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2015
Sheet Diamond that lasts 2x to 3x longer than PCD
Cartridges & Inserts
The “Ultimate” Milling Cutter
Cartridges, Inserts & Round Tools
Page 1/1
The world’s first cutting tool was likely a sharp stone wielded by a cave dweller to sharpen a piece of wood for use as a spear. How far we have come since then! Cutting materials have evolved from stone to carbon steel, to Fredrick Winslow Taylor’s High Speed Cutting steels, to Krupp’s first carbides and now to hundreds of grades of carbide and coating iterations. One of the greatest advancements in cutting technology for abrasive materials was the use of natural and later, synthetic diamond to take advantage of diamond’s miraculous properties of hardness, abrasion resistance, and chemical inertness.
Synthetic diamond was first created much in the same way as diamonds found in nature: with a combination of heat and pressure. The founders of sp3, Jim Herlinger and Jerry Zimmer developed the first commercial process using heat and vacuum to grow diamond as a part of their work as Silicon Valley innovators. The process they perfected uses carbon-rich gases introduced into a heated vacuum chamber (a reactor); to grow diamond crystals on carbide.
This process was first used to coat carbide inserts, then carbide round tools, and later we developed the ability to grow free-standing sheets of diamond using a similar, but larger scale CVD process (TFd, a pure polycrystalline diamond with 3x the wear resistance of PCD). As sp3 evolved as a cutting tool manufacturer, we broadened our offering to include fabricated diamond tools using both conventional PCD and CVD sheet diamond. We developed an innovative line of milling tools and consolidated sp3’s Cutting Tool engineering, marketing, sales, customer service, and manufacturing functions in Indiana in order to be more centrally located to better support our customer base.
In 2013, we purchased the assets of Winco Industries, Inc., a pioneer in the design and manufacture of ultra high precision PCD round tools. This adds additional products such as reamers, step drills, valve seat and guide tools, and transmission spool bore tools to sp3’s capabilities, as well as adding engineering talent, and manufacturing facilities and skills to our portfolio.
Over the past 20 years, sp3 has been an innovator in diamond technology, manufacturing processes, and in the design and application of diamond tooling for a variety of industries. We are not a “fabricator” or a “make to print (somebody else’s design)” company; we are a designer, developer, and application specialist for diamond tools that improve our customers’ manufacturing operations.
Our philosophy is simple: make better tools than our competitors, deliver them when we promise to deliver them, always strive for perfect quality, and continuously engineer and develop better designs that benefit our customers. Our philosophy is not perfectly realized (yet), but we ask you for the chance to work together to improve your company’s performance.
No other diamond cutting tool company provides such broad and deep technical understanding of diamond for use in cutting tools and no one has more field-proven experience in applying diamond tools to real world machining problems.
Definitions of Diamond Technologies..................................2Ultra-Mill Features..............................................................3Ultra-Mill Cutter Body Offerings.......................................4-5Ultra-Mill Coolant Attachments............................................6Ultra-Mill Cartridges............................................................7Ultra-Mill Intermediate Cutter Body Offerings....................8-9Ultra-Mill Intermediate Coolant Attachments........................10Ultra-Mill Intermediate Cartridges.........................................11Ultra-Mill Mini Endmills and Cartridges.........................12-13Ultra Endmill Cutters and Cartridges Inch....................14-15Ultra-Mill Spare Parts.........................................................16Setup Procedure for Ultra-Mill Milling Cutters...................17PCD Tipped ISO Inserts..................................................18-19 Milling Theory and Calculations.........................................20Cutting Data.....................................................................21Ultra-Mill Special Tools................................................22-23sp3-Round Special Tools..............................................24-25Tool Quote Request Form...........................................26-29
sp3 Cutting Tools, Inc3531 West U.S. Highway 224
Decatur, IN 46733Customer Service: (888) 547-4156Email: cuttingtools@sp3inc.com
Website: www.sp3cuttingtools.com
1
2
WWW.SP3CUTTINGTOOLS.COM
sp3 Cutting Tools Inc., located in Decatur, IN, manufactures and services a broad range of super-hard inserts, end mills, drills, cartridges, and cutter bodies for machining applications that demand the use of diamond. sp3 tools are used to machine:
•Abrasive non-metallic materials such as graphite, green ceramics, ceramic matrix composites, filled plastics, and carbon fiber composites.•Non-ferrous metals such as cast aluminums, metal matrix composites, copper, brass, and bronze.•Ferrous metals such as nodular iron, CGI, and steel.
sp3 Cutting Tools is the the only manufacturer of diamond cutting tools to offer the following three major types of diamond materials and cBN:
or TFd – sp3 has extended CVD diamond technology to develop TFd, a free standing thick sheet pure diamond material. By manufacturing the thicker material and then segmenting the sheet, sp3 has essentially created a pure diamond material that can be applied in much the same manner as PCD, offering a cutting surface of pure diamond with no binder. TFd indexable inserts provide a wear life 2 to 3 times that of PCD, and maintain edge sharpness longer. Absence of binder avoids chemical interaction with coolant or workpiece material and allows for a sharper edge.
The world’s leading supplier of diamond tooling
Soft, free-cutting non-ferrous metals. e.g. 6061 aluminum, brass, copper
Graphite, carbon, green ceramics, fiber-enforced plastics, fiberboard
Low-silicon aluminum. e.g. 380
High-silicon aluminum.e.g. 390
Metal Matrix Composites.e.g. Duraclan
or PCD tools are an alternative to tungsten carbide (uncoated and coated) tools and are designed to meet the needs of more demanding non-ferrous machining applications. PCD contains diamond particles and non-diamond metallic synthesis materials. sp3 offers PCD inserts, PCD brazed cartridges, and round tools. We also design and manufacture custom tools and we have a comprehensive tool refurbishing service.
or DIAbide – The Chemical Vapor Deposition or CVD coating of tungsten carbide enables sp3 to provide diamond-coated carbide tools using our patented DIAbide process. The sp3 DIAbide material has gained worldwide acceptance as the proven diamond tool solution for high-speed CNC machining applications using graphite and other non-ferrous materials. We offer a wide array of DIAbide tools, including endmills, profiling endmills, premium mold mills, drills, indexable inserts, profiling inserts, and grooving, cut-off and threading inserts.
Thin-film diamond, Thick-film diamond,
Polycrystaline diamond,
Cubic Boron Nitride,
or cBN, is used for machining a wide variety of ferrous materials. cBN provides increased productivity and cost savings over conventional carbide and ceramic tools. In many cases cBN tools make it possible to machine materials where conventional tools have failed.
cBN tools are typically most effective for alloy steels hardened to a minimum of 45 HRC, cast iron, and powder metals. Although there are exceptions to this rule, it is important to note that if the material being machined does not meet the required hardness, the cBN tool life may be affected.
sp3 offers cBN cartridges that fit our Ultra-Mill line of milling cutters.
Ask your sp3 representative how you can apply the best diamond alternative for your application.
Complete Diamond Tool Solutions
sp3 DIABide™
sp3 PCDsp3 TFd™
Bare Carbidesp3 DIABide™
Coated Carbide
easy Performance Difficulty—Abrasive Index hard
3
CALL TOLL FREE! 1-888-547-4156
The beauty of the Ultra-Mill V-style milling cutter is that it is designed to
accommodate a wide range of coarse, medium and fine pitch cutting
applications. This common body style allows the user to adapt to
different applications simply by changing cartridge styles. For machining
ferrous metals, brazed cBN cartridges are available. For non-ferrous
materials brazed PCD and TFd cartridges are available.
Ultra-Mill Features, Benefits, and Advantages Include:Features Benefits Advantages
Higher density than most
competitive milling cutters
Higher machining speeds Faster throughput (increased
production) or longer tool life
(reduction in tool costs)
2 stage design capacity Rough and Finish in one
pass,aids in reducing
vibration on difficult to clamp
or thin section parts
Faster throughput (increased
production) or better asset
utilization (increased capacity)
Symmetrical cutter body Left hand and right hand
mounting with the same body
Reduced cutter body inventory
and increased flexibility
(reduced tooling costs)
Open design Improved chip evacuation—
less chip damage
Increased cutter body life
(lower tooling costs)
Geometry in the cartridge, not
the body
Fewer application limitations —
PCD, TFd, and cBN brazed cutting
tips, positive or negative rake and
lead angles are available
Faster throughput (increased
production) or longer tool life
(reduction in tool costs)
– Patented Milling Cutter System
4
WWW.SP3CUTTINGTOOLS.COM
A= Aluminum Body S= Steel Body
UM-2.50-3-1A/SUM-2.50-6-1A/SUM-3.00-4-1A/SUM-3.00-8-1A/SUM-3.00-10-1A/SUM-4.00-6-1A/SUM-4.00-12-1A/SUM-5.00-8-1A/SUM-5.00-16-1A/SUM-6.00-8-1A/SUM-6.00-12-1A/SUM-6.00-20-1A/SUM-8.00-10-1A/SUM-8.00-12-1A/SUM-8.00-24-1A/SUM-10.00-12-1A/S UM-10.00-28-1A/SUM-12.00-18-1A/SUM-12.00-36-1A/SUM-14.00-16-1A/SUM-14.00-32-1A/SUM-14.00-42-1A/S
3648
106
128
168
122010122412281836163242
2.5002.5003.0003.0003.0004.0004.0005.0005.0006.0006.0006.0008.0008.0008.00010.00010.00012.00012.00014.00014.00014.000
0.7500.7501.0001.0001.0001.2501.2501.5001.5001.5001.5001.5002.5002.5002.5002.5002.5002.5002.5002.5002.5002.500
2.0002.0002.0002.0002.0002.0002.0002.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.3752.375
0.3120.3120.3750.3750.3750.5000.5000.6250.6250.6250.6250.6251.0001.0001.0001.0001.0001.0001.0001.0001.0001.000
15,50015,50014,20014,20014,20012,25012,25011,00011,00010,00010,00010,0008,6008,6008,6007,7507,7507,2507,2506,7506,7506,750
Cutter Bodies
UM 20 1 A6.00
Ultra-MillTM
Cutting Diameter
Number of Pockets
A = Aluminum Body
S = Steel Body
1-Series = Single Stage2-Series = Double Stage
– – –
Standard Cutter Body Offerings
CutterOrder Number
Number of Pockets
Effective Cutting Dia. A (in.)
