General Cutting Tools is an authorized Ingersoll Cutting Tools distributor. We are based in Chicago serving Illinois, Wisconsin and Indiana and ship nationwide as well as around the world. Contact us for more information.

SERIES: 12Y1N_D, 12Y1S_D, 12Y1U_D

Series Features:

Ingersoll Rapid Thread Mill

• Insert length: 21mm, 30mm, 40mm
• Available for both 4 and 5 insert style holders
• Used for large diameters, long threads and long overhangs
• Standard inserts are suitable for multi-insert tools
• All inserts have the same profile position
• Bodies can be mounted on standard Shell Mill adapters
• One tool for external and internal right and left hand threads

Diameters:
2.480″, 3.150″, 3.940″

Insert Sizes:
21mm (0.827), 30mm (1.181), 40mm (1.575)

Thread Form:
ISO, UN, NPT, NPTF, BSPT, W

Applications:
Internal and External Thread Milling

Materials:
Cast Iron, Steel, Stainless Steel, Aluminum, Titanium and other high temperature or nickel-based alloys.

For turning in stainless steel and exotic alloys.

Ingersoll previously introduced two new chipbreakers for machining stainless steels and exotic materials: The EA chipbreaker for finish to semi-finish operations in low depths of cut, and the ET chipbreaker for rough machining of these materials. The new EM chipbreaker is designed for medium applications where customers desire a single insert that encompasses many of the same features offered by the EA and ET.

The EM chipbreaker features a sharp land that reduces machining load during medium machining applications, while simultaneously reducing build up material on the cutting edge. The design also includes a broad boss face that dissipates heat on the upper side of the chipbreaker, improving the surface contact ratio while maximizing tool life. The result is an insert that provides stable performance in difficult to machine materials over a wide range of feed rates and cutting depths.

Insert Styles:
CNMG
DNMG
SNMG
TNMG
VNMG
WNMG

Grades:
TT9215
TT9225
TT9235
TT5030
TT9080

Feed Rates:
.005~.024 ipr (0.13~0.60 mm/rev)

Cutting Depths:
.020~.315 inches (0.5~8.0 mm)

Applications:
• General purpose & medium turning applications in stainless steel and exotic alloys
• Medium machining operations where lower cutting forces are needed

General Cutting Tools is an authorized Ingersoll Cutting Tools distributor.  Contact us today for a quote.
info@generalcuttingtools.com
(847) 677-8770

Most cutting tool manufacturers design and produce single-sided ISO turning inserts in order to provide high levels of strength and toughness in heavy turning applications. Ingersoll has developed a new concept that utilizes the otherwise useless underside of these single-sided inserts for finish turning capacity. The result is the T-FORCE product line that combines a heavy roughing insert with a finishing insert.

The new concept of double-sided inserts utilizes our most aggressive chip breaker geometry types such as the HT, HY, and HZ for 80 degree CNMD and 90 degree SNMD inserts for heavy rough machining. Also new is the HD roughing chip breaker, which is designed to protect the insert with a smooth chip-breaking action when machining deeply stepped parts such as shafts. The underside of all these inserts contains a common style, finishing chip breaker that allows each insert to be used in the same holder, under different operating conditions, for final finishing passes on large work pieces.

This new product summarizes the Ingersoll spirit that never stops developing innovative new products to improve cost reduction solutions to its customers.

Insert Styles:
CNMD646
CNMD866
SNMD646
SNMD866

Chipbreakers:
HD (new)
HT
HY
HZ

Holders:
Compatible with all ISO standard turning holders

Feed Rates:
Upper Side: .014~.059 ipr
(0.35~1.5mm/rev)
Under Side: .016~.032 ipr
(0.4~0.8mm/rev)
Cutting Depths:
Upper Side: .160~.590 inches
(4.0~15.0mm)
Under Side: .120~.200 inches

(3.0~5.0mm)

Grades:
TT8115 TT8125

Applications:
Heavy duty machining applications
Ideal for large diameter shafts and vertical turret lathes.

FEATURES
• Utilizes both sides to improve economy & cost reduction
• Offers a variety of sizes and chip breakers to meet customers specific heavy rough machining requirements
• Economy is further improved by using one tool holder for rough to finish machining.

