HP Variable Index 4-Flute Tools Speeds & Feeds. Feed (Inches Per Tooth) Speed (M /

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1 Endmills - Technical Information HP Variable Index 4-Flute Tools Technical Information RedLine HP Variable 4-Flute tools are designed for fast metal removal. We control vibration and chatter through a unique dampening geometry and can handle faster speeds and feeds generated by the application of our AlTiN & AlCrN coating. Our HP Variable 4-flute tools can be run wet or dry and can be used in a wide variety of applications, from roughing and finishing to slotting and pocketing. Designed to run in a wide range of materials from cast irons and steels to titanium and high temperature alloys. Variable 4-Flute, High Performance Endmills found on pages Cast Iron - Gray Cast Iron - Ductile Cast Iron - Malleable Low Carbon Steel 38 HRc 1018, 12L14, 8620 Medium Carbon Steels 38 HRc 4140, 4340 Tool & Die Steels 38 HRc A2, D2, H13, P20 Tool Steels - 39 HRc to 48 HRc Easy to Machine Stainless Steel 416, 410, 302, 303 Moderately Difficult Stainless Steel 304, 316, Invar, Kovar Difficult to Machine 316L, 17-4 PH, 15-5 PH, 13-8 PH HP Variable Index 4-Flute Tools s & Feeds Type of Feed (Inches Per Tooth) (M / Feed (mm Per Tooth) 1/8 1/4 3/8 1/2 5/8 3/4 1 min) Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot.75 x D 1 x D Rough 1 x D.75 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot.75 x D 1 x D Rough 1 x D.5 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot.75 x D 1 x D Rough 1.5 x D.5 x D Slot.5 x D 1 x D Rough 1 x D.5 x D Slot.5 x D 1 x D Rough 1 x D.5 x D High Temperature Alloys Slot.25 x D 1 x D Rough 1 x D.25 x D

2 Technical Information - Endmills HP Variable Index 5-Flute Tools Technical Information RedLine HP Variable 5-Flute tools offer optimum metal removal rates. By controlling the vibration and chatter through a unique dampening geometry, and through the application of our advanced heat resistant coating over a fine micro-grain carbide substrate, our tools can handle faster speeds and feeds with excellent tool life in even the most difficult to machine materials like Stainless and Titanium. Can be used to Ramp, Plunge, Slot, Rough and Finish Profiles. Variable 5-Flute, High Performance Endmills found on pages HP Variable Index 5-Flute Tools s & Feeds Cast Iron - Gray ASTM-A48 Class 20, 25, 30, 35 & 40 Cast Iron - Malleable Martensitic & Ferritic 410, 416, 440 Low Carbon Steels 1018, 1020, 12L14, 5120, 8620 Medium Carbon Steels 48 HRc 1045, 4140, 4340, 5140 Tool & Die Steels 48 HRc A2, D2, O1, S7, P20, H13 Austenitic Stainless Steels, FeNi Alloys 303, 304, 316, Invar, Kovar Precipitation Hardening 17-4, 15-5, Al-4V, Difficult to Machine Type of Feed (Inches Per Tooth) 1/8 1/4 3/8 1/2 5/8 3/4 1 Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.1 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 1.5 x D.1 x D Finish 1.5 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1 x D.3 x D Peripheral - OCE* 1.5 x D.1 x D Finish 1.5 x D.01 x D Slotting.25 x D 1 x D Peripheral - Rough 1 x D.25 x D Peripheral - OCE* 1.5 x D.1 x D Finish 1.5 x D.01 x D