B Dim.Bore Dia.
C Dim.Set Hgt. Keyway
MAXRPM
RH/LH
B
C
A
5
CALL TOLL FREE! 1-888-547-4156
UM-63MM-3-1A/SUM-63MM-6-1A/S UM-80MM-8-1A/SUM-80MM-10-1A/SUM-100MM-6-1A/SUM-100MM-8-1A/SUM-100MM-12-1A/SUM-125MM-12-1A/SUM-125MM-16-1A/SUM-160MM-10-1A/SUM-160MM-20-1A/SUM-200MM-12-1A/SUM-200MM-24-1A/SUM-250MM-32-1A/S
36 8
1068
1212161020122432
6363 8080100100100125125160160200200250
2222 222232323240404040606060
6363 505050505063636363636363
15,00015,00014,00014,00012,25012,25012,25011,00011,00010,00010,0008,6008,6007,750
1010 101014141416161616252525
Cutter Bodies —Metric
UM 20 1 A160MM
Ultra-MillTM
Cutting Diameter
Number of Pockets
A = Aluminum Body
S = Steel Body
1-Series = Single Stage2-Series = Double Stage
– – –
Metric Cutter Body OfferingsCutterOrder Number
Number of Pockets
Effective Cutting Dia. A (mm)
B Dim.Bore Dia.
C Dim.Set Hgt.
MAXRPMKeyway
RH/LH
B
C
A
A= Aluminum Body S= Steel Body
sp3 will design special cutter bodies to your specifications:
• Special mounts
• Application specific diameters
• Required number of pockets, etc.
Please call to inquire on further details or request a quote.
6
WWW.SP3CUTTINGTOOLS.COM
For operations that require light weight tooling, sp3 Cutting Tools offers our LW-series Coolant Cap Assemblies.
Screw
Cap Assembly
Plate
UM-SS-2.50UM-SS-3.00UM-SS-4.00UM-SS-5.00UM-SS-6.00UM-SS-8.00UM-SS-10.00UM-SS-12.00UM-SS-14.00
UM-SS-5.00-LWUM-SS-6.00-LW
UM-SS-63MMUM-SS-80MM-22UM-SS-80MM-27UM-SS-100MMUM-SS-125MMUM-SS-160MMUM-SS-200MMUM-SS-250MM
UM-SS-125MM-LWUM-SS-160MM-LW
2.50”3.00”4.00”5.00”6.00”8.00”
10.00”12.00”14.00”
5.006.00
63mm80mm80mm
100mm125mm160mm200mm250mm
125mm160mm
3/8 – 241/2 – 205/8 – 183/4 – 163/4 – 16
————
3/4-163/4-16
M10x1.5M10x1.5M12x1.75M16x2.0M20x2.5M20x2.5
——
M20 X 2.5M20 X 2.5
3/165/163/83/85/8————
8mm8mm8mm
10mm14mm14mm
——
35 ft/lbs40 ft/lbs45 ft/lbs55 ft/lbs55 ft/lbs
————
45Nm45Nm60Nm68Nm80Nm80Nm
——
Coolant Attachment Order Number
Coolant Attachment Order Number
Coolant Attachment Order Number
Coolant Attachment Order Number
Metric
Metric
Inch
Inch
Cutter Diameter
Cutter Diameter
Cutter Diameter
Cutter Diameter
Thread
Arbor Screw Thread
Arbor Screw Thread
ThreadHex Size
Hex Size
Hex Size
Hex Size
Torque
Torque
Torque
Torque
Thru Spindle Coolant Attachments for Standard Cutters
7
CALL TOLL FREE! 1-888-547-4156
Cartridge Identification
UC 2 0D R 2 0
UC - Ultra-MillTM
C= CarbideD= PCDT= TFdB=cBN
0= .200” (5,0mm) Standard1= .250” (6,3mm)2= .375” (9,5mm)3= .500” (12,7mm)4= .625” (15,8mm)5= .750” (19,0mm)
0= No Wiper1= .060” (1,52mm)2= .080” (2,03mm)3= .100” (2,54mm)4= .120” (3,05mm)
Maximum Depth of Cut (DOC)Wiper FlatR= Right HandL= Left Hand
– ––
Nose Radius
1= .010” (0,25mm)2= .030” (0,76mm)3= .060” (1,52mm)4= .090” (2,28mm)5= .016” (0,40mm)6= .100” (2,54mm)7= 1,0mm (.039”)8= 1,5mm (.059”)9= 2,0mm (.078”)0= 2,5mm (.098”)C= Chamfer
0= 0/P1= 0/N2= 0/03= P/P4= P/N5= P/06= N/P7= N/N8= N/0
Axial/Radial Rake*
For recomendation on selecting the proper cartridge for your application please visit
www.sp3cuttingtools.com or call sp3 at the number on top of this page.
DOC
NOSE RADIUS
WIPER FLAT DOC
NOSE RADIUS
WIPER FLAT
For information on chip control, contact sp3.
* 0= Neutral P= Positive N= Negative
Wiper Cartridge Identification
UC W1D R N
UC - Ultra-MillTM
D= PCDT= TFdB= cBN
R= Right HandL= Left Hand
–
Wiper Type
Axial Rake
W1= Crowned W2= Flat
P= PositiveN= Negative0= Neutral
Crowned Wiper
1 : 1 1 OF 1
-
-
UT'S/UT-203
ULTRAMILL RH FLAT TOP WIPER
UT-203
AXIAL RAKE AND .0002/.0005 DROPCARTRIDGE WITH 5° NEGATIVE
A
SBD 13JAN07
11JAN07
.005 .XXXX±.0005
NOT OTHERWISE SPECIFIED: ANGLE ±
.XX ±
DO NOT SCALE DRAWING
DEC.: .X ±.03
FINISH
.XXX ±.01FIN.
.25°SCALE
FILE NO.
SHEET
INFORMATION RIGHTS ARE RETAINED BY SP3.BE IN WRITING. ALL COMMON LAW COPYRIGHT & CONFIDENTIALFABRICATE THIS ARTICLE. ALL AUTHORIZATION TO DO SO MUSTAND POSSESSION OF IT DOES NOT CONVEY PERMISSION TORIGHT OF USE. THIS DRAWING IS ISSUED IN STRICT CONFIDENCEA PROPRIETARY ARTICLE TO WHICH SP3 RETAINS EXCLUSIVETHIS DRAWING IS THE PROPERTY OF SP3 AND REPRESENTS
MATERIAL
REV
ASIZE DRAWING NO
DATE
DATE
UT-154B
58028-07
DRAWING NO
Fax (260) 547-4214Phone (888) 547-4156DECATUR, IN 467333531 WEST US HIGHWAY 224
CUTTING TOOLSDIAMOND
Flat Wiper
8
WWW.SP3CUTTINGTOOLS.COM
A 10AUG10INITIAL RELEASE KAB KAB
DREV DESCRIPTION APPROVEDDATEBY
INFORMATION RIGHTS ARE RETAINED BY SP3.BE IN WRITING. ALL COMMON LAW COPYRIGHT & CONFIDENTIALFABRICATE THIS ARTICLE. ALL AUTHORIZATION TO DO SO MUSTAND POSSESSION OF IT DOES NOT CONVEY PERMISSION TORIGHT OF USE. THIS DRAWING IS ISSUED IN STRICT CONFIDENCEA PROPRIETARY ARTICLE TO WHICH SP3 RETAINS EXCLUSIVETHIS DRAWING IS THE PROPERTY OF SP3 AND REPRESENTS
MATERIAL
FINISH
TREATMENT
DEC.: .X ±.03
DO NOT SCALE DRAWING
NOT OTHERWISE SPECIFIED: ANGLE ±
.005 .XXXX±.0005.XX ± .XXX ±.01FIN.
.25°SCALE
1:1
FILE NO.
DRAWN
CHECKED
REV1 of 1SHEET
DSIZE DRAWING NO
A
DATE
DATE
APPROVED DATE
DATE
CUST/UT3957ASSM
4140 STEEL
UT3957ASSM
-
UT3957ASSM
BLACK-OXIDE
CUTTING TOOLSDIAMOND
DESIGN APPROVAL
PLEASE CONFIRM OVERALL DIMENSION, ANGLES, MOUNTING, MARKING AND HAND OF ROTATION.