The upper-side of the double sided insert can be used in the same manner as a single-sided insert.
The under-side can then be used when finish machining is required.

The precision bodies have an improved pocket design and innovative clamping system that provide stable performance after multiple tip indexes. These drill bodies also feature twisted coolant holes, polished flutes, and a PVD-coating that allows smooth chip evacuation and prolonged body life. Each body accepts a range of tips that covers .040” (1mm).

The drill tips are offered in grade IN2505 which features a multi layered PVD coating that provides excellent performance, improved wear resistance and increased tool life in a large variety of applications. The initial cutting edge geometry is designed for Steel applications. Additional cutting edge geometries for Stainless Steel, Cast Iron and Non-Ferrous materials will be available at a later date.

Ingersoll’s Gold-Twist Drilling Line is excellent in higher speed applications, providing guaranteed performance and excellent results in a unique, rigid and fast-indexing clamping system. The result is a product that combines cost efficiency and higher productivity in all your drilling applications.

Tip Geometry: TPA-Steel Geometry

Bodies:

• 3xD
• 5xD
• 8xD

Grade: IN2505

Applications:

• Die & Mold
• General Purpose
• Aero Space
• Automotive
• Shipbuilding
• Heat Exchangers

DRILL BODY COMPARISON: GOLD TWIST VS. QWIK TWIST
The new Gold Twist pocket design’s contact/clamping area is three times deeper than our current Qwik Twist drill. The accuracy of the added cylinder to the clamping area improves rigidity and helps reduce internal stresses. The two precision ground positive stop locations improve the drilling tips’ position and support.

General Cutting Tools is an authorized Ingersoll Cutting Tools Distributor. For more information about Gold-Twist, Qwik-Twist or any other Ingersoll product, please contact us.

Contact us to learn more about how General Cutting Tools can save you money by sharpening and reconditioning your used tooling.

General Cutting Tools is an authorized Ingersoll Cutting Tools distributor.

We serve Illinois, Indiana, Wisconsin, Michigan, Iowa and ship the rest of the United States.

Contact us to learn more about how you can save money by sharpening and reconditioning your used tooling with General Cutting Tools.

General Cutting Tools is an authorized Ingersoll representative. We ship to Illinois, Indiana, Wisconsin, Michigan, Iowa and the rest of the United States.

The combination of true 0º lead angle and a wiper flat combined on the same insert design is a relatively new feature for Ingersoll’s Maxline family of face mills. The only other standard product line that combines these two features today in the Maxline family is the long edged VMAX inserts (NNE324R/L109). Due to their size, these VMAX inserts are not capable of the same axial depth of cut and feedrate as the new 18 MM SMAX inserts. Traditionally, this combination of true 0º lead angle combined with wiper flats has been featured in the Hi-Positive insert lines of Ingersoll and our competition. The new 4 edged 18 MM SMAX insert will allow our Maxline product to offer an alternative for shoulder milling applications where large 2 index Hi-Positive inserts have historically been used.

The 45º lead angle face mill provides potential for even higher chip thicknesses than the 0º lead angle series. As with any 45º face mill the effective chip thickness is only 71% (chip thinning) of the calculated chip thickness at the centerline of the tool. The potential for higher feedrates and reduced radial cutting pressures result. Lead angle face mills also improve heat dissipation and reduce the rate of tool wear, both by spreading the work of chip creation along a longer section of carbide when compared to 0º lead face mills at the same axial depth of cut. Another advantage of lead angle face mills is that entering and exiting of the work piece is “softened” because the entire leading edge of the insert does not contact the work piece simultaneously, as the top of the insert enters the cut first.

Advantages:

The figures below further explain some of the technical advantages of the new SMAX face mill product compared to older Maxline product; as well as much of our competition. For the purposes of this comparison we will compare the new SMAX 18 MM face milling insert to CDE style inserts that Ingersoll Cutting Tools originally developed, and are an industry standard today.

SMAX leading edge image

It is clear from the above figures that the wiper flat on the end of the SMAX 18 MM insert is a significant design enhancement for the Maxline product line. This new face mill series allows us to give our customers the combination of “tangential” insert orientation strength, true square shoulders when necessary, and the consistent finishes that result from a ground wiper flat on the inserts.