3 Endmills - Technical Information XHP XHP Variable Index 4-Flute Tools Technical Information RedLine XHP Variable 4-Flute tools are designed for faster metal removal. We control vibration and chatter through a unique dampening geometry and can handle faster speeds and feeds generated by the application of our AlCrNX coating. Our XHP Variable 4-flute tools can be run wet or dry and can be used in a wide variety of applications, from roughing and finishing to slotting and pocketing. Designed to run in a wide range of materials from cast irons and steels to titanium and high temperature alloys. These tools are the ultimate for versatility, performance and lowest overall cost. Variable 4-Flute, Extra High Performance Endmills found on pages Cast Iron - Gray Cast Iron - Ductile Cast Iron - Malleable Low Carbon Steel 38 HRc 1018, 12L14, 8620 Medium Carbon Steels 38 HRc 4140, 4340 Tool & Die Steels 38 HRc A2, D2, H13, P20 Tool Steels - 39 HRc to 48 HRc Easy to Machine Stainless Steel 416, 410, 302, 303 Moderately Difficult Stainless Steel 304, 316, Invar, Kovar Difficult to Machine 316L, 17-4 PH, 15-5 PH, 13-8 PH XHP Variable Index 4-Flute Tools s & Feeds Type of Feed (Inches Per Tooth) (M / Feed (mm Per Tooth) 1/8 1/4 3/8 1/2 5/8 3/4 1 min) Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot.75 x D 1 x D Rough 1 x D.75 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot.75 x D 1 x D Rough 1 x D.5 x D Slot 1 x D 1 x D Rough 1.5 x D.5 x D Slot.75 x D 1 x D Rough 1.5 x D.5 x D Slot.5 x D 1 x D Rough 1 x D.5 x D Slot.5 x D 1 x D Rough 1 x D.5 x D High Temperature Alloys Slot.25 x D 1 x D Rough 1 x D.25 x D

4 Technical Information - Endmills XHP XHP Variable Index 5-Flute Tools Technical Information RedLine XHP Variable 5-Flute tools offer optimum metal removal rates. By controlling the vibration and chatter through a unique dampening geometry, and through the application of our advanced heat resistant coating over a fine micro-grain carbide substrate, our tools can handle faster speeds and feeds with excellent tool life in even the most difficult to machine materials like Stainless and Titanium. Can be used to Ramp, Plunge, Slot, Rough and Finish Profiles. These tools can be optimized by using Optimal ter Engagement technology. Variable 5-Flute, Extra High Performance Endmills found on pages XHP Variable Index 5-Flute Tools s & Feeds Cast Iron - Gray ASTM-A48 Class 20, 25, 30, 35 & 40 Cast Iron - Malleable Martensitic & Ferritic 410, 416, 440 Low Carbon Steels 1018, 1020, 12L14, 5120, 8620 Medium Carbon Steels 48 HRc 1045, 4140, 4340, 5140 Tool & Die Steels 48 HRc A2, D2, O1, S7, P20, H13 Austenitic Stainless Steels, FeNi Alloys 303, 304, 316, Invar, Kovar Precipitation Hardening 17-4, 15-5, Al-4V, Difficult to Machine Type of Feed (Inches Per Tooth) 1/8 1/4 3/8 1/2 5/8 3/4 1 Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.15 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 2 x D.1 x D Finish 2 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1.25 x D.3 x D Peripheral - OCE* 1.5 x D.1 x D Finish 1.5 x D.01 x D Slotting.5 x D 1 x D Peripheral - Rough 1 x D.3 x D Peripheral - OCE* 1.5 x D.1 x D Finish 1.5 x D.01 x D Slotting.25 x D 1 x D Peripheral - Rough 1 x D.25 x D Peripheral - OCE* 1.5 x D.1 x D Finish 1.5 x D.01 x D * Parameters to use when utilizing OCE Optimal ter Engagement found on next page. Important application specific & Feed information found on next page. 153

5 Endmills - Technical Information XHP XHP Variable Index 5-Flute Tools Technical Information XHP Variable 5-Flute Applications & Adjustments Ball Nose Endmills - > 3/4 Diameter Dc Reduce Chip Load by 25% from the recommended Roughing and Slotting s & Feeds when axial exceeds 75% of the cutter diameter. Reduce chipload by 80% of the chipload for slotting. Peck Milling is required if the axial depth of cut exceeds 50% of the cutter diameter. Reduce speed and chipload by 10% Plunging Applications Milling Long Reach or with Long Overhang Ramp Milling Dc ap overhang ap Ramp at degree angle. Reduce chipload by 20% of the chipload for slotting. 154