APPROVED
APPROVED AS MARKED RESUBMIT
BY DATE
REVISION OF KEY FEATURES QUOTED, ARE SUBJECT TO PRICE ADJUSTMENT.
CUTTING TOOLSDIAMOND
KAB 10AUG10
DESCRIPTIONITEM QTY DRAWING NO
LOCK SCREW, 8-32 X 1/2 T.B.H.
ADJUSTMENT NUT, 10-32 X .25
SET SCREW, 10-32 X 1/2 S.H.S.S.
WASHER
ULTRA-MILL CUTTER
63
1
2
1
6
4
5
6
6 97416A113
63506
63500
-
UT3957
DECATUR, IN 46733Phone (888) 547-4156Fax (260) 547-4214
3531 WEST US HIGHWAY 224
CARTRIDGE 6 6 UT-223
ENGRAVE:ULTRA-MILL ®UT3957S.H. 128.0MMPAT. #5,788,426
Ø1.500 6 STATION ULTRA-MILL ® ASSEMBLY
CARTRIDGE SET-UP PROCEDURE:1 CLEAN POCKETS AND CARTRIDGES THOROUGHLY.2 TURN HEX NUTS DOWN ONE TURN.3 INSTALL CARTRIDGES AND WITH TORX LOCK SCREWS TORQUED TO 10-15 IN/LBS.4 SET INDICATOR TO DESIRED SET HEIGHT.5 MOVE CARTRIDGES TO .001" BELOW SET HEIGHT WITH HEX NUTS.6 TIGHTEN LOCK SCREWS TO 23 IN/LBS. (TORQUE WRENCH REQUIRED)7 MOVE CARTRIDGES TO "SET HEIGHT" USING HEX NUT. (FOR BEST RESULTS ALL EDGES SHOULD BE +/-.0001")8 CHECK ALL SCREWS ARE SET TO PROPER TORQUE.
UMI 28 1 A6.00Cutting Diameter
Number of Pockets
A = Aluminum Body
S = Steel Body
– – –
Standard Cutter Body Offerings
Endmill Style Cutter Body Offerings
A= Aluminum Body S= Steel Body
UMI-2.00-8-1A/SUMI-2.50-10-1A/SUMI-3.00-12-1A/SUMI-4.00-18-1A/SUMI-5.00-22-1A/SUMI-6.00-28-1A/SUMI-8.00-38-1A/SUMI-10.00-48-1A/S
2.002.503.004.005.006.008.00
10.00
0.7500.7501.0001.2501.5001.5002.5002.500
2.3752.3752.3752.3752.3752.3752.3752.375
810121822283848
CutterOrder Number
Number of Pockets
B Dim.Bore Dia.
C Dim.Set Hgt. Keyway
MAXRPM
0.3120.3120.3750.5000.6250.6251.0001.000
17,00015,50014,20012,25011,00010,0008,6007,750
UMI-1.50-4-SS-1.00UMI-1.50-4-SS-1.50UMI-2.00-8-SS-1.00UMI-2.00-8-SS-1.50
4488
1.501.502.002.00
5.005.755.005.75
3.0003.7503.0003.750
20,00020,00015,50015,500
1.0001.5001.0001.500
CutterOrder Number
Number of Pockets
Overall Length L
Shank Length C
MAXRPM
Shank Dia. D
Note: These endmills are manufactured to H6 tolerance in order to maximize tool life, thus we discourage the use of standard endmill holders. We recommend hydraulic chucks or Shrink-fit adapters for these tools. Alternately, these tools can also be made with integral shank holders such as HSK, CAT, ANSI, etc. Upon request, we can supply these endmills with a Weldon flat but tool life will suffer due to excessive runout.
RH/LH
B
C
A
A
C
D
L
UMI - Ultra-MillTM Intermediate
UMI - Ultra-MillTM Intermediate
Intermediate Cutter Bodies—Inch
Intermediate Endmill Bodies—Inch
1-Series = Single Stage2-Series = Double Stage
Effective Cutting Dia. A (in.)
Effective Cutting Dia. A (in.)
UMI 8 SS 1.002.00Cutting Diameter
Number of Pockets Shank Diameter
– – –Shank Style
SS= Straight ShankWD= Weldon ShankCAT= Cat ShankBT= BT ShankHSK= HSK Shank
9
CALL TOLL FREE! 1-888-547-4156
UMI 18 1 A
Number of Pockets
A = Aluminum Body
S = Steel Body
– – –
Standard Cutter Body Offerings
Endmill Style Cutter Body Offerings
A= Aluminum Body S= Steel Body
UMI-50MM-8-1A/SUMI-63MM-10-1A/SUMI-75MM-12-1A/SUMI-100MM-18-1A/SUMI-125MM-22-1A/SUMI-150MM-26-1A/SUMI-200MM-36-1A/SUMI-250MM-46-1A/S
506375100125150200250
1622223240406060
6060606060606060
810121822263646
CutterOrder Number
Number of Pockets
B Dim.Bore Dia.
C Dim.Set Hgt. Keyway
MAXRPM
810141416162525
17,00015,50014,20012,25011,00010,0008,6007,750
UMI-38MM-4-SS-25MMUMI-38MM-4-SS-32MMUMI-50MM-8-SS-25MMUMI-50MM-8-SS-32MM
4488
38385050
126130126130
76807680
20,00020,00015,50015,500
25322532
CutterOrder Number
Number of Pockets
Overall Length L
ShankLength C
MAXRPM
Shank Dia. D
Note: These endmills are manufactured to H6 tolerance in order to maximize tool life, thus we discourage the use of standard endmill holders. We recommend hydraulic chucks or Shrink-fit adapters for these tools. Alternately, these tools can also be made with integral shank holders such as HSK, CAT, ANSI, etc. Upon request, we can supply these endmills with a Weldon flat but tool life will suffer due to excessive runout.
RH/LH
B
C
A
UMI - Ultra-MillTM Intermediate
UMI - Ultra-MillTM Intermediate
Intermediate Cutter Bodies—Metric
Intermediate Endmill Bodies—Metric
1-Series = Single Stage2-Series = Double Stage
Effective Cutting Dia. A (mm)
Effective Cutting Dia. A (mm)
UMI 8 SS 25MM50MMCutting Diameter
Number of Pockets Shank Diameter
– – –Shank Style
SS= Straight ShankWD= Weldon ShankHSK= HSK Shank
A 10AUG10INITIAL RELEASE KAB KAB
DREV DESCRIPTION APPROVEDDATEBY
INFORMATION RIGHTS ARE RETAINED BY SP3.BE IN WRITING. ALL COMMON LAW COPYRIGHT & CONFIDENTIALFABRICATE THIS ARTICLE. ALL AUTHORIZATION TO DO SO MUSTAND POSSESSION OF IT DOES NOT CONVEY PERMISSION TORIGHT OF USE. THIS DRAWING IS ISSUED IN STRICT CONFIDENCEA PROPRIETARY ARTICLE TO WHICH SP3 RETAINS EXCLUSIVETHIS DRAWING IS THE PROPERTY OF SP3 AND REPRESENTS
MATERIAL
FINISH
TREATMENT
DEC.: .X ±.03
DO NOT SCALE DRAWING
NOT OTHERWISE SPECIFIED: ANGLE ±
.005 .XXXX±.0005.XX ± .XXX ±.01FIN.
.25°SCALE
1:1
FILE NO.
DRAWN
CHECKED
REV1 of 1SHEET
DSIZE DRAWING NO
A
DATE
DATE
APPROVED DATE
DATE
CUST/UT3957ASSM
4140 STEEL
UT3957ASSM
-
UT3957ASSM
BLACK-OXIDE
CUTTING TOOLSDIAMOND
DESIGN APPROVAL
PLEASE CONFIRM OVERALL DIMENSION, ANGLES, MOUNTING, MARKING AND HAND OF ROTATION.
APPROVED
APPROVED AS MARKED RESUBMIT
BY DATE
REVISION OF KEY FEATURES QUOTED, ARE SUBJECT TO PRICE ADJUSTMENT.
CUTTING TOOLSDIAMOND
KAB 10AUG10
DESCRIPTIONITEM QTY DRAWING NO
LOCK SCREW, 8-32 X 1/2 T.B.H.
ADJUSTMENT NUT, 10-32 X .25
SET SCREW, 10-32 X 1/2 S.H.S.S.
WASHER
ULTRA-MILL CUTTER
63
1
2
1
6
4
5
6
6 97416A113
63506
63500
-
UT3957
DECATUR, IN 46733Phone (888) 547-4156Fax (260) 547-4214
3531 WEST US HIGHWAY 224
CARTRIDGE 6 6 UT-223
ENGRAVE:ULTRA-MILL ®UT3957S.H. 128.0MMPAT. #5,788,426
Ø1.500 6 STATION ULTRA-MILL ® ASSEMBLY
CARTRIDGE SET-UP PROCEDURE:1 CLEAN POCKETS AND CARTRIDGES THOROUGHLY.2 TURN HEX NUTS DOWN ONE TURN.3 INSTALL CARTRIDGES AND WITH TORX LOCK SCREWS TORQUED TO 10-15 IN/LBS.4 SET INDICATOR TO DESIRED SET HEIGHT.5 MOVE CARTRIDGES TO .001" BELOW SET HEIGHT WITH HEX NUTS.6 TIGHTEN LOCK SCREWS TO 23 IN/LBS. (TORQUE WRENCH REQUIRED)7 MOVE CARTRIDGES TO "SET HEIGHT" USING HEX NUT. (FOR BEST RESULTS ALL EDGES SHOULD BE +/-.0001")8 CHECK ALL SCREWS ARE SET TO PROPER TORQUE.
