KENNAMETAL’s next generation Mill 16 has a wedge-style clamping system, numbered pockets and inserts, and an open pocket design to increase chip flow in heavy roughing.
As automakers strive to introduce more fuel efficient and environmentally friendly vehicles, they’re shifting from gray and ductile iron castings for engine and drivetrain parts to compacted graphite iron (CGI), sometimes known as vermiculate graphite iron.
“Compared to cast iron, CGI has lower weight and greater strength, and is ideal for components that are exposed to both thermal and mechanical stresses like engine blocks and heads for cars and trucks, exhaust manifolds, and brake parts,” according to Kennametal’s senior global product manager for indexable milling, Marcelo Campos. “As with other cast irons, however, it is quite abrasive, and somewhat gummy to machine. We developed Mill 16 as a best-in-class face mill not only for CGI, but for all types of cast iron, which remains a popular choice for gear boxes, housings, pump bodies, and other components used in the automotive, agricultural, and heavy equipment sectors.”
Campos outlined Mill 16’s strengths as follows:
— Mill 16 has a fine-pitch and medium pitch cutter body equipped with an innovative single-screw, wedge-style clamping system. This reduces time spent in the tool crib setting the tool and assures rigid, no-fail tool placement. Each pocket on the cutter body is numbered, as are each of the insert’s cutting edges, assuring maximum accuracy and ease of use when indexing to a new cutting edge.
— The heart of the Mill 16 is an octagonal, double-sided insert with 16 effective cutting edges, providing the lowest tooling cost per part possible. The face of each cutting edge contains an aggressive chip-breaker for positive cutting action and increased chip flow. The wedge clamp on either side of the insert’s top face is likewise chamfered to improve chip evacuation.
— Mill 16 is available in cutter diameters ranging from 2 in. to 10 in. (50 mm to 250 mm). Kennametal has rated the maximum axial depth of cut (Ap1) at 5.5 mm (0.216 in.), although depths to 9 mm (0.35 in.) or greater are achievable, an important consideration where casting variation is a concern. Due to the cutter’s low cutting forces, up to 100% radial cutter engagement is possible. All cutters have internal coolant supply capability.
— The carbide is new. Kennametal’s grade KCK20 is a PVD AlTiN/AlTiCrN multilayer coating bonded to a wear resistant substrate which provides an average tool life of 30% greater than comparable TiAlN-coated grades.
— A wide assortment of insert edge preps, geometries, corner radii, as well as a number of complementary grades assure the Mill 16 is a top performer in a variety of machining conditions, from heavy roughing to semi-finishing and, because of the insert’s integrated wiper facet, fine finishing to Ra 3.2 Œºm or better.
Learn more at www.kennametal.com