6 Technical Information - XHP Endmills XHP Variable Index 5-Flute Optimal ter Engagement There are several software products that will allow you to utilize tool paths for optimum cutter engagement to maximize the performance of RedLine s Variable 5-Flute tools. Optimal ter Engagement effectively gives you a constant radial engagement while cutting which reduces cutting forces, and increases metal removal rates. Application of Optimal ter Engagement for Straight s Application of Optimal ter Engagement for Corners 1. Improve tool life by arc milling counter clockwise. Step 1 Increase tool life and productivity Step 1 by slicing then driving internal corners. This example shows a part profile with a.250 radius. R educes chip thickness as each cutting edge exits the material. Step 1 R educes cutter vibration during entry into the workpiece. Step 1 Step 1 Corner removal at accelerated speed and feed using light stepovers with 1/2" endmill. 2. A reduced radial cut will allow for higher feed rates. C reates a thinner chip, which reduces the heat at the cutting zone. I mproves cutter stability and improves straightness and finish by reducing radial forces. Use a straight line tool path and a radial stepover of 10% of the cutter diameter to slice away material from the corners. Program speeds at 1.5x to 2x normal slotting speeds. Step 2 Step 2 Step 2 Step 2 R e =.10x to.15x Depth of R e =.10x to.15x Depth of Re of R e =.10x to.15x Depth Re R.400 R.400 Step 3 R Deep axial cuts with high metal removal rates. I ncreases tool engagement and stability. Step 3 A xial depth of cut should be 1.5x to 2x the cutter diameter. Step 2 Corner drive the endmill to remove most of the material by programming a radius 40% greater than the final radius. Re R.400 Corner drive a smaller endmill into the corner programmed for the desired radius. Step 3 ae ae ae Step 3 Machine the finished.250 radius with Stepa33/8" endmill, allowing you to drive the corner. a e =1.5x to 2x Depth of a e =1.5x to 2x Depth of a e =1.5x to 2x Depth of 155 These tool paths utilize light stepovers, deep axial cuts, rolling entries and exits, and corner driving to form internal corners. By applying this technology you will maximize tool life, improve surface finish and create straighter walls.

7 Endmills - Technical Information 6-Flute Finishers Technical Information RedLine 6-flute Finishers are the 1st choice for milling a wide variety of difficult to machine alloys. Our high performance TiAlN coating allows you to run our tools wet or dry in many materials with excellent tool life. 6-flute Finisher, High Performance Endmills found on pages Note: For added tool life apply tools with a corner radius. Do not use tools with Weldon Flats in milling chucks or collet chucks for high speed applications. High Temperature Alloys, Inconel, Haynes, Stellite, Hastalloy, Waspalloy Carbon & Tool Steels 38 HRc Carbon & Tool Steels 39 HRc to 48 HRc Carbon & Tool Steels 49 HRc to 57 HRc Carbon & Tool Steels 58 HRc to 62 HRc Type of 6-Flute Finishers Tools s & Feeds Feed (Inches Per Tooth) (M/ Feed (mm Per Tooth) 1/8 1/4 3/8 1/2 5/8 3/4 1 min) Slot.25 x D 1 x D Rough 1 x D.25 x D Finish 1.5 x D.01 x D Slot.25 x D 1 x D Rough 1 x D.25 x D Finish 1.5 x D.01 x D Slot.5 x D 1 x D Rough 1 x D.5 x D Finish 1.5 x D.01 x D HSM 1 x D.1 x D Slot.5 x D 1 x D Rough 1 x D.5 x D Finish 1.5 x D.01 x D HSM 1 x D.1 x D Slot.25 x D 1 x D Rough 1 x D.25 x D Finish 1.5 x D.01 x D HSM 1 x D.1 x D Slot.20 x D 1 x D Rough 1 x D.20 x D Finish 1.5 x D.01 x D HSM 1 x D.1 x D High Temp Alloys Technical Information RedLine 3-flute 60 endmills are perfect for slotting and profiling in all high temperature alloys like Hastalloy, Waspalloy, Inconel, and Titanium. If you are looking for additional speed you can achieve up to a 40% increase in surface footage over uncoated tools by purchasing tools with the AlTiN coating. High Temp Alloy, high performance endmills found on page 63. High Temp Alloys Tools s & Feeds High Temperature Alloys, Inconel, Haynes, Stellite, Hastalloy, Waspalloy Type of Feed (Inches Per Tooth) (M/ Feed (mm Per Tooth) 1/8 1/4 3/8 1/2 5/8 3/4 1 min) Slot.5 x D 1 x D Rough 1 x D.5 x D Finish 1.5 x D.01 x D Slot.25 x D 1 x D Rough 1 x D.25 x D Finish 1.5 x D.01 x D