100MMCutting Diameter
10
WWW.SP3CUTTINGTOOLS.COM
Screw
Cap Assembly
Plate
UI-SS-2.00UI-SS-2.50UI-SS-3.00UI-SS-4.00UI-SS-5.00UI-SS-6.00UI-SS-8.00UI-SS-10.00UI-SS-12.00UI-SS-14.00
UI-SS-5.00-LWUI-SS-6.00-LW
UI-SS-50MMUI-SS-63MMUI-SS-75MMUI-SS-80MMUI-SS-80MMUI-SS-100MMUI-SS-125MMUI-SS-150MMUI-SS-200MMUI-SS-250MM
UI-SS-125MM-LWUI-SS-160MM-LW
2.002.503.004.005.006.008.00
10.0012.0014.00
5.006.00
50mm63mm75mm80mm80mm
100mm125mm150mm200mm250mm
125mm160mm
3/8-243/8-241/2-205/8-183/4-163/4-16
————
3/4-163/4-16
M8 x1.25M10x1.5M10x1.5M10x1.5M12x1.75M16x2.0M20x2.5M20x2.5
——
3/163/165/163/83/85/8————
5mm8mm8mm8mm8mm
10mm14mm14mm
——
35 ft/lbs35 ft/lbs40ft/lbs45 ft/lbs55ft/lbs55ft/lbs
————
50 Nm45Nm45Nm45Nm60 Nm68Nm80Nm80Nm
——
Coolant Attachment Order Number
Coolant Attachment Order Number
Coolant Attachment Order Number
Coolant Attachment Order Number
Metric
Metric
Inch
Inch
Cutter Diameter
Cutter Diameter
Cutter Diameter
Cutter Diameter
Thread
Arbor Screw Thread
Arbor Screw Thread
ThreadHex Size
Hex Size
Hex Size
Hex Size
Torque
Torque
Torque
Torque
For operations that require light weight tooling, sp3 Cutting Tools offers our LW-series Coolant Cap Assemblies.
Thru Spindle Coolant Attachments for Intermediate Cutters
11
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UI 2 0D R 2 0
UI - Ultra-MillTM Intermediate
C= CarbideD= PCDT= TFdB= cBN
0= .200” (5,0mm) Standard1= .250” (6,3mm)2= .375” (9,5mm)
0= No Wiper1= .060” (1,52mm)2= .080” (2,03mm)3= .100” (2.54mm)
Maximum Depth of Cut (DOC)Wiper FlatR= Right HandL= Left Hand
– ––
Nose Radius1= .010” (0,25mm)2= .030” (0,76mm)3= .060” (1,52mm)7= 1,0mm (.039”)8= 1,5mm (.059”)C= Chamfer
0= 0/P1= 0/N2= 0/03= P/P4= P/N5= P/06= N/P7= N/N8= N/0
Axial/Radial Rake*
For recomendation on selecting the proper cartridge for your application please visit
www.sp3cuttingtools.com or call sp3 at the number on top of this page.
DOC
NOSE RADIUS
WIPER FLAT DOC
NOSE RADIUS
WIPER FLAT
For information on chip control, contact sp3.
* 0= Neutral P= Positive N= Negative
Intermediate Cartridge Identification
Intermediate Wiper Cartridge Identification
UI W1D R ND= PCDT= TFdB= cBN
R= Right HandL= Left Hand
–
UI - Ultra-MillTM Intermediate
Wiper Type
Axial Rake
W1= Crowned W2= Flat
P= PositiveN= Negative0= Neutral
Crowned Wiper
1 : 1 1 OF 1
-
-
UT'S/UT-203
ULTRAMILL RH FLAT TOP WIPER
UT-203
AXIAL RAKE AND .0002/.0005 DROPCARTRIDGE WITH 5° NEGATIVE
A
SBD 13JAN07
11JAN07
.005 .XXXX±.0005
NOT OTHERWISE SPECIFIED: ANGLE ±
.XX ±
DO NOT SCALE DRAWING
DEC.: .X ±.03
FINISH
.XXX ±.01FIN.
.25°SCALE
FILE NO.
SHEET
INFORMATION RIGHTS ARE RETAINED BY SP3.BE IN WRITING. ALL COMMON LAW COPYRIGHT & CONFIDENTIALFABRICATE THIS ARTICLE. ALL AUTHORIZATION TO DO SO MUSTAND POSSESSION OF IT DOES NOT CONVEY PERMISSION TORIGHT OF USE. THIS DRAWING IS ISSUED IN STRICT CONFIDENCEA PROPRIETARY ARTICLE TO WHICH SP3 RETAINS EXCLUSIVETHIS DRAWING IS THE PROPERTY OF SP3 AND REPRESENTS
MATERIAL
REV
ASIZE DRAWING NO
DATE
DATE
UT-154B
58028-07
DRAWING NO
Fax (260) 547-4214Phone (888) 547-4156DECATUR, IN 467333531 WEST US HIGHWAY 224
CUTTING TOOLSDIAMOND
Flat Wiper
12
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Mini Endmill Identification—Inch
sp3 offers the Ultra-Mill Mini Endmill when machining small areas as well. What separates the Mini Endmill from its Ultra Endmill counterpart is that it has more cartridges per cutting diameter, which allows the user to increase the feed rate and hence increase throughput and production.
MUE 10 SS 1.002.00
MUE - Mini Endmill
Cutting Diameter
Number of Pockets Shank Diameter
– – –Shank Style
SS= Straight ShankWD= Weldon ShankCAT= Cat ShankBT= BT ShankHSK= HSK Shank
MUE-1.00-6-SS-.75MUE-1.00-6-SS-1.00MUE-1.25-6-SS-.625MUE-1.25-6-SS-.75MUE-1.25-6-SS-1.00MUE-1.50-6-SS-.625MUE-1.50-6-SS-.75MUE-1.75-8-SS-1.00MUE-1.75-8-SS-1.25MUE-2.00-10-SS-1.25
1.001.001.251.251.251.501.501.751.752.00
3.754.003.503.754.003.503.754.004.254.25
666666688
10
2.7503.0002.5002.7503.0002.500 2.750 3.000 3.250 3.250
0.7501.0000.6250.7501.0000.6250.7501.0001.2501.250
.150
.150
.150
.150
.150
.150
.150
.150
.150
.150
Standard Mini Endmill BodiesEffective Cutting Dia.A (in.)
Cutter Order Number
Overall Length L
No.Inserts
Shank Length C
Shank Dia. D
D.O.C. Max
C
A D
L
Note: These endmills are manufactured to H6 tolerance in order to maximize tool life, thus we discourage the use of standard endmill holders. We recommend hydraulic chucks or Shrink-fit adapters for these tools. Alternately, these tools can also be made with integral shank holders such as HSK, CAT, ANSI, etc. Upon request, we can supply these endmills with a Weldon flat but tool life will suffer due to excessive runout.
Mini Endmill Cartridge Identification—Inch
WIPER FLAT
NOSE RADIUSDOC
* 0= Neutral P= Positive N= Negative
2= 0/05= P/08= N/0
Axial/Radial Rake* Nose Radius
2 5
1= .006” (0,15mm)2= .015” (0,38mm)3= .030” (0,76mm)C= Chamfer
0= .150” (3,8mm) Standard0= No Wiper1= .015” (0,38mm)2= .030” (0,76mm)3= .060” (1,52mm)
Maximum Depth of Cut (DOC)Wiper Flat
C
A D
L
13
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Mini Endmill Identification—Metric
sp3 offers the Ultra-Mill Mini Endmill when machining small areas as well. What separates the Mini Endmill from its Ultra Endmill counterpart is that it has more cartridges per cutting diameter, which allows the user to increase the feed rate and hence increase throughput and production.
MUE 10 SS 32MM50MM
MUE - Mini Endmill
Cutting Diameter
Number of Pockets Shank Diameter
– – –Shank Style
SS= Straight ShankWD= Weldon ShankHSK= HSK Shank
MUE-25MM-6-SS-20MMMUE-25MM-6-SS-25MMMUE-32MM-6-SS-20MMMUE-32MM-6-SS-25MMMUE-38MM-6-SS-20MMMUE-38MM-6-SS-25MMMUE-45MM-8-SS-20MMMUE-45MM-8-SS-32MMMUE-50MM-10-SS-32MM
252532323838454550
104121104121104121104133133
66666688
10
74917491749174103103
202520252025203232
3,53,53,53,53,53,53,53,53,5
Standard Mini Endmill BodiesEffective Cutting Dia.A (mm)
Cutter Order Number
Overall Length L
No.Inserts
Shank Length C
Shank Dia. D
D.O.C. Max
Note: These endmills are manufactured to H6 tolerance in order to maximize tool life, thus we discourage the use of standard endmill holders. We recommend hydraulic chucks or Shrink-fit adapters for these tools. Alternately, these tools can also be made with integral shank holders such as HSK, CAT, ANSI, etc. Upon request, we can supply these endmills with a Weldon flat but tool life will suffer due to excessive runout.
