Heat resistant super alloys

Application Guide

Head office:
AB Sandvik Coromant
SE-811 81 Sandviken, Sweden
www.sandvik.coromant.com
E-mail: [email protected]

© AB Sandvik Coromant 2025

Contents
Introduction 2 5. Solid Carbide Milling 126
Solid carbide in HRSA 127
1. Heat resistant super alloys – HRSA 3
Application hints 133
Alloy groups 4
CoroMill® Plura for HRSA 140
Machinability/raw material condition 5
CoroMill® Plura profiling 150
Common component types 7
Component/feature based solutions 158
Machining stages 8
Coolant 11 6. Hole Making 162
Solid carbide drills 166
2. Turning of nickel-based materials 12 Exchangable tip drill 170
Insert shape selection 12 Indexable insert drills 172
Typical wear mechanisms 14 Material Edge Preparation 176
ISO Geometry selection 18 Thread Milling 178
Sandvik Coromant concepts 20 Component/Feature Solutions 180
Round insert application hints 44
Carbide insert grades 50 7. Digital & services 184
Geometries and chip breaking 62
8. Technical data 190
Chip charts 63
Tailor Made 66 9. Material cross-reference list 192
Modular holders - CoroTurn®SL 68
10. Notes 198
Engineered solutions 70
Component/feature solutions 77

3. Milling 84
Cutter concept 90
Effect of entering angle 94
Milling grades 95
Face milling with carbide inserts 100
End milling/90 degree approach 106
High feed milling 116
Ceramic milling 124

©2025 Sandvik Coromant AB. All rights reserved. This document may not be copied or reproduced in whole or
in part, or transferred to any other media or language, by any means, without the prior written permission of
Sandvik Coromant AB
Introduction Heat resistant super alloys
This application guide concentrates on optimising machining of heat resistant super Heat resistant super alloys (HRSA) are a family of alloys utilised in various
alloys (HRSA). industry segments:

For one of the most challenging material groups to machine, optimised tools are Aerospace engine – combustion and turbine sections.
naturally a prerequisite, but equally important is how to apply them.
Stationary gas turbines – combustion and turbine sections.
We will guide you through the most common materials and machining applications. Oil and gas – marine applications.
We aim to give you application and process recommendations that will help you use
our products in the most productive manner with maximum process reliability and
component quality.
The properties which make them attractive are:
Our goal is to support customers with complete tooling solutions that meet cost – Retention of strength and hardness at high temperatures.
reduction and quality improvement initiatives. – Corrosion resistance.

Productivity along with quality and reliability are our focus. When we talk about
productivity you will see that we measure this in terms of cm3/min (in3/min). It is
important to understand the relationship between the combination of speed, feed
and depth of cut and not just cutting speed alone which is often the most damaging
parameter when considering tool life.

Aerospace engine Stationary gas turbines Oil and gas

2 3
 With such a wide spread of materials under the generic heading of HRSA the machining
Alloy groups behaviour can vary greatly even within the same alloy group. In fact the same material
can have numerous machining recommendations.
HRSA materials fall into three groups: (such as Incoloy 909) which make them
nickel-based, iron-based and cobalt- especially suited for shafts, rings, and
based alloys. The physical properties casings.
Heat generated during cutting
and machining behaviour of each varies However, they have the poorest hot (tendency for plastic deformation)
considerably, due both to the chemical strength properties of the three groups.
nature of the alloy and the precise Simplified alloy classification : Hardness vs Ni/Co content
Common types:
metallurgical processing it receives Alloy types
Nimonic 1023
during manufacture. Whether the metal is – Inconel 909 Stainless steel
annealed or aged is particularly influential – A286 400 Fe-based Inconel 718
Waspaloy
on the subsequent machining properties.

Tendency for notch wear

– Greek Ascoloy Ni-based
Nimonic 90
Nickel-based are the most widely used, Cobalt-based display superior hot 350
17-4 PH
and currently constitute over 50% of corrosion resistance at high temperatures
the weight of advanced aircraft engines. compared to nickel-based alloys. They are

Hardness (HB)
Jethete M152
The trend is that this will increase in new more expensive and also more difficult to 300

engines in the future. machine due to their great wearability. Nimonic 263

Common types : The use in turbines is restricted to Crucible A286

250
combustion parts in the hottest engine Nimonic 75
– Inconel 718,
areas.
– Waspaloy, Incoloy 901
Common types: 200 Inconel 625
– Udimet 720 Austenitics
– CoCr
Incoloy 800
– Haynes 25 150
Iron-based have been developed from
– Stellite 31 10 20 30 40 50 60 70 80
austenitic stainless steels. Some have Weight % Nickel + Cobalt
very low thermal expansion coefficients

Machinability/raw material condition

The most common HRSA alloys Heat treatment

Heating to controlled temperature then <30HRC

Annealing cooling at controlled rate.

Solution treatment Heating followed by rapid cooling <30HRC

Ageing Slow cooling after solution treatment Up to 48HRC

The heat treatment state determines and a heat-resistant coating.

component hardness and influences wear Softer materials machine similarly to
mechanisms. Chip formation reflects stainless steels. These require tougher
hardness, harder materials break chips insert grades with lower hot hardness,
more easily. as reduced cutting temperatures and
Hardened materials generate higher increased chip hammering can damage
cutting temperatures and tend to notch areas beyond the cutting edge when chips
the cutting edge at the depth of cut. Use break against the insert.
a low entering angle with a hard substrate

4 5
Comparison of wear depending upon Common component types
material hardness Typical HRSA components, and an indication of the different machining methods
involved for each include:
Hard material 43 Hrc Soft material 36 Hrc

Aerospace and gas turbine – nickel based

Component Turning Milling Drilling Others

Discs 60% 10% 5% 25%

9 minutes contact 10.5 minutes contact
Insert RCMT1204MP-M3 S205
vc, m/min (ft/min) 80 (262)
fn, mm/rev (in/rev) 0.5 (0.020)
ap, mm (inch) 2 (0.079)
Casings 45% 40% 15%

Raw material production method

Depending upon the size, shape and The production method varies the
strength requirements of the component, machinability of the material and will
various production methods for the blank change the wear characteristics. Rings 95%  5%
material will be adopted.

Material Components Advantage/suitability Machinability

Forging Large High strength Medium

Blades 10%  50% 40%
Blisks
Casting Complex shape Low strength Poor Impellers

Bar stock <200 mm diameter Availability/strength Good

Shafts 70%  
5% 25%
Each of these raw material types directly machinability and tend to be most
affects the alloy’s micro structure, and so sensitive to notch wear and abrasive wear.
also affects the subsequent machining They can be easily identified due to their
behaviour: visibly mottled surface (the ‘orange peel’
Forged materials have a finer grain size effect).
than in castings, which improves the Bar stock material is the easiest form of
strength and grain flow of the component. raw material to deal with. Notching is not
When machining forgings, reducing the so much of a problem, which allows harder
speed and increasing the feed generally and more wear resistant insert grades to
gives the maximum possible metal be used than for forgings.
removal rate with good tool life.
In castings the opposite applies, and
applying low feeds (0.1 mm / .0039
in chip thickness) and higher speeds
can be beneficial. Castings have poor

6 7
Turning of nickel-based materials ISM – Intermediate stage machining
0.5 to 5 mm (0.02 - 0.197 inch) depth of cut
Classification of machining stages At this stage the material is mainly in the
The production cycle for the machining of a HRSA component can be broken into three final hard/aged condition, (the hardness is
distinct stages, each with specific demands on the tooling and the machined surface. typically 36 to 46 HRC) having undergone
some form of heat treatment after FSM.
The ISM process involves profiling of the

FSM – First stage machining component with varying depths of cut at

moderate tolerances, where productivity
Up to 10 mm (0.393inch) depth of cut is important but insert security is equally
vital.
The forged components often have In this area, ceramics offer the best
rough, uneven skin or scale. They are productivity where stability allows. Due
generally machined in the soft condition to the complex shape of the components,
(the hardness is typically 26 HRC) at the ISM may involve a high degree of
foundry to the basic component shape. grooving/ recessing and profiling, which
Coated carbide grades are used at high can require a large amount of special tool
feed rates, large depths of cut and low holders.
speeds.
Ceramics may also be used with good
machine and forging conditions. Here the
main priorities are productivity and large LSM – Last stage machining
stock removal – in the total machining 0.2 to 1 mm (0.008 - 0.039 inch) depth of cut
process, up to 80% of the original weight LSM represents the least amount of
will be machined away, and the bulk of it material removal, but imposes the highest
will be removed during FSM. demands on surface quality. For this
The component shapes are simple and critical stage of production, the tools, tool
standard general turning tool holders paths and cutting data are sometimes
can be used. Many critical parts have a certified by end producers of the
ring removed at this stage for material aerospace engine.
analysis. CoroCut2® Insert geometry -TF These parts should be machined with
and grade GC1205 is outstanding for this cemented carbide grades, to ensure a
operation. minimal deformation zone and correct
residual stresses in the finished
component surface.

8 9
Surface integrity Coolant
“Surface integrity is the surface condition of a workpiece after being modified by a Coolant should be used in all operations
manufacturing process." The term was coined by Michael Field and John F. Kahles in except milling with ceramics. Apply a high
1964. volume with well-directed flow.
The aerospace industry lacks a universal standard for surface integrity. Consequently,
Original Equipment Manufacturers (OEMs) establish their own requirements, which can High-pressure coolant (HPC) up to 80
be documented in various ways. bar improves tool life and consistency.
Engine components endure extreme heat and loads, spinning rapidly while withstanding Dedicated HPC tools with fixed nozzles
repetitive stress. The onset of wear typically begins with surface micro-defects which deliver parallel, laminar coolant jets at
makes detecting and managing even minor surface anomalies, critical for maintaining high velocity, precisely aimed between the HPC improves the chip control
engine integrity. insert and chip.
Insert CNGG 120408-SGF
Strain Plucking We also offer engineered special vc, m/min (ft/min) 65 (213)
toolholders for ultra-high-pressure coolant fn, mm/rev (in/rev) 0.2 (0.008)
Surface integrity studies include (UHPC) over 200 bar (2,900 psi). ap, mm (inch) 1 (0.039)
parameter checks such as:
• Distorted layer/surface drag For milling and drilling, all tools with
internal coolant supply benefit from HPC.
• Laps Tools designed for nozzles allow smaller
• Plucking nozzle diameters, optimising high-pressure
Surface Drag Laps use. CoroTurn HP tool, 80 bar Conventional tool
• Flaking
• Cracks Minimum coolant recommendations:
• Strain/work hardening
Turning: ≥ 20 l/min at 70 bar (1,015 psi)
• Residual stress
Milling & drilling: ≥ 50 l/min (13 gal/min) to supply multiple milling nozzles and large drills

Cut Direction Cut Direction Flow at 80 bar (1,160 psi) for specified nozzle — HPC
New Tool Worn Tool
The pressure (p) hitting the
cutting zone is dependent
on the number of nozzles,
the nozzle diameter (d) and
the flow (v) given from the
pump.
Grain boundary
deformation A higher flow rate is needed
for tools with many outlets
or large hole diameter for
the coolant.

10 11
Insert shape selection Selecting the right insert for the job
Entering angle – KAPR
When selecting the right insert for turning , the choice depends on the balance
With a standard C/D/SNMG style insert However, with round inserts the entering between accessibility, productivity, and tool life. Large entering angle inserts (e.g.,
for roughing, the entering angle is angle varies from 0 to 90° depending CNMG, DNMG) are easy to use and provide good accessibility but suffer from
constant regardless of depth of cut. upon the ratio between depth of cut and shorter tool life and lower productivity.
diameter.
Small entering angle inserts (e.g., SNMG, RNGN, RCMT) offer better tool life and
higher productivity, especially when using ceramic or CBN grades, but may require
a CAM system and have restricted accessibility. For optimal performance, consider
the machine setup, material hardness, and required surface finish when choosing
between these insert types.
CNMX CNMG DNMG SNMG RCMT

Effect of entering angle

Best productivity
Notch wear on the inserts is the major SNMG
problem when machining HRSA. The worst FSM
notching occurs when the depth of cut is
greater than the nose radius, and the SNMG
CNMG
entering angle is 90°. (The depth of cut is CNMX
the influencing factor – with a depth of cut
smaller than the nose radius, the effective ISM
entering angle is reduced even when the

Depth of cut
RCMT
angle on the insert itself is 90°). CP-B
By following some general rules the wear
can be controlled allowing more productive
CNMG RCMT
grades to be used.
LSM

Thin walls

Effect of entering angle on wear mechanism

Notch resistance

Material: Inconel 718 (46 HRC) – ap 2.0 mm (.0787 inch)

Notch No notch

12 13
Typical wear mechanisms Top slice wear
With carbide grades two wear mechanisms dominate – plastic deformation and notch
wear. It is important to identify which is the most prominent before selecting the correct Top slice wear is common for ceramics in
grade and strategy. HRSA. Small slices of the cutting tool material
are lost around the insert’s top face. When
Notch wear the flank of the insert is worn, the workpiece
pressure against the periphery will be high
Notch wear on the main cutting edge is mechanical
enough to break small slices away along the
wear concentrated at the depth of cut. The extent of
edge line.
notch wear is directly related to several factors:
The recently sliced area will then form a new
sharp edge that again cuts well, and the
cutting process can continue under these Small slices are lost around the
Factors Least notch wear Most notch wear
circumstances for a long time without posing insert’s top face
Entering angle CoroTurn® prime / round insert C/DNMG 95° a threat to the overall quality, in less sensitive
Depth of cut Below nose radius Above nose radius
roughing or semi-finishing operations.
In finishing operations, where surface quality and/or burr formation is important, top
Geometry Positive Negative
slicing can be critical. This tendency increases with high feed rates due to increased
Material hardness Soft condition Hardened radial pressure.
Material condition Bar stock Forged / cast

Grade PVD (GC1210, 1205) CVD / Ceramic (S205, CC6160)

Because of these factors, notching is the critical wear for ISM where the material is hard
and the depth of cut is relatively high. To reduce notching, use as small entering angle To reduce top slice
as possible.

In stable conditions:
Plastic deformation Lower the cutting pressure by reducing
Plastic deformation (PD)/even flank wear the chip area:
is a result of combined high temperatures – feed rate
and high pressure on the cutting edge. – depth of cut, ap
This wear is much more of a grade specific – arc of engagement
issue than notch wear, which is more
Use optimised programming techniques
application related. Good wear resistance
and hot hardness will reduce the likelihood Use CC675 which is stronger due to
of plastic deformation. whisker reinforcement.
Flank wear resistance
Hot hardness Turning Grooving In case of excessive flank wear, use a
Ceramic CC6160, more wear resistant grade or reduce the In unstable conditions where top slice is
CC6165 cutting speed. caused by vibrations:
CC675 CC675
Reduce engagement angle with
S205 programming techniques
S05F
Carbide GC1205 GC1205 Use CC6165 rather than CC6160
GC1210
H13A H13A
Bulk toughness GC1125 GC1225
GC2025 GC1205
GC2035 GC1135
GC1145

14 15
Pre-chamfering Pre-chamfering
Pre-chamfering is a critical step in machining heat-resistant super alloys (HRSA) Performance
This comparison shows the impact the sharp corner has on the insert.
These materials are tough, work-harden quickly, and put extreme stress on cutting
tools. By adding a small chamfer before other turning operations, it can improve The insert is heavily worn at the depth of cut point
tool engagement, reduce notch wear, and enhance overall process stability. When the test is repeated at the same parameters but with a chamfer the tool life
increases significantly

Feature Material Operation Coolant press.

Longitudinal turning Age-hardened Inconel Turning 60 bars (870 PSI)
718, S2.0.Z.AG, 43
HRc
Insert SNMG 12 04 08-SMR S205
When using a square insert with a 45º
vc, m/min (ft/min) 60 (197)
entering (lead) angle, you can prepare the
chamfer before each turning pass with fn, mm/rev (in/rev) 0.35 (0.014)
the same tool ap, mm (inch) 4 (0.157)
Plunging into the corner is the best way
to machine the chamfer
If using a square insert with a 45-degree No pre-chamfering
entering angle, the chamfer can be
prepared before each pass with the same
tool used for the pass.

Insert after 2 passes

2.9 minutes contact
240 cm³ (14.6 in³)
First contact point with workpiece
should not overlap area used during
the main cutting pass
Depth of chamfer should be less
Pre-chamfer
than depth of cut
Chamfer size, 1–2 mm (0.039–
0.079 inch) is enough

Edge area used for chamfering

Edge area used for turning
Insert after 2 passes Insert after 6 passes Insert after 10 passes
2.9 minutes contact 8.6 minutes contact 14.3 minutes contact
240 cm³ (14.6 in³) 720 cm³ (43.9 in³) 1200 cm³ (73.2 in³)

Pre-chamfering extended tool life from 2.9 minutes to 14.3 minutes under identical
cutting conditions

16 17
Geometries ISO inserts Geometry selection
When turning HRSA materials selecting the correct insert geometry is crucial due to the
SMR Geometry QM Geometry challenging nature of these materials and can be broken down into a few key
considerations which change due to the operation being carried out:

Chip Control – HRSA forms tough, stringy chips that risk tool and part damage.

Heat Management – High temperatures require optimised edge prep and rake angles to
minimize heat buildup and wear.
SMR above IC12 has a negative Very strong geometry which
land giving extra edge security. It is good for tough applications Cutting Forces – Tough, work-hardening materials demand geometries that reduce
can achieve large depths of cut such as interrupted cuts, older force and vibration.
and high feed rates. machines or material with a skin.
Edge Strength vs. Sharpness – Sharp edges cut easier but wear faster; strong edges
last longer but raise cutting forces.

SM Geometry SMR Geometry Surface Finish & Accuracy – Stable, precise geometries help reduce chatter and deliver
tight tolerances.

Tool Life & Cost Efficiency – Optimised shapes reduce wear and extend tool life, mini-
mizing changes and downtime.

1st choice geometry for medium SMR below IC12 has a positive
to semi finishing conditions. land but has a wider groove, it
Creates low tool pressure and low can be a good choice for medium
heat generation resulting in long conditions with higher feed rates. Geometry application areas
tool life and good surface quality.
Relative edge security Roughing area

Medium area
SF Geometry SGF Geometry
SMR
SM IC>12
QM IC>12

SMR
IC≤12

Finishing area

Similar to SM but designed to Extremely sharp insert which SM

SF
maintain chip control at lower is periphery ground resulting in IC≤12

feeds and depths of cut. Can high accuracy and high quality
achieve excellent surface finish. surface integrity. Works well at SGF
small depths of cuts and small
feed rates. Corner radius (RE) Relative
Feed , fnfeed, fn
available from .1mm

18 19
Sandvik Coromant Concepts
Sandvik Coromant turning tools are engineered to boost productivity, extend tool life,
and improve performance in demanding operations.

Unlike standard ISO inserts, our unique concepts like CoroTurn® Prime, CoroTurn®
107, and CoroCut® 2 feature advanced geometries, unique clamping systems, and
chip control for stability and efficiency.

These solutions deliver better surface finishes, shorter cycle times, and reliable
chip evacuation ideal for high-volume or difficult materials in modern machining
environments

20 21
Xcel CNMX insert Holders
To utilise the CNMX inserts requires a
standard holder that uses CNMG inserts
such as PCLNR / DCLNR but it requires a
new shim to allow clearance for the insert

Insert compatibility
Fits standard CNMG holders Coromant Capto®
C6 with a new shim size 12 and 19 inserts are
available

T-Max P: 5322 234-07

Xcel combines the benefits of square and rhombic inserts into one tool, ideal for semi-
rough turning in HRSA materials.
CNMG vs CNMX notch wear
CNMG inserts are often used to turn to a shoulder in HRSA
Key benefits: application which is demanding on the insert and leads to
notch wear.
– Reduced notch wear and higher feeds vs rhombic. Below is a comparison of the same grade cutting inconel.
Image A insert is a CNMG 120408 SM S205 and B is a
– Lower radial forces and consistent chip thickness vs round inserts.
CNMX 1204A2-SM S205 to compare how notch wear
– Better access in tight spaces with predictable cutting edge positioning. develops.
Material inconel 718 (43 HRc)
– Two chamfer sizes for depths up to 2.7 mm, ideal for intermediate stage machining.

– Proven grades for ISO S materials, carbide and ceramic. CNMG Xcel
vc 60 m/min (196 ft/min) vc 60 m/min (196 ft/min)

S205 S205

A 8 min 12 min B 7 min 22 min

Xcel CNMX-SM S-style SNMG

Insert code Max ap mm
CNMX 1204A1-SM 1.7 (0.066 inch)
CNMX 1204A2-SM 2.7 (0.106 inch)

Grade recommendations – first

choice
<35 HRC S205
>35 HRC GC1205
Ceramic CC6160

22 23
CNMX Productivity CoroTurn® Prime
PrimeTurning™ enables multidirectional
CNMX inserts double productivity in nickel
turning, increasing efficiency and productivity
based HRSA by enabling higher cutting data
over conventional methods.
and longer tool life.
It combines CoroTurn® Prime tools and tool
This example compares CNMX 12 with path software to maximize metal removal
CNMG 12 on a 650 mm (25.6 in) Ø ring. rates and process reliability.
The small entry angle concept is perfectly
suited for machining HRSA
Benefits of small entry angle:

– Chip thinning increases metal removal rate

Performance
– Efficient heat distribution reduce notch wear
CNMG vs Xcel turning to a shoulder
– Extended tool life due to reduced wear
Conventional turning PrimeTurning

Feature Material Operation Coolant press. – Secure insert tip lowers part damage CVD grade
Conventional turning
CVD grade
Prime Turning™
risk
Intermediate stage Age-hardened Inconel Turning to a shoulder 60 bars (870 PSI)
machining of ring 718, S2.0.Z.AG,
Ring Ø650mm 43 HRc
(25.6in) CoroTurn® Prime uses two insert styles:
Prime A and Prime B
Insert CNMG 12 04 08 CNMX 12 04 A2 - SM S205
vc, m/min (ft/min) 40 (131) 60 (196)
fn, mm/rev (in/rev) 0.25 (0.009) 0.35 (0.013)
ap, mm (inch) 2 (0.078) 2 (0.078) 2 minutes
2 minutes 12 minutes
12 minutes
Notch wear No notch
Notching No notch
contact time, min 15 22
TMR cm3 (in/3) 300 (18.3) 628 (38.3)
CoroTurn® Prime A CoroTurn® Prime B
Finishing to medium operations Medium to roughing operations
Excellent for profiling Ideal for longitudinal and face turning
Three 35° corners Four-edge double-sided insert
Cut depth up to 3 mm (0.118 in) Cut depth up to 4 mm (0.157 in)
Feed: 0.2–0.4 mm/rev (0.008–0.016 in) Feed: 0.4–0.8 mm/rev (0.016–0.031 in)

Result
CNMX with S205 grade increased TMR from 300 cm³ to 628 cm³, more than doubling
productivity.

24 25
CoroTurn® Prime Round profiling inserts
Cutting forces
Round inserts are the strongest insert geometry, enabling high productivity.
CoroTurn® Prime’s unique cutting force distribution improves tool life and stability over They’re ideal for aerospace components, which are typically large with generous
conventional turning. Forces are split into feed (Fa) driving the tool forward, radial (Fr) radii and blended profiles. These inserts minimize stress concentrations and excel in
affecting chip thickness and vibration, and tangential (Ft) pushing the tool downward machining such features.
and influencing clearance angles. Effective management of these forces boosts
performance, surface finish, and process stability.
T-Max® P insert CoroTurn® Prime B

Fa Axial force

Fr Radial force

Ft Tangential force

F Resulting force

Performance
Prime B type compared to CNMG 12
Feature Material Operation Coolant press.
Longitudinal turning Age-hardened Inconel Turning 60 bars (870 PSI)
718, S2.0.Z.AG, 43
HRc
Entering angle – KAPR
Round inserts’ KAPR is directly linked to KAPR
Insert CNMG 120408-QM CP-B1108-H3 their depth of cut. iC
vc, m/min (ft/min) 40 (131) 40 (131) Best results are achieved with a KAPR
fn, mm/rev (in/rev) 0.25 (0.010) 0.6 (0.024) under 45°, giving a typical depth of cut
ap, mm (inch) 2 (0.079) 2 (0.079) of 0.15× the insert diameter (maximum
0.25×).
For deeper cuts, square inserts with a
fixed 45° angle are recommended. cos KAPR = (0.5iC–ap)
0.5iC

Insert after 960 cm3 (58in3)

Insert after 480 cm3 (29in3)
material removed material removed Entering angle rule of thumb Note: this principle also applies to
standard inserts when the depth of cut
Optimal: ap ≤ 0.15 × insert Ø is less than the nose radius.
Max limit: ap ≤ 0.25 × insert Ø

Learn more about CoroTurn® Prime

www.sandvik.coromant.com

26 27
CoroTurn® 107 holders CoroTurn® 107 geometries
The rail interface for round inserts and tool
holders, combined with advanced machining
techniques, makes it an excellent choice for L3 Geometry M3 geometry
disc machining, particularly in aerospace
applications.
Aerospace engine components often feature
spline surfaces and large internal corner
radii, where the round insert shape minimizes
notches, ensures even wear, and enhances
heat resistance.
The fixed insert indexes guarantee
consistent positioning, improving quality
L3 is ideal for finishing and non- M3 offers the best tool life in
and productivity in profiling and pocketing
linear turning. stable conditions.
operations.
It solves problems related to thin It performs well in semi-finishing
Additionally, the system supports modern chips. to medium machining.
programming techniques and is ideal Best suited for medium depth of Use it for medium depth and
for ramping, profiling, and machining cut and low feed, or small depth medium to high feed.
restricted pockets, making it highly efficient and high feed.
for demanding materials and complex
geometries. CBN Insert
H7 Geometry

H7 is a good choice for interrupted CBN is optimised for finishing in

cuts or skin passes. HRSA.
Rail interface Precise shim Precision coolant It’s designed for medium to It features a flat-top design with
Insert grooves align to the Shim with rail enhances Tool holders are equipped roughing operations. no chip breaker.
holder stopping the insert accuracy and adds with nozzles that direct The open geometry suits high Ideal for components with open
from turning when in cut. protection to the holder precision coolant right at depth and high feed rates. features.
It also guarantees accurate the insert edge to boost
indexing process security and
provide excellent chip
control.
Learn more about CoroTurn® 107
www.sandvik.coromant.com

28 29
CoroTurn® 107 CoroTurn® 107 finishing
CoroTurn® 107 is an excellent choice for roughing radial pockets and large grooves CoroTurn® 107 with Its secure rail interface and strong insert shape make it highly
effective for finishing, with the flexibility to use both carbide and CBN inserts.
40
Performance (1.57) Performance
Dynamic turning radial pocket with CoroTurn® 107 Finishing with CoroTurn® 107 at different speeds with carbide
R8

Feature Material Operation Coolant press.

Finishing carbide Age-hardened Inconel Turning 60 bars (870 PSI)
202Ø 228Ø
(7.95) (8.98) 718, S2.0.Z.AG, 43
HRc
Feature Material Method Coolant press.
Insert RCMT 1204MP M3 S205
Radial pocket Inconel 718, Dynamic 60 bars (870 PSI)
S2.0.Z.AG, 43 HRC fn, mm/rev (in/rev) 0.25 (0.010)
ap, mm (inch) 0.25 (0.010)

Insert RCMT 1204MP M3 S205

vc, m/min (ft/min) 80 (262) Vc 80 m/min (362 ft/min) Vc 100 m/min (328 ft/min) Vc 120 m/min (394 ft/min)
fn, mm/rev (in/rev) 0.6 (0.024)
ap, mm (inch) 1 (0.039

Vb = 0.16 (0.006 inch) Vb = 0.18 (0.007 inch) Vb = 0.25 (0.006 inch)

FSA 2000cm2 (310 in2) FSA 2500cm2 (388 in2) FSA 2250cm2 (349 in2)

Vb = flank wear in mm (inch)

FSA = Finished surface area

Performance
Finishing with CoroTurn® 107 with CBN at 250 m/min (820 ft/min)

Feature Material Operation Coolant press.

Finishing CBN Age-hardened Inconel Turning 60 bars (870 PSI)
718, S2.0.Z.AG, 43
HRc
Insert RCGW 0803 MTED 7014
vc, m/min (ft/min) 250 (820)
Insert wear after 1 pocket Insert wear after 2 pockets
fn, mm/rev (in/rev) 0.25 (0.010)
6.9 minutes 13.8 minutes
332 cm3 (20.3 in/3) 664 cm3 (40.5 in/3) ap, mm (inch) 0.3 (0.012)

Vb = 0.31 (0.012 inch)

FSA 9060cm2 (1404 in2)

30 31
CoroCut® 2 CoroCut® 2 - Geometries
The CoroCut® 2 concept is engineered for high- RM Geometry RF geometry
precision grooving and parting operations in
turning. Designed with stability and versatility in
mind, it features robust tool holders and a wide
range of insert geometries optimised for various
materials and applications.
One of its key strengths lies in the insert-seat
interface, which ensures excellent repeatability
and secure clamping, even under demanding Medium profiling geometry Finishing geometry for profiling
conditions. with a wide cutting data operations with low feeds
window. Excellent performance and small depth of cuts while
The system also supports both internal and when used in non-linear maintaining chip control. The
external machining, offering reliable performance profiling. perfect choice for finishing of
in deep grooves and narrow parting cuts. HRSA components.
With options for coolant-through tooling, CoroCut®
2 improves chip control and extends tool life,
particularly in HRSA materials CoroCut® 2 delivers GF Geometry RO Geometry
consistent results, making it a go-to solution for
precision and productivity in grooving.

Ground geometry used with Ground finishing, positive

low feed for precision grooving. profiling geometry with a sharp
Low cutting forces and good edge for low-feed machining
surface finish. Available in in demanding, powder-based
many cutting widths and HRSA materials
grades.

TF Geometry

Insert rail Over / Under coolant Versatile

CoroCut® 2 inserts feature Tool holders with precision Available in a wide range
patented rail interface coolant are updated with of geometries covering
technology that improves a screw clamp solution. all parting and grooving
edge quality and tool life. Combined with the new applications and backed up
The stable clamping design rigid rail insert seat design, with the grades to perform The most universal geometry in
ensures excellent surface insert movement is reduced in HRSA. All CoroCut® 2 CoroCut®, possible to use in all
finish and precision on to a minimum without any inserts will fit CoroCut® 1-2 application areas. Designed for
parting geometries. clamping force lost. holders. low feed and good chip control.
Good surface finish due to the
wiper design.

32 33
CoroCut 2® profiling CoroCut 2® grooving
CoroCut® 2 features a stable clamping rail, minimizing vibration and ensuring the insert CoroCut® 2 is available with over and under coolant options, significantly improving tool
remains secure during machining. This improves productivity and insert life. life and wear stability.

Performance Performance
Pocket feature Over under coolant impact on tool life
Feature Material Method Coolant press.
Feature Material Method Coolant press.
117Ømm (4.6) Age-hardened Plunge 60 bars
OD 200mm Age-hardened Dynamic 60 bars Inconel 718,
Inconel 718, 4mm (.15) wide (870 PSI)
(7.87) turning (870 PSI) S2.0.Z.AG,
S2.0.Z.AG, 12mm (.47) deep
ID 60mm 43 HRc
(2.36) 43 HRc

Insert C2I-J2N-0600 RO S205 Insert C2I-H2N-0400-0004 TF 1205

vc, m/min (ft/min) 100 (328) vc, m/min (ft/min) 45 (148)
fn, mm/rev (in/rev) 0.4 (0.0157) fn, mm/rev (in/rev) 0.12 (0.005)
ap, mm (inch) 1 (0.039) ap, mm (inch) 4 (0.157)

Roll in method Over / Under coolant

Insert wear 10 grooves Insert wear 18 grooves Insert wear 20 grooves

Insert wear 8 passes Insert wear 12 passes 7.3 minutes 13.2 minutes 14.7 minutes
6 minutes 9 minutes 158 cm3 (9.64 in/3) 285 cm3 (17.4 in/3) 317 cm3 (19.3 in/3)
240 cm3 (14.7 in/3) 360 cm3 (22.0 in/3)

Dynamic turning method Standard coolant

Insert wear 8 grooves Insert wear 12 grooves Insert wear 14 grooves

Insert wear 12 passes Insert wear 20 passes 5.9 minutes 8.8 minutes 10.3 minutes
8.5 minutes 14 minutes 127 cm3 (7.75 in/3) 190 cm3 (11.6 in/3) 222 cm3 (13.5 in/3)
337 cm3 (20.6 in/3) 560 cm3 (34.2 in/3)

CoroCut® 2 provides excellent insert clamping, enabling higher productivity especially Over and under coolant with CoroCut® 2 improves tool life by up to 43% and delivers a
when using methods that utilise the full insert profile such as dynamic turning more predictable wear pattern for increased reliability

34 35
CoroCut® CoroCut®
Seal fin grooves Angled inserts
Seal fin grooves are challenging to Angled “hockey-stick” inserts are ideal
machine due to their narrow width, tight for machining intricate features, making
tolerances, and position in tough materials it easier to access areas where other
like Inconel. They play a key role in sealing tooling struggles. They are only available
systems, so precision and surface finish in grade GC1115 due to the toughness
are critical to prevent leakage. Access can required and should be used with SL70
be difficult so we have inserts optimised blades(page 42), which provide optimised
profiling inserts for this operation. coolant flow to suit the insert’s needs

Performance Performance
Seal fin grooving Angled grooves insert test

Feature Material Method Coolant press. Feature Material Method Coolant press.
Seal fin Age-hardened Roll in roll out 60 bars (870 Angled profile Age-hardened One way 60 bars (870
Inconel 718, PSI) Inconel 718, turning PSI)
S2.0.Z.AG, 43 S2.0.Z.AG, 43
HRc HRc
Insert L123H1-0200-RO S205 Insert LG123H1-0300-RO 1115
vc, m/min (ft/min) 60 (197) vc, m/min (ft/min) 35 (115)
fn, mm/rev (in/rev) 0.4 (0.016) fn, mm/rev (in/rev) 0.3 (0.012)
ap, mm (inch) 0.3 (0.012 ap, mm (inch) 0.5 (0.020
Contact time, min 25 Contact time, min 23
TMR cm3 (in/3) 180 (11.0) TMR cm3 (in/3) 120 (7.3)

Insert wear 2 passes Insert wear 5 passes Insert wear 20 passes

5.7 minutes 14.3 minutes 23 minutes
30 cm3 (1.83 in/3) 75 cm3 (4.58 in/3) 120 cm3 (7.32 in/3)

Insert wear 6 passes Insert wear 16 passes Insert wear 20 passes

7.5 minutes 20 minutes 25 minutes
54 cm3 (3.30 in/3) 54 cm3 (8.79 in/3) 180 cm3 (11.0 in/3)

36 37
T-Max® for difficult to machine materials T-Max® grooving example
T-Max® is designed for productive external Performance
and internal turning of HRSA materials. T-Max CSGX 090708T01020 675
It provides excellent wear resistance for
secure, stable machining and extended
Feature Material Operation Coolant press.
tool life. Capable of performing multiple
operations from roughing to finishing. Groove Age-hardened plunge 60 bars (870
It enables high metal removal rates for 60mm wide Inconel 718, grooving PSI)
increased productivity. S2.0.Z.AG, 43
20mm deep
The system is optimised to take full HRc
advantage of advanced cutting materials Insert CSGX 090708T01020 675
such as ceramics, CBN, and Sandvik vc, m/min (ft/min) 250 (820)
Coromant’s range of carbide grades. fn, mm/rev (in/rev) 0.04 (0.0016)
ap, mm (inch) 9.5 (0.375)

Insert after 6.2 mins in cut

Insert after 6.2 mins in cut
Vb 0.47 (0.019 inch)
Vb 0.47 (0.019 inch)
Stable insert clamping High performing grades Secure machining T-Max® when combined with the SL70 system (page 43) can be utilised on numerous
It is very important to have With our latest Ceramic Wide assortment of aerospace components offering a very stable and productive system that can utilise a
a stable clamping while and CBN grades you can V-bottom and double-sided wide range of insert shapes
turning difficult-to-machine increase the cutting speeds flat inserts and modern
materials. T-Max offers to achieve higher metal grades have strong edges Application examples
stable clamping for both removal rates and maximize that offer reliable and
insert without hole and with production output. secure machining for
dimple-hole. all roughing to finishing
operations.

38 39
T-Max® dynamic turning T-Max® dynamic turning
T-Max® can utilise a wide range of cutting materials and grades, including various insert In this application, using the RCGX ceramic insert in the same setup resulted in a
shapes. Below, we compare the productivity of a carbide grade machining the feature, significant productivity gain, despite the previous insert already delivering a respectable
followed by a comparison with a ceramic insert. metal removal rate.

Performance Performance
T-Max RCMX carbide S205 insert T-Max RCMX with ceramic CC6160 insert

Feature Material Operation Coolant press. Feature Material Operation Coolant press.

Radial groove Age-hardened Dynamic 60 bars Radial groove Age-hardened Dynamic 60 bars (870
Inconel 718, turning Inconel 718, turning PSI)
(870 PSI)
S2.0.Z.AG, 43 S2.0.Z.AG, 43
HRc HRc
Insert RCGX 09 07 00 E 6160
Insert RCMX 09 07 00 SM S205
vc, m/min (ft/min) 220 (210)
vc, m/min (ft/min) 64 (210) 40 40
(1.57) fn, mm/rev (in/rev) 0.25 (0.0098) (1.57)
fn, mm/rev (in/rev) 0.6 (0.023)
ap, mm (inch) 1.5 (0.059)
ap, mm (inch) 1 (0.039) R8 R8
Q cm3/min (in3/min) 83 (5.06)
Q cm3/min (in3/min) 38.4 (2.34

202Ø 228Ø 202Ø 228Ø

(7.95) (8.98) (7.95) (8.98)

SM S205 Carbide wear E 6160 Ceramic wear

Insert wear after 1 Insert wear after 1

pocket pocket
8.65 minutes 4 minutes
332 cm3 (20.3 in/3) 332 cm3 (20.3 in/3)

Learn more about T-Max®

www.sandvik.coromant.com

40 41
CoroTurn® SL70 CoroTurn® SL70
Modular flexibility for complex machining
By combining different adaptors and
The CoroTurn® SL70 system is purpose built for
blades, it is possible to assemble
demanding aerospace components like turbine
multiple variants of tools. This will
discs, where deep profiles, profiled pockets, and
allow machining of several restricted
tight clearance requirements make traditional setups
features without need of special
challenging.
tools.
Its modular design allows you to build nearly any tool
configuration by combining adaptors and blades from
a wide assortment enabling you to machine even the
most complex features using standard tool elements.
With a large selection of adaptors (in multiple angles
between machine interface and SL70 coupling) and
blades in different lengths, widths, and shapes (straight
or angled), CoroTurn® SL70 gives you the flexibility Disc machining example using straight and angled blades
to tackle tough alloys and intricate geometries with
confidence.

Straight blades can be utilised Angled blades utilise RCGX 09

for radial and axial machining inserts, enabling the use of both
carbide and ceramic grades for
optimised performance

Disc machining using angled adaptors

CoroTurn® SL70 Adaptors CoroTurn® SL70 Tools
Adaptors with fixed angles Tools are available to suit
between the machine interface a wide range of standard
and SL70 coupling: 0°, 5°, 45°, inserts, including CoroTurn®
90°, 95°, and 135° 107, CoroCut® 2, and
T-Max®. They are offered in
various lengths, widths, and
are available in straight or
angled versions to suit your
specific requirements.

5° angle adaptors

42 43
Application hints Chip thickness
fn
‘Wrap-around’ is a problem which occurs The chip thickness varies with round
with round inserts when plunging or inserts, and depends upon the entering
profiling into corners. Due to high angular angle. With low ap/iC ratios, the feed can
engagement creating high cutting be increased in order to raise the chip
pressures, the feed needs to be reduced. thickness to a desired level.
To reduce this problem, optimised Recommended chip thicknesses hex for
programming strategies together with HRSA are:
smaller insert radii should be used. 0.1 to 0.35 mm (.0039-.0138)
Carbide hex
Recommendations fn =
Ceramic 0.08 to 0.15 mm (.0031-.0059) sinKAPR
– Never plunge straight into cut.
– Roll in and out of cut.
–  oughing programmed radius
R
same size as insert diameter.
–  inishing insert diameter
F
no greater than 1.75 times
programmed radius.

The component feature to be machined

needs to be broken down into stages so
that a face and diameter are not machined
simultaneously as this will naturally
Example
increase the depth of cut and cause ‘wrap- 6 mm diameter CoroCut® RO insert. To machine with:
around’ Depth of cut 0.9 mm (.0354) gives a Minimum 0.1 (.0039) mm chip thickness
maximum entering angle KAPR = 46°. the correct feed is 0.14 mm/r.(.0055 in/r)
Maximum 0.35 mm (.0138) chip thickness
the correct feed is 0.49 mm/r (.0193 in/r).
Face and

Programming recommendations –
diameter
Surface finish
Because of the wrap around problem in + Only
diameter
The surface finish generated has a direct Therefore, for the highest productivity the
the radii, the feed needs to be reduced as relationship to both the nose radius size nose radius should be as large as possible
the size of cut increases. The larger the and the feed rate. To achieve a certain – the largest of all being round inserts.
difference between the radius and the surface finish, a small nose radius requires
insert diameter, the less the feed needs to a lower feed rate than a large nose radius
be reduced. – which in practical terms means that
However a good starting point is to use small nose radius inserts lead to lower
50% feed rolling into radius compared to productivity.
parallel cuts.
Maximum feed fn mm/r to achieve surface finish Rmax 8.0 (.315) – Ra 1.6 µm (.624 µinch) – N7

Nose radius size mm (inch) Insert diameter mm (inch)

0.4 (.016) 0.8 (.031) 1.2 (.047) 1.6 (.063) 8 (.315) 10 (.394) 12 (.472) 16 (.630)
fn 0.17 (.007) 0.22 (.009) 0.27 (.011) 0.32 (.013) 0.5 (.020) 0.57 (.022) 0.62 (.024) 0.7 (.028)

44 45
Benefits of rolling in and out of cut Profiling and pocketing methods
Choosing the right entering strategy is key to
maximizing tool life in Inconel 718 machining. This
data compares roll-in, straight 100% feed, and
Dynamic turning
1st choice method utilising non linear tool path
straight 50% feed over six passes. Roll-in extends and maintaining a constant hex.
tool life by 40–50%, while reducing feed during
straight entry has little effect. Optimising entry Dynamic turning with round inserts offers
methods improves efficiency and cost-effectiveness improved tool life, reduced cycle times, better
in face turning chip control, and enhanced surface finish. It
allows for more efficient material removal and
increased productivity
Performance
Comparing rolling and out with straight feeding
Feature Material Operation Coolant press. Trochoidal turning
Outside diameter Age-hardened Face turning 60 bars (870 PSI)
200mm(7.87in) Inconel 718, By breaking the part into manageable
Finished diameter S2.0.Z.AG, 43 HRc pieces this method can be used for all
40mm (1.57in) profiling requirements. The direction of
passes can be alternated when using
Insert RCMT1204MP-M3 S205
CoroCut 2 and RCGX inserts to best utilise
vc, m/min (ft/min) 80 (262) the edge.
fn, mm/rev (in/rev) 0.5 (0.020)
ap, mm (inch) 2 (0.079)
TMR cm3 (in/3) 322 (20.3)
Plunge turning
Plunge turning is a traditional method, with a
simple tool path, involves a straight plunge-in
Roll-in Straight 100% feed Straight 50% feed
followed by 90-degree turning. Though simple,
it has drawbacks like high edge security
requirements, poor chip control, and low
productivity.

6 passes with each insert each image after 4.5minutes contact time
Ramp turning
Ramping balances efficiency and tool
longevity by gradually increasing cut depth.
It reduces notch wear, smooths insert load
change, and is effective for profiling and
shallow pockets, but requires varying feed
and has limitations at pocket walls.
12 passes 9 minutes 9 passes 6.8 minute 9 passes 6.8 minute

Roll-in is the first choice, providing 40–50% longer tool life compared to a straight entrance, while
feed reduction during straight entrance has little impact.

46 47
Tool holder impact - Long holder Tool holder impact - Short holder
The tool holder set up has a very large A longer tool than necessary, results in When running the same feature but utilising a shorter more secure Coromant Capto®
impact on the surface finish and tool life more vibrations which can be overcome by tool.
of the insert. reducing the cutting data but it will cost
productivity

Performance Performance
Holder impact with longer holder Holder impact with shorter tool

Feature Material Operation Coolant Feature Material Operation Coolant

Groove Age-hardened Dynamic press. Groove Age-hardened Dynamic press.
Inconel 718, grooving 60 bars (870 Inconel 718, grooving 60 bars (870
S2.0.Z.AG, PSI) S2.0.Z.AG, PSI)
43 HRc 43 HRc
This SL70 head has a This time the insert is mounted
maximum cutting depth (CDX) Insert C2l-J2N-0600-RM S205 Insert C2l-J2N-0600-RM S205 into a Coromant Capto® tool
of 40mm and consists of a vc, m/min (ft/min) 80 (262) vc, m/min (ft/min) 80 (262) with a CDX of 25mm and more
blade mounted to an adaptor rigid assembly
fn, mm/rev (in/rev) 0.4 (0.016) fn, mm/rev (in/rev) 0.4 (0.016)
ap, mm (inch) 1 & 0.7 (0.039 & 0.027) ap, mm (inch) 1 (0.039)
contact time, min 15 contact time, min 12
TMR cm3 (in/3) 322 (20.3) TMR cm3 (in/3) 322 (20.3)

Stopped after 1 minute

due to vibrations
Insert after 1 pocket Rigid tool gives much better
12 minutes contact surface quality and allows the
Ap reduced to 0.7 (0.027 in) 332 cm³ (20.3 in³)
tool to run at more productive
parameters

By switching to a shorter, more rigid holder, stability improves significantly. This

results in better surface finish, longer insert life, and the ability to run at more
productive parameters, in this case delivering over 20% higher productivity.

Insert after 1 pocket Reducing the depth of cut

15 minutes contact allows the tool to perform but
time is 15 minutes
332 cm³ (20.3 in³)

48 49
Carbide insert grades Carbide insert grade selection
GC1205 S205 Grade selection when machining
Depth of cut (ap) mm
PVD coated fine-grain carbide with a hard Carbide CVD grade developed for turning HRSA (Heat-Resistant Super Alloys)
8
oxide layer that improves hot hardness. It HRSA at elevated speeds under stable should not be viewed solely in terms of
Toughness/PD – interrupted cut
is optimised for machining HRSA materials conditions finishing or roughing operations. While
plastic deformation (PD) is a factor in PD demanding – continuous cut
as all-round grade giving effective Great performance when applied with an
performance through FSM, ISM and LSM all cutting processes, notch wear is
entry (lead) angle 45º and smaller (larger) primarily influenced by the entering
5
areas.
Light-roughing to finishing angle of the insert. Therefore, tool
The coating gives extremely good selection should focus on optimising
Designed and proven for finishing critical
adhesion which is required for lower edge strength and wear resistance
components with attention to surface
feeds and depths of cut. SGF is a relative to the cutting angle, rather
integrity PD & notch demanding PD demanding
ground insert with sharp edges, this than just the operation type.
combined with GC1205 is outstanding in Next generation version of S05F
0.5
extreme finishing on vibration sensitive 90º 75º 60º 45º 30º 15º
components with low feeds. Entering angle (KAPRPR)
GC1210
A micro-grained carbide providing security
in more edge toughness demanding
operations, e.g. Reduce problems with
notch wear or chip hammering.
The PVD coating contains TiAlN for edge
line toughness as well as an aluminium
chromium oxide providing resistance
Optimised grade per area Depth of cut (ap)

8
against built-up edge & crater wear. Good GC2015 – interrupted cut
balance of toughness and wear resistance In practice this means that the grade S205 GC1205 – continuous cut
makes ideal for unstable conditions. selection is optimised depending upon
the shape of the insert.
5
PD and notch PD demanding
For lower speed operations GC1205 is demanding
+Vc ISO Ceramic
first choice. For high speed operations GC1205 S205
CBN S205 is the most productive carbide GC1210 (GC1205)
S00 grade and excellent in finishing. (GC1125
intermittent)
S205

S05 0.5 GC1205 S205 (GC1205)

S05F
90º 75º 60º 45º 30º 15º
S15 Entering angle (KAPR)
GC1205 Notch = depth of cut notching
FSM ISM LSM
S25 GC1210 = = =
26 HRC 46 HRC 46 HRC
GC1425

-Vc

Good Average Difficult

50 51
S205 finishing Predictive Machining –SCL & TMR
Surface integrity tests have shown coning/taper is also seen to eliminate the Spiral Cutting Length (SCL) and Total Material Removed (TMR) are two
that S205, applied at vc 125 m/min, need for re-cutting or spring passes. Both predictive machining tools developed to increase process reliability, especially
gives extremely consistent deformation of these are the result of minimal wear for tough materials like HRSA (Heat Resistant Super Alloys), where tool life is
depth and residual stress profiles, when on the trailing edge compared to other short and consistent performance is critical.
comparing new and worn inserts. The grades.
dimensional accuracy and lack of any Why use SCL?
Performance SCL predicts the total Roughing: Insert wear is Finishing: SCL ensures
S205 high speed finishing compared with S05F cutting path length an fast, so SCL helps define the tool lasts through
insert will travel during when to stop and change the pass with predictable
Feature Material Method Coolant press. one pass. It’s used to: the insert before failure. wear, avoiding mid-cut
Longitudinal Age-hardened High speed 60 bars (870 indexing or rework.
turning Inconel 718, ­finishing PSI)
S2.0.Z.AG, 43 Each insert has a defined SCL capability based on its geometry,
HRc
grade, and cutting conditions. Use the SCL formula:
Dm = mean diameter
Insert N123J2-0600-RO S05F N123J2-0600-RO S205 Dm x π lm
lm = machining length SCL = x
vc, m/min (ft/min) 125 (410) 125 (410) fn = Feed per revolution
1000 fn
fn, mm/rev (in/rev) 0.15 (0.006) 0.15 (0.006)
ap, mm (inch) 0.25 (0.010) 0.25 (0.010)
lm
contact time, min 13.35 13.35 Example
SCL, m (ft) 1668 (5472) 1668 (5472) fn
Parameter Dm = 450mm, lm = 150mm, fn = 0.35
SCL = 606m
Dm
If the insert has SCL capability is 450m then we
N123J2-0600-RO S05F N123J2-0600-RO S205 know 2 edges will be needed to achieve 606m
Flank wear average (max) = 378 µm (517) Flank wear average (max) = 84 µm (103)

Why use TMR ?

Total Material Removed (TMR) tells you how much material (in volume) is removed
during the cut, helping assess productivity and machine load:

Q = Metal removal rate (cm3/min) TMR = Q x TiC

TiC = Time in cut (min)

Example
If Q = 150cm3/min and TiC = 2.5 minutes
TMR = 375 cm3

SCL helps ensure tool life matches the programmed cut, while TMR tracks volume
removed. Together, they improve predictability, tool planning, and efficiency which
are essential for roughing and finishing high-value components with minimal waste
or rework

52 53
Ceramic insert grades Grade application areas
Ceramic cutting materials offer excellent
productivity in roughing operations in FSM
and ISM. Their application differs greatly
compared to carbide due to their:
– High temperature resistance – allows
high cutting speed to be applied
to produce a highly plasticised and Ceramics Carbide
sheared chip.
– Low toughness – can lead to edge
frittering, top slice and notch wear.
Both of these factors mean that for
successful application the following rules
need to be applied:
– Optimise entering angle at about 45° to
reduce notch, round or square inserts
should be used.
– Maximum chip thickness – between Grade application areas
0.08 to 0.15 mm.
Optimised programming techniques The speed should be balanced to
- To minimize notch on entry and long create enough heat in the cutting
passes. zone to plasticise the chip but not
- Control the cutting arc of engagement too high to unbalance the ceramic.
in corners. The feed should be selected to
give a chip thickness which is high
Ceramic types enough to not work-harden the
material but not be too high to cause
SiAlON – (Silicon, Aluminium, Oxygen, Whisker-reinforced ceramics
edge frittering.
Nitrogen) – a mixture of silicon nitride and Advanced cutting tool material
aluminium oxide. It has the best chemical where silicon carbide (SiC) whiskers Higher feeds and depths of cut
stability resisting notch wear: are embedded into an alumina require a reduction of the cutting
(Al₂O₃) ceramic matrix. This speed.
-
reinforcement dramatically improves These boundaries will change
Composite ceramic
the toughness, thermal resistance, depending upon the component
Blends the properties of carbide and and overall performance of the material hardness and grain size.
SiALON offering good notch resistance ceramic
and also a good level of toughness.
Perform well on powder metal materials

0.5 mm

10–80 mm

54 55
Application hints Notch wear
mm mm
Trouble shooting – wear mechanisms Notch wear can be minimized with good 6.35 0.9
planning and some general advice: 9.52 1.4
Top slice Notch wear 12.70 1.9
_ Use round inserts whenever possible 19.06 2.8
Reason Remedy Reason Remedy ensure the relationship between depth 25.40 3.8
of cut ap and insert diameter does not
Too high Reduce feed Sensitive Careful exceed 25%.
cutting cutting tool programming
techniques
pressure Reduce ap
on round
material – Use 45º entering angle when depth of
insert Reduce cut exceeds 25% of iC.
Specific to entering angle
Use CC675 HRSA – “Roll over action” in programming to
Use CC6160
or CC6165 eliminate the need for pre-chamfering
and minimize the notch wear. There
will be one contact point where the
insert hits the hard scale/surface at
the corner of the component and one
Application hints for ceramic inserts different point at the ap line.

Low Productivity High

Insert selection
– Ramping ensures that any damage is
– Where possible use round or square spread out along the cutting edge.
inserts with a small entering angle The depth of cut should be varied
and large nose radius. Low Radial forces High between 25% iC to 15% (do not ramp
– Always use the strongest insert nose to zero).
angle.
– Thick inserts give additional strength.

Pre-chamfering – Multiple passes with varying ap can be

– Protects the insert when it first enters an alternative.
from initial chipping/notch formation.
– To avoid notch wear when chamfering,
use a direction feed at 90° to the
produced chamfer.

Turning to a shoulder either:

– For RCGX/RPGX inserts, program in
– Roll up to the shoulder with a radius the both directions to utilise more edges
size of the insert diameter to prevent on the insert.
increased depth of cut. fn/2 fn fn/2

– Reduce feed by 50% (fn/2) when

approaching a shoulder due to the
depth of cut increasing.

56 57
SCL recommendations Roughing recommendations
All cutting trials for these data recommendations are in Inconel 718 (46 HRC) and vc ap fn Tool life SCL Q Qtot
have been found to be true for other nickel alloys in the same hardness – Udimet 720, m/min mm mm/r min m cm3/min cm3
Waspaloy. (ft/min) (in) (in/rev) (ft) (in3/min) (in3)

Performance
SGF & SF Geometry with S205 finishing wear chart
CNMG 120408 Grade S205 ap = 0.25 (0.010inch)
60 2 0.25 840 30 420
CNMG 120408-SM S205 (196) (.0787) (.009) 14 (2755) (1.83) (25.6) 95º KAPR
Feed mm/r SGF 9 min TiC SF 12 min TiC
(inch/r)

0.2
(0.008) 900 SCL 1200 SCL
(2952ft) (3937ft)
SGF 15 min TiC SF 15 min TiC SGF 10.7 min TiC SF 8.9 min TiC SGF 6.1 min TiC SF 6.1 min TiC 60 2 0.35 1318 42 924
0.14 CNMX 1204A2-SM S205 (196) (.0787) (.0138) 22 (2755) (2.56) (56.38)
(0.006) 45º KAPR

1500 SCL 1500 SCL 1284 SCL 1068 SCL 854 SCL 854 SCL
(4921ft) (4921ft) (4212ft) (3503ft) (2801ft) (2801ft)
SGF 7.5 min TiC SF 7.5 min TiC
0.08
(0.003) 60 4 0.35 858 84 1200
SNMG 120408-SMR S205 (196) (.1575) (.0138) 14 (2755) (5.13) (71.82)
750 SCL 750 SCL
(2460ft) (2460ft)
100 120 140 vc m/min
(328) (394) (460) (ft/min)
45º KAPR
Performance 160 2 0.25 1759 80 960
RO Geometry with S205 finishing wear chart SNMG 150616-QM 6160 (524) (.0787) (.009) 12 (2755) (4.88) (58.56)
ap = 0.25 (0.010inch)
Feed mm/r
(inch/r) 12 min TiC

0.4
(0.016) 70 2 0.5 1400 70 1400
1200 SCL
(3937ft) RCMT 1204M0-SM S205 (229) (.0787) (.0197) 20 (2755) (4.27) (85.43)
15 min TiC 13.3 min TiC 16.3 min TiC 13 min TiC

0.3
(0.012)
600 SCL 798 SCL 1304 SCL 1300 SCL > 45º KAPR
(1968ft) (2618ft) (4278ft) (4265ft)
9 min TiC 240 2 0.24 1440 115 690

0.2 RNGN 120700 E 6160 (656) (.0787) (.009) 6 (2755) (7.03) (42.18)
(0.008)
900 SCL
(2952ft)
40 60 80 100 vc m/min
(131) (197) (262) (328) (ft/min)

58 59
 Recommended starting choices for Grooving and profiling
nickel based HRSA Machining 1st 2nd Cutting Feed, Depth Insert Comments
1st 2nd Cutting Feed, Depth of Insert style Metal Comments stage choice choice speed, mm/rev of cut, style
speed, mm/r cut, removal rate, m/min mm
Choice Choice (ft/min) (in/rev)
m/min mm cm /min
3

GC1210 S205 25-60 0.2–0.3 3 - 10 SNMG 15, 120 Use 45° approach to
19 -SMR reduce chip thickness
and notching. For rough grooving
GC1205 GC1225 40–80 0.1–0.15 TF
Use largest rad possible
(131 - 262) (.040 - .060)

FSM CC675 CC6165 150–200 0.15–0.2 Up to 3 RNGN 19 200 Use 45° approach to CM
reduce chip thickness
and notching – first ISM
choice on good q­ uality
forgings.
SNGN 19 S205 GC1225 60–120 0.2–0.4 Max ap
RM For profiling
(196 - 393) (.040 - .060) .15 x D
CC6160 CC6165 200–300 0.1–0.2 1 to 3 RNGN 12 120 Use round inserts
wherever possible to RM
minimize notching.
CC6220 300–500 0.05–0.1 0.25 - 0.5
CC6160 CC6165 200–250 0.1–0.2 1 to 3 RPGX 80 For pocketing use For rough grooving under
positive inserts. (656 - 1312) (.040 - .060) (.010 -.020) good conditions
RE
S205 GC1210 40–60 0.3–0.45 3 to 5 SNMG 15, 90 Where large depths of
19 -SMR cut are possible.
GC1225 GC1125 40–60 0.1–0.15 0.25 - 0.5 For finish grooving
S205 GC1210 60–100 0.25– 3 to 5 SNMG 15, 90 (131 - 196) (.040 - .060) (.010 -.020) GF Use 0.4 radius where
0.35 19 -SM possible
S205 GC1205 60–100 0.2–0.45 1 to 3 SNMG -SMR 50 Always use an entering
angle less than 75°
ISM if possible to reduce
0.2–0.35 1 to 3 SNMG -SM 50 LSM
notching ie
Round RCMT, square S205 GC1205 60–100 0.1–0.35 0.25 - 0.5 For finish profiling
SNMG, CNMX. RO
0.2–0.5 1 to 3 RCMT -M3 50 (196 - 328) (.040 - .060) (.010 -.020)

RF
0.2–0.35 1 to 2.5 CNMX -SM 50

GC1205 GC1210 50–80 0.15– 1 to 3 SNMG -SMR 25 For 90° entering angle.
0.25

SNMG -SM

DNMG -SMR

DNMG -SM

S205 GC1205 60–100 0.25–0.5 0.25 to RCMT -SM Profiling

0.5

S205 GC1205 60–100 0.15 0.25 *NMG -SF Use speed according
LSM
to the SCL required
for each operation.

GC1205 GC1205 40–60 0.15 0.25 *NGG -SGF Use the ground
-SGF for thin wall
components.

60 61
Geometries and chip breaking Chip breaking diagrams
KAPR 45° – ISM Cutting speed 65 m/min, Inconel 718 – 44 HRC
SNMG 120408-SMR CNMX 1204A2-SM
Application Feed range, Edge Geometry Geometry recommendation
ap mm (Inch) ap mm inch)
area mm rounding requirements
(inch) General turning Grooving
2.5 2.5
Double Positive CoroCut® Q-Cut (.100)
(.100)
sided
FSM 0.25 to 0.4 Medium Direct pressed
– primary land
(.0098-.0157) QM 1.5 1.5
TF (.060) (.060)

SM SMR
ISM 0.15 to 0.25 Medium to Direct pressed 0.5 0.5
(.0059-.0098) small positive rake (.02) (.02)
angle QM MM TF CM
0.2(.008) 0.25(.001) 0.3(.012) 0.35(.014) 0.2(.008) 0.25(.001) 0.3(.012) 0.35(.014)
fn mm/r (in/r) fn mm/r (in/r)

SM SMR
MR RM RM Round inserts – ISM/LSM
RCMT 1204M0-M3 C2I-J2N-0600-RO
ap mm (inch) ap mm (inch)
Xcel SM 1)

LSM 0.1 to 0.2 Small Direct pressed 1.0

MF 2.5 (.04)
(.0039-.0079) ground (.100)
SF 4G
GF
0.75
RF (.03)
*CGT-UM
SGF RF 1.5
(.060)
0.5
1) (.02)
SM
1) CoroCut® angled inserts, see page 37. 0.5 0.25
(.02) (.01)
Note: the ground inserts -SGF and *CGT-UM should be used for thin walled components to minimize the c
­ utting
forces and hence risk of distortion.
0.2(.008) 0.25(.001) 0.3(.012) 0.35(.014) 0.4(.016) 0.15(.006) 0.2(.008) 0.25(.001) 0.3(.012) 0.35(.014)
fn mm/r (in/r) fn mm/r (in/r)

C2I-H2N-0500-RM C2I-H2N-0500-RF
ISO S geometries ap
ap mm ap mm
First choice
1.0 1.0
recommendations for First choice (.04) (.04)
general turning with double
sided inserts. 0.75
0.75 (.03)
-SMR High feed rates, (.03)
Lowest tool interruptions
pressure 0.5
-SGF -SM (.02)

0.5
Chip
breaking -SF (.02) 0.25
(.01)

0.2(.008) 0.3(.012) 0.4(.016) 0.5(.019) 0.6(.023) 0.2(.008) 0.3(.012) 0.4(.016) 0.5(.019) 0.6(.023)
fn fn mm/r(in/rev) fn mm/r(in/rev)

62 63
 KAPR 95° – ISM
CNMG 12 04 08-SM CNMG 12 04 08-SMR
CoroPlus® Tool Guide
ap mm (Inch) ap mm (Inch)
Smarter tool selection. Faster machining decisions
2.0 2.0
(.080) (.080) The CoroPlus® Tool Guide from Sandvik
Coromant is a powerful, web-based tool
1.0 1.0 selection platform that helps you find the
(.040) (.040)
right cutting tools and optimised cutting data
for your specific machining task. Whether
0.5 0.5
(.020) (.020) you're drilling, turning, or milling, the Tool
Guide simplifies and accelerates decision
0.25 0.25
making.
(.010) (.010)

0.15(.006) 0.25(.008) 0.35(.014) 0.15(.006) 0.25(.008) 0.35(.014)

fn mm/r (in/r) fn mm/r (in/r)

KAPR 95° – LSM Select material Define operation

VBGT 16 04 08-UM DNGG 15 06 08-SGF
ap mm (Inch) ap mm (Inch)

2.0
2.0
(.080) (.080)

1.0
1.0
(.040) (.040)

Select the material you are machining Define the feature to be machined and the
0.5
0.5
(.020)
from a wide range of HRSA materials dimensions of them along with machine
(.020)
parameters
0.25
0.25
(.010) (.010) Tool recommendation
0.15(.006) 0.2(.008) 0.25(.010) 0.15(.006) 0.2(.008) 0.25(.010)
fn mm/r (in/r) fn mm/r (in/r)

CNGG 12 04 08-SGF CNMG 12 04 08-SF

ap mm (Inch) ap mm (Inch)

2.0 2.0
(.080) (.080)

1.0 1.0 Receive tool recommendation and detailed information on cutting parameters, spiral
(.040) (.040)
cut length, tool life, and CO2 emissions.
0.5 0.5
(.020) (.020)

0.25 0.25
(.010) (.010) Start using CoroPlus® Tool Guide today
0.15(.006) 0.2(.008) 0.25(.010) 0.15(.006) 0.2(.008) 0.25(.010)
www.sandvik.coromant.com
fn mm/r (in/r) fn mm/r (in/r)

64 65
Tailor Made Tailor Made
Within many of Sandvik Coromant’s
product families, the available range of
Tailor made web
inserts and tools is not limited to those
Registered Sandvik Coromant website users
specifically listed in the catalogues.
can take advantage of Tailor‑Made web
Tooling designed to individual
service. This empowers users to specify,
customer requirements is available
configure, and receive cutting tools precisely
through the Tailor Made service,
matched to their machining tasks across a
allowing customers to specify
broad spectrum of tooling types. By using the
their cutting tool requirements for
online tool you get a rapid quotation along
particular machining operations.
with the supporting information you need
The Tailor Made service will provide such as DXF files and 3D step files within 20
a ­quotation and proposal drawing minutes.
within 24 hours of a customer
specifying their requirements, and the finished
tools within 10 to 20 working days. Select tool type Tailor to your needs

Select the type of tool you want to Tailor the tools features like length,
customize coupling and coolant options

Finishing groove with Tailor Made CoroCut.

Tool creation

1 2

Tailor Made with CoroCut.

Tool is designed and quoted within 20 minutes.
Your receive the ordering code, 2D Drawing (DXF), 3D models, and delivery time

5°
Start using tailor made web
www.sandvik.coromant.com

Finish groove with small radius.

66 67
 Modular
Advanced holders - CoroTurn® SL CoroTurn® SL is a modular system of adaptors and cutting
CoroTurn® SL is a modular tooling system developed and designed to provide flexibility heads with which you can build customized tools for a variety
and stability in various turning operations, including internal turning, grooving, threading, of turning applications with a minimum amount of items.
boring, and multi-task machining. The system comprises interchangeable adapters and The robust coupling and many combination possibilities
cutting heads, allowing for customized tool configurations tailored to specific machining makes it ultimate for building a tool for machining complex
requirements components.

Silent Tools
The modularity of CoroTurn® SL opens the door to Silent
Tools™ damped boring bars. This solution ensures maintained
productivity and close tolerances in operations with long
overhangs and other vibration-prone situations. As the same
boring bar can be used for various types of cutting heads, you
can use it for several operations.

SL70
CoroTurn® SL includes SL70 interface, an oval coupling
which provides both excellent rigidity and accessibility,
making it optimum for profiling and grooving operations on
large components. Clearance is applied for external and
internal machining so each cutting head can be used in both
configurations.

Coupling stability
The secret to CoroTurn® SL lies Application examples
in the locking interface between
adaptor and cutting head. The
robust Serration Lock (SL) interface
allows you to combine exchangeable
cutting heads and adaptors as you
please with maintained stability and
performance.

68 69
Boring deep holes - Silent Tools™ Silent Tools™ Plus
Silent Tools™ Plus Improved decision making
Certain features in components, such as Knowing what is happening inside the component is a challenge when doing internal
deep bores in shafts, require long tools turning in slender components. The dashboard clearly shows when the tool is in cut,
which can pose serious challenges for giving the operator immediate insight into the machining process. Thus, time when the
machining. machine is running without the tool in cut can be reduced.
Sandvik Coromant has offered Silent Tools The Silent Tools™ Plus vibration sensors will pick up issues with your machining in an
for many years to help reduce vibration early stage, helping you take action in your daily work.
and improve machining stability. Now, with
Silent Tools Plus, it's possible to receive
live feedback from the tool, providing
insights into what's happening at the
cutting edge which is especially useful
when it's not possible to see or hear
issues in time, risking part damage.

Short set up times Next gen vibration elimination

A properly mounted tool reduces the risk Thanks to a major upgrade to the
of undersized holes that require re-work damping mechanism, Silent Tools™
but also improves the cutting ability of the turning adaptors are now more
insert to ensure maximum tool life. effective than ever at suppressing
The Silent Tools™ Plus centre height vibration during long overhang
indicator helps the operator to set up the machining. The damper body, which
tool quicker and with increased accuracy. previously required manual fine-
tuning, is now automatically calibrated
and assembled by machine. This
automation ensures a precise and Learn more about the next generation
of Silent Tools™ turning adaptors:
predictable frequency range, perfectly www.sandvik.coromant.com/silent-tools-turning
matched to the adaptor’s intended
overhang and application.

70 71
Engineered solutions for industry Deep grooving and profiling
We have developed engineered solutions to specific application requirements in Discs and spool components have deep
industry. The solutions will be developed to a specific component, contact your Sandvik cavities which have to be machined from solid
Coromant technical representative for more details. or finish machined after welding. The long
depth to width ratio required for the tool means
CoroCut®angled inserts for grooving that there is a high tendency to vibration.
Thin walls and complex shapes for components in the aero engine leads to a
requirement for grooving and profiling inserts within tightly confined spaces. Standard
inserts and tool holders often do not offer the combination of sufficient accessibility and
rigidity, which is required in tough-to-machine materials. The blade solution is developed to
To overcome these obstacles Sandvik Coromant has developed engineered inserts, optimise this difficult application offering
which utilise the outstanding stability of the CoroCut tip seat design and optimised maximum rigidity and minimized vibration
grades providing security and productivity. allowing high productivity where long slender
tools are required.
– Dampened mechanism incorporated in the blade.
– Coromant Capto® (C6 or C8) spindle adaptor.
Order finished ground engineered inserts Left hand Right hand – Oval shaft.
according to your specific requirement: – Serration coupling.
Width la – High blade.
Depth iW
– Over and under coolant.
Radii rε1, rε2
Chipformers
Width/depth limitations Dampened mechanism
A patented solution is applied when the
Available grades:
blade length to width ratio is greater than
GC1205 –first choice for HRSA 5:1. Carbide discs are assembled into the
Applications blade which opposes the vibration induced
H13A – for interrupted cuts by the cutting process. The effect is that
typically 4 times greater depth of cut can
be achieved.

Effect on insert
Typical features/applications are Ceramic RCGX 090700 T01020 675
found in casings, discs, rings and vc 250 m/min, ap 1.5 mm
fn 0.15 mm/r (G1), fn 0.075 mm/r (G2/G3)
shafts
Disc, shaft

Vane/stator segment Casing Non damped Damped

72 73
 Component solutions
Sandvik Coromant’s component solutions are the result of decades of innovation,
close industry collaboration, and deep application knowledge. With a strong
heritage of working alongside the aerospace sector since our foundation in
1942, we’ve developed optimised tools and machining strategies for the most
demanding component features.

Our focus on advanced research and development, combined with partnerships

with OEMs and machine builders, ensures that our aerospace offer is built on real-
world challenges and verified success. These solutions provide measurable gains
in productivity, surface finish, tool life, and process security—enabling efficient
machining of complex parts such as casings, rotors, frames, and structural
elements.

74 75
Aeroknowledge Sandvik Coromant component
Expert knowledge for aeroengine machining feature solutions
FSM –
Inconel 718
26 HRC
Roughing with high
depth of cut

We’ve created a dedicated platform for aeroengine machining knowledge, offering

component-specific guidance, in-depth articles, and exclusive video content including
Insert Geometry Grade Cutting Depth of Feed MRR
webinars and live machining. Speed cut mm mm/rev cm3/min
m/min (inch) (in/rev) (in3/min)
(sf/m)
Component Solutions S-SNMM 190616 SR GC2015 20 (65) 10 (0.39) 0.6 (.023) 120(7.32)
Solutions for key aeroengine components
S-SNMM 250924 SR GC2015 20 (65) 15 (0.59) 0.6 (.023) 180(10.98)

Articles
Insights on industry trends and machining
innovation

Video
Watch videos and webinars focused
on HRSA and aerospace component
machining

Stop groove 2 mm (0.079 inch) short

of breaking through.

Groove 2 mm (0.079 inch) past outside Breakthrough with carbide insert 1 mm

diameter of the test ring. (0.039) inch narrower.

Ceramic 150.23 0635 08E 675 Carbide C2I-0635-0003-GM1225

Start using Aeroknowledge today
CW 6.35 mm (0.250 inch) CW 6 mm (0.236 inch)
www.sandvik.coromant.com
vc 300 m/min (984 ft/min) vc 50 m/min (164 ft/min)

fn 0.07 mm/r (0.003 in/rev) fn 0.12 mm/r (0.005 in/rev)

76 77
ISM – Max. Ramping angle ISM –
40° for DSDNN Inconel 46 HRC
Inconel 718 46 HRC 25° for DSSNL/R
Roughing with high Profiling and
depth of cut. pocketing.
Ceramic

Insert Geometry Grade Cutting Depth of Feed MRR Insert RNGN 120700 E 6160 150.23 0952 08T01020 675 RCGX 090700 E 6160
Speed cut mm mm/rev cm3/min
m/min (inch) (in/rev) (in3/min)
(sf/m) Speed vc m/min (sf/m) 300 (984) 300 (984) 300 (984)
SNMG 190616 SM S205 60 (196) 5 (0.169) 0 .35 (.013) 105(6.41) Depth of cut ap mm (in) 2 (.078) 9.5 (.374) 1.5 (.059)
SNMG 120408 SMR S205 60 (196) 3 (0.118) 0.35 (.013) 63(3.84) Feed mm/r (in/rev) 0.15 (.0059) 0.07 (.0028) 0.15 (.0059)

ISM –
Inconel 718 46 HRC
Machining into a
corner
Ceramic

Insert Geometry Grade Cutting Depth of Feed MRR Insert RCGX 090700 E 6160
Speed cut mm mm/rev cm3/min
m/min (inch) (in/rev) (in3/min)
(sf/m) Speed vc m/min (sf/m) 240 (787)
RNGN 120700 E CC6160 250(820) 2.4(0.0945) 0.2 (.007) 120(7.32)) Depth of cut ap mm (in) 1 (0.039)
RNGN 120700 E CC6165 250(820) 2 (0.0787) 0.2 (.007) 100(6.10) Feed mm/r (in/rev) 0.24 (.0094)

Carbide

Carbide

Insert Geometry Grade Cutting Depth of Feed MRR Insert Geometry Grade Cutting Depth of Feed MRR
Speed cut mm mm/rev Speed cut mm mm/rev
cm3/min cm3/min
m/min (inch) (in/rev) m/min (inch) (in/rev)
(in3/min) (in3/min)
(sf/m) (sf/m)

CP-B1208D M7 S205 70(229) 2(0.0787) 0.2 (.007) 28(1.71)) RCMT 10T3M0 M3 S205 90(161) 1 (0.0394) 0.3(.011) 27(1.65)

CP-B1208D M7 S205 70(229) 2(0.0787) 0.2 (.007) 28(1.71)) RCMT 12T3M0 H7 S205 70(229) 1.8(0.0709) 0.5(.019) 63(3.84)

78 79
ISM – Inconel 718 46 ISM – Inconel 718
HRC 46 HRC
Profiling and Wide grooving.
pocketing.
CoroCut® 2.

Use trochoidal turning method described on page 23.

Insert Geometry Grade Cutting Depth of Feed MRR
Speed cut mm mm/rev cm3/min
m/min (inch) (in/rev) (in3/min)
(sf/m)

150.23-0635 T01020 CC675 300(984) 6.35(0.250) 0.07(.0028) 133(8.14)

CSGX 090708 T01020 CC675 300(984) 9.5(0.374) 0.07(.0028) 199(12.17)

C2I-K2N-0600 TF GC1205 75(246) 6(0.236) .16(.0063) 72(4.39)

Narrow grooving.

Insert Geometry Grade Cutting Depth of Feed MRR

Speed cut mm mm/rev cm3/min
m/min (inch) (in/rev) (in3/min)
(sf/m)

C2I-L2N-0800 RM S205 80(262) 1.2 (0.0472) 0.5(.0197) 48(2.93)

C2I-J2N-0600 RM S205 80(262) 1 (0.0394) 0.4(.0157) 32(1.95) Insert Geometry Grade Cutting Depth of Feed MRR
Speed cut mm mm/rev cm3/min
C2I-H2N-0600 RF S205 80(262) 0.6 (0.0236) 0.3(.0118) 14.4(0.88) m/min (inch) (in/rev) (in3/min)
(sf/m)

C2I-G2N-0300 0004 GF GC1205 85(278) 3(0.118) 0.09(.0035) 22(1.4)

C2I-G2N-0300 0004 TF GC1205 95(311) 3(.118) 0.1(.0035) 25(1.57

Narrow grooving
full radius.

Insert Geometry Grade Cutting Depth of Feed MRR

Speed cut mm mm/rev cm3/min
m/min (inch) (in/rev) (in3/min)
(sf/m)

C2I-F2N-0300 RM S205 95 3(0.118) 0.12(.0047) 34(2.09)

80 81
 ISM – Inconel 718 46 ISM – Inconel 718 Operation 1a Operation 1b
Insert L123H1-0200-RO S205
HRC 46 HRC
Seal-fin grooves Speed vc m/min (sf/m) 60 (197) Rings
Depth of cut ap mm (in) 0.3 (.012)

Feed mm/r (in/rev) 0.4 (.016)

Operation Insert Geometry Grade Cutting Depth of Feed

Speed cut mm mm/rev
m/min (inch) (in/rev)
(sf/m)

1a CNMG 120408 SM S205 75(246) 1.5(.059) 0.2(.0079)

Blade grooves on
1b C2I-G2N-0300 0004 GF GC1205 85(278) 3(0.118) 0.09(.0035)
disc/spool.

Insert C2I-H2N-0400-0004 TF 1205 C2I-F2N-0300 RM S205 CoroCut®

Engineered
insert GC1205

Speed vc m/min (sf/m) 90 (295) 75 (246) 60 (196)

Operation Insert Geometry Grade Cutting Depth of Feed
Speed cut mm mm/rev
Depth of cut ap mm (in) 4 (.157) 0.6 (.023) 0.5 (.019)
m/min (inch) (in/rev)
Feed mm/r (in/rev) 0.12 (.0047) 0.4 (.0157) 0.25 (.0098) (sf/m)

1c DNMG 150612 SM GC1205 60(196) 1.0(.0394) 0.2(.0079)

1d DNGG 150604 SGF GC1205 80(262) 0.3(.0118) 0.12(.0047)

Grooves on stator
vanes.
Operation 1e Operation 1f

Insert CoroCut 90° insert CoroCut 90° insert

GC1115 GC1115

Speed vc m/min (sf/m) 30 (98) 30 (98)

Operation Insert Geometry Grade Cutting Depth of Feed
Depth of cut ap mm (in) 2 (0.078) 0.25 (.0098) Speed cut mm mm/rev
m/min (inch) (in/rev)
Feed mm/r (in/rev) 0.1 (.0039) 0.15 (.0059) (sf/m)

1e C2I-G2N-0300 0004 GF GC1205 85(278) 3(0.118) 0.09(.0035)

1f C2I-G2N-0300 0003 TF GC1205 85(278) 3(0.118) 0.1(.0039)

82 83
 ISM – Inconel 718 46
HRC
Thin walls/unstable.

Insert Geometry Grade Cutting Depth of Feed MRR Insert Geometry Grade Cutting Depth of Feed MRR
Speed cut mm mm/rev Speed cut mm mm/rev
cm3/min cm3/min
m/min (inch) (in/rev) m/min (inch) (in/rev)
(in3/min) (in3/min)
(sf/m) (sf/m)

CNMG 120408 SM GC1205 50(164) 1.5(0.0591) 0.2(.0079) 15(0.92) RCMT 1204MP M3 S205 75(246) .25(0.0098) .5(.0197) 9.38(0.57)

CNMG 120404 SF GC1205 50(164) 1(0.0394) 0.2(.0079) 10(0.61) RCMT 10T3MP L3 S205 75(246) .25(0.0098) .45(.0177) 8.44(0.51)

RCMT 0803MP L3 S205 75(246) .25(0.0098) .4(.0157) 7.5(0.46)

Internal machining.

For overhangs up to 14 x dmm, use Silent Tools carbide reinforced boring bars. Insert Geometry Grade Cutting Depth of Feed MRR
Speed cut mm mm/rev cm3/min
m/min (inch) (in/rev) (in3/min)
Bar type selection (sf/m)

Insert DNMG 150608 SM GC1205 C2I-J2N-0600 RM S205 80(262) .25 (0.0098) 0.35(.0157) 32(1.95)

C2I-H2N-0500 RF S205 80(262) .25 (0.0098) 0.3(.0118) 6(0.37)

Speed vc m/min (sf/m) 60 (196) C2I-H2N-0400 RF S205 80(262) .25 (0.0098) 0.25(.0098) 5(0.31)
Depth of cut ap mm (in) 2 (.0787)

Feed mm/r (in/rev) 0.15 (.0059)

Insert Geometry Grade Cutting Depth of Feed MRR

Speed cut mm mm/rev cm3/min
m/min (inch) (in/rev) (in3/min)
(sf/m)

CNMG 120404 SGF GC1205 50(164) .3(0.0118) 0.1(.0039) 1.5(0.09)

84 85
 Milling

84 85
Milling of HRSA materials Production planning process
When milling super alloys, there are - If special design cutters are being To optimise a machining operation all Optimising the above is of course
certain process requirements which must considered for an application, it is aspects of the application should be necessary, however, to achieve an
be observed. essential to allow sufficient space considered: optimised process these must be
between each tooth for effective chip – Type of operation? combined with process and application
- Milling of high-temperature alloys ‘know how’ to achieve secure productive
often requires more rigid and powerful evacuation around the cutting edge. – Tool paths?
machining. This information considers in
equipment than the milling of carbon - Flank wear around the cutting edge – Conventional or climb milling? which order to build an optimised process
steels. should not exceed 0.2 mm for R390, 0.3 – C
 utting tool type and material? for HRSA milling and discusses important
- Cutter accuracy in both radial and mm for round inserts in carbide, and 0.6 ‘success factors’ for each stage.
mm in ceramics. Otherwise the chance of – Change of operation sequence?
axial directions is essential to maintain
a constant tooth load and a smooth a catastrophic failure increases rapidly.
operation, and to prevent premature Normal best practice is to index the
failure of individual cutter teeth. cutting edges at frequent intervals, to
ensure a reliable process.
- Cutting edges must be sharp with an Optimised production planning process
optimised edge-rounding, to prevent chip -D
 own milling (climb milling) should
adherence at the point where the edge be used, to obtain the smallest chip
exits the cut. thickness where the edge exits cut and
- The number of cutting teeth actually
reduce any chip adherence 1 2 3 4 5
in cut during the milling cycle must be - The machining of iron-based super Analysis Machining Cutter style Cutting Program
as high as possible. This will give good alloys, and solution treated, nickel-based of features strategy selection data, tool CAM
productivity provided that the stability is alloys (Inconel 625), usually machine selection
good enough. easier than nickel-based and cobalt-
based super alloys.
- Cutting speeds for super alloys are
generally low. Common practice is to Typical components
employ a fairly low cutting speed in
combination with a moderately high feed Because of HRSA’s excellent metallurgical By far the most common application for
per tooth, to produce a chip thickness properties they are used in a variety of HRSA materials is the aircraft engine. The
not less than 0.1 mm which prevents industries including: use of HRSA in the combustion part of the
work-hardening of the material. engine is increasing. This is typified by
Aerospace engine
- Coolant should be applied in generous –C
 ombustion & turbine components, the fact that, whereas in 1950 only about
quantities around the cutting edge when mounting brackets 10% of the total weight of an aircraft gas
the cutting speeds are low, in order to turbine engine was made of super alloys,
reduce chip adhesion. Coolant supplied Selected automotive components
this has now risen to 50% in today’s
through the machine tool spindle is – Turbo chargers, exhaust valves
modern engines.
recommended for HRSA materials. High Space vehicle components
It is predicted that HRSA will continue to
pressure coolant (HPC) will give better – Aerodynamically heated skins, rocket
be used extensively in the combustion
tool life. (No coolant for ceramic milling) engine parts
parts of an aircraft engine and recent
- The cutting edge geometry should Nuclear power systems developments have seen the next
always be positive. – Valve stems, drive mechanisms generation of HRSA materials being
- For cutting depths below 5 mm, the Oil and gas industry developed and implemented in production.
entering angle should be less than 45°. – Marine applications
In practice, a round, positive-rake insert
is recommended.

86 87
Typical components – aerospace Power/torque requirement through the spindle/tools and externally
has been seen to give good benefits
Basically, the power requirement varies compared to low pressure.
with the amount of metal to be removed,
average chip thickness, cutter geometry Fixturing
and speed. The greater the metal removal The shape and fixturing of the component
rate (Q cm3/min) the higher the power is of great importance. Aerospace engine
Combustion casings Discs Rings Blades/blisks Mounting brackets
requirement. components are often thin-walled and
With spindle speeds for roughing much have a lot of complex features which easily
lower than for less exotic materials, it puts create distortion and vibration.
Machining strategy great importance on ensuring that power
and torque are available at low rpms This is often the reason why engine
Features Spindle speed (a machine with insufficient torque and casings have complex fixtures to reduce
power will give fluctuating chip thickness vibration and support the workpiece in
Most HRSA components are critical parts of Three cutting strategies dictate the relation to the direction of the cutting
the aircraft engine with complex features to spindle speed requirements: in turn giving unstable performance).
forces. Light cutting tools with positive
be machined. For example when machining a) Solid carbide tools – (low torque) – The diagram below shows how a typical
geometries can help to ensure a safe,
an engine casing the most time consuming the cutting speed (vc) is between 30 to machine power diagram looks with lower
distortion-free machining operation.
operation is machining the band between 100 m/min. For cutter diameters 8 to power at low rpms.
the bosses. Careful planning and application 16 mm this will give an rpm requirement Spindle coupling Stability
of modern cutting tool materials can between 4000 to 600 rpm The condition and stability of the machine
dramatically reduce cycle time. Planning the Most HRSA alloys work-harden during
has an effect on the quality of the surface
order of operations in order to reduce part b) Carbide inserts – (high torque) - the machining and have higher strength and
and can impair tool life. Excessive wear of
distortion is also an important factor when cutting speed (vc) is normally limited ‘gumminess’ not typical in other materials.
the spindle bearings or feed mechanism
planning the machining strategy. to a maximum of 40 m/min, for cutter Heavy duty machining equipment and an
can result in a poor surface structure.
diameters 25 mm to 80 mm this will give ISO 50 taper (or equivalent) spindle is
an rpm requirement of 500 rpm to 159 recommended to minimise chatter and As well as ensuring a stable machine
Machine requirement rpm. work-hardening of the alloy ahead of the
cutting.
tool, other factors such as tool overhang,
Coromant Capto coupling, tuned adaptors
c) Ceramic inserts – (high power and
Horizontal/Vertical torque) – typically cutting speeds (vc) Coolant etc should be considered.

For larger components such as engine can be as high as 1000 m/min, for cutter Unlike milling in most other materials,
casings where there are many different diameters 50 mm this will give an rpm coolant is always recommended to assist
features and where access is an issue it of 6365. in chip removal, control heat at the cutting
is best to use a horizontal machine. This edge and prevent re-cutting of the chips.
also makes it easier to evacuate the chips, Table feed High pressure coolant (70 bars) applied
preventing re-cutting of the chips, giving For roughing, using carbide inserts, the
a more secure tool life. For some ring table feed is naturally relatively low, Pc
components and mounting brackets vertical putting demands on stability rather than kW
machine tools can create improved stability. speed.
For roughing, with ceramics, the table
Configuration – 3/4/5-axis feed can be up to around 2.5 m/min.
It is common to have a fourth/fifth axis on Whilst this
horizontal machines to give good is not an extreme table feed, care must Risk of power being too low
accessibility e.g. For casings and closed be taken that the control system can with the large diameters and
faces. low cutting speed.
cope with direction change at this feed
For complex parts (3D profiles, blisks) to avoid undercutting/shortcuts etc.
5-axis rigid machines are used, with fully
n
simultaneous five access control. m/min

88 89
Cutter concept
Modern milling is a very universal The aim is to have a strategy suited to the
The cutter diameter is more or less The kr/insert style (round, 45º, or 90º)
selected by the operation and the and number of teeth selected will have a
machining method. During the past few machine tool and feature to be machined
machine capability. The choice of ceramic dramatic effect on the machining strategy
years hand in hand with machine tool giving a maximum metal removal rate (Q
insert, carbide inserts or solid carbide is and ultimately on the tool life and Q.
developments, milling has evolved into a cm3/min) that can be balanced with an
determined by productivity calculations, Therefore the feature type and machining
method that machines a very broad range economic tool life.
surface requirements and process strategy will influence which concept style
of configurations. The choice of cutter
For milling there are many variables to limitations (machine, fixturing etc). should be selected.
concept is no longer straightforward
– in addition to all the conventional consider:
applications, milling is a strong contender
DC – cutter diameter
for producing holes, threads, cavities
and surfaces that used to be turned, CICT – number of effective teeth Milling process
drilled, or tapped etc. (See hole making KAPR – entering angle
chapter). Tooling developments have also APMX – maximum cutting depth
contributed to the new possibilities along
AERMX – maximum radial cut
Milling direction
with the gains in productivity, reliability • In down milling (also called climb
During a milling operation, the workpiece
and quality consistency that have been milling) – the insert starts its cut with
is fed either with or against the direction
made in indexable and ceramic inserts. a large chip thickness. This avoids the
of rotation and this affects the nature of
burnishing effect with less heat and
Concept types the start and finish of cut.
minimal work-hardening tendencies.
Face mills • In up milling (also called conventional
Always use down milling for machining of
milling) – the chip thickness starts at
HRSA materials with carbide inserts.
zero and increases to the end of the cut.
There are high cutting forces which tend
to push the cutter and workpiece away
from each other. The insert is forced into
cut, creating a rubbing or burnishing
CoroMill® 300 CoroMill® 245 CoroMill® MH20 effect work-hardening the surface.

End mills
Round inserts 90º Solid carbide Exchangeable head

CoroMill® 300

Ceramic insert cutter

CoroMill® MS20

Ball nose
CoroMill® Plura

Barrel
CoroMill® 316

Conical ball nose

– Up milling + Down milling

CoroMill® CoroMill® Plura CoroMill® Plura

S-R120R/CoroMill® 300C Ball nose 216 barrel conical

90 91
 When profile milling, cutter position is fixed; in face milling, the flexible position can lead
Milling with indexable inserts to misapplication.
Program entry carefully until full cut is achieved using one of the following methods:

Cutter diameter Entry into and exit from the – ae: 30–75% of cutter diameter, with ≥2 teeth in contact (if zn > 2).
and position in face milling workpiece considerations – Offset the cutter for near-zero chip thickness on exit.
The selection of milling cutter diameter Each time one of the milling cutter – Program entry carefully until full cut is achieved using one of the following methods:
is usually made on the basis of the inserts enters into cut, the cutting edge
workpiece width with the power availability is subjected to a varying shock load.
of the machine also being taken into The right type of initial contact, and final
account. The position of the cutter in contact, between edge and material is an Roll on entry Reduced feed on entry
relation to the workpiece engagement and important aspect of the milling process. Prog. rad. = (De) + 2
the number of teeth in contact are all vital Positioning the cutter right as regards 2
factors for successful operation. entry and exit of the cutting edge is
When machining in a single pass, a cutter important – always avoid a thick chip on
diameter 20 to 30% larger than the exit.
workpiece width is recommended. The
milling cutter should always be positioned 2 mm
off-centre producing the thinnest chip on
exit. If several passes need to be taken,
a radial cut (ae) of 75% Dc should be
applied to ensure good chip formation and
suitable cutting edge load. Thick chip on exit of
a = 100% DC
Avoid positioning cutter on-centre.
e ae= 50% DC ae= 80-60% DC ae < 25% DC cut until cutter is fully
• Full slotting milling • Unfavorable option • Productivity in stable • Low forces and heat load
conditions
engaged
• Sometimes the only way • Capability for high vc, fz
• Often the best for and ap
indexable tools
• Often the best for solid
tools Rolling into cut impact
Feature Material Milling Body Coolant press.

Keep the cutter in contact Facing Age-hardened Inconel

718, S2.0.Z.AG,
R300-063Q22-12H 20 bars (290 PSI)
63mmØ (2.48inch)
Also when milling large workpiece surface areas, select tool path to keep the milling 43 HRc 7 insert pockets
cutter in full contact rather than perform several parallel passes. When changing
direction, include a radial tool path to keep cutter moving, avoiding dwell and chatter Tool R300-1240 E-PM
tendencies. vc, m/min(ft/min) 25 (114)
fn, mm/rev (in/rev) 0.25 (0.079)
ap, mm (inch) 2 (0.0787)
ae, mm (inch) 48 (1.91)

Grade Roll in entry Straight 100 % feed Straight 50 % feed

S40T

After 10 passes After 3 passes After 4 passes

Many entries/exits. Constant contact. S30T

92 93
Effect of insert style Carbide milling grades
The entering angle (KAPR) is the angle between the insert's leading edge and the First choice grades
workpiece surface. It influences chip thickness, cutting forces, and tool life. Common
angles include 90°, 15°, and round inserts.
S30T
Smaller entering angles reduce chip thickness (hex) at a given feed, spreading the S30T is a PVD-coated carbide grade designed
load over a larger edge area. This chip thinning effect lowers radial pressure and specifically for milling heat-resistant superalloys
improves edge protection. (HRSA) such as Inconel and other nickel-
based alloys. It offers a strong balance of wear
resistance and edge security, making it ideal
90° approach angle for shoulder milling, face milling, and profiling
The main application area for a 90 degree under stable conditions. The TiAlN-based coating
cutter is square shoulder milling. handles the high temperatures generated during
A 90 degree cutter generates mostly radial HRSA machining, helping to reduce flank wear
forces, in direction of the feed. This means that and extend tool life.
the surface being machined will not be exposed S40T
to high axial pressure, which is advantageous S40T is a tough, CVD-coated carbide grade
for milling work pieces with a weak structure or
developed for demanding milling operations in
thin walls, and in cases of unstable fixture.
heat-resistant superalloys (HRSA), especially
where edge security is critical. It features a
thicker coating to enhance wear resistance
15° approach angle and compensate for the lower hot hardness
Cutters with a 15° entering angle are used for of its substrate. This makes it well-suited for
high-feed and plunge milling. They generate applications involving interrupted cuts, higher
thin chips, enabling high feed rates at shallow loads, or unstable conditions. S40T is often the
depths. The axial cutting force stabilizes the preferred choice when tool reliability is prioritised
spindle, making them ideal for weak setups, over maximum wear resistance.
deep cavities, and hole making using 3-axis
milling.

Complementary grades
GC1010 GC2040
0 - 90° approach angle Tough MT-CVD coated carbide
Hard PVD grade with a thin
Round insert cutters are versatile tools ideal for milling of cast heat resistant
coating for light roughing to
for roughing. Their strong cutting edge handles alloys. Offers good resistance
finishing of material above 36
high feed rates, thanks to chip thinning along to high temperatures and
HRC and higher, best suited
the edge. This makes them well-suited for performs well under difficult
for stable conditions to avoid
titanium and heat-resistant alloys. The entering conditions.
chipping.
angle varies with depth of cut, changing cutting
forces along the edge.

94 95
Typical wear patterns in HRSA
Flank wear Notch wear
Flank wear is gradual wear along the side of the insert, caused by high cutting Notch wear is localized damage at the depth-of-cut line, caused by work hardening in
temperatures and abrasion. It leads to poor surface finish and dimensional inaccuracy. HRSA materials. It results in poor surface finish and potential insert breakage.

Problem: Rapid flank wear causing poor surface finish or out of Problem: Notch wear causing poor surface finish and risk of insert
tolerance features breakage.
Cause: Cutting speed too high or insufficient wear resistance. Cause: Work hardening materials.
Remedy: Reduce cutting speed. Remedy: Use a round insert and/or reduce depth of cut (ap).
Select a more wear resistant grade.

Feature Material Milling Body Coolant press. Feature Material Milling Body Coolant press.

Shoulder Age-hardened R390-063Q22-11M 20 bars (290 PSI) Shoulder Age-hardened Inconel R390-063Q22-11M 20 bars (290 PSI)
Inconel 718, 718, S2.0.Z.AG, 43 R300-063Q22-12L
63mmØ (2.48inch)
S2.0.Z.AG, 43 HRc HRc
7 insert pockets 63mmØ (2.48inch)
7 insert pockets
Tool R390-11T3 08 M
Tool R390-11T3 08 M-PM S30T
vc, m/min (ft/min) 30 (98)
R300-1240M-PM S30T
fz, mm/min (in/min) 0.117 (.005)
vc, m/min (ft/min) 30 (98)
ap, mm (inch) 2 (0.0787)
ap, mm (inch) 2 (0.0787)
ae, mm (inch) 15 (0.591)
ae, mm (inch) 48.5 (1.91)

S40T grade 1010 grade R390-11 R300-12

Edge after 6 passes Edge after 6 passes Edge after 4 passes Edge after 4 passes

Switching to a harder, more wear-resistant grade results in more controlled edge wear, Round inserts like CoroMill® 300 resist notching far better than typical 90 degree
helping maintain surface finish and extending tool life shoulder mills, thanks to the chip thinning effect as clearly shown above.

96 97
Circular ramping from solid Circular milling of existing hole
Hole diameters can be finish machined
Milling of holes is a flexible process able using circular milling as an alternative to
to produce a range of hole sizes with boring depending on the surface finish
each cutter. It produces low axial cutting requirement. The feed rate (vf) must be
forces and copes well with interrupted reduced compared to straight line milling
entrances and exits which are a problem due to that in internal applications. fz
fz =
when machining into curved surfaces such sinθ
as casings.
– The periphery of the tool will be moving
vfm = n x fz x zn
faster than the centre line of the tool.
Programming of the feed rate (mm/
Dvf
min) on most milling machines/CAM vf = x vfm
Cutter and hole diameter systems is based on the centre line of Dm
The ramping process requires a cutter the spindle.
Dm
which is capable of axial cutting. Max D3 = + 0.5iC – The radial engagement (ae) increases
The diameter selection is very important 2
Min Dm = (D3 – 0.5iC) x 2 compared to that of a straight cut
when using cutters which are not centre increasing the chip thickness, hex.
cutting. The diameter of the cutter, minus
– The effect of both of these factors is
the insert radius, should not exceed half
increased with the increase in cutter
the hole diameter. This is to ensure that
diameter relative to the hole size.
there is no ‘pip’ remaining.
– The correct feed reduction compared to
straight cutting can be selected from
Pitch the diagram.
The axial pitch (P) per revolution is – Allowing for stability use Dc = 0.4 x Dm
determined by the max depth of cut and reduce feed by 50% of normal.
limitation for the cutter concept (0.15 x iC
for round inserts).

Feed rate Tool centre feed reduction factor for given cutter dia.
The feed rate must be reduced in internal hole dia. ratio (Dc/Dm) and constant chip thickness.
applications due to the periphery of the Feed reduction factor
tool moving faster than the centre line of
the tool. 10
9
Programming of the feed rate (mm/min)
on most milling machines/CAM systems 8
20%
is based on the centre line of the spindle 7
40%
requiring a manual recalculation. 6
Tool centre feed diameter – Dvf 60%
Dvf = Dm – D3 5
80%
Programmed feed rates 4
Example
3
Dm = 58
ap = 2
• vfm – when using radius compensation
D3 = 35 2
zn = 4 • vf – when using the tool centre feed
vc = 25 1
n = 227 Percentage
fz = 0.2 Dvf 0
vfm = 182 vfm = n x fz x zn vf = x vfm ae/Dc
Dvf = 18 5% 10% 15% 20% 25%
vf = 76 Dm

98 99
 Effect of Cutting Speed, vc
CoroMill®300
CoroMill® 300 is a round insert cutter for a broad range of Performance
operations such as face milling, pocketing, and profiling. Its Surface speed and material hardness are key factors in tool life when machining superalloys.
light cutting action allows for smooth entries and exits and for Cutting temperatures for HRSA materials range from 750 to 1020ºC, high enough to cause
use of extended tool set-ups. oxidation and work-hardening, accelerating tool wear.
The cutters generate low cutting forces and little heat when
machining with small depths of cut which makes this an Feature Material Milling Body Coolant press.
excellent choice for milling HRSA materials.
Facing Age-hardened Inconel R300-063Q22-12H 20 bars (290 PSI)
718, S2.0.Z.AG, 63mmØ (2.48inch)
43 HRc 7 insert pockets

Tool R300-1240 M-PM S40T

ap, mm (inch) 2 (0.0787)
ae, mm (inch) 36 (0.0275)

TMR per insert edge cm3 (in3)

250
(15.3)
200
(12.2) Feed 0.2 mm/z (0.008 in/z)
150
(9.15) Feed 0.25 mm/z (0.010 in/z)
CoroMill® 300 application examples
100
(6.10)
Geometries for HRSA 50
(3.05)
0
Direct pressed Precision ground Precision ground
15 20 25 30 35 40 45
M-PM E-PL E-PM (49) (66) (82) (98) (115) (131) (148)
vc m/min (ft/min)

Cutting speed plays a critical role in HRSA

High edge sharpness and High edge sharpness and Balanced geometry ensures machining, directly affecting tool life. Lower
precision. Positive geometry precision in combination with stable, precise milling with speeds allow inserts to withstand more flank wear
with edge reinforcement. First security. reduced vibration and use before failure, helping balance productivity and
choice with S30/S40T. Works well combined with S30/ with S30/S40T tool longevity. The recommended cutting speed
range for optimal performance is 25–35 m/min S40T insert after 8 S40T insert after 8
S40T
(82–115 ft/min) passes vc 25m/min passes vc 30 m/min
(82 ft/min) (98ft/min)

100 101
Effect of Feed Per Tooth / fz Effect of Geometry
As with other workpiece materials, feed and depth of cut are also important for tool Performance
life when machining HRSA materials. The feed per tooth value is calculated from the
The graph below shows the effect of the geometry cutting at the same parameters
recommended maximum chip thickness (hex) – this deviates from the feed per tooth
depending upon the following two factors:
Feature Material Milling Body Coolant press.
Facing Age-hardened Inconel R300-063Q22-12H 20 bars (290 PSI)
718, S2.0.Z.AG, 43 63mmØ (2.48inch)
Entering Angle (KAPR) Max chip thickness hex = f z × sin KAPRr
HRc
7 insert pockets
For inserts with an entering angle of 45º
and round inserts there is a chip thinning Tool R300-1204
effect – this allows greater feed than vc, m/min (ft/min) 30 (98)
iC fz
inserts with KAPR 90º. fz, mm/min (in/min) 0.25 (.010)
ap, mm (inch) 2 (0.0787)

hex ae, mm (inch) 36 (0.0275)

Round inserts
Minutes in cut = Average time in cut Total metal removed, cm3(in3)
hex = f z × √ 4aiCp – ( 2a )
iC
p 2

40 = Average volume removed 100

(3.93)

30 75
(2.95)

Radial Immersion, (ae/Dc) 20 50

(1.96)
This is the width of the component engaged
in cut in relation to the diameter of the 10 25
cutter. It is the distance across the surface (0.98)
being machined covered by the tool. 0 0
When the ae is below half the diameter R300-1240M-PM S30T R300-1240E-PM S30T R300-1240E-PL S30T
the maximum chip thickness is reduced
relative to the fz – therefore the feed can M-PM E-PM E-PL
be increased.

10 passes, 25.1 minutes 6 passes, 15.1 minutes 10 passes, 25.1 minutes

97 cm3 (5.92 in3) 58 cm3 (3.55 in3) 97 cm3 (5.92 in3)

Depth of cut Entering angle, Modification value, fn fz mm/tooth for given

diameter ratio, KAPR chip thickness in mm:
ae/Dc Recommendation maximum productivity and metal removal rates were achieved using
hex hex hex M-PM.
0.1 0.15 0.2
0.25 60° 1.16 0.12 0.17 0.23
0.2 53° 1.25 0.13 0.19 0.25
0.15 46° 1.4 0.14 0.21 0.28
0.1 37° 1.66 0.17 0.25 0.33
0.05 26° 2.3 0.23 0.34 0.46

102 103
Effect of ap / Entering Angle Effect of Material Hardness
Small variations in material hardness will have a significant effect on tool life.
Selecting the correct cutting depth/ aerospace frame components HRSA
entering angle when face milling in HRSA components tend to have geometries that Feature Material Milling Body Coolant press.
materials has an effect on tool life and require high metal removal rates but not Facing Age-hardened Inconel R300-063Q22-12H 20 bars (290 PSI)
productivity. Despite limitations on depth at high depth of cut, for example blades, 718, S2.0.Z.AG, 63mmØ (2.48inch)
of cut when using round insert cutters casings etc. This allows optimisation of
7 insert pockets
these are still the most productive method the entering angle at varying depth of cut. min
when milling HRSA. Unlike typical titanium Insert R300-1240M-PM S30T 30

vc, m/min(ft/min) 30 (98) 25

Depth of cut Depth of cut for insert Entering angle
to diameter diameter, in mm (inch) fz, mm/z (in/z) 0.24 (0.0276)
KAPR 20
ratio ap/iC ap, mm (inch) 2 (0.0787)
8 10 12 16
0.25 2(.0787) 2.5(.0984) 3(.1181) 4(.1575) 60° ae, mm (inch) 36 (1.41) 15
0.2 1.6(.0630) 2(.0787) 2.4(.0945) 3.2(.1260) 53° iC
hex mm (inch) 0.18 (0.0071)
KAPR 10
0.15 1.2(.0472) 1.5(.0591) 1.8(.0709) 2.4(.0945) 46°
0.1 0.8(.0315) 1(.0394) 1.2(.0472) 1.6(.0630) 37° 5
0.05 0.6(.0236
0.4(.0157 0.5(.0197 0.8(.0315) 26° ap 0
40 43 46 HRC

Feature Material Milling Body Coolant press.

Facing Age-hardened Inconel R300-063Q22-12H 20 bars (290 PSI)
Summary - Face milling using carbide inserts in HRSA
718, S2.0.Z.AG, 63mmØ (2.48inch)
40 HRc 7 insert pockets - Grade S30T/S40T has the best performance.
Insert R300-1240M-PM S30T - Increase in cutting speed reduces tool life significantly;
25 m/min (82 ft/min) to 30 m/min (98 ft/min) offers the best
vc, m/min(ft/min) 30 (98)
balance of tool life and productivity.
fz, mm/z (in/z) 0.25 (0.010)
- Tool life reduces with an increase in axial depth of cut (ap).
ae, mm (inch) 48 (1.91) Volume of material removed is less affected and running at
ap = 2 mm achieves 40% more volume removed as at 1.0 mm.
Minutes in cut Total metal removed per insert, cm3(in3)
35 100

(3.93)

25 75 Insert S30T M-PM Insert S40T M-PM

(2.95) 0.2 mm/tooth feed rate 0.2 mm/tooth feed rate
15 50 30 m/min cutting speed 25 m/min cutting speed
(1.96)
2 mm axial depth of cut 2 mm axial depth of cut
5 25 Best productivity Best toughness/security
(0.98)

0
ap 1.0 mm (.0394) ap 2.0 mm(.0591) ap 3.0 mm(.0787)
hex 0.16mm(.0000) hex 0.21 mm(.0000) hex 0.24 mm(.0000) Learn more about CoroMill® 300
www.sandvik.coromant.com
= Average time in cut
= Average volume removed

104 105
CoroMill®390 Shoulder milling engagement
CoroMill 390 is a versatile shoulder milling Shoulder milling can be applied in numerous ways and how it's applied has a bearing
cutter designed to meet the demanding on the tool life, surface quality and productivity. We can break it down into 3 common
requirements of modern machining scenarios:
operations, particularly in the processing of
heat resistant super alloys (HRSA). With its
extensive range of cutter versions, CoroMill Large depth of cut (ap) Large width of cut (ae)
390 is engineered to deliver high precision
This approach involves using both a deep cut (large
and excellent surface finish, making it an
ap) and a wide engagement (large ae). It allows for
ideal choice for industries that require
high material removal rates but is often limited
superior quality components.
by spindle power, torque, and the stability of
the machine and setup. It’s best suited for rigid
machines, stable workpieces, and when maximum
productivity is required.

Small depth of cut (ap) Large width of cut (ae)

Here, the depth of cut is kept small while the
width of cut is maximized. This strategy is ideal for
machining wide shoulders and features with limited
height. By spreading the engagement across a larger
width, it provides stable cutting conditions and
helps maintain accuracy in applications where deep
cutting is not necessary.

CoroMill® 390 covers a The light-cutting insert When combined with Large depth of cut (ap) Small width of cut (ae)
comprehensive range of geometries and high Silent tools® the
This strategy uses a deep cut with a narrow
application from long edge performance grades CoroMill® 390 can
engagement. It is particularly useful in less stable
milling with large ap down of CoroMill® 390 are make setups with long
setups or when machining narrow shoulders.
to small modular cutters designed for low cutting overhangs easy to
By reducing the width of cut, cutting forces
starting at diameter 9.7 forces and vibration overcome and deliver
are lowered, which helps maintain tool life and
free machining for secure, reliable tool life.
performance even under challenging conditions.
secure milling in HRSA
materials

106 107
End milling – low depth of cut (ap) and immersion (ae) Effect of chip thickness, hex

Performance of grades and geometries Impact of hex

What impact does hex have on productivity ? In this test the tool has a fixed vc and larger
Cutting with a low depth of cut (ap), ae = 24% of Dc (cutter diameter)
ap but we will increase the feed and ae to demonstrate its impact on productivity.

Feature Material Milling Body Coolant press. Feature Material Milling Body Coolant press.
Shoulder Age-hardened Inconel R390-063Q22-11M 20 bars (290 PSI) Shoulder Age-hardened Inconel R390-025A25-11H 20 bars (290 PSI)
718, S2.0.Z.AG, 63mmØ (2.48 inch) 718, S2.0.Z.AG, 25mmØ (0.9843inch)
43 HRc 6 insert pockets 44 HRc 4 insert pockets
Tool R390-11 T308M-MM Tool R390-11 T308E-ML S30T
vc, m/min(ft/min) 30 (98) vc, m/min(ft/min) 25 (114)
fz, mm/z (in/z) 0.11 (0.005) ap, mm (inch) 5 (0.1969)
ap, mm (inch) 2 (0.079)
ae, mm (inch) 15 (0.591)

Total metal removed,

Minutes in cut cm3 (in3)
ae 3.1 mm (12.5% of Dc) ae 12.5 mm (45% of Dc)
50 200
(12.2)
Minutes in cut Total metal removed, cm3(in3)
= Average time in cut
50 250 40 = Average volume removed 160
(15.2) (9.76)
= Average time in cut
= Average volume removed 30 120
40 200 (7.32)
(12.2)
20 80
(4.88)
30 150 S40T S30T
(9.1) 08M-MM 08M-MM 10 40
(2.44)
20 100
(6.1) 0 0
hex 0.07 mm hex 0.13 mm hex 0.07 mm hex 0.1 mm hex 0.13 mm
fz 0.11 mm/tooth fz 0.20 mm/tooth fz 0.07 mm/tooth fz 0.1 mm/tooth fz 0.13 mm/tooth
10 50
(3.0) Inserts after 33 minutes

0 0 Recommendation
S30T S40T
08M-MM 08M-MM Maintaining the correct chip thickness (hex) is key to balancing tool life and productivity.
At low radial engagement, too small a feed leads to rubbing and poor efficiency, while
too large a feed shortens tool life. With larger engagement, aim for a moderate hex
In stable conditions, S30T delivers significantly longer tool life and higher metal
that avoids rubbing yet keeps forces controlled. This maximizes material removal and
removal compared to S40T.
efficiency, even if tool life is slightly reduced.

108 109
Full slotting Effect of overhang
Full slotting with CoroMill 390® at different ap
Tools with longer overhangs are more affected by
Full slotting with a 90 degree approach is a difficult application this example shows the deflection compared to shorter, more rigid assemblies..
effect of different depths of cut Sometimes it's unavoidable and you need a tool that can
reach a feature.
Silent Tools are available for milling and can produce the
Feature Material Milling Body Coolant press.
same impressive results as they do in turning applications
Slot Age-hardened Inconel R390-025A25-11L 20 bars (290 PSI)
Length 200mm 718, S2.0.Z.AG, 25mmØ (0.9843inch)
(7.87 inch) 43 HRc 2 insert pockets

Tool R390-11 T308E-MM S30T

vc, m/min(ft/min) 26 (85)
fz, mm/z (in/z) 0.1 (0.004)
Impact of overhang
A long tool would normally need to compromise and use a tough impact resistant grade (S40T) to
ae, mm (inch) 25
avoid chipping. This test uses a hard wear resistant grade (GC1010) not typically suited to long
unstable set ups.

Material Milling Body Insert R390-11 T3 08 GC1010

Age-hardened Inconel R390-063Q22-11M vc, m/min(ft/min) 35 (114)
718, S2.0.Z.AG, 63mmØ (2.480inch) fz, mm/z (in/z) 0.117 (0.0028)
43 HRc 6 insert pockets ap, mm (inch) 2 (0.1969)
2 mm ap 6 slots (18.1 minutes) 8 slots (24.2 minutes)
ae, mm (inch) 15 (0.7480)
(0.079 inch) 30cm3 (1.83in3) 40cm3 (2.44in3)
Total metal removed, cm3 (in3)
35 (2.14) = Total material removed

30 (1.83)

25 (1.53)

20 (1.22)

4 mm ap 6 slots (18.1 minutes) 8 slots (24.2 minutes) 15 (0.92)

(0.157 inch) 60cm3 (3.66in3) 80cm3 (4.88in3)
10 (0.61)

Increasing ap from 2 mm to 4 mm increased the total metal removed 100% with no 5 (0.31)
loss in tool life. When stability allows, a larger ap delivers much higher productivity 0 0
without compromising insert performance.
Short assembly Long Steel assembly Silent tool assembly
155mm LTA ( 6.1 inch) 355mm LTA (14.0 inch) 355mm LTA (14.0 inch)

Learn more about CoroMill® 390 Using a Silent Tools damped milling adapter at 355 mm (14.0 inch) overhang increased
www.sandvik.coromant.com productivity by nearly 90% compared to a standard steel holder at the same length,
and maintained over 90% of the performance of a short, rigid assembly.

110 111
CoroMill®MS20 CoroMill® MS20 insert geometries
Introducing our latest true 90
degree shoulder milling solution, the
Direct pressed insert geometries
CoroMill®MS20, engineered for precision The CoroMill® MS20 inserts are manufactured using new, improved flash-light
and reliability. With a robust new interface, technology, which provides better dimensional control along the cutting edge, resulting
optimised insert geometries for various in improved shoulder accuracy and surface finish
ISO materials, and superior chip control
near walls or in repeated cuts, this cutter
ensures consistent performance. The
improved cutter body material and high
dimensional accuracy deliver excellent
surface finishes and repeatability,
enabling safe, unmanned machining with
confidence and control.

M-M20 M-M30
Optimised geometry for HRSA Ideal for medium to heavy cuts
materials, enables light cutting, in Inconel and other HRSA, this
stable performance at long geometry offers strong radius
overhangs, good edge-line security, high metal removal rates,
security, and predictable wear and controlled wear for optimal
for reliable shoulder milling in all pocketing and contouring in HRSA
applications. materials.

Periphery ground insert geometry

The open pocket design CoroMill® MS20 boasts Versatile true

improves chip evacuation, a robust cutter body and 90-degree cutter for
reduces re-cutting, and a dependable interface, shoulder, face, pocket,
minimizes chip smearing. carefully crafted using corner, ramping, helical
The reinforced pocket the latest production ramping, full slotting,
seat limits deformation technologies with and plunge milling ideal
E-L50
and insert movement, the demands of our for both roughing and
resulting in less vibration customers in mind. finishing operations Optimised geometry for shoulder
and significantly improved across applications. milling and pocketing applications.
cutter and insert tool life. Light cutting action. Closer
tolerance improves component
quality and extends insert tool
life. Regulates chip formation
and evacuation in long-chipping
materials. Predictable, gradual
wear characteristics

112 113
CoroMill®MS20 – Shoulder milling Performance
Face milling / Surface milling of Stellite weld.
90 degree entering angle is the least favourable design for milling in HRSA due to the
high notching tendencies. The CoroMill® MS20 has been engineered to deliver secure and reliable Feature Material Milling Body Coolant press.
shoulder milling in demanding applications.
Face milling off weld Stellite 300 HB MS20-R063Q22-10M 20 bars (290 PSI)
S3.0.C.NS 63mmØ (2.48inch)
Performance 6 insert pockets

Shoulder / edging with low radial immersion Insert MS20-10T308E-L50 S30T

ae = 8% of Dc (cutter diameter) vc, m/min(ft/min) 20 (65)

Feature Material Milling Body Coolant press. fz, mm/z (in/z) 0.1 (0.0039)

Shoulder milling with Inconel 625, MS20-R025A25-10M 20 bars (290 PSI) ap, mm (inch) 2 (0.0787)
low radial immersion S2.0.Z.AN, 258 HB 25mmØ (0.9843inch) ae, mm (inch) 13 (0.5118)

3 insert pockets

Insert MS20-10T308E-L50
vc, m/min(ft/min) S30T

fz, mm/z (in/z) 40 (131)

ap, mm (inch) 0.11 (0.0043)

ae, mm (inch) 5 (0.1969)

2 (0.0787)

Weld before machining After machining

Tool life achieved in this application was 150 minutes contact time

CoroMill® MS20 application areas

Inserts after 105 minutes contact

Inserts achieved 105 minutes contact time and was stopped due to no longer achieving
the surface finish requirements on the part

Learn more about CoroMill® MS20

www.sandvik.coromant.com

114 115
CoroMill®MH20 MH20 features for HRSA
CoroMill MH20 is a high-feed milling tool optimised The open pocket design improves chip
for tough materials like heat-resistant super alloys. evacuation and reduces re-cutting. The
Designed for pocketing, it's ideal for aerospace and oil design is optimised for chips generated by
& gas industries. a high feed tool and minimizes smearing of
Its light-cutting action and rigid cutter body allow chips, especially in ISO S applications.
stable, vibration-free machining—even with long
overhangs. The open insert pockets improve chip
evacuation, while the curved-edge insert boosts
security against notch wear, making it reliable in
corners and shoulders.

The single-sided two-edged positive insert

has a curved and strong edge with a
reinforced corner radius, ensuring secure
and reliable machining against shoulders and
corners in pocketing.

Geometries for HRSA

E-L30 E-L50
Light cutting applications in ISO S Medium and heavy cutting
and M applications in ISO S and M
CoroMill® MH20 application examples
Optimised geometry for pocketing Optimised geometry for pocketing
applications in titanium and applications in HRSA
austenitic stainless steel Highest metal removal rate in stable
Edge-line security and trouble-free applications
machining at long overhangs

116 117
 Pocketing - Helical ramping
MH20 Insert Benchmarking
Helical ramping is an effective way to
produce circular pockets without drilling,
especially when large diameters are
Performance
required but machine power or set up
In this test we show the impact grade and geometry have in a life test running inserts constraints the tool size you can use.
until the edge fails

Feature Material Milling Body Coolant press. The MH20 allows for high angles of ramping
Face milling Age-hardened Inconel MH20-R020A20-08L 20 bars (290 PSI) based on insert size
718, S2.0.Z.AG, 20mmØ (2.48inch) RMPX
43 HRc 2 insert pockets • IC06 Insert size 3.6° - 10.1°
• IC08 Insert size 1.7° - 10.7°
Insert MH20-080425
vc, m/min(ft/min) 30 (98)
fz, mm/z (in/z) 0.4 (0.0157)
ap, mm (inch) 1 (0.0394)
ae, mm (inch) 16 (0.6229) Performance
Helical ramping pockets in Inconel 718

E-L50 S30T E-L50 S40T M-M20 S30T Feature Material Milling Body Coolant press.
Inserts after 45 passes Inserts after 20 passes Inserts after 30 passes Helical ramping Age-hardened Inconel MH20-R020A20-08L 20 bars (290 PSI)
20 minutes in cut 9 minutes in cut 13 minutes in cut 30mm(1.18in) 718, S2.0.Z.AG, 43 20mmØ (2.48inch)
diameter and 18mm HRc
2 insert pockets
(.70in) deep

Insert MH20-080425E-L50 S30T

vc, m/min(ft/min) 30 (98)
fz, mm/z (in/z) 0.4 (0.0157)
ap, mm (inch) 1 (0.0394)
ae, mm (inch) 16 (0.6229)
Pitch (P) 1mm (0.0394)
TMR = 72 cm3 (4.39 in3) TMR = 32 cm3 (1.95 in3) TMR = 48 cm3 (2.93 in3)

Insert after 4 pockets Insert after 10 pockets

E-L50 geometry in combination with S30T delivers the best performance machining 8 minutes contact 20 minutes contact
HRSA and is 1st choice

118 119
Shoulder milling Slot milling
CoroMill MH20 delivers high metal removal rates with minimal vibration, making it The MH20 is an effective tool for creating slots and can perform well shoulder .
ideal for shoulder milling in HRSA. Optimised geometries like E-L30 and M-M50 ensure Note: Some stock will remain in the corners due to the insert radius and entering angle
predictable wear and secure performance, even in unstable setups. of the tool.
Performance Performance

Feature Material Milling Body Coolant press. Feature Material Milling Body Coolant press.
Shoulder milling Age-hardened Inconel MH20-R020A20-08L 20 bars (290 PSI) Slot milling Age-hardened Inconel MH20-R020A20-08L 20 bars (290 PSI)
718, S2.0.Z.AG, 20mmØ (2.48inch) 718, S2.0.Z.AG, 20mmØ (2.48inch)
43 HRc 2 insert pockets 43 HRc 2 insert pockets

Insert MH20-080425E L50 S30T Insert MH20-080425E L50 S30T

vc, m/min(ft/min) 30 (98) vc, m/min(ft/min) 20 (66)
fz, mm/z (in/z) 0.4 (0.0157) fz, mm/z (in/z) 0.4 (0.0157)
ap, mm (inch) 1 (0.0394) ap, mm (inch) 1 (0.0394)
ae, mm (inch) 16 (0.6229) ae, mm (inch) 20 (0.787)

Insert after 10 passes Insert after 36 passes

6 minutes contact 23.9 minutes contact
20 cm3 (1.22in3) 72cm3(4.39 in3)

Inserts after 24 passes Inserts after 36 passes Inserts after 40 passes Performance
10 minutes in cut 16 minutes in cut 18 minutes in cut
38 cm3 (2.34 in3) 58 cm3 (3.51 in3) 64 cm3 (3.91 in3) Doing the same feature with a 90° cutter to highlight productivity difference

Insert after 4 passes Insert after 8 passes Insert R390-11T308M-MM S30T

Performance
12 minutes in cut 24 minutes in cut
vc, m/min(sf/m) 26 (85)
Impact of reducing cutting speed by 30% (vc = 21 m/min / 69 sf/min) under the same 20cm3(1.22 in3) 40cm3(2.44 in3)
test conditions fz, mm/z (in/z) 0.1 (0.0039)
ap, mm (inch) 2 (0.0787)
ae, mm (inch) 20 (0.787)

Learn more about CoroMill® MH20

Inserts after 24 passes Inserts after 40 passes Inserts after 56 passes www.sandvik.coromant.com
15 minutes in cut 25 minutes in cut 35 minutes in cut
38 cm3 (2.34 in3) 64 cm3 (3.91 in3) 90 cm3 (5.57 in3)

120 121
Engineered solutions Engineered solutions - M5C331
Slotting HRSA blisks using solid round tools
In the aerospace industry, especially when
machining heat-resistant superalloys Feature Material Coolant press.
(HRSA), our standard tools already perform 1st stage roughing Age-hardened Inconel 718, 20 bars (290 PSI)
exceptionally well. However, certain S2.0.Z.AG, 43 HRc
components present unique features
or specific challenges such as complex
geometries, difficult-to-reach areas,
or stability issues that require tailored Method 1 : Full slotting & plunge milling 10mm Ø (0.394)
solutions. In these cases, engineered milling
tools are developed to address the exact Tool 2S440-1000-100-SD-1725 2P070-1000-PB 1610
demands of the application, whether that vc, m/min(ft/min) 20 (66) 25 (82)
means optimising chip control, improving
fz, mm/z (in/z) 0.02 (0.0276) 0.04 (0.0276)
access, or enhancing tool life under extreme
conditions. These special solutions ensure ap, mm (inch) 2 (0.0787) 24 (0.0787)
reliable performance, precision, and ae, mm (inch) Variable 2.5 (1.41)
efficiency where standard tools might not hex mm (inch) 0.18 (0.0071) 0.18 (0.0071)
be the perfect fit.
MRR cm3 (in3) 1.26 (0.077)

Slotting HRSA blisks using M5C331

M5C331 Example Method 2 : Slotting with M5C331 193mm Ø (7.598)

Tool M5C331
vc, m/min(ft/min) 40 (131)
fz, mm/z (in/z) 0.1 (0.0004)
ap, mm (inch) 11 (0.433)
ae, mm (inch) 43 (1.693)

MRR cm3/min (in3/min) 5 (0.305)

It is possible to modify the Its design is based on Available in diameters
diameter, width, number the industry tested starting at 150 and
Time per slot 6.5 minutes
of teeth, radius of arc and CoroMill®331 and utilises going up to 250mm
pitch to perfectly suit the the same standard inserts diameter. Tool life 13 slots (84.5 minutes contact time)
blisks you are machining.
The M5C331 delivers significant productivity gains
over traditional methods and can reduce tooling
spend per component.

122 123
 Cutter types
Ceramic milling
Ceramic cutting tool properties have a much higher resistance to heat compared to
carbide tools, making it an excellent option for machining HRSA where high cutting
temperatures are present.
Ceramic milling typically runs at 20 to 30 times the speed of carbide, although at lower
S-R120R
The S-R120 cutter with RNGN 12 ceramic inserts designed for
feed rates, which results in high productivity gains. They show a high tendency to
high-speed rough milling of heat-resistant superalloys. It offers
notching, which is why round inserts are mainly used to ensure a low entering angle.
excellent wear resistance, high productivity, and cost efficiency,
Ceramics have a negative effect on the surface integrity and topography and are
making it the first choice for roughing HRSA components like
therefore not used when machining close to the finished component shape.
turbine casings and blades.
The main application for ceramic milling is machining of engine casings and oil drilling
Size range 50 - 80mm Ø
equipment due to the high metal removal rates over carbide inserts, combined with large
stock removal.

S-R300C
The R300C cutter body uses RPGN positive ceramic inserts
(sizes 12, 09, 06) for HRSA milling. It offers lower cutting forces
and supports smaller diameters than negative setups, making it
ideal for light roughing and reduced machine load
Size range 20-35mmØ

316 - Ceramic
The 316 ceramic tools enables cutting speeds far beyond
carbide. It features a negative rake angle, reinforced cutting edge,
and optimised core for stability and chip evacuation. With four-
flute geometry for face milling, six-flute for side milling, and the
advanced S1KU ceramic grade, it's ideal for HRSA applications
where productivity is the priority and limited access like pockets
and slots
Size range 10 - 25mm Ø

124 125
Coolant and ceramic milling Feed impact
As with round carbide inserts the chip Selecting the correct hex value when
When milling using ceramic inserts, coolant should normally not be used. In most
thickness varies and depends upon the milling with ceramic inserts is critical.
operations the use of coolant has a negative effect on tool life. This is due to the
entering angle. With low ap/iC ratios the Always modify the feed depending upon
increase in thermal shock with cooling and heating of the cutting zone as the insert
feed can be increased in order to raise the the entering angle, max chip thickness
enters and then exits the workpiece. This increases the chance of top slice of the
chip thickness to the desired level. (hex).
ceramic.
Insert RNGN 120700E CC6160 Material
vc, m/min(ft/min) 1000 (3280) Age-hardened Inconel
fz, mm/z (in/z) 0.1 (0.0039) 718, S2.0.Z.AG,

ap, mm (inch) 2 (0.0787) 43 HRc

ae, mm (inch) 20 (0.787)

Without coolant With coolant

0.07 mm/z 0.1 mm/z 0.13 mm/z
(0.0028 in/z) (0.0039 in/z) (0.0118 in/z)
15 passes 15 passes 15 passes

A low feed increases insert wear with RNGN, keep feed about 0.1 mm/z (0.0039 in/z)

Effect of cutting speed, vc

When milling in ceramics, due to The cutting speed should be balanced to Ceramic versus carbide comparison milling in Inconel 718
intermittent cutting, it is a much cooler create enough heat in the cutting zone but
Maintain constant engagement where possible – soft entry into cut.
operation than turning. For this reason not too high to unbalance the ceramic. Too
speeds of 700-1000 m/min when milling low cutting speed can result in top slice Ceramic Carbide
are adopted compared with 200-300 m/ of the insert, too high cutting speed can
Application Conventional/up milling Climb/down milling
min for turning. The high cutting speed result in insert failure.
Coolant Dry Wet
used when milling with ceramic inserts
Insert RNGN 120700E 6160 R300-1240E-MM S30T
increases the temperature of the chip
Cutting speed, vc (m/min) 850 30
making the chip highly sheared.
Diameter, D3 (mm) 63 63
Spindle speed, n (r/min) 4295 152
Feed rate, fz (mm/tooth) 0.1 0.3
Number of teeth, zn 4 6
Depth of cut, ap (mm) 2 2
Radial immersion, ae (mm) 35 35
Metal removal rate, Q (cm3/min) 130 19
Tool life, (min) 3.6 25
650m/min 850m/min 1100m/min
(1968 ft/min) (2789 ft/min) (3609 ft/min)
Total material removed, Qt (cm3) Ceramic TMR after 3.6 minutes Carbide TMR after 25 minutes
468cm3 (18.42in3) 475cm3 (18.70in3)

Recommendation – 1000 m/min cutting speed gives most balanced speed.

126 127
Solid carbide milling CoroMill®Plura in HRSA
Due to the high hot hardness and to the short contact time, compared to
toughness of HRSA they are one of the conventional milling techniques.
most difficult to machine materials placing However low radial cuts are required to
great demands on the tool. The outcome is keep the chip thickness small and allow for
traditionally, low cutting speeds and hence the higher feed rate.
lower productivity/higher machining costs.
High speed machining (HSM) techniques
offer an effective way to increase
productivity and to mill intricate and
thin-walled components. The high feed
rates do not allow as much heat to get
transferred into the component, due

Feed faster than heat propagation. Traditional milling, time for heat propagation.

HSM uses high rpm and axial cut (ap) but with only small radial engagements (ae) and
feed per tooth (fz). This is possible due to:

Factor Effect Benefit

Thin chip thickness Lower cutting force/deflection Deeper axial cuts

Small arc of engagement Reduced temperature at Higher speeds
cutting zone

This method requires a machine with high

spindle speed and high feed dynamics
putting no extra demands upon rigidity.

128 129
Processes using HSM techniques Application recommendations
Trochoidal milling Down milling
A roughing/high material removal method It is almost always more favourable to apply down milling rather than up milling. When
used when in a confined space or slot. the cutting edge goes into contact in down milling, the chip thickness has its maximum
value, in up milling the chip thickness is zero.
A continuous spiralling path feeding in
the radial direction to form a groove or a The tool life is generally shorter in up milling due to the fact that there is considerably
profile. more heat generated due to the rubbing action that takes place on entry. The radial
forces are also considerably higher in up milling.
It requires specialised programming and
machine capabilities.

Slicing
A semi-roughing technique used to
produce a profile. Multiple passes to
reduce the radial immersion. It requires
a machine with high spindle speed and
Down milling (climb milling). Up milling (conventional milling).
dynamic capability.

Profiling
A finishing technique used to produce a Avoid excessive deflection
finished profile e.g. Flank milling which
reduces the number of axial passes. Shallow radial cuts (ae) should be applied to avoid excessive deflection of the cutting
Requires a machine with high spindle tool
speed and specialised programming and to keep a high tolerance level and geometrical accuracies on the machined
techniques for simultaneous 5 axis for component.
blisk/impellor machining. It is important to use a tool with a maximum core diameter (higher bending stiffness).

Components/features where HSM can be applied

Some of the typical components that can be machined using CoroMill Plura tools and l = overhang
HSM techniques for example are blisks, impellers, turbines (LPT and HPT) and exhaust Dc = tool diameter
casings. F = radial force
δ = deflection
E = modulus of rigidity of the tool
F x l3
δ≈
E x (π x Dc4)

20% overhang reduction reduces tool deflection by 50%.

20% increased Dc (10 to 12 mm) reduces tool deflection by 50%.

Slots – shafts Blisk/impeller Scallops – casings

130 131
Excessive tool overhang Tool holding
A CoroChuck930® or shrink fit should be
One of the main criteria when deciding
Tool length impact used due to:
both the tool and holding device is to
have as small a run out as possible. This Minimised run out
This example shows the effect of having a small change in the tools over hang can keeps a uniform chip thickness on each - increased tool life.
have. This 10mm end mill has a functional length (LF) of 72mm cutting edge and hence has an even load Stability
distribution. The total indicator run out - reduced vibrations allowing higher
(TIR) should not be more than 10 microns. depths of cut.
Feature Material Coolant press. A good rule of thumb is that ‘For every Clamping forces
Full slot milling Age-hardened 20 bars (290 PSI) 10 microns in added run out the tool life - resists pull out with high helix cutters.
Inconel 718, reduces by 50%’
S2.0.Z.AG, 43 HRc

Tool 2S440-1000-100-SD 1725 Tool life

vc, m/min(ft/min) 18 (59)
fz, mm/z (in/z) 0.02 (0.0008)
OH
ap, mm (inch) 7.5 (0.295)
ae, mm (inch) 10 (0.394)

10 passes TIR
OH = 31mm (1.22inch) 26 passes 52 passes

Programming feed rate (peripheral and central feed of the

tool)
When programming with the feed applied to the tool centre, the feed must be reduced
when producing an internal radius or a circular motion (G2 or G3) if not using radius
compensation. Due to the fact that the periphery has to travel further than the tool
OH = 38mm (1.5 inch) 10 passes 12th pass centre for the same angular rotation.

Constant tool centre feed Reduced feed for radius

vfm = n x fz x zn
Dvf = Dm – Dc
Dvf
vf = x vfm
Dm

132 133
Wear mechanisms Helix angles & WhisperKut™
Typical wear observed on CoroMill Plura therefore once this wear is observed the
tools in the case of Inconel is micro tool should be immediately changed. This An end mill’s helix angle affects chip flow,
chipping rather than flank wear. The edge can be monitored with the power/load cutting forces, and tool performance. A
line starts frittering before it leads to total gauge or by sound. higher helix provides smoother cutting,
cutting edge failure. The transition from reduced deflection, and longer tool life,
micro chipping to failure is exponential, making it ideal for finishing. Lower helix
angles offer greater strength, better for
roughing. The helix also influences entry
and exit angles, impacting machining
smoothness and force distribution.
Not all tools in our range have a constant
helix angle and apply different angles to
each tooth.
The unique advanced unequal helix
Feature Material
concept effectively eliminates vibration
Tool R216.24-12050-AK26P 1620
vc, m/min(ft/min) 75 (246)
and makes machining smooth, secure and
HSM profile milling Age-hardened Inconel
fz, mm/z (in/z) 0.1 (0.0039)
silent. On every level of the cutting edge,
718, S2.0.Z.AG, 43
HRc ap, mm (inch) 10 (0.3937)
each flute is unequally spaced from the
ae, mm (inch) .5 (0.0197)
others, reducing the constant harmonics
Time in cut 15 minutes
typically produced with conventional end
mills.
Corner geometry
The main wear observed in the case of HSM in Inconel is micro chipping at the cutting
edge. A radius end mill, due to increased strength is always better compared to a
chamfer or sharp corner.
Tooth pitch
Tool R216.24-12050
vc, m/min(ft/min) 100 (328) The spacing between each tooth is called
fz, mm/z (in/z) 0.05 (0.0020) the pitch and this has an influence on the
ap, mm (inch) 10 (0.3937) cutting process. An equal tooth pitch can
ae, mm (inch) .5 (0.0197) make a tool more prone to uncontrolled
vibrations.
Minutes cm3 (in3)
= Total metal removed Tools with a differential pitch or uneven
80 73
= Tool life 80 (4.88) spacing between an end mill's teeth helps
reduce vibration and chatter by disrupting
70 70 (4.27) Chamfer harmonics. As a result, you get a smoother
60 60 (3.66)
52 cut, better surface finish, and longer tool
50 50 (3.05) life. It also allows for higher feed rates,
40 40 (2.44) making machining more efficient and
27 productive.
30 30 (1.83)
20
20 20 (1.22)
10 10 (0.61)
0 0 0
R216.24-12050-GAK26P R216.34-12050-AK26P
1620/R3 1620/Chamfer Radius

134 135
Radial cut (ae) Cutting speed effect in traditional methods (vc)
For roughing applications it can be seen Traditional methods of large radial engagements in HRSA materials follow the pattern
in the diagram that the maximum total Tool life minutes
Total metal removal
that increasing the speed reduces the tool life and the best productivity for the tool will
material removed, when running with a Time, min cm3 be found at lower cutting speed (vc)
constant speed and chip thickness, can be 94
100 90 100
achieved with ae = 1.0 mm.(.0394) 87
90 90
77 77
This equates to 8% ae/Dc and should be 80 80
used as a base when roughing operations 70 70
60 60
are required.
50 50
40 40
Total metal removed tool life vs radial cut 30 22 30
18 16
Tool R216.24-12050-GAK26P 1620 20 12 11 20
vc, m/min(ft/min) 75 (246) 10 10
0 0
fz, mm/z (in/z) 0.1 (0.0039)
0.5 0.75 1 1.25 1.5
ap, mm (inch) 10 (0.3937) (.0197) (.0295) (.0394) (.0492) (.0591)
Radial cut, ae mm (in)
Material: Inconel 718

High feed side milling

(Dynamic) TMR = Total material removed TIC = Time in cut
Dynamic milling is a high-efficiency
roughing strategy that uses constant
tool engagement and full flute length
to optimise material removal. It relies Cutting speed when HSM / Dynamic (vc)
on lighter radial depths and higher Because of the relatively low radial engagements in HSM one can make use of higher
axial depths, reducing heat buildup than normal cutting speed (vc), 75 to 100 m/min gives the best balance between
and extending tool life. By maintaining productivity and tool life. The chart shows the difference in performance relative to
consistent chip load and minimizing cutting speed.
sudden direction changes, it lowers
cutting forces and prevents tool breakage. Depth
ap
This method increases productivity,
improves tool wear, and is ideal for tough
materials like HRSA alloys.
Width

TMR = Total material removed TIC = Time in cut

136 137
Chip Thickness (hex)
The low radial engagement (ae) reduces It can be seen in the diagram that a
the chip thickness compared to the reduction of chip thickness reduces the
feed per tooth. Using the optimised chip material removed due to rubbing rather
thickness is pivotal in optimisation of than cutting. Optimal area is between
finishing, trochoidal milling or high feed 0.06 and 0.08 when using dynamic milling.
side milling.

Tool 2F341-1000-100 SD 1710

hex = fz × sin(KAPR) × ae / D
vc, m/min(ft/min) 75 (246)
ap, mm (inch) 20 (0.3937)
ae,mm (inch) 0.7 (0.0275)

KAPR
R

KAPR
ae
ae

Depth of cut Entering angle, Modification value, fn fz mm/tooth for given

diameter ratio, KAPR chip thickness in mm:
ae/Dc
hex hex hex
0.1 0.15 0.2
0.25 60° 1.16 0.12 0.17 0.23
0.2 53° 1.25 0.13 0.19 0.25
0.15 46° 1.4 0.14 0.21 0.28
0.1 37° 1.66 0.17 0.25 0.33
0.05 26° 2.3 0.23 0.34 0.46

138 139
 Influence of Chip Thickness hex (fz)
CoroMill® Plura HD
CoroMill® Plura HD Engineered for efficient
and reliable performance in Ni-based
alloys. With grade 1725, optimised for
traditional roughing, and micro-geometry
tailored for tough materials, it delivers the
highest productivity and tool life.
Added corner radius protection ensures
reliable, durable machining where it
matters most.
This tool excels in applications such as full
slotting and heavy tool engagement

Tool life drops faster at higher feeds.

While 0.01 mm/z gives the best tool life, using 0.016 mm/z boosts productivity by
Influence of Cutting Speed 60% with only a 16% drop in tool life.
The optimal feed range is between 0.01–0.02 mm/z, depending on conditions.
Feature Material Coolant press.
Full slot milling 1 x D Age-hardened Inconel 718, 20 bars (290 PSI) Optimising Speed and Feed
S2.0.Z.AG, 43 HRc

Tool 2S440-1000-100 SD 1725

fz, mm/z (in/z) 0.02 (0.0008)
ap, mm (inch) 10 (0.3937)
ae, mm (inch) 10 (0.3937)

12 m/min (39 ft/min) n = 382 RPM 18 m/min (59 ft/min) n = 573 RPM 25 m/min (82 ft/min) n = 796 RPM

This chart shows that 15 m/min (49 ft/min) combined with 0.016 fz delivers a good balance of
tool life and productivity. If productivity is the main priority then 18 m/min (59 ft/min) and fz
0.02 is a good choice.

38 passes 28 passes 18 passes

Learn more about CoroMill® HD
TMR = 114 cm3 (6.96 in3) TMR = 84 cm3 (5.13 in3) TMR = 54 cm3 (3.30 in3) www.sandvik.coromant.com
Lower speeds allow for more predictable and even flank wear. The increase in speed doesn't
offset the gain in productivity

140 141
CoroMill® Gannet - Plunge milling CoroMill® Gannet - Plunge milling
CoroMill® Plura Gannet – specifically CoroMill® Plura Gannet is only used for roughing due to the
designed for plunge milling in HRSA and rest material it leaves behind.
other hard-to-machine materials. With a Due to the machining forces acting in an axial direction the
patented geometry specially designed for tool can work even with longer over hangs.
efficient plunging operations. Engineered
In this case the tool over hang is 4 x DC
with wear-resistant grade 1610 and
coolant grooves on the shank, it ensures
safe chip evacuation and excellent
bending control. Its self-stabilizing design
enables reliable machining even with Wall cusp
long overhangs, delivering outstanding Slot performance
productivity in demanding applications.
In this test we will create slots in inconel 718 using this tool and method slot details are:
Width 10mm (0.394 inch) Length 30mm (1.81 inch) Depth 20mm (0.787 inch)

Feature Material Coolant press.

Full slot milling tool 2 x D Age-hardened Inconel 718, 20 bars (290 PSI)
S2.0.Z.AG, 43 HRc

Tool 2P070-1000-PB 1610 (4 teeth)

vc, m/min (ft/min) 25 (82)
ap ae fz, mm/z (in/z) 0.02 (0.0008)
ap, mm (inch) 20 (0.787)
S ae, mm (inch) 2.5(0.0984) Tool overhang 42mm

Regular milling Plunge milling

Applying the CoroMill® Plura Gannet differs

from regular end mills. Due to the tool being
designed to only plunge ae corresponds the
steps between plunges.
ap is the depth of the plunge similar to a
Climb milling - Always thick to thick
drilling operation thick to thin Tool wear after 12 slots - 45 minutes in cut
If the slot being machined is wider then tools TMR 72cm3 (4.39 in3)
diameter than S is the step over
CoroMill® Plura Gannet for long and difficult to access slots is an excellent choice
without having to compromise on productivity

Learn more about CoroMill® Plura Gannet

www.sandvik.coromant.com

142 143
 Influence of Cutting Speed vc
CoroMill® Plura HFS
Feature Material Operation Coolant press.
CoroMill® Plura HFS – HFS (High Feed
Side) Milling is a strategy using end mills Closed slot Age-hardened Inconel Milling 60 bars (290 PSI)
for shallow radial cuts and high feed rates. 718, S2.0.Z.AG, 43
With optimised geometry and high axial HRc
engagement, it minimises vibration and Tool 2F341-1000-100 SD 1710 (5 teeth)
maximises metal removal. Ideal for slotting, fz, mm/z (in/z) 0.078 (0.078)
pocketing, and deep milling in tough ap, mm (inch) 20 (0.787)
materials, it ensures stable, productive ae, mm (inch) 0.7 (0.0275)
machining even in challenging setups.
This method has become increasingly
popular thanks to strong support from CAM 30 m/min (98 ft/min) 75 m/min (246 ft/min) 95 m/min (312 ft/min) 112 m/min (367 ft/min)
systems.
This strategy and tool combination performs
well on pockets and closed slots where the
tool won’t break through.

8 slots - Chipped 16 slots 18 slots 13 slots

TMR = 69.6 cm3 TMR = 130 cm3 TMR = 156.6 cm3 TMR = 95.7 cm3
Performance (4.25 in3) (7.93 in3) (9.56 in3) (5.84 in3)

Feature Material Operation Coolant press. Influence of Chip Thickness hex (fz)
Closed slot Age-hardened Inconel Milling 20 bars (290 PSI)
When slotting using a conventional strategy feed has a big impact on tool life in
718, S2.0.Z.AG,
conventional strategies, but this effect is reduced with HFS.
43 HRc

Tool 2F341-1000-100 SD 1710 (5 teeth) Tool 2F341-1000-100 SD 1710 (5 teeth)

vc, m/min(ft/min) 75 (246) vc, m/min(ft/min) 75 (246)

fz, mm/z (in/z) 0.078 (0.276) ap, mm (inch) 20 (0.787)

ap, mm (inch) 20 (0.787) ae, mm (inch) 0.7 (0.0276)

ae, mm (inch) 0.7 (0.0276) fz 0.078 mm/z fz 0.12 mm/z fz 0.16 mm/z fz 0.2 mm/z
hex mm (inch) 0.04 (0.002) (0.0031 in/z) (0.0047 in/z) (0.0063 in/z) (0.0079 in/z)
hex 0.04 (0.0016 inch) hex 0.061 (0.0024 inch) hex 0.082 (0.0032 inch) hex 0.102 (0.0013 inch)

16 slots 26 slots 26 slots 20 slots

Tool wear after 16 slots 139 cm3 material removed (8.48 in3) TMR = 139 cm3 TMR = 226 cm3 TMR = 226 cm3 TMR = 174 cm3
(8.5 in3) (13.8 in3) (13.8 in3) (10.6 in3)

144 145
Influence of Chip Thickness hex (fz) Influence of Depth of Cut ap

Feature Material Operation Coolant press.

Shoulder milling Age-hardened Inconel Milling 20 bars (290 PSI)
200mm long (7.87 in) 718, S2.0.Z.AG, 43
HRc

Tool 2F341-100-100 SD 1710 (5 teeth)

vc, m/min(ft/min) 75 (246)
fz, mm/z (in/z) 0.078 (0.276)
ae, mm (inch) 0.7 (0.0276)

Using a chip thickness that is too low increases tool wear by causing rubbing instead of
cutting, higher cut frequency, longer engagement time, and stress on the cutting edge. -18%
Tool life
Maintaining chip thickness above 0.06 improves cutting efficiency, reduces mechanical +66%
TMR
load, and significantly extends tool life

Influence of Depth of Cut ap

Using a large ap and utilising the full cutting edge is the most productive method. The
Depth of cut directly influences cutting forces, tool life drops by a small amount but the material removal is increased significantly.
number of engaged edges, chip length, time in cut, hex Total material removed cm3 (in3)
bending forces, and cutting-edge usage. mm(inch)

For HRSA roughing and semi-finishing, depths ≤1×D

are common. A lower ap is traditionally preferred for
increased process safety and reduced tool stress
however, when applying HFS tools, this rule does not
apply in the same way.
This test demonstrates the impact of depth of cut
(ap).

vc m/min (ft/min)

Learn more about CoroMill® Plura HFS For pockets and enclosed slots HFS is an excellent choice which gives predictable and
www.sandvik.coromant.com controllable wear while achieving good material removal rates.

146 147
Exchangeable-head – CoroMill® 316 Exchangeable-head – CoroMill®316
CoroMill 316 is a complement to our The modular Coromant EH system helps you maximize
existing solid carbide programme. Tool cutting edge performance. Achieve the needed reach
geometry is based on CoroMill Plura tools. and accessibility with modular shanks and adaptors.
-R
 oughing, semi finishing and finishing For short overhangs, productivity can increase using
applications in general machining. integrated machine adaptors.
- Cost effective solution compared to
Modularity removes the need for separate tools per
CoroMill Plura for larger tool diameters
machine or feature. Mix and match holders and heads
- Different head geometries for roughing, finishing , profiling for optimised solutions.
- Suitable for operations that demand long reach, for example deep pockets
- High accuracy in finishing operations with long overhangs The Coromant EH coupling uses a centring screw for
quick head changes. A physical stop ensures correct
tightening, preventing overstressing and making setup
fast and reliable.

The 316 head is based on the EH coupling, offering a wide range of flexibility for
combining indexable milling heads, solid carbide milling heads, and modular boring tools.
Access Productivity Clearance
The flexible range of Shanks in different lengths The short gauge length
undersized shanks in various and materials enable you of an integrated machine
lengths enables milling of to bore hard-to-access adaptor and cutter head
deep shoulders with stability features with ease. boosts productivity, even
and clearance. on compact, vibration-
sensitive machines
Learn more about Coromant® EH Modular
www.sandvik.coromant.com

148 149
CoroMill® plura profiling finishing Cutter types
The demands placed on tools for finishing for finishing HRSAs. It can withstand
HRSA materials are just as demanding as the high heat and abrasion allowing the
when roughing. With finishing our tools for tools edge to maintain its accuracy and
HRSA are made from R2AH grade which is sharpness.
an advanced grade engineered specifically Ball nose Lollipop

First choice for all point milling For challenging point milling operations
operations, with high flexibility in tilt with undercuts and complex shape
angle and reach. deburring.

The CoroMill® Plura profiling tools 2A146-1000A050-TCMH R2AH

10mm diameter barrel tool
Barrel Conical ball
are produced to extremely accurate
Roundness deviation:RDBN = 5 µm
tolerances with very little deviation
of form which gives consistent
engagement and delivers an improved
surface finish

2B56-0600 Ball nose

6mm diameter tool

For high productivity surfacing needs. For flank milling or point milling
The optimal solution for productivity operations where accessibility is
gains and cycle-time reductions. challenging.

150 151
CoroMill® plura profiling ball nose
Performance
The ball nose is first choice for all point Feature Material Coolant press.
milling operations, with high flexibility in
Contour finishing Age-hardened Inconel 20 bars (290 PSI)
tilt angle and reach.
718, S2.0.Z.AG, 43
HRc

Tool 2B286-0800-RA R2AH

vc, m/min(ft/min) 40 (82)
fz, mm/z (in/z) 0.08 (0.0016)
ap, mm (inch) .3 (0.0787)
ae, mm (inch) .4 (0.0157)
flutes / teeth 6

Blisk machining - roughing in 3 steps

Performance
Feature Material Coolant press.
Profile milling Age-hardened Inconel 20 bars (290 PSI)
718, S2.0.Z.AG, 43
HRc

Tool 2S440-1200-050 SD 1725

vc, m/min(ft/min) 18 (59)
fz, mm/z (in/z) 0.04 (0.0016)
Tool -2B286-0800-RA R2AH (6mm Ø)
ap, mm (inch) 7.3 (0.2874)
Edge after 6 blades
ae, mm (inch) 2.2 (0.0866)
50 minutes contact time
Flutes / teeth 6

Burrs
CoroMill® Plura ball nose provides safe, reliable performance. The R2AH grades delivers
excellent wear in HRSA materials and the uneven tooth pitch helps avoid vibrations
Tool edge after machining with which lead to micro cracks.
It's important to remove the burrs left on
burrs left over from roughing.
These can damage the tool
edge and significantly reduce
tool life. Learn more about CoroMill® Plura ball nose ISO S
www.sandvik.coromant.com

152 153
CoroMill® plura profiling barrel tool
CoroMill® Plura barrel end mills Performance
feature two advanced geometries
Feature Material Coolant press.
and Zertivo® 2.0-coated grades,
Contour finishing Age-hardened Inconel 20 bars (290 PSI)
delivering high performance, 718, S2.0.Z.AG, 43
10mm Ø (.393)
security, and cost-efficiency in ISO HRc
S materials. Ideal for blisks, blades,
and surface machining, the large Tool 2A146-1000A020-RCMI R2AH
barrel radius boosts step-over vc, m/min(ft/min) 100 (328)
rates, reduces cycle times by up to
fz, mm/z (in/z) 0.05 (0.002)
90%, improves surface finish, and
ap, mm (inch) .5 (0.020)
minimizes secondary operations
ae, mm (inch) .2 (0.0008)
compared to traditional ball nose
tools. flutes / teeth 6

Strategy
The tool is constantly
engaged with workpiece
Taking a 10mm ball nose as an example
and always in cut.
we have a profile radius of 5mm. If we
Maintaining contact
compare that with a 10mm barrel tool as
improves tool life and
standard, we can have a 50mm profile
finish
radius.
This allows you to increase depth of cut
while maintaining a low cusp height and
excellent finish

Surface finish Ra 0.22 88 minutes contact time

Small step down to ensure good surface quality Larger step down while maintaining surface
quality
Learn more about CoroMill® Plura barrel for ISO S
www.sandvik.coromant.com

154 155
CoroMill® plura profiling conical ball
CoroMill® Plura barrel conical ball mill
Optimised for flank and point milling in Performance
hard-to-reach areas like blade fillets Feature Material Coolant press.
and impellers. Ideal for semi-finishing
Contour finishing Age-hardened Inconel 20 bars (290 PSI)
to finishing. TiAlSiN-coated with a fine-
718, S2.0.Z.AG, 43
grained cobalt substrate for sharpness 10mm Ø (.393)
HRc
and hardness. Delivers high productivity
and extended tool life in profile milling
Tool 2A146-1000A020-RCMI R2AH
operations
vc, m/min(ft/min) 100 (328)
fz, mm/z (in/z) 0.05 (0.002)
ap, mm (inch) .44 (0.020)
ae, mm (inch) .6 (0.0008)
flutes / teeth 6

CoroMill® Plura conical ball nose

combines a tapered design with a ball Taper angle (PSIR) 3°
nose feature. Designed for semi-finishing
to finishing operations in heat-resistant
super alloys, this tool excels in flank
and point milling creating intricate 3D
profiles with stability and precision.

The CoroMill® Plura range for profiling applications offers a comprehensive suite of
solid carbide tools engineered to handle the most demanding milling operations with
precision and efficiency.

With optimised geometries for HRSA, these tools deliver excellent surface quality,
extended tool life, and reduced machining time across ISO S materials.
CoroMill® Plura profiling tools empower manufacturers with the precision, productivity,
With different cutting lengths and
and reliability needed for today’s advanced machining challenges
overhangs available, selecting the
perfect tool for your specific needs
is straightforward, ensuring optimal
results for challenging areas.

Learn more about CoroMill® Plura conical ball nose for ISO S
www.sandvik.coromant.com

156 157
Component/Feature based solutions Component/Feature based solutions
Engine Casing - Ceramic Engine Casing - Machine radius

Feature Material Milling Body Coolant press. Feature Material Milling Body Coolant press.
Rough mill sole plate Age-hardened Inconel S-R210R-068C6- No coolant Radius Age-hardened Inconel R216-20B25-050 20 bars (290 PSI)
band 718, S2.0.Z.AG, 43 12X05 718, S2.0.Z.AG, 43 20mmØ (0.7874inch)
HRc 80 mmØ (3.14inch) HRc
6 insert pockets
5 insert pockets
Tool R216-20T3E-M 1230
Tool RNGN 120700E 6160
vc, m/min(ft/min) 45 (147)
vc, m/min(ft/min) 1000 (3280)
fz, mm/z (in/z) 0.15 (0.0059)
fz, mm/z (in/z) 0.1 (0.0039)
ap, mm (inch) 3 (0.1181)
ap, mm (inch) 2 (0.0787)
ae, mm (inch) 3 (0.1181)
ae, mm (inch) 50 (1.9685)
flutes / teeth 2
flutes / teeth 5

Engine Casing - Carbide Engine Casing - Finish mill ignitor face

Feature Material Milling Body Coolant press.
Feature Material Milling Body Coolant press.
Rough mill sole plate Age-hardened Inconel MH20-R054Q22-08H 20 bars (290 PSI)
Finish mill ignitor face Age-hardened Inconel R300-050Q22-08H 20 bars (290 PSI)
band 718, S2.0.Z.AG, 43 54mmØ (2.12inch) 718, S2.0.Z.AG, 43 50mmØ (1.968inch)
HRc
6 insert pockets HRc
6 insert pockets

Tool MH20-080425E-L50 S30T Tool R300-0828E-PL S30T

vc, m/min(ft/min) 30 (98) vc, m/min(ft/min) 45 (147)
fz, mm/z (in/z) 0.5 (0.0197) fz, mm/z (in/z) 0.25 (0.0098)
ap, mm (inch) 1 (0.0394) ap, mm (inch) 0.7 (0.0276)
ae, mm (inch) 38 (1.4961) ae, mm (inch) 38 (1.4961)
flutes / teeth 6 flutes / teeth 8

158 159
Component/Feature based solutions Component/Feature based solutions
Opening pre drilled hole with high feed side milling Blisk slot roughing

Feature Material Coolant press. Feature Material Milling Body Coolant press.
Sole plate hole 20mm Age-hardened Inconel 20 bars (290 PSI) Roughing slot Age-hardened Inconel M5C331 20 bars (290 PSI)
opening to 59mm 718, S2.0.Z.AG, 43 718, S2.0.Z.AG, 43 193mmØ (7.598inch)
(2.32inch) HRc HRc
10 insert pockets

Inserts R331.1A-084515H-WL S30T

Tool 2F341-1600-300-SC 1710 L331.1A-084515H-WL S30T
vc, m/min(ft/min) 75 (246) vc, m/min(ft/min) 40 (131)
fz, mm/z (in/z) 0.12 (.0047) fz, mm/z (in/z) 0.1 (0.0039
ap, mm (inch) 30 (1.1811) ap, mm (inch) 11 (0.433)
ae, mm (inch) 1.1 (0.0433) ae, mm (inch) 43 (1.693)
flutes / teeth 5 flutes / teeth 8

Milling engine scallops Blisk finishing

Feature Material Coolant press.
Feature Material Coolant press.
Contour finishing Age-hardened Inconel 20 bars (290 PSI)
Engine scallops Age-hardened Inconel 20 bars (290 PSI)
10mm Ø (.393) 718, S2.0.Z.AG, 43
718, S2.0.Z.AG, 43
HRc
HRc

Tool 2F341-1000-100-SC 1710 Tool 2A146-1000A020-RCMI R2AH

vc, m/min(ft/min) 75 (246) vc, m/min(ft/min) 100 (328)
fz, mm/z (in/z) 0.1 (.0039) fz, mm/z (in/z) 0.05 (0.002)
ap, mm (inch) 10 (0.3937) ap, mm (inch) .5 (0.020)
ae, mm (inch) 0.8 (0.0315) ae, mm (inch) .2 (0.0008)
flutes / teeth 5 flutes / teeth 6

Utilise the full edge of the end

mill by changing the depth of
cut as the tool wears

160 161
Hole making

162 163
Hole making in HRSA alloys
Ø 20 to Ø 80 mm through holes in thin
Hole types and hole making methods wall or unstable components
Aerospace casings, which are large thin wall
Hole making in HRSA can be split up into components with large diameter boss holes,
distinct areas: use circular ramping to produce the hole.
While slower than drilling, this method produces
Through holes > Ø 16 for low axial cutting forces, making it the most
assembly reliable option.
In aerospace engines: casings, flanges,
rings, discs, shafts, etc usually have
identical, relatively small holes drilled in large
numbers.
These holes are typically within diameters suited
to solid carbide drills.
For critical parts the hole is often made
in up to 5 steps to guarantee quality and
consistency.
– Drilled
– Bored (using a sized milling tool) to make
concentric
– Finish bored (using a sized milling tool)
– Chamfer front
– Chamfer back
Ø 12 to Ø 84 mm through holes
As one of the final machining steps, reliability is in stable components
critical especially when hundreds of holes are
required per component.
For stable components in oil & gas, bearing,
and mechanical industries, indexable insert
drills are ideal for roughing operations.
Indexable insert drills are used as the first
roughing operation on either lathes or
machining centres. Subsequent operations can
include boring and turning.

164 165
CoroDrill® 860 SD Performance - CoroDrill® 860 SD

The 860 performs similarly across its entire diameter range. In the first tests we have
Solid carbide drill drilled holes in inconel 718 with 3 different diameters and measured the tool wear
patterns and chip formation
CoroDrill® 860 SD is optimised for specific
materials. For HRSA alloys, it’s the first choice
for holes under 16 mm. Its geometry, grade, and
coating are all tailored to ensure secure, reliable
performance with excellent hole quality.
The result is consistently high performance and
excellent hole quality.

CoroDrill® 860 - SD Positional accuracy and cutting forces

The drill’s design enables a smooth material entry, ensuring consistent forces and
excellent positional accuracy.
Performance - CoroDrill® 860 SD
Cordrill® 860 SD 6.8mm (0.268inch) Competitor 6.8mm (0.268inch)
Chart 1 Chart 2 Feature Material Coolant press.
Drilled blind hole Age-hardened Inconel 718, 20 bars (290 PSI)
6.8mmØ (.2677) S2.0.Z.AG, 43 HRc Through coolant

Tool 860.1-0680-035A1-SD S2BM

vc, m/min (ft/min) 25 (82)
fn,mm/rev (inch/rev) 0.16 (0.0063)
ap, mm (inch) 24.5 (0.9646)

Chart 1 shows drill forces measured Chart 2 shows force spikes during entry,
in real time using a dynamometer. A followed by rising force at depth signs of
smooth, consistent force curve indicates instability. This can lead to tool breakage,
stable cutting across the drill. poor hole quality, and reduced accuracy.

CoroDrill® 860 SD 6.8mm (0.268inch) Competitor 6.8mm (0.268inch)

Accuracy Accuracy

Tool after 200 holes 2% diameter flank wear (102µm)

166 167
CoroDrill® 860 SD CoroDrill® 860 SD
Drilling powder metal alloys CoroDrill® 860 SD chip form
The chips are mostly small and tightly curled,
Performance - CoroDrill® 860 SD indicating stable conditions and effective cutting.
Feature Material Coolant press.
A few slightly longer tails are typical and not
Drilling through hole Advanced powder metallurgy 20 bars (290 PSI) problematic. One longer chip is likely an exit chip
5.5mmØ (.2165) material Through coolant from the drill breaking through the bottom surface.
S2.0.Z.AG, Overall, chip shape confirms reliable and controlled
drilling.
Tool 860.1-0550-017A1-SD S2BM
vc, m/min (ft/min) 24 (78)
fn,mm/rev (inch/rev) 0.13 (0.0051)
depth, mm (inch) 17 (0.6693)

CoroDrill® 860 SD hole size consistency

To assess dimensional consistency, the holes were measured in four locations: the first
hole, two randomly selected ones, and the final hole.

H8 tolerance = +0.00/+0.018
H9 tolerance = +0.00/+0.030

Measured holes
Hole 1 5.518 mm (.2172)
Random sample 1 5.512 mm (.2170)
Random sample 2 5.516 mm (.2172)
New tool before use Drill after 349 holes Final hole 349 5.515 mm (.2171)

CoroDrill® 860 SD achieved 5.9 meters (223 in) of tool life, with consistently controlled
wear that minimizes failure risk.

Learn more about CoroDrill® 860 SD

www.sandvik.coromant.com

168 169
 CoroDrill® DE10 Tool performance
CoroDrill® DE10
Performance - CoroDrill® DE10
CoroDrill® DE10 is a high-performance
exchangeable-tip drill designed for efficient, high- Feature Material Coolant press.
volume hole-making. Drilled through hole 1 x D Hastelloy C-22, 20 bars (290 PSI)
Exchangeable tip drills offer more accurate holes Drill diameter 17Ø (.5118) S2.0.Z.AN, 250HB Through coolant
the indexable drills and still offer lower cost per
hole over solid carbide drills. Tool DE10-D1700-170L20-3
The DE10 offers seamless plug-and-play Insert DE10-1700-170-M5 2334
functionality without the requirement of a pilot vc, m/min (ft/min) 26.7 (87)
drill, reducing inventory and cycle times. With fn,mm/rev (inch/rev) 0.1 (0.0039)
high-feed capabilities, a patented pre-tension
depth, mm (inch) 11 (.433)
interface for strong clamping, and optimised chip
flute geometry, it ensures durability, precision,
and sustainability. Fast tip changes and wear
resistance further boost productivity while Size range diameter 13mm - 18mm
lowering costs and environmental impact. Lengths 3, 5, 8 x D

Previous tools chips DE10 chips

In this case the tool life was 540 holes or 5.4 meters drilled

Performance - CoroDrill® DE10 8 x D

Feature Material Coolant press.
Drilled blind hole 8 x D Age-hardened Inconel 718, 20 bars (290 PSI)
S2.0.Z.AG, 43 HRc
Easy to use Optimised insert Patented interface Drill diameter 13Ø (.5118) Through coolant

design
Our patented pre-tension Tool DE10-D1300-130L16-8
With the universal -M5 Thanks to its robust design,
interface provides Insert DE10-1300-130-M5 2334
geometry, CoroDrill® DE10 CoroDrill® DE10 excels at
exceptional strength and vc, m/min (ft/min) 26 (85)
offers seamless plug- high feed rates. Using high
high clamping forces. fn,mm/rev (inch/rev) 0.14 (0.0055)
and-play functionality feed rates means higher
Optimised contact points ap, mm (inch) 100 (3.937)
and uncompromising penetration rates which
between drill tip and drill
performance across a not only boost productivity
body ensure excellent
wide range of cutting data. but also lower cost-per-
centring capabilities and
In addition, no pilot drill component and reduced
less run-out. Overall, more
is needed, which means CO2 emissions.
tips per drill body can be
less stock inventory and
used.
reduced cycle time. Learn more about CoroDrill® DE10
www.sandvik.coromant.com

DE10 chips

170 171
 CoroDrill® 880 - Tool performance
CoroDrill® 880
Performance - CoroDrill® 880
The CoroDrill® 880 is a versatile indexable insert Feature Material Coolant press.
drill for hole diameters from 12–84 mm, capable Drilled through hole 1 x D Age-hardened Inconel 718, 20 bars (290 PSI)
of drilling up to 5×D depths. It handles standard S2.0.Z.AG, 43 HRc
Drill diameter 20Ø (.7874) Through coolant
drilling, helical interpolation, boring, plunging and
offering reliable performance across materials,
especially in unstable conditions. Tool 880-D20000L 25-02
Insert peripheral 880-04 03 W07H-P-MS 2044
Insert central 880-04 03 05H-C-LM 1044

vc, m/min (ft/min) 30 (98)

fn,mm/rev (inch/rev) 0.12 (0.0047)
ap, mm (inch)
22 (0.866)
Drills overall length 60mm (2.362)

Size range diameter 13mm - 18mm

Lengths 2, 3, 5 x D

CoroDrill® 880 - Geometry

The 880 drill can work across all materials but for HRSA materials then we recommend P-MS 2044
using LM 1044 for the centre insert and LM 4344 for the peripheral insert. Peripheral insert

880 - P - LM 4344 880- * C-LM 1044 centre insert

C-LM 1044
Central insert
Indexable drills provide a lower cost per hole compared to solid carbide drills, making
them a more economical choice for high-volume production. However, the trade-off is
that they generally do not achieve the same level of hole quality.

CoroDrill® 880 Hole tolerance 2 - 3 x DC(Ø)

Drill diameter, mm(inch) Hole tolerance, mm(inch)
Inserts after 10 hole Inserts after 14 hole Inserts after 20 hole
12.00-43.99 (0.472-1.732) 0/+0.25 (0/+0.010)

44.00-52.99 (1.732-2.086) 0/+0.28 (0/+0.011)

Learn more about CoroDrill® 880
www.sandvik.coromant.com
53.00-63.50 (2.087-2.500) 0/+0.30 (0/+0.012)

172 173
 CoroDrill® DS20 - Comparing grades
CoroDrill® DS20
Performance - CoroDrill® DS20
CoroDrill DS20 is ideal for machining Heat Feature Material Coolant press.
Resistant Super Alloys (HRSA) due to its stiff drill
Drilled through hole 1 x D Age-hardened Inconel 718, 20 bars (290 PSI)
body, high-performance coating, and optimised
Drill diameter 20Ø (.7874) S2.0.Z.AG, 43 HRc Through coolant
insert design. These features ensure stability,
wear resistance even under extreme conditions.
Its chip evacuation system manages tough HRSA Tool DS20-D20000L 25-04
Insert peripheral
chips effectively, supporting deep-hole drilling. Insert central
DS20-0205-P
DS20-0205-C
Together, these attributes deliver consistent,
precise performance, making DS20 a reliable vc, m/min (ft/min) 30 (98)
solution for industries dealing with demanding fn,mm/rev (inch/rev) 0.06 (0.0024)
HRSA materials depth, mm (inch) 22 (0.866)
Drills overall length 104mm (4.094)

Size range diameter 15mm - 65mm

Lengths 4, 5, 6 & 7 x D

P-L6W 4344
Peripheral insert

C-L5W 1344
Central insert

Strong and fatigue Optimised insert For holes up to 7 x D

Inserts after 8 holes Inserts after 16 hole Inserts after 20 hole
resistant drill design 6.1 minutes 12.3 minutes 15.4 minutes
55 cm3 (3.36 in3) 111 cm3 (6.77 in3) 138 cm3 (8.42 in3)
Each drill body size is The robust insert seats This 7×DC insert drill with
individually optimised have three support contact innovative drill body and
and has a never-before- surfaces for less insert insert designs makes it
seen stiffness to ensure movements. The inserts possible for cost-effective P-L6W 2044
high process security, are strong and have a bulk and reliable drilling of deep Peripheral insert
repeatability, consistent strength that provides holes with less demanding
quality and good run-out extra toughness resulting hole tolerances. No pilot
accuracy. Twisted coolant in unmatched insert tool drilling needed which saves
holes for maintained drill life. The ground peripheral both time and money. C-L5W 1144
body rigidity and variable insert allows for closer hole Central insert
chip flutes with optimised tolerance, predictability and
shapes for safe chip consistent performance.
evacuation.
Inserts after 8 holes Inserts after 16 hole Inserts after 20 hole
6.1 minutes 12.3 minutes 15.4 minutes
55 cm3 (3.36 in3) 111 cm3 (6.77 in3) 138 cm3 (8.42 in3)

174 175
Material edge preparation Back chamfering / deburring
CoroMill®326 solid carbide end mill for chamfer milling
Material Edge Preparation (MEP) is a critical process When machining aerospace engine components, one
in the aerospace industry, focused on the precise tricky but often neglected operation is deburring holes.
conditioning of component edges to enhance By using a CoroMill 327 or CoroTurn XS back chamfering
performance, safety, and longevity. By removing tool it is possible to increase productivity while providing
sharp edges, burrs, and micro-cracks, MEP ensures a repeatable, mechanised, safe process – eliminating
improved fatigue resistance, better stress distribution, the need for manual deburring and special tools.
and reduced risk of crack initiation under cyclic
The CoroTurn XS tool must be used with a Coromant
loading conditions.
Capto adaptor to provide the correct clearance when
used in rotating applications.
In high-performance aerospace environments, even
minor edge imperfections can compromise structural CoroTurn®XS
integrity. Through controlled techniques such as
Adaptor Insert Min hole size Max hole depth
micro-chamfering, radiusing, and polishing, MEP
creates consistent edge geometry that supports tight C4-CXS-47-05 CXS-05T045-20-5215R 7 15

tolerances and surface integrity

CoroMill®326 CXS-05T045-20-5220R 20
C4-CXS-47-06 CXS-06T045-20-6220R 8 20
CXS-06T045-20-6225R 25
C4CXS-47-07 CXS-07T045-20-7220R 9 20
CXS-07T045-20-7240R 40

CoroMill®327
Size Insert Min hole size Max hole depth
06 327R06-12045-CH 11.7 40
12 327R12-20045-CH 21.7 85

Programming sequence method

CoroMill® 326 can be utilised in MEP due to its extremely high precision and
1. Position the cutter cen- 2. Feed cutter to engage 4. Feed back to hole
very low cutting forces. It can be used on holes 6mm and above . It can also trally over the drilled with radius compensa- centre.
be used in back chamfering applications. hole with the cutter ro- tion (Y = hole radius). 5. Retract cutter.
tating (vc 75) and move 3. Interpolate 360° (fz 0.1
axially to flange depth mm). Offset point
(Z = flange height – for tool length
chamfer size). and radius.

176 177
Thread milling Single-point threading
Many holes in a typical aerospace engine casing require threads. Machining the thread
in smaller holes can prove to be a difficult operation. This can be performed using a tap
CoroMill®327
to machine the thread. However in HRSA materials this can cause problems with chip Designed for holes over 12 mm, CoroMill 327 offers inserts for
jamming resulting in tap breakage and ultimately scrapping of an expensive component. metric, UN and Whitworth threads.
The main options for thread milling using Sandvik Coromant tools are single-point The front-mounted inserts are positioned in grooves for secure
threading with CoroMill 327 and CoroMill 328, and multi-point threading with CoroMill® mounting, and through-tool coolant aids chip evacuation, giving
Plura. secure and continuous performance. CoroMill 327 is available in
versatile grade GC1025, for all material types.
All tools produce different threads of the same pitch with one tool.
CoroMill 327 has Weldon shanks, steel or solid carbide.

CoroMill®328
For larger holes over 39 mm, CoroMill 328 offers inserts for
metric and UN threads. Inserts are pocket-mounted for safe
and stable positioning, with 3 cutting edges per insert and high-
pitch cutter bodies. CoroMill 328 is available in versatile grade
GC1025, for all material types.
CoroMill 328 has Weldon, arbor and bore with keyway mounting.

Main considerations
To achieve the best results in a thread milling operation, always consider the following
CoroMill® Plura CoroMill® 327 Coromill® 328 points.
Pitch 0.7-3 (10 - 64tpi) 1 - 4.5 (8-20 tpi) 1.5 - 6 (16 - 4 tpi) – A smaller cutting diameter will help to achieve higher quality threads.
Cutter dia mm Tool path is important:
1.35 - 19 11.7 - 17.7 39 - 80
– Tool path will give right or left hand threads, using down- or upmilling.

Multi-point threading
– Always engage and retract the thread mill in a smooth path, i.e. roll in and out of cut.
Be aware of feed per tooth:
– Always work with small feed per tooth values (very small hex) to achieve best quality.
CoroMill®Plura threadmill
Always calculate the correct feed required by the machine software:
Threads are milled in one pass and this multi-point tool gives a
true full-profile thread form, with 60° metric, UNC/UNF and NPT/ – To ensure the correct insert load.
NPTF options available. Several infeed passes may be needed:
Designed for smaller thread sizes and in two optimised grade – In difficult applications, it may be necessary to separate the operation into several
choices, with or without through coolant. Ideal tool for mass infeed passes to achieve higher quality threads.
production.

Learn more about thread milling

www.sandvik.coromant.com

178 179
 Hole making in the aerospace industry – aero engine
Component/feature solutions
Engine casing Drilling boss face holes
CoroDrill® 860 SD
Tool 860.1-0680-035A1-SD S2BM
vc, m/min (ft/min) 25 (82)
fn,mm/rev (inch/rev) 0.16 (0.0063)
depth, mm (inch) 24.5 (0.9646)

Drilling flange / scallop holes

CoroDrill® 860 SD
Tool 860.1-0510-016A1-SD S2BM
vc, m/min (ft/min) 25 (82)
fn,mm/rev (inch/rev) 0.13 (0.0051)
depth, mm (inch) 6 (0.2362)

Drilling boss hole

CoroDrill® 880
Tool 880-D20000L 25-02
Insert peripheral 880-04 03 W07H-P-MS 2044
Insert central 880-04 03 05H-C-LM 1044

vc, m/min (ft/min) 30 (98)

fn,mm/rev (inch/rev) 0.12 (0.0047)
depth, mm (inch) 22 (0.866)

Thread milling boss face 5/16 UNF

CoroMill® Plura
Tool R217.33C060240AC13N 1630
vc, m/min (ft/min) 25 (82)
fz,mm/tooth (inch/tooth) 0.05 (0.0051)
depth, mm (inch) 12 (0.2362)
Passes 3

180 181
Component/feature solutions Hole making in the aerospace industry – aero engine

Turbine disc Drilling boss face hole

CoroDrill® 860 SD
Tool 860.1-0750-023A1-SD S2BM
vc, m/min (ft/min) 25 (82)
fn,mm/rev (inch/rev) 0.16 (0.0063)

Plunge mill / ream face hole

CoroMilll® Dura
Tool 1K333-0800-XB 1730
vc, m/min (ft/min) 20 (82)
fn,mm/rev (inch/rev) 0.1 (0.0063)

Chamfer
CoroMill® 326
Tool 326R06-B1502006-CH 1025
vc, m/min (ft/min) 40 (82)
fn,mm/rev (inch/rev) 0.1 (0.0051)
ap, mm (inch) 0.2 (0.2362)

182 183
Digital and services

Even in optimised processes, finding further improvements can be

challenging. Advanced software, connected services, and expert training
unlock new efficiencies from planning and design, through tool management
and production analysis

184 185
CoroPlus® Machining Insights CoroPlus® Tool Library

Manufacturing data analytics Simplify and optimise your tool selection

CoroPlus® Machining Insights is a cloud based
monitoring solution designed to give manufacturers
real time visibility into machine and production
performance. It helps identify inefficiencies, reduce CoroPlus® Tool Library is a powerful, cloud-first tool
downtime, and optimise utilization by turning management solution aimed at CAM users. It streamlines
machine data into actionable insights, supporting tool selection, automates assembly creation, and
smarter decisions and more efficient operations integrates tightly with major CAM platforms all while
across your shop floor. ensuring accuracy and data consistency across your
organization.

Collect data: Uncover opportunities for improvements and a deeper, more Save time: Automate time-consuming tasks in CAM programming and tool
accurate, understanding of the manufacturing process with data directly setup.
from your machines.
Reduce errors: Work with standardized, verified tool data for consistent
Reduce errors: Get insights on your machine utilization and performance
machining results
with reports consisting of real-time and historical data. With access to data
about when a machine is running and not, stop causes, faults and alarm rea-
sons it is possible to gain insights into optimization opportunities Improve productivity: Optimise workflows with reliable data and faster tool
selection
Take Actions: Utilise tickets to improve communication throughout the
workshop and take action on opportunities to optimise activities

Learn more about CoroPlus® Machining Insights Learn more about CoroPlus® Tool Library
www.sandvik.coromant.com www.sandvik.coromant.com

186 187
CoroPlus® Tool Supply Sandvik Coromant Academy

Smarter tool inventory management Turn knowledge into a competitive edge

Tool inventory is often the hidden inefficiency in Skill gaps and evolving technology are constant
a workshop. Operators spend 20% of their time challenges in manufacturing. To stay ahead, your team
searching for tools, while 15% of jobs are delayed needs the ability to solve problems, reduce costs, and
due to missing items. What’s more, 80% of regularly work with confidence. Sandvik Coromant Academy
stocked articles are rarely used, tying up capital in provides structured training, expert-led events, and
wasted items. flexible e-learning to build the knowledge that drives
performance on the shop floor and beyond.

CoroPlus® Tool Supply is a connected inventory management solution that ensures tools Sandvik Coromant Academy offers in person technical training at our global centres or
are always available when needed. With automated dispensing, full traceability, and directly at customer sites
integration to purchasing systems, it optimises stock levels and reduces waste.

Save time: Reduce searching and waiting by ensuring tools are always at hand. Technical training: Hands-on learning with real applications

Cut costs: Minimise capital tied up in stock and reduce tool obsolescence. Events: Connect and share with experts and peers

Boost efficiency: Improve tool availability and eliminate unplanned downtime. E-learning: Access flexible digital courses anytime

Gain control: Track usage and consumption patterns for smarter purchasing decisions.

Learn more about CoroPlus® Tool Supply Learn more about Sandvik Coromant Academy
www.sandvik.coromant.com www.sandvik.coromant.com

188 189
Technical data
Turning Milling
Terminology and units Terminology and units
Dm = Machined diameter mm fn = Feed per revolution mm/r Dcap = Cutting diameter at actual depth of cut, ap mm hm = Average chip thickness mm
vc = Cutting speed m/min kr = Entering angle degree lm = Machined length mm zc = Effective number of teeth piece
n = Spindle speed r/min Rmax = Profile depth µm ap = Cutting depth mm kc1 = S
 pecific cutting force (for hex = 1 mm) N/mm2
Tc = Machining time min r1 = Insert nose radius mm ae = Working engagement mm n = Spindle speed r/min
Q = Metal removal rate cm3/min ap = Depth of cut mm vc = Cutting speed m/min Pc = Cutting power net kW
lm = Machined length mm hex = Max chip thickness mm Q = Metal removal rate cm3/min KAPRr = Entering angle degrees
Pc =N
 et power kW SCL = Spiral Cutting Length m Tc = Machining time min mc = R
 ise in specific cutting force (kc)
zn = Total number of teeth in cutter piece as a function of chip thickness
k c 0,4 = Specific cutting force for chip N/mm2
fz = Feed per tooth mm/r iC = Inscribed circle
thickness 0.4 mm
fn = Feed per revolution mm γ0 =C
 hip rake angle

Formulas vf = Table feed (feed speed) mm/min

Dm × π × n vc × 1000 hex = Max chip thickness mm
vc = n=
Cutting speed (m/min) 1000 Spindle speed (r/min) π × Dm

Metal removal rate Q = vc × ap × fn

(cm 3/min) Formulas
Cutting speed
Dcap × π × n
vc × ap × f n× k c 0.4
 0.4  0.29 (m/min) vc =
1000
Power requirement (kW) Pc =  
60 × 103  n
f × sin kr  Spindle speed
vc × 1000
(r/min) n=
Machining time (min) Constant n π × Dcap

lm Table feed (feed speed)

Tc =
fn × n (mm/min) vf = fz × n × zn

f n 2× 125 Feed per tooth vf

Profile depth (µm) R max = (mm) fz =
rε n × zc

Feed per revolution vf

(mm/r) fn =
Max chip thickness Insert shapes: Round inserts n
C, D, S, T, V, W

hex = f n × sin kr hex = f n × √ 4ap

iC
– ( 2a )
p
iC
2 Metal removal rate
(cm 3 ) Q=
ap × ae × vf
1000

SCL (Spiral Cutting Length) – input info in mm – result in m Specific cutting force γ0
External or internal turning Facing Taper cutting
(N/mm 2) kc = kc1 × hm-mc × (1 - 100 )
Average chip thickness (mm) sin κr × 180 × ae × f z
when ae/Dc ≥ 0.1 hm =
a
π × Dcap × arcsin
( Dcape )
Machining time lm
(min) Tc =
vf
Dm x π x lm
( ) ( )
Dm1+Dm2 x π x lm1 Dm1+Dm2 x π
SCL = SCL = SCL = x lm2
1000 fn 2 1000 fn 2 1000 fn Net power ap × ae × vf × kc
(kW) Pc =
60 × 106
How to calculate: lm2

Machining time (min) Tc =

SCL
vc (
lm2 = √ (lm1)2 + Dm1 - Dm2 2
2
)
190 191
 HRSA – Material cross-reference list
Material Commercial Hardness Brinell HB Code Nominal composition approximate content in %
condition designation Ann. Aged
USA USA UK France Germany Germany Others
Ni Cr Co Fe Mo C Mn Si Al Ti Others SAE AMS BS ANFOR Werkst. Nr DIN 1706
Haynes 75 - - 76.01) 20.0 - 5.0 - 0.11 1.03) 1.02) - 0.4 0.52) - - - - - - -

MC S2.0.Z.AN
CMC 20.2
Haynes 263 - - 52.01) 20.0 20.0 0.72) 6.0 0.06 0.63) 0.42) 0.62) 2.42) 0.22) - 5886 - - - - N07263
Haynes 625 - - 62.01) 21.0 1.02) 5.02) 9.0 0.1 0.53) 0.52) 0.42) 0.42) 3.7 - 5666 - - - - N06625
Haynes X-750 - - 70.01) 16.0 1.02) 8.0 - 0.08 0.352) 0.352) 0.8 2.5 1.5 - 5542 - NC15TNbA - - N07750
Haynes 718 - - 52.01) 18.0 1.03) 19.0 3.0 0.05 0.352) 0.352) 0.5 0.9 5.109 - 5662/5664 - - - N07718
Incoloy 864 - - 30.0-38.0 20.0-25.0 - Balance 4.0-4.8 0.082) 1.03) 0.6-1.0 - 0.4-1.0 - - - - - - - S35135
Nimocast PE10 - - 56.4 20.0 - - 6.0 - - - - - 9.0 - - HC202 NC20N13 - - -

MC S2.0.Z.AN
Nimocast PD16 - - 43.8 16.5 - 34.0 - 0.06 - - 1.2 1.2 - - 5397 HC204 NK15CAT LW2.4674 NiFe33Cr17Mo -

CMC 20.2
Nimocast PK24 - - 61.1 9.5 15.0 - 9.0 0.17 - - 5.5 4.7 1.0 - - 3146 - - S-NiCr13Al16MoNb -
Nimocast 842 - - 57.7 22.0 10.0 - - 0.3 - - - - - 5391A - HC203 NC13AD 2.4670 S-NiCr13Al16MoNb SS071712
Ni-based
Nimocast 713 - - 72.6 13.4 - - - 0.12 - - 6.2 1.0 2.3 5931A - HC203 NC13AD - G-NiCr13A16MoNb -
Refractaloy 26 - - 36.1 17.21 18.51 Balance 2.62 0.03 0.55 0.23 0.21 2.66 0.019 - - - Z6NKCDT38 - - -
Rene 63 - - Balance 14.0 15.0 3.5 6.0 0.05 0.1 0.2 3.8 2.5 3.5 - - - - - - -
Rene 77 - - Balance 15.0 15.0 0.4 4.2 0.07 0.1 0.1 4.3 3.3 - - - - - - - -

MC S2.0.Z.AG
Rene 80 - - Balance 14.0 9.5 - 4.0 0.17 - - 3.0 5.0 - - - - - - - -

CMC 20.2
Rene 95 500 300 64.5 14.0 8.0 - 3.5 0.15 - - - 2.5 3.5 - - - NC14K8 - - -
Rene 100 - - Balance 10.0 15.0 - 3.0 0.18 - - 5.5 4.7 - - - - - - NiCo15Cr10MoAlTi -
Rene 125 - - Balance 8.9 10.0 - 2.0 0.1 - - 4.7 2.5 4.05 - - - - - - -
TRW 1800 - - 70.0 13.0 - - - 0.1 - - 6.0 0.06 10.5 - - - - - - -
TRW VIA - - Balance 6.0 7.5 - 2.0 0.13 - - 5.4 1.0 6.3 - - - - - NiTa9Co8W6CrAl -
Hastelloy B* 140 - 67.02) 1.03) 2.5 5.0 28.0 0.052) 1.02) 1.02) - - 0.352) 5396A 5396 - ND37FeV 2.4800 S-NiMo30 N10001
Hastelloy S* 200 - 67.01) 16.0 2.02) 3.02) 15.0 0.022) 0.5 0.4 0.25 - 1.0352) - - - - - - -
Hastelloy W* - - 63.01) 5.0 2.5 6.0 24.0 0.122) 1.02) 1.02) - - 0.6* - 5755 - - - - N10004
MC S2.0.Z.AN
CMC 20.21

Hastelloy X* 160 - 47.01) 22.0 1.5 18.0 9.0 0.1 1.02) 1.0 - - 0.6080 2) 5390A 5390 - NC22FeD 2.4603 - N06002
Haynes HR-120 37.0 25.0 3.02) 331) 2.52) 0.05 0.7 0.6 0.1 - 3.404 - - - - - - N08120
Haynes HR-160 - - 37.01) 28.0 29.0 2.02) 1.02) 0.05 0.5 2.75 - 0.5 2.02) - - - - - - N12160
Haynes 214* - - 75.01) 16.0 - 3.0 - 0.05 0.52) 0.22) 4.5 - 0.12 2) - - - - - DIN 177444 No 2.4646 N07214
Haynes 230 - - 57.01) 22.0 5.02) 3.02) 2.0 0.1 0.5 0.4 0.3 - 14.035 - 5891 - - - DIN 177444 No 2.4733 N06230
Haynes 242* 65.01) 8.0 2.52) 2.02) 25.0 0.032) 0.82) 0.82) 0.52) - - - - - - - - -
Incoloy 825* 180 - 38.0-46.0 19.5-23.5 - min 22.0 2.5-3.5 0.052) 1.02) 0.52) 0.22) 0.6-1.2 3.0 - - 30072-76 NC21FeDU 2.4858 NiCr21Mo N08825
Incoloy 890 - - 42.5 25.0 - Balance 1.5 0.1 1.02) 1.8 0.1 1.02) 1.0 - - - - - - N08890
MC S2.0.Z.AN
CMC 20.21

Annealed Incoloy 909 - - 35.0-40.0 - 12-16.0 Balance - 0.062) - 0.25-0.5 0.152) 1.3-1.8 5.0 - - - - - - N19909
or solution Incoloy 330 - - 34.0-37.0 17-20.0 - Balance - 0.082) 2.02) 0.75-1.5 - - 0,06* - - - - 1.4886 - N08330
treated Inconel 600* 170 - 72.0 14.0-17.0 - 6-10 - 0.152) 1.02) 0.52) - - 0.5152) 5540 5580 3072-76 NC15Fe 2.4816 NiCr15Fe N06600
Inconel 601* 150 - 58.0-63.0 21.0-25.0 - 3) - 0.12) 1.02) 0.52) 1-1.7 - 1.0152) - 5715 - - 2.4851 NiCr23Fe N06601
Inconel 603 XL - - Balance 15.0-23.0 - - 4.02) 0.32) 0.32) 2.02) 0.52) 0.52) 0.1 - - - - - - -
Inconel 617* - - min 44.5 20.0-24.0 10-15 3.02) 8-10 0.05-1.5 1.02) 1.02) 0.8-1.5 0.62) 1.02) - - - - 2.4663a - N06617
Inconel 625* 180 - min 58.0 20.0-23.0 1.02) 5.03) 8-10 0.12) 0.52) 0.52) 0.42) 0.42) 4.0 - 5666 - NC22FeDNB 2.4856 NiCr22Mo9Nd N06625
Inconel 690 - - min 58.0 27.0-31.0 - 7.0-11.0 - 0.052) 0.52) 0.52) - - 0.5152) - - - - 2.4642 - N06690
MC S2.0.Z.AN
CMC 20.21

Inconel 693 - - 3) 27.0-31.0 - 2.5-6.0 - 0.152) 1.02) 0.52) 2.4-4 1.02) 1.0 - - - - - - N06693
Nimonic 75* 170 - Balance 18.0-21.0 - 5.02) - 0.08-0.15 1.02) 1.02) - 0.2-0.6 0.52) - - HR5, 203,-4 NC20T 2.4630 NiCr20Ti N06075
Udimet 520 - - Balance 18.0-20.0 11.014.0 - 5.5-7.0 0.02-0.06 - - 1.8-2.3 2.9-3.25 1.0 - - - - - - -
Udimet 720 - - Balance 15.5-16.5 14.0-15.5 - 2.75-3.25 0.01-0.02 - - 2.25-2.75 4.75-5.25 1.5 - - - - - - -
Udimet D-979 - - 42.0-48.0 14.0-16.0 - Balance 3.0-4.5 0.082) 0.752) 0.752) 0.75-1.3 2.7-3.3 4.0 - - - - - - N09979
Udimet R-41 - - Balance 18.0-20.0 10.0-12.0 5.02) 9.0-10.5 0.122) - - 1.4-1.8 3.0-3.3 0.012) N07041
Nimonic 86 - - Balance 25.0 - - 10.0 0 05 0.015 - - - 0.03 - - - - - - -
Astroloy* - 370 Balance 15.0 17.0 - 5.0 0.04 - - 4.0 3.5 0.025 - - - - - - N13017
MC S2.0.Z.AG
CMC 20.22

Hastelloy R-235* 310 61.0 15.0 2.5 10.0 5.5 0.15 0.25 0.6 3.0 2.0 - AISI 686
Haynes R-41 - - 52.01) 19.0 11.0 5.0 10.0 0.09 0.12) 0.5* 1.5 3.1 0.006 - - - - - - -
Incoloy 901* 180 300 44.3 12.5 - 34.0 6.0 0.05 0.24 0.12 0.15 2.7 0.15 - 5660 - ZSNCDT42 LW2.4662 NiFe33Cr14MoTi N09901
Incoloy 903* - 380 36.0-40.0 - 13.0-17.0 Balance - - - - 0.3-1.15 1.0-1.85 3.0 - - - - - - N19903
Aged or Incoloy 907 - - 35.0-40.0 - 12.0-16.0 Balance - - - 0.07-0.35 0.22) 1.3-1.8 5.0 - - - - - - N19907
solution Incoloy 908 - - 47.0-51.0 3.75-4.5 0.52) Balance - 0.032) 1.02) 0.52) 0.75-1.25 1.2-1.8 3.5 - - - - - - N09908
treated Inconel 706* - - 39.0-44.0 14.5-17.5 1.02) Balance - 0.062) 0.352) 0.352) 0.42) 1.5-2 3.4 - - - - - - N09706
MC S2.0.Z.AG

Inconel 718* 180 380 50.0-55.0 17.0-21.0 1.02) Balance 2.8-3.3 0.082) 0.352) 0.352) 0.2-0.8 0.65-1.15 5.3 5383 5589 HR8 NC19FeNB LW 2.4668 NiCr19Fe19NbMo N07718