8 Technical Information - Endmills Technical Information RedLine 3-flute 45 lead tools are recommended for slotting and profiling of stainless steel and other similar alloys. This tool is designed to run at higher speeds and feeds while producing excellent part finishes. Stainless Steel, High Performance Endmills found on page 64. Easy to Machine Stainless Steels 416, 410, 302, 303 Medium Difficulty 304, 316, Invar, Kovar Difficult to Machine 316L, 17-4 PH, 15-5 PH, 13-8 PH Low Carbon Steels 32 HRc, 1018, 12L14, 8620 Carbon & Tool Steels 33 HRc to 38 HRc Carbon & Tool Steels 39 HRc to 48 HRc Copper, Brass, & Bronze Aluminum Bronze & Beryllium Copper Type of Tools s & Feeds Feed (Inches Per Tooth) (M/ Feed (mm Per Tooth) 1/8 1/4 3/8 1/2 5/8 3/4 1 min) Finish 1.5 x D.01 x D Finish 1.5 x D.01 x D Rough 1 x D.5 x D Finish 1.5 x D.01 x D Finish 1.5 x D.01 x D Finish 1.5 x D.01 x D Slot.5 x D 1 x D Rough 1 x D.5 x D Finish 1.5 x D.01 x D Finish 1.5 x D.01 x D Finish 1.5 x D.01 x D Slot.5 x D 1 x D Rough 1 x D.5 x D Finish 1.5 x D.01 x D

9 Endmills - Technical Information ZrN Coated for Aluminum & Non-Ferrous Technical Information RedLine 2-flute and 3-flute ZrN coated tools are designed for high speed machining in aluminum brass and bronze, and can be used for plunging, slotting and profiling in all non-ferrous materials. The ZrN coating allows for higher speeds, better tool life and a low affinity for aluminum. ZrN coated aluminum and Non-Ferrous, High Performance Endmills found on pages 65 and 72. Aluminum Alloys 2024, 6061, 7075 High Silicon Aluminum A380, A390 Magnesium Alloys Copper Alloys Brass, Bronze Composites Plastics, Fiberglass ZrN Coated for Aluminum & Non-Ferrous Tools s & Feeds Non-Ferrous s s (Feed Per Tooth) by Endmill Diameter (Inches) 1/8 1/4 3/8 1/2 5/8 3/4 1 Aluminum Brass/Bronze Copper/Copper Alloys Plastics NOTES: (1) s and Feeds listed are estimated and will vary by application. (2) Reduce s by 20% when slotting. (3) When exceeding 1/2 the end mill diameter while profiling, reduce feed rate by 25%. (4) The use of Long and Extra Long Endmills require a reduction in feed by up to 50%. (5) Optimum performance can be achieved when using coated & stub length tools. Aluminum & Non-Ferrous Technical Information RedLine has a comprehensive offering of shank designs, corner radii, and tool lengths for milling all aluminums including die cast, extrusions and non-ferrous alloys. Increased feed rates, lower cycle times and excellent surface finishes can be achieved using these tools. Aluminum and Non-Ferrous, High Performance Endmills found on pages Aluminum & Non-Ferrous Tools s & Feeds Type of Feed (Inches Per Tooth) (M/ Feed (mm Per Tooth) 1/8 1/4 3/8 1/2 5/8 3/4 1 min) Slotting 1 x D 1 x D Rough 1 x D.75 x D Finish 1.5 x D.01 x D Slotting.5 x D 1 x D Rough 1 x D.5 x D Finish 1.5 x D.01 x D Slotting 1 x D 1 x D Rough 1 x D.75 x D Finish 1.5 x D.01 x D Slotting.75 x D 1 x D Rough 1 x D.75 x D Finish 1.5 x D.01 x D Slotting 1 x D 1 x D Rough 1 x D.75 x D Finish 1.5 x D.01 x D