WIPER FLAT
NOSE RADIUSDOC
2= 0/05= P/08= N/0
Axial/Radial Rake*
Mini Endmill Cartridge Identification—Metric
Nose Radius
MU 2 5D R 2 0
MU - Mini Endmill
C= CarbideD= PCDT= TFd
1= .006” (0,15mm)2= .015” (0,38mm)3= .030” (0,76mm)C= Chamfer
0= .150” (3,8mm) Standard0= No Wiper1= .015” (0,38mm)2= .030” (0,76mm)3= .060” (1,52mm)
Maximum Depth of Cut (DOC)Wiper FlatR= Right HandL= Left Hand
– ––
* 0= Neutral P= Positive N= Negative
14
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UE 4 SS 1.00D1.25
UE - Ultra Endmill
Cutting Diameter
Number of Pockets Shank Diameter
– – –
Shank StyleSS= Straight ShankWD= Weldon ShankCAT= Cat ShankBT= BT ShankHSK= HSK Shank
Endmill Identification —Inch
Endmill Cartridge Identification —Inch
Wiper Flat
Nose RadiusDOC
UE-D0.75-3-SS-0.75UE-D1.00-3-SS-1.00UE-D1.25-4-SS-1.00UE-D1.50-4-SS-1.00UE-D1.75-4-SS-1.25UE-D2.00-4-SS-1.25
0.751.001.251.501.752.00
4.254.504.504.504.754.75
334444
2.7503.0003.0003.0003.2503.250
0.751.001.001.001.251.25
1.001.001.001.001.001.00
25,00025,00025,00025,00025,00019,000
Effective Cutting Dia.A (in.)
Cutter Order Number
Overall Length L
Number of Pockets
DimensionsShank
Length CShank Dia. D
D.O.C. Max
Maxrpm
Nose Radius
EI 2 2D R 2 0
Endmill Inch
C= CarbideD= PCDT= TFd
1= .0102= .0303= .0604= .090**5= .0166= .100**C= Chamfer
0= 0/P1= 0/N2= 0/0
0= .2001= .3752= .5003= .6254= 1.0005= .750
0= No Wiper1= .0302= .0603= .1004= .120
Axial/Radial Rake*
Maximum Depth of CutWiper FlatR= Right HandL= Left Hand
– ––
Note: These endmills are manufactured to H6 tolerance in order to maximize tool life, thus we discourage the use of standard endmill holders. We recommend hydraulic chucks or Shrink-fit adapters for these tools. Alternately, these tools can also be made with integral shank holders such as HSK, CAT, ANSI, etc. Upon request, we can supply these endmills with a Weldon flat but tool life will suffer due to excessive runout.
* 0= Neutral P= Positive N= Negative
** Use of .090 nose radius or larger requires use of modified tool body.
A
C
D
L
UE 3 SS 25mmD25mm
UE - Ultra Endmill
Cutting Diameter
Number of Pockets Shank Diameter
– – –
Shank StyleSS= Straight ShankWD= Weldon ShankCAT= Cat ShankBT= BT ShankHSK= HSK Shank
Endmill Identification—Metric
Note: These endmills are manufactured to H6 tolerance in order to maximize tool life, thus we discourage the use of standard endmill holders. We recommend hydraulic chucks or Shrink-fit adapters for these tools. Alternately, these tools can also be made with integral shank holders such as HSK, CAT, ANSI, etc. Upon request, we can supply these endmills with a Weldon flat but tool life will suffer due to excessive runout.
15
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Endmill Cartridge Identification—Metric
Wiper Flat
Nose RadiusDOC
Nose Radius
EM 2 2D R 2 0
Endmill Metric
C= CarbideD= PCDT= TFd
1= 0.252= 0.753= 1.504= 2.25**5= 0.406= 2.50**C= Chamfer
0= 0/P1= 0/N2= 0/0
0= 5.001= 9.502= 12.003= 16.004= 25.005= 19.00
0= No Wiper1= 0.752= 1.503= 2.504= 3.00
Axial/Radial Rake*
Maximum Depth of CutWiper FlatR= Right HandL= Left Hand
– ––
* 0= Neutral P= Positive N= Negative
** Use of 2.25mm nose radius or larger requires use of modified tool body.
A
C
D
L
UE-D20MM-3-SS-20MMUE-D25MM-3-SS-25MMUE-D32MM-3-SS-32MMUE-D40MM-4-SS-32MMUE-D50MM-4-SS-32MM
2025324050
106116120120120
33344
6676808080
2025323232
25.025.025.025.025.0
25,00025,00025,00025,00019,000
Effective Cutting Dia.A (mm)
Cutter Order Number
DimensionsShank
Length CShank Dia. D
D.O.C. Max
Maxrpm
Overall Length L
Number of Pockets
16
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Miscellaneous Adjustment Tools
sp3 is not responsible for any defects caused by improper use or setting of its milling cutters. Care should be taken and exercised when handling aluminum cutter bodies. Although the outside surface is hard, aluminum will dent or nick from improper handling. Extreme caution should be taken when handling and setting to ensure maximum cutter performance.
Hardware
Hardware and Adjustment Tools
Part # Description Cutter Family
63600 3/16" & 1/4" Cartridge Adjustment Wrench Ultra-Mills Standard and Intermediate - INCH
63601 Pre-set 45 in-lbs Torque Wrench Ultra-Mills Standard and Intermediate - INCH
63616 Replacement T-25+ 1/4" Drive Socket Ultra-Mills Standard and Intermediate - INCH
63602 Torx T-25+ T-handle Wrench Ultra-Mills Standard and Intermediate - INCH
63605 6mm & 7mm Cartridge Adjustment Wrench Ultra-Mills Standard and Intermediate - METRIC
63606 Pre-set 50 in-lbs Torque Wrench Ultra-Mills Standard and Intermediate - METRIC
63615 Replacement T-25 1/4" Drive Socket Ultra-Mills Standard and Intermediate - METRIC
63611 Torx T-25 T-handle Wrench Ultra-Mills Standard and Intermediate - METRIC
63603 Pre-set 14.5 in-lbs Torque Wrench Mini Ultra-Mills - INCH and METRIC
63604 Torx T-9 T-handle Wrench Mini Ultra-Mills - INCH and METRIC
63600 3/16” & 1/4” Cartridge Adjustment Wrench Mini Ultra-Mills - INCH
63624 5mm Cartridge Adjustment Wrench Mini Ultra-Mills - METRIC
63607 Torx T-15 Wing Style Handle Wrench Ultra-Endmills - INCH and METRIC
63609 Pre-set 19 in/lbs Torque Wrench Ultra-Endmills - INCH and METRIC
63627 1/16” Allen Cartridge Adjustment Wrench Ultra-Endmills - INCH
63626 1.5mm Allen Cartridge Adjustment Wrench Ultra-Endmills - METRIC
63350 UMPP - Pocket Protector Ultra-Mills - INCH and METRIC
63351 UMIPP - Pocket Protector Ultra-Mill Intermediate - INCH and METRIC
Description Cartridge Mount Screw
Cartridge Adjustment
Nut
Stud for Adjustment
Nut
Cartridge Adjustment
Screw
Ultra-Mill 2-1/2” Diameter thru 4.0” using UCxx style cartridges 63501 63500 63502
Ultra-Mill 4-1/2” Diameter or larger using UCxx style cartridges 63503 63500 63504
Ultra-Mill 63.5mm Diameter thru 76.2mm using UCxx style cartridges 63521 63520 63522
Ultra-Mill 76.3mm Diameter or larger using UCxx style cartridges 63523 63520 63524
Ultra-Mill Intermediate 2” Diameter thru 4.0” using UIxx cartridges 63501 63500 63502
Ultra-Mill Intermediate 4-1/2” Diameter or larger using UIxx cartridges 63503 63500 63504
Ultra-Mill Intermediate 75.0mm using UIxx cartridges 63521 63520 63522
Ultra-Mill Intermediate 80.0mm Diameter or larger using UIxx cartridges 63523 63520 63524
Mini Ultra Endmill 1.0” Diameter Only using MUxx cartridges 63540 63541
Mini Ultra Endmill 1.25” Diameter and Larger using MUxx cartridges 63542 63541
Mini Ultra Endmill 25mm Diameter Only using MUxx cartridges 63540 63568
Mini Ultra Endmill 32mm Diameter and Larger using MUxx cartridges 63542 63568
Ultra Endmill .75” Diameter thru 1.25” using EIxx cartridges 63300 63547
Ultra Endmill 1.50” and larger using EIxx cartridges 63302 63547
Ultra Endmill 20mm Diameter thru 32mm using EMxx cartridges 63527 63528
Ultra Endmill 40mm Diameter and larger using EMxx cartridges 63549 63528
1.) When installing new cartridges, ensure pockets are clean and free of burrs.
2.) Clean bottom of cutter to ensure it is free of burrs and dirt. Cutter must sit flat on surface or setting fixture.
3.) Turn axial adjusting nuts or screws down one turn.
4.) Install cartridges in body and tighten mounting screw to:
a.) Ultra-Mill and Ultra-Mill Intermediate - 15-20 in/lbs or 1.7-2.3 Nm
b.) Ultra-Mill Mini Endmill – 8-10 in/lbs or .9-1.2 Nm
c.) Ultra Endmill – 10-12 in/lbs or 1-1.5 Nm
5.) Set indicator to desired height.