Ingersoll SMAX Pocket

As with any indexable face mill designed specifically for heavy duty applications, the ability of the cutter body to adequately locate and hold the inserts in place is of primary concern. The design of the new SMAX insert allows our pocket to trap the insert in the correct location, and in a secure “dovetail” configuration that eliminates some of the holding stress on the insert screw. Most positive geometry inserts in the market today rely on holding the insert in a pocket with obtuse angles between the bottom of the insert and the rake face or flank face, depending on the insert design. A design with obtuse pocket angles allows a percentage of the cutting force on the leading edge of the insert, to be transferred to lifting the back of the insert out of the pocket. Typically, the insert screw has sufficient axial strength to deep the insert in the correct position, but over time the insert screw can become fatigued and may lead to failure. However, when using the SMAX pocket design, the higher the cutting force on the leading edge of the insert, the more force that is translated into holding the back of the insert down and into the locating corner where it belongs. To explain this SMAX pocket feature see the above figures. Also note that when using the SMAX insert design, the bottom of the insert that sits against the pocket is as wide as the top of the insert. This wide insert bottom provides better stability as a larger bearing surface between cutter and insert is achieved. Most positive geometry inserts in the market do not offer this feature, whether “tangential” (like the CDE example shown), or “conventional” (like a positive square SEKT or similar).

Both the 0º and the 45º lead angle cutter bodies feature differential radial spacing between insert pockets. This variable angle allows unequal insert spacing around the circumference of the cutter. The unequal spacing of insert pockets is helpful in dampening harmonic vibrations that can be otherwise present in the milling system.

Metric face mills using the SMAX 18 MM will also be available from our Ingersoll Germany division in the first half of 2005; for applications where metric diameters or adaptations are necessary.

Competitive Information:

There is significant competition for rough milling and one-cut applications. This type of face milling has been a strength for Ingersoll since the first tangential insert designs were used decades ago. Below is a table, divided by lead angle, showing some of our competitors’ cutter series. The table identifies only clear advantages the SMAX product family has over each competitor cutter and does not include an “X” where performance levels are similar and would typically be proven through customer testing.

In general, the primary performance advantages of the 18 MM SMAX face mill family is the size of the insert (large depths of cut), the surface finishes than can be created, and the free cutting molded rake face of the insert to reduce power consumption. Use these advantages to your benefit when promoting the SMAX family over our competition, and use the size and strength of the inserts to over power the feedrate capabilities of our competitors smaller inserts when testing on the customers’ spindle.

Carbide Grade Information:

The introduction of the 18 MM SMAX face mill line will include four standard insert grades.

Grades IN2015, IN2040, IN1530 and IN2005 will be the grade options for standard face mill inserts.

The intended applications are as follows: (Also refer to the Maxline catalog)

• IN2015: Grey, Ductile, and Nodular Irons.
• IN2040: Carbon Steels with good work piece rigidity. Dry only.
• IN2005: Hi-Temp Alloys and Inconel
• IN1530: Stainless Steel, Titanium, Carbon Steels with poor work piece rigidity. Wet or dry.

Hardware and Components:

All of the standard 18 MM SMAX inserts for the 0º and 45º lead angle face mills use insert screw SE03-70. This insert screw features a strong M5 thread and is tightened with a Torx-20 driver. Spare screwdrivers are available, and can be ordered as part number DS-0034. The insert screws should be torqued to 35-40 inch/lbs. There is no other hardware to replace or maintain in the standard face mills.

Maintenance:

Maintenance of this face mill family is similar to any indexable face mill design. The fixed pocket design and tangential style of insert screw location minimize the necessary spare part inventory and related maintenance. For repeatable performance, the cutter pockets should be wiped clean during indexing, and the insert screws periodically replaced. Accurate projections of insert screw life are difficult to state, as insert screw life is dependent on consistently applying the recommended torque when indexing, as well as the degree of abuse that the milling system encounters during operation.

