Karan Industries

Category

U-Series Application

Increase Productivity and Surface Finish

The U-Series end mill’s high strength design allows it to run at higher feed rates than conventional end mills in hard materials, and increased metal removal rates mean higher productivity.
One customer was haing difficulty meeting surface finish and job deadlines on a milling application in D2 steel hardened to 60 Hrc. The thick core and strong cutting edge design of the U-Series.

Use the advanced tool geometry of our U-Series end mill for high performance milling of hard, difficult to machine materials. this high strength tool is engineered to give great surface finishes at light to medium cuts at high speeds in a variety of difficult to machine alloys.This tool is coated with a thick ALCRONA coating for longer tool life and can run dry in many materials.

TYPES OF MILLING PROCEDURES

Work Material	Type of Cut	Axial DOC	Radial DOC	No. of Flutes	Speed (M/min)	Feed (MM Per Tooth)
Work Material	Type of Cut	Axial DOC	Radial DOC	No. of Flutes	Speed (M/min)	3,0	6,0	9,0	12,0	16,0	19,0	25,0
Titanium Alloys	Slotting Rough Finish	.25 x D 1 x D 1.5 x D	1 x D .25 x D .01 x D	6 6 6	69 76 107	.0051 .0076 .0127	.0127 .0132 .0254	.0178 .0229 .0381	.0254 .0330 .0508	.0330 .0406 .0635	.0406 .0508 .0762	.0508 .0660 .1016
High Temperature Alloys, iconel, Haynes, Stellite, Hastalloy, waspalloy	Slotting Rough Finish	.25 x D 1 x D 1.5 x D	1 x D .25 x D .01 x D	6 6 6	21 29 34	.0076 .0102 .0127	.0178 .0229 .0229	.0279 .0330 .0356	.0356 .0432 .0483	.0432 .0559 .0584	.0559 .0660 .0711	.0711 .0864 .0965
Carbon & Tool Steels< 38 Rc	Slotting Rough Finish HSM	.5 x D 1 x D 1.5 x D .1 x D	1 x D .5 x D .01 x D .1 x D	6 6 6 6	84 99 122 244	.0076 .0127 .0152 .0381	.0178 .0254 .0305 .0762	.0254 .0381 .0457 .1143	.0381 .0508 .0635 .1524	.0483 .0635 .0787 .1905	.0610 .0762 .0940 .2286	.0762 .1016 .1270 .3048
Carbon & Tool Steels 39 Rc to 48 Rc	Slotting Rough Finish HSM	.5 x D 1 x D 1.5 x D .1 x D	1 x D .5 x D .01 x D .1 x D	6 6 6 6	61 76 99 183	.0051 .0102 .0102 .0279	.0127 .0178 .0229 .0559	.0178 .0279 .0330 .0838	.0254 .0381 .0457 .1143	.0330 .0483 .0559 .1422	.0406 .0610 .0686 .1727	.0508 .0762 .0914 .2286
Carbon & Tool Steels 49 Rc to 57 Rc	Slotting Rough Finish HSM	.25 x D 1 x D 1.5 x D .1 x D	1 x D .25 x D .01 x D .1 x D	6 6 6 6	46 61 84 152	.0051 .0076 .0076 .0152	.0127 .0178 .0178 .0305	.0178 .0279 .0279 .0432	.0254 .0381 .0381 .0584	.0305 .0457 .0457 .0711	.0381 .0559 .0559 .0864	.0508 .0762 .0762 .1168
Carbon & Tool Steels 58 Rc to 62 Rc	Slotting Rough Finish HSm	.20 x D 1 x D 1.5 x D .1 x D	1 x D .20 x D .01 x D .1 x D	6 6 6 6	14 20 30 122	.0051 .0102 .0102 .0127	.0127 .0178 .0178 .0254	.0178 .0279 .0279 .0381	.0254 .0381 .0381 .0508	.0330 .0483 .0483 .0635	.0406 .0610 .0610 .0762	.0508 .0762 .0762 .1016

End Mill Troubleshooting

Situation	Causes	Solution
Tool deflection or unequal widhts of cut	Tool size	Always select the largest poosible for the cut to be made
Poor Surface finish	Number of flutes on tool, Rigidity of set-up, Depth of cut	Increase the number of flutes, Make a secure and rigid set-up, Take a lighter cut a higher speed
Tool breakage	Set-up, Loose or worn toolholders, Tool extension	End Mills should be mounted as radially and axially true to the spindle as possible, Replace loose or owrn toolholders, Keep overhang to a minimum
Tool Life	Heat, End mill style, Improper speeds and feeds	Use a coated tool, Use tooling designed for specific materials and applications, Increase the number of flutes, Lighten Chip load, Use proper speeds for tool style and material

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Karan Industries
Plot No.357-i,Pace City-2,Sector-37,Near BSNL Telephone Exchange,Gurgaon-122001 (Haryana) INDIA.