6.) Using the proper wrench, adjust cartridges to within .001” or .03mm from setting height.
7.) Tighten mounting screws to:
a.) Ultra-Mill and Ultra-Mill Intermediate - INCH - 45 in/lbs or 5.1 Nm
b.) Ultra-Mill and Ultra-Mill Intermediate - METRIC - 50 in/lbs or 5.7 Nm
c.) Ultra-Mill Mini Endmill – 15.5 in/lbs or 1.8 Nm
d.) Ultra Endmill – 19 in/lbs or 2.1 Nm
i.) Make sure screws are securely tightened
8.) Using the proper wrench, adjust cartridges to finished setting height. To achieve the best surface finishes, all cartridges need to be within +/- .0001” or .0025mm.
Setup Procedure for Milling Cutters
Page 1/1
Scan this code with your smart phone to view sp3’s online setup video.
Note: sp3 recommends that any tool running at 10,000 rpm or greater be balanced as an assembly to G2.5 or better.
17
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18
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sp3 offers a standard family of Positive Rake PCD tipped ANSI/ISO inserts for your turning and boring needs. Utilizing a premium grade of PCD, sp3 inserts offer excellent tool life and performance to suit your application. Please contact your local sp3 sales representative for assistance in selecting the proper insert for your requirements.
55°80°60°
5°5°5°
Part # ANSI Description ISO Description Tip Size Top Rake
41990-01 TCGX-21.51 4mm PCD TCGX-110204 4mm PCD 4.0MM 5°
41990-02 TCGX-21.52 4mm PCD TCGX-110208 4mm PCD 4.0MM 5°
41990-03 TCGX-32.51 4mm PCD TCGX-16T304 4mm PCD 4.0MM 5°
41990-04 TCGX-32.52 4mm PCD TCGX-16T308 4mm PCD 4.0MM 5°
41991-01 TPGX-21.51 4mm PCD TPGX-110204 4mm PCD 4.0MM 5°
41991-02 TPGX-21.52 4mm PCD TPGX-110208 4mm PCD 4.0MM 5°
41991-03 TPGX-32.51 4mm PCD TPGX-16T304 4mm PCD 4.0MM 5°
41991-04 TPGX-32.52 4mm PCD TPGX-16T308 4mm PCD 4.0MM 5°
41992-01 CCGX-21.51 4mm PCD CCGX-060204 4mm PCD 4.0MM 5°
41992-02 CCGX-21.52 4mm PCD CCGX-060208 4mm PCD 4.0MM 5°
41992-03 CCGX-32.51 4mm PCD CCGX-09T304 4mm PCD 4.0MM 5°
41992-04 CCGX-32.52 4mm PCD CCGX-09T308 4mm PCD 4.0MM 5°
41993-01 CPGX-21.51 4mm PCD CPGX-060204 4mm PCD 4.0MM 5°
41993-02 CPGX-21.52 4mm PCD CPGX-060208 4mm PCD 4.0MM 5°
41993-03 CPGX-32.51 4mm PCD CPGX-09T304 4mm PCD 4.0MM 5°
41993-04 CPGX-32.52 4mm PCD CPGX-09T308 4mm PCD 4.0MM 5°
41994-01 DCGX-21.51 4mm PCD DCGX-070204 4mm PCD 4.0MM 5°
41994-02 DCGX-21.52 4mm PCD DCGX-070208 4mm PCD 4.0MM 5°
41994-03 DCGX-32.51 4mm PCD DCGX-11T304 4mm PCD 4.0MM 5°
41994-04 DCGX-32.52 4mm PCD DCGX-11T308 4mm PCD 4.0MM 5°
41995-01 DPGX-21.51 4mm PCD DPGX-070204 4mm PCD 4.0MM 5°
41995-02 DPGX-21.52 4mm PCD DPGX-070208 4mm PCD 4.0MM 5°
41995-03 DPGX-32.51 4mm PCD DPGX-11T304 4mm PCD 4.0MM 5°
41995-04 DPGX-32.52 4mm PCD DPGX-11T308 4mm PCD 4.0MM 5°
PCD Tipped ANSI/ISO Screwdown Inserts - 5° Positive Rake
sp3 offers a standard family of Flat Top PCD tipped ANSI/ISO inserts for your turning and boring needs. Utilizing a premium grade of PCD, sp3 inserts offer excellent tool life and performance to suit your application. Please contact your local sp3 sales representative for assistance in selecting the proper insert for your requirements.
19
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PCD Tipped ANSI/ISO Screwdown Inserts - Flat Top
Part # ANSI Description ISO Description Tip Size Top Rake
41984-01 TCGW-21.51 4mm PCD TCGW-110204 4mm PCD 4.0MM 0°
41984-02 TCGW-21.52 4mm PCD TCGW-110208 4mm PCD 4.0MM 0°
41984-03 TCGW-32.51 4mm PCD TCGW-16T304 4mm PCD 4.0MM 0°
41984-04 TCGW-32.52 4mm PCD TCGW-16T308 4mm PCD 4.0MM 0°
41985-01 TPGW-21.51 4mm PCD TPGW-110204 4mm PCD 4.0MM 0°
41985-02 TPGW-21.52 4mm PCD TPGW-110208 4mm PCD 4.0MM 0°
41985-03 TPGW-32.51 4mm PCD TPGW-16T304 4mm PCD 4.0MM 0°
41985-04 TPGW-32.52 4mm PCD TPGW-16T308 4mm PCD 4.0MM 0°
41986-01 CCGW-21.51 4mm PCD CCGW-060204 4mm PCD 4.0MM 0°
41986-02 CCGW-21.52 4mm PCD CCGW-060208 4mm PCD 4.0MM 0°
41986-03 CCGW-32.51 4mm PCD CCGW-09T304 4mm PCD 4.0MM 0°
41986-04 CCGW-32.52 4mm PCD CCGW-09T308 4mm PCD 4.0MM 0°
41987-01 CPGW-21.51 4mm PCD CPGW-060204 4mm PCD 4.0MM 0°
41987-02 CPGW-21.52 4mm PCD CPGW-060208 4mm PCD 4.0MM 0°
41987-03 CPGW-32.51 4mm PCD CPGW-09T304 4mm PCD 4.0MM 0°
41987-04 CPGW-32.52 4mm PCD CPGW-09T308 4mm PCD 4.0MM 0°
41988-01 DCGW-21.51 4mm PCD DCGW-070204 4mm PCD 4.0MM 0°
41988-02 DCGW-21.52 4mm PCD DCGW-070208 4mm PCD 4.0MM 0°
41988-03 DCGW-32.51 4mm PCD DCGW-11T304 4mm PCD 4.0MM 0°
41988-04 DCGW-32.52 4mm PCD DCGW-11T308 4mm PCD 4.0MM 0°
41989-01 DPGW-21.51 4mm PCD DPGW-070204 4mm PCD 4.0MM 0°
41989-02 DPGW-21.52 4mm PCD DPGW-070208 4mm PCD 4.0MM 0°
41989-03 DPGW-32.51 4mm PCD DPGW-11T304 4mm PCD 4.0MM 0°
41989-04 DPGW-32.52 4mm PCD DPGW-11T308 4mm PCD 4.0MM 0°
55°80°60°
Quick Reference:ae=
35%25%10%
5%
1.201.452.053.00
increase feed by:
Feed Rates:vf= n · z · fz
f= z · fz
vf= n · zc · fz
f= zc · fz
or
or
Metal Removal Rates:Q= ae · ap · vf
Average Chip Thickness:
hm= fz · ae
Dfz= hm · D
ae
Note: If using a two- or three-stage Ultramill, use the effective (zc) number of teeth to calculate feed rate.
Note: Use to calculate when width of cut (ae) is less than 50% of D.
Milling Theory and Calculations:
Formulas and Legend
D =Dw=R =z =zc=n =vc=vf=f =fz=
hm=ae=ap=Q =K =π=
Cutting DiameterWorking DiameterCutter RadiusNumber of TeethEffective Number of TeethRPMSurface Feet/Meters per MinuteCutter Feed—Inches/mm per MinuteFeed per RevolutionFeed per ToothAverage Chip ThicknessWidth of Cut —Radial Depth of CutDepth of Cut—Axial Depth of CutMetal Removal Rate—in3/min or mm3/min Lead AnglePi (3.1415)
100%75%50%25%
Axial chip thinning requires increase in feed rate to maintain proper chip thickness.
If ap≤
If ap=If ap=If ap=
25% of cartridge radius, increase feed by 4x26-50% of cartridge radius, increase feed by 2x51-75% of cartridge radius, increase feed by 25%100% or more of cartridge radius, do not increase feed
Cutting Speed and RPM–Inch:
Cutting Speed and RPM–Metric:
Vc=
Vc=
Vc= n ÷ 3.82 · D
Vc= n · .00314 · D
n=
n=
n= Vc · 3.82 ÷ D
n= Vc · 318.057÷ D
n · π · D
n · π · D
Vc · 12
Vc · 1,000
12
1,000
π · D
π · D
Note:The equations and quick-reference charts below do not take into account the condition of the machine or spindle, fixture design or condition, part configuration, size / condition of taper or any other applicaton specific data. Before relying on data gathered from any calculations, please make an assesment of your specfic machining conditions and adjust feeds, speeds and depths of cut accordingly. Please do not adjust feed-per-tooth to a value greater than your wiper flat.