Operating Parameters:

The suggested operating parameters see the table below. The parameters are suggested starting ranges; and the optimum spindle RPM and feedrate will be dependent on the actual milling system rigidity, type of coolant used, depths of cut, etc. Remember to consider radial chip thinning when applying feedrates to the 45º lead face mills. Chip thinning will be compounded when considering applications with low percentages of radial engagement coupled with the 71% thinning factor of the 45º lead angle cutter series. Use these thinning factors to your advantage when feedrates of previously applied tooling have not been properly adjusted. As with most Maxline cutter designs, the 18MM SMAX face mills have not been designed for helical interpolation or ramping applications. A constant “Z plane” circular interpolation is acceptable.

Modified Standards & Specials:

We are anticipating high quantities of modified standard and special cutters to be quoted and manufactured using the 18 MM SMAX inserts. The product worksheets located in the back of the Maxline catalog have been included in that literature for the purposes of making things easier in communicating the necessary design parameters to our quotation department. Modified standards and specials using the 18 MM SMAX insert should be no smaller than 3.00” in diameter. To qualify as a modified standard, the cutter requested shall be no larger than 14.000” in diameter. Modified standards will also be fixed pocket face mills only. The diameter tolerance will be +/- .010” and the overall extension length tolerance will be +/- .005”. Some adjustments to these modified standard rules may be allowed, for example, a cutter with extension length tolerance +/- .003” is possible but the feature will carry additional delivery lead time and pricing adders that will be determined by the quotation department. The expected lead time for modified standard face mills below 5.00” in diameter should be 6 weeks. The expected lead time for modified standard face mills at 5.00”diameter and above should be 8 weeks. Approval drawings will add one week to the expected delivery. Not only are modified standard and special face mills available for quotation, but special inserts may also be quoted. We have the ability to grind radii or chamfers ranging from .031” to .125” on the 18 MM face mill inserts without effecting the number of insert indexes. The wiper flat on the end of the insert also allows the effective length of the tool to remain constant throughout the entire corner radius range of the insert.

Ingersoll’s series 45D…RP solid carbide roughing endmills give you the optimal solution for all roughing operations. This series covers a wide range of applications including slotting, pocketing, helical interpolation and contouring.

Features and Benefits

• 4- and 5-flutes with 38° and large corner radii
• An end mill that provides the highest advantage in cavity milling and heavy roughing cuts
• The serrated cutting edge features fl at peaks which leave a better surface finish when compared to competitors’ roughing endmills

Tool Diameter Range: 0.250″ – 0.750″
Number of Flutes: 4 and 5
Overall Length Range: 2.50″ – 4.00″
Helix Angle: 38°
Corner: 0.050″ – 0.150″
Grade: IN2005

Ingersoll 3n1 end mills

ADVANTAGES:

This cutter is able to eliminate the need for grinding operations in many cases. Surface finishes of 32 microinches or less are very achievable. The insert has a parallelogram as compared to the former rectangular design. This allows closer cutting to a shoulder when this type of feature exists on the work piece. It is also more positive radially to make the cut more cleanly than before. The highest point of the insert is at the center of the insert. The drop from the highest point of the insert to the lower point on the face of the insert is .0003 inches on both the large and small insert. This acts like an extremely shallow lead angle and allows you to take up to .080 advances per tooth per revolution. The chip load you finally achieve is ultimately a function on what you are trying to achieve for surface finish and flatness. The OVERALL DIAMETER is .49″ larger on the YXM324 inserts and .70″ larger on the YXM434 inserts when compared to the effective finishing diameter. This difference is smaller than the older 7F2K series tools.

Surface finish is measured in many ways, either by comparison “scratch pad” specimen standards for rougher finishes, or by profilometers used to measure finely machined surfaces. Surface finishes can be described in terms of Ra, Rq and others, but these are simply different methods used to measure the deviation of the actual surface from the nominal surface. The deviation can be measured in terms of microinches or micrometers. It is important to know which one you are using. Microinches are one millionth of an inch (.000 001 inch) and micrometers are one millionth of a meter (.000 001 meter). Another term for micrometers is microns. One microinch = .0254 micrometer. Profilometers do not measure flatness, they simply look for surface irregularities as compared to the nominal surface. Flatness can be measured with a CMM or a dial indicator once a plane of reference is established.

CARBIDE INSERTS:

There are TWO different sizes of STOCK carbide inserts used in the Ingersoll S-MAX Finish Face Mills.

The larger insert is the YXM434 size which is 18mm (.708″) long, fitting into the SF6N series.

The smaller insert is the YXM324 size which is 10.50 mm (.400″) long, fitting into the SN6H series.

IN1505: Alloyed, Low and Med Carbon, and Tool Steels, Titanium, Hi-Temp Nickel Alloys, Stainless Steels, Aluminum

IN1540: Alloyed, Low and Med Carbon, and Tool Steels, Stainless Steels

IN1510: Gray Cast, Ductile and Nodular Irons, Aluminum

CUTTER BODIES & HARDWARE:

There are no pins in this design, or other hardware items to be concerned with, other than the insert screws. There are two different types of screws used in the face mills. The smaller YXM324 insert uses SM40-120-20 (DS-T20T) screws and a T15 Torx bit driver Tx-15 (DS-T15T). These screws should be tightened to 30-35 inch pounds. The larger YXM434 insert uses SM50-160-10 (SE03-70) screws and a T20 Torx bit driver Tx-20 (DS-0034). Screws should be tightened to 35-40 inch pounds.

OPERATING GUIDELINES:

For this group of cutters, the speed can be higher than you are accustom to for a given material. Generally, a higher speed will yield a shinier, more reflective finish. A slower speed will give a more brushed finish. Although you may be able to accomplish single digit micro-inch finishes with a fully loaded cutter, if an extremely good finish is required, one option you could try is to fly cut. This method uses only one insert in the cutter and thus reduces runout to zero. Also, if there are issues with steps between passes at the same Z depth, a fly cut will reduce the pressures to a minimum. This problem may be more noticeable when the material is softer, and is a function of a machine tool which may be deflecting more than it should. Lighter feed rates generally leave better finishes, but not loading up the cutter properly will create drag and rubbing as opposed to clean cutting. If there is a difference between the larger and smaller inserts, the larger one could a get better finish because it thins the chip over a longer distance, but may result in higher axial pressure.

Coolant may help you get a better finish by providing lubricity to the operation. It is not necessarily recommended in terms of tool life gains, however in trying to gain improved surface finishes, you may find a situation where it gains you just enough improvement to keep this cutter on the spindle.

The following guidelines are correct, but updated from those on page M493 in the Super Catalog. The original guidelines were printed incorrectly.

MAINTENANCE:

Maintenance is very similar to any indexable milling cutter. Cleanliness is essential to proper function and seating of the insert in the cutter pocket. Wiping, brushing, or compressed air blasts are all proven methods of cleaning the inserts and cutter pockets. Indexing a cutter in a well lit area also helps identify any foreign materials which might interfere with the fit between the insert and the cutter. Using a .001” feeler shim stock between the seating surfaces of the carbide and steel body, help to reassure the user of a properly seated insert.

Insert screws should be replaced periodically. The exact timing depends on what type of cutting is done and how well the screws are consistently torqued during insert indexing. If the countersink under the heads looks worn and smeared, and the screw seems to have less holding power than a new screw, it should be replaced.

LITERATURE:

SMAX Finishing Face mills are listed in the SuperCatalog on page M260 and M261.

The catalog pages in this announcement are updated with correct information and supercede the data in the SuperCatalog.

General Cutting Tools is an authorized Ingersoll Cutting Tools distributor.

For more information about these products or any others in the Ingersoll product line, call 847-677-8770.

Ingersoll announces Evo-Tec, the next generation in their MAXline family! A dynamic combination of strength and stability lift chip control to a new level. Longer tool life results from a larger insert seating surface plus a stronger cutting edge.

The multi-purpose insert works well in all materials, its primary land, dramatically improving cutting edge strength. 4-edged inserts offer an economical advantage over the 2-edged competition and a DOC capability of up to .420″. Available corner radii are .031″, .062″, .093″, & .125″r. Cutter diameters range from 1.250″ thru 4.00″ and coolant/air through the tool is available. Medium and High Density versions are also available.

General Cutting Tools is an authorized distributor for  Ingersoll Cutting tools in Chicago.

We carry a full line of tools to choose from.  Contact us for more information or for a quote.

(847) 677-8770 or info@generalcuttingtools.com