements (80–100% of cutter diameter) | |
| Machine | OKUMA MA550-VB | |
| Adapter | C5-Q22D-048-220 | |
| Conventional CoroMill® 390 | Lightweight CoroMill® 390 | |
| Tool material | Steel | Titanium alloy |
| Tool diameter, mm | 50 | 50 |
| Weight, g (oz) | 317 (11.2) | 66 (2.33) |
| Insert | R390-11T308M-PM 1130 | R390-11T308M-PM 1130 |
| zn | 3 | 3 |
| n rpm | 1,273 | 1,273 |
| vc m/min (ft/min) | 200 (656) | 200 (656) |
| vf mm/min (in/min) | 573 (22.6) | 573 (22.6) |
| fz mm/z (in/z) | 0.15 (0.006) | 0.15 (0.006) |
| ap mm (inch) | 1.5 (0.059) | 4.5 (0.177) |
| ae mm (inch) | 50 (1.97) | 50 (1.97) |
| MRR cm3/min (in3/min) | 43 (2.62) | 129 (7.87) |
| Result: 200% increased productivity |
Performance: Slot milling in steel
A subcontractor’s productivity was limited by its end mill, as the two-insert
cutter could only manage a 2 mm (0.079 inch) cutting depth. After switching to a CoroMill® 390 cutter with three size 07 inserts, the cutting depth could be increased to 3 mm (0.118 inch). As a bonus, the burr formation caused by the previous tool was nowhere to be seen when milling with the new cutter. The overall verdict: a double win for CoroMill® 390, with increased productivity and tool life.
+225%
PRODUCTIVITY
| Operation | Slot milling | |
| Tool | R390-012A12-07M | Existing solution |
| Insert | 390R-070204M-PM 1130 | |
| vc m/min (ft/min) | 200 (656.166) | 150 (492.125) |
| vf mm/min (in/min) | 900 (35.433) | 600 (23.622) |
| hex mm (inch) | 0.1 (0.004) | 0.1 (0.004) |
| ap mm (inch) | 3 (1.118) | 2 (0.079) |
| ae mm (inch) | 12 (0.472) | 12 (0.472) |
| Result | ||
| Time in cut, min | 3.76 | 5.5 |
Performance: CoroMill® 390 with size 07 inserts
To achieve acceptable component quality, maximum cutting depth was restricted in this application. After switching to the 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.
+47%
TOOL LIFE
| Workpiece material | P2.5.Z.HT | |
| Operation | Slot and pocket milling | |
| GC1130 | Existing solution | |
| Tool | R390-012A12-07M | |
| Insert | 390R-070204M-PM 1130 | |
| zn | 3 | 3 |
| n rpm | 4,005 | 3,979 |
| 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 | 30 minutes |
Performance: Slot and shoulder milling with long overhangs
Unstable conditions with long overhangs, 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, limited insert tool life. By exchanging the existing solution with GC1130 inserts, flaking was significantly reduced and 57% more components could be machined.
+57%
TOOL LIFE
| Workpiece material | P2.5.Z.HT | |
| Operation | Slot and pocket milling | |
| GC1130 | Existing solution | |
| Tool | R390-020A20-11M | |
| Insert | R390-11 T3 08M-PM 1130 | |
| zn | 3 | 3 |
| n rpm | 2,400 | 2,400 |
| 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 | 280 components |
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