20
WWW.SP3CUTTINGTOOLS.COM
Cutting DataInch
Metric
High Silicon Aluminum
>10% Silicon
Cutting Speed Vc
1000 1500 2000
Feed Rate per Tooth fz
0.001 0.004 0.008
0.001 0.004 0.006
0.001 0.003 0.004
0.001 0.003 0.004
Carbide and Ceramic (Green)
Cutting Speed Vc
500 1000 1500
Feed Rate per Tooth fz
0.002 0.004 0.008
0.002 0.004 0.006
0.001 0.003 0.004
0.001 0.003 0.004
Manufactured Wood
Cutting Speed Vc
3000 6000 8000
Feed Rate per Tooth fz
0.004 0.006 0.010
0.004 0.006 0.008
0.003 0.005 0.008
0.003 0.005 0.008
Medium Silicon Aluminums
8-10% Silicon
Cutting Speed Vc
2000 3000 6000
Feed Rate per Tooth fz
0.001 0.004 0.008
0.001 0.004 0.006
0.001 0.003 0.004
0.001 0.003 0.004
Free Machining Alloys
ie: Gold, Platinum, Lead
Cutting Speed Vc
500 1000 1500
Feed Rate per Tooth fz
0.003 0.004 0.007
0.003 0.004 0.006
0.002 0.003 0.005
0.002 0.003 0.005
Reinforced Plastics
ie: Carbon Fiber Composites
Cutting Speed Vc
1500 2500 5000
Feed Rate per Tooth fz
0.002 0.003 0.005
0.002 0.003 0.004
0.001 0.002 0.004
0.001 0.002 0.004
Copper - Bronze - Zinc
Cutting Speed Vc
1000 1500 2500
Feed Rate per Tooth fz
0.001 0.003 0.006
0.001 0.003 0.005
0.001 0.002 0.005
0.001 0.002 0.005
Unfilled Plastics
Cutting Speed Vc
1500 2500 5000
Feed Rate per Tooth fz
0.001 0.003 0.006
0.001 0.003 0.005
0.001 0.002 0.005
0.001 0.002 0.005
Low Silicon Aluminums
<8% Silicon
Cutting Speed Vc
2000 4000 10,000
Feed Rate per Tooth fz
0.001 0.004 0.008
0.001 0.004 0.006
0.001 0.003 0.004
0.001 0.003 0.004
High Silicon Aluminum
>10% Silicon
Cutting Speed Vc
305 460 610
Feed Rate per Tooth fz
0.025 0.100 0.200
0.025 0.100 0.150
0.025 0.075 0.100
0.025 0.075 0.100
Carbide and Ceramic (Green)
Cutting Speed Vc
150 305 460
Feed Rate per Tooth fz
0.050 0.100 0.200
0.050 0.100 0.150
0.025 0.075 0.100
0.025 0.075 0.100
Manufactured Wood
Cutting Speed Vc
915 1830 2440
Feed Rate per Tooth fz
0.100 0.150 0.250
0.100 0.150 0.200
0.075 0.120 0.200
0.075 0.120 0.200
Medium Silicon Aluminums
8-10% Silicon
Cutting Speed Vc
610 915 1830
Feed Rate per Tooth fz
0.025 0.100 0.200
0.025 0.100 0.150
0.025 0.075 0.100
0.025 0.075 0.100
Free Machining Alloys
ie: Gold, Platinum, Lead
Cutting Speed Vc
150 305 460
Feed Rate per Tooth fz
0.075 0.100 0.180
0.075 0.100 0.150
0.050 0.080 0.120
0.050 0.080 0.120
Reinforced Plastics
ie: Carbon Fiber Composites
Cutting Speed Vc
460 760 1525
Feed Rate per Tooth fz
0.050 0.075 0.120
0.050 0.075 0.100
0.025 0.050 0.100
0.025 0.050 0.100
Copper - Bronze - Zinc
Cutting Speed Vc
305 460 760
Feed Rate per Tooth fz
0.025 0.075 0.150
0.025 0.075 0.120
0.025 0.050 0.120
0.025 0.050 0.120
Unfilled Plastics
Cutting Speed Vc
460 760 1525
Feed Rate per Tooth fz
0.025 0.075 0.150
0.025 0.075 0.150
0.025 0.050 0.150
0.025 0.050 0.120
Low Silicon Aluminums
<8% Silicon
Cutting Speed Vc
610 1220 3050
Feed Rate per Tooth fz
0.025 0.100 0.200
0.025 0.100 0.150
0.025 0.075 0.100
0.025 0.075 0.100
Cutter Family
Ultramill
Ultramill Intermediate
Ultramill Mini
Ultra Endmill
Cutter Family
Ultramill
Ultramill Intermediate
Ultramill Mini
Ultra Endmill
Cutter Family
Ultramill
Ultramill Intermediate
Ultramill Mini
Ultra Endmill
Sample
Cutting Speed Vc
Low Starting High
Feed Rate per Tooth fz
Low Starting High
Lowest
recommended
cutting data
Recommended
starting cutting data
Not recommended to
exceed without calling sp3
Cutter Family
Ultramill
Ultramill Intermediate
Ultramill Mini
Ultra Endmill
Cutter Family
Ultramill
Ultramill Intermediate
Ultramill Mini
Ultra Endmill
Cutter Family
Ultramill
Ultramill Intermediate
Ultramill Mini
Ultra Endmill
Note: Do not exceed maximum RPM listed on product pages.21
CALL TOLL FREE! 1-888-547-4156
22
WWW.SP3CUTTINGTOOLS.COM
Tool Function: Drills thru from a blind hole, creates 3 diameters, a chamfer and 2 shoulders for a differential carrier housing.
Benefits: The Ultra-Mill Boring Bar features replaceable and axially adjustable cartridges. The adjustable cartridges vs. a fixed pocket insert provide a more uniform cut and load sharing which provides more even wear. Their replaceable trait reduces cost compared to a fixed pocket PCD
Tool Function: Drills through for a pipe thread, chamfers and faces the holes and faces the outer seal surface for an oil filter housing.
Benefits: The replaceable core drill that threads into the tool body allows for easy maintenance and replacement. Axially and radially adjustable cartridges
Tool Function: Boring and chamfering 2 diameters and facing one surface.
Benefits: The full form is in each cartridge and each cartridge is radially adjustable for ease of setting.
tool. This boring bar also features coolant thru which removes the chips from the cutting edge.
Advantages: The Ultra-Mill Multi-Step Boring Bar replaced a core drill and a fixed pocket boring bar. It provides reduced tooling costs. In addition, the cost to refurbish the
diamond components in the bar is much less than retipping a fixed pocket boring bar.
allow for more uniform wear, which enhances tool life and provides improved part finish.
Advantages: This tool configuration replaced 3 tools – therefore reducing cycle time and lowering overall tooling cost.
Advantages: The Ultra-Mill Form Boring Tool replaced 2 tools that interpolated the form. Therefore, this tool has reduced cycle time and has provided a reduction in tool inventory, reducing tool costs.
Ultra-MillTM Multi-Step Boring Bar
Ultra-MillTM Core Drill and Facing Tool
Ultra-MillTM OD Form Trepannng Tool
Ultra-MillTM Fin Mill
Tool Function: Removing casting flash and temporary reinforcements used to equalize cooling rates on die cast cylinder housings.
Benefits: We designed this mill to replace the additional handling and band saw labor used previously to allow the task to be completed within the machining center used to process the part from as-cast to finish machined part.
23
CALL TOLL FREE! 1-888-547-4156
Special Tools
Tool Function: The face milling of a remote deep cavity limited access area.
Benefits: The Ultra-Mill Mini-Mill with integral shank provides improved rigidity. The axially adjustable cartridges allow for more uniform load sharing. The through spindle coolant provides better chip evacuation and reduces heat.
Tool Function: The face milling of a throttle body.
Benefits: The Ultra-Mill with integral shank provides improved rigidity. The axially adjustable cartridges allow for more uniform load sharing. The through spindle coolant provides better chip evacuation and reduces heat.
Advantages: This Ultra-Mill replaced an indexable 5 blade
Tool Function: Quickly and efficiently removing excess casting stock and establishing locating surfaces prior to loading the casting into a machining center for complete processing
Benefits: This special Ultra-Mill Cubing Mill allows for higher metal removal rates, reducing machining time and longer tool life than the previous indexable carbide mill.
Advantages: The versatility of a Mini Ultra-Mill allows for additional cartridges in the same cutting diameter which allows for increased feed rates and therefore faster throughput. The integral shank reduces deflections during the cut, which was critical in this long reach application.
cutter. The versatility of an Ultra-Mill allows for additional cartridges in the same cutting diameter which allows for increased feed rates and therefore faster throughput. In this particular application, the Ultra-Mill is providing a significant annual tool reduction cost (in excess of $150,000) to this particular customer.
Advantages: The UltraMill provides almost unlimited freedom to create special tools for specific applications often replacing multiple tools in the process with one tool.
Ultra-MillTM Cubing Mill
Ultra-MillTM Mini Mill with CAT40 Integral Shank
Ultra-MillTM with HSK63 Integral Shank
Ultra-MillTM Fin Mill
Advantages: A classic example of using the Ultra Mill base to design a special purpose cutter with special form cartridges allows for standardization of spare parts and hardware, as well as reduction of previously required operations.
24
WWW.SP3CUTTINGTOOLS.COM
Roundsp3-Round Monoblock Tool
sp3-Round Monoblock Tool
sp3-Round High Precision Reamer
sp3-Round Modular Tooling
Tool Design: PCD tipped monoblock tools with multiple steps and cutting edges. All tool bodies are machined from tool steel and are precision ground from the taper to the PCD blades between centers for the best possible TIR. HSK, CAT, BT and tapers for wet and MQL machining are available. All tools are balanced by design as well as mechanically before shipment.
Tool Design: Built of modular exchangeable components to accommodate exhaust and intake machining of the parent seat and valve guide holes. The body is solid carbide with solid carbide guide pads and PCD blades for precision reaming. Mounted on the reamer is a bushing made from tool steel and PCD tipped. All parts are precision ground between centers for the best possible TIR.
Tool Design: This high precision reaming system is based on using multiple solid carbide guides and PCD inserts to ensure precision hole making with diametric and geometric consistency. For optimal TIR the system is paired with a simple runout adjustment and clamping system designed for this precision reamer system.
Tool Design: PCD tipped monoblock tools with multiple steps and cutting. All tool bodies are machined from tool steel and are precision ground from the taper to the PCD blades between centers for the best possible TIR. HSK, CAT, BT and tapers for wet and MQL machining are available. All tools are balanced by design as well as mechanically before shipment.
Application: This tool is used in a cylinder head for the cup plug bore. Challenges are machining the feature in one step and not allowing chips/swarf to fall into the water passages.
Advantages: No assembly, no runout adjustment, no setup of cutting edges to size.
Application: Components are interchangeable to accommodate different exhaust and intake valve seat parent holes. Similar modular solutions are available for engine, transmission, fluid technology, chassis and brake as well as aircraft parts.
Advantages: No assembly, no runout adjustment, no setup of cutting edges to size.
Application: For use in all reaming operations requiring precise diameter consistency, straightness and roundness requirements.
Advantages: Precision holes; the operation doesn’t follow the pre-bored holes. This system is ideal when more open tolerance requirements exist in situations with low component, fixture or machine spindle rigidity.
Application: This tool is used in a cylinder head for the springseat face and diameter. Challenges are machining the hole in one step into the casting and not allowing chips in the head nor ring or half ring inside the part.
Advantages: No assembly, no runout adjustment, no setup of cutting edges to size.
*Solutions are available for engine, transmission, fluid technology, chassis and brake as well as aircraft parts.
Round
25
CALL TOLL FREE! 1-888-547-4156
sp3-Round Tool Holders for Runout Adjustment
sp3-Round Special Tools
sp3-Round PCD Contour Milling Cutter
sp3-Round PCD Drills
Tool Design: Multiple contoured, precision PCD tips match your required complex contouring operation. The tools are available as steel body monoblock tools, with solid carbide body, and as combination tools.
Holder Design: We have multiple precision ground holder solutions with adjustment capabilities for HSK, CAT and BT.
Application: All precision machining operations with weak spindle interface conditions, or high length to diameter ratios.
Tool Design: Our drills are based on solid carbide bodies and either PCD wing tipped, across center or sandwich diamond tipped.
Application: If diametric consistency is needed in your drilled hole or longer life is needed, or
Tool Design: If you did not see an obvious solution above, please contact us with your requirements and we will develop one for you.
Application: Solutions are available for engine, transmission, fluid technology, chassis and brake as well as aircraft parts.
Application: All axial, radial, circular milling, grooving, and plunging contour operations.
Advantages: No restrictions due to clamping/location of inserts. No difficult set up of multiple inserts to match your contour.
Advantages: Eliminate runout issues and improve the quality of your machining operation.
you have high silicon content in your material this is the way to go.
Advantages: PCD drills will hold hole size to your specification longer than solid carbide drills can.
Advantages: If you are using multiple tools and cycle time is an issue, let us deal with tooling solutions that work and which will improve your operations, lower your costs, and improve throughput.
*Solutions are available for engine, transmission, fluid technology, chassis and brake as well as aircraft parts.
26
WWW.SP3CUTTINGTOOLS.COM
Intermediate Quote Request Formandsp3
"H""E" "F"
"C"
"D"
"I"
"A"
"B"
A: C
utter Diam
eter _______________
B: S
et Height __________________
C: P
ilot Diam
eter _______________
D: P
ilot Dep
th _________________
E: K
ey Way W
idth _______________
F: Key W
ay Dep
th _______________
G: N
umb
er of Teeth _______________
H: M
at'l Being C
ut _______________
I: Show
er Screw
Need
ed? ____________
J: Show
er Screw
Thread _____________
K: C
utter Bod
y Material _____________
"L"
"M"
"N"
CH
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D
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NO
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D: A
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±.03
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XX
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INF
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3531 WE
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224
Phone (888) 547-4156
CU
TT
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TO
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Fax (260) 547-4214
DE
CATU
R, IN
46733
DIA
MO
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CU
STO
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DIS
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CU
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TYP
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STA
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DIN
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ME
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___________________
CA
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_____________
L: Dep
th of Cut ___________________
M: N
ose Rad
ius ___________________
N: W
idth of W
iper Flat ______________
O: Tip
Material: P
CD
___ CB
N ___
Axial R
ake:______
Rad
ial Rake:_______
NE
UTR
AL 0
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"J"
27
CALL TOLL FREE! 1-888-547-4156
Intermediate Endmill Quote Request FormMini andsp3
C
UTT
ER
A: C
utte
r D
iam
eter
___
____
____
____
B: O
vera
ll Le
ngth
___
____
____
____
_
C: S
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t __
____
____
____
____
D: S
hank
Dia
met
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____
____
____
__
E: S
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Tol
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____
____
____
__
F: F
lat
Wid
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____
____
____
____
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G: N
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____
____
____
__
H: M
at'l
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____
____
____
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I: Th
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____
____
____
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"B"
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24
Pho
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Fax
(260
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-421
4
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467
33
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____
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J: D
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____
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K: N
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____
____
____
____
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L: W
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____
____
____
Axi
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____
__
Rad
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____
___
NE
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28
WWW.SP3CUTTINGTOOLS.COM
Endmill Quote Request Formsp3
CH
EC
KE
D
.XX
X ±
NO
T OTH
ER
WIS
E S
PE
CIFIE
D: A
NG
LE ±
DE
C.: .X
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±FIN
. .01
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XX
±.0005
INF
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DR
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VSIZE
BD
RA
WIN
G N
O
DATE
DATE
AP
PR
OV
ED
DATE
DATE
A
3531 WE
ST U
S H
IGH
WAY
224
Phone (888) 547-4156
CU
TT
ING
TO
OL
SFax (260) 547-4214
DE
CATU
R, IN
46733
DIA
MO
ND
CU
STO
ME
R
DIS
TRIB
UTO
R
DR
AW
N B
Y:
"K" "L"
"J"
"B"
"D"&
"E"
"C"
"A"
"F" CU
TTER
A: C
utter Diam
eter _______________
B: O
verall Length ________________
C: S
hank Length __________________
D: S
hank Diam
eter _______________
E: S
hank Tolerance _______________
F: Flat Wid
th ___________________
G: N
umb
er of Teeth _______________
H: M
at'l Being C
ut _______________
I: Through Coolant? _______________
CA
RTR
IDG
E:
_____________
J: Dep
th of Cut ___________________
K: N
ose Rad
ius ___________________
L: Wid
th of Wip
er Flat ______________
Axial R
ake:______
Rad
ial Rake:_______
NE
UTR
AL 0
PO
SITIV
E P
NE
GATIV
E N
29
CALL TOLL FREE! 1-888-547-4156
Quote Request
Ship To: Customer: Distributor: Other: Special Instructions (Note Below)
Distributor:
Contact Person:
Phone Number:
Address:
End User:
Contact Person:
Phone Number:
Address:
Customer Data
Special Requirements
Reference Quote #
Sales Person:
Date Entered: Date Required:
Request for Quote
Test
Projected Annual Usage:
New Tool #:
Description:
Cutter Diameter / IC:
# of Stations / Blades: LH: RH:
Cartridge Style / Insert: (Geometry) PDC TFd
Depth of Cut:
Customer Supplied Insert / Tool: Yes No Grade: Manufacturer
Proposed ToolCatalog: Yes No
Quote Quantity:
Current Process Conditions
Material to Cut: Spindle RPM: Feed Rate IPM: DOC:
Current Tool: Carbide: PCD: Other:
Surface Finish Required: Coolant: Thru Spindle: Shower Screw: Flood:
Common Failure Mode: Finish: Wear: Chipping: Burr: Other:
Desired Improvement Over Current Tool: Life: Cost: Finish: Other:
Inch: Metric:
Other:Milling: Turning: Boring: Drilling:
sp3 Cutting Tools, Inc.3531 West US Hwy 224, Decatur, IN 46733
Phone: 888-547-4156 • Phone 260-547-4150 • Fax: 260-547-4214 • E-Mail: cuttingtools@sp3inc.comwww.sp3cuttingtools.com
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