10 Technical Information - Endmills Roughers Technical Information RedLine High Performance Roughers are designed to perform in hard to machine materials like stainless steel and titanium. Higher feed rates can be attained because of our radius chip breaker, without sacrificing finish. High Performance Roughers and Finishers found on pages 88 and 89. Solid Carbide Roughers s & Feeds Hardness HRc s Uncoated Chip Load per Tooth AlTiN Coated 1/4"-1/2" 1/2"-1" Low and Plain Carbon, Alloy & Tool Steels < Low and Plain Carbon, Alloy & Tool Steels Low and Plain Carbon, Alloy & Tool Steels Austenitic, 200 & 300 < Ferritic, Martensitic 400, 500 & PH < Nickel-Based High Temperature Alloys < Nickel-Based High Temperature Alloys Cobalt-Based High Temperature Alloys < NOTES: s and Feeds listed are estimated and will vary by application. 159

11 Endmills - Technical Information General Purpose Carbide Endmills s & Feeds Non-Ferrous s s (Feed Per Tooth) by Endmill Diameter (Inches) 1/8 1/4 1/2 3/4 1 Aluminum/Aluminum Alloy Aluminum/Aluminum Alloy +10% Brass Bronze Copper/Copper Alloys Fiberglass Graphites Graphite/Epoxy Magnesium 1000 min Cast Iron Ductile Gray Malleable Steels Low Alloy Medium Alloy High Alloy Mold Die High Strength Free Machine Work Hardening High Temp Alloys Nickel Base Titanium Soft Hard NOTES: (1) s and Feeds listed are estimated and will vary by application. (2) s and Feeds listed above are for uncoated tools. For coated tools, SFM may increase by +25% for TiCN and +40% for AlTiN. (3) Maximize rigidity to reduce chatter and increase tool life by applying the following tips. Choose the largest diameter possible Use the shortest LOC (Length of ) available Use the toolholder which offers the shortest gage length (4) To control chatter, increase feed or reduce speed. (5) For extra long endmills, reduce SFM by 25%. (6) Keep to a minimum at all times. As runout increases, the tools performance decreases and tool life will be reduced. (7) Use a coolant or air blast to evacuate chips to avoid premature damage to your carbide cutting tool, which may occur if chips are recut. 160

12 Technical Information - Endmills High Steel and Cobalt Endmills s & Feeds s Uncoated AlTiN Coated Chip Load Per Flute Non-Ferrous s Aluminum Brass/Bronze Copper/Copper Alloys Plastics Cast Iron Malleable Ductile Steels Low Carbon Steels Medium Alloy Steels 200, 250, High Strength Steels PH Series Austenitic 200,302, 303, 304, 304(L), 316(L) Martensitic 403,410,416,420, High Temp Alloys Nickel Base Inconel 601,625,718 Waspalloy, Hastelloy Cobalt Base Stellite, Haynes Iron Base Incolloy Haynes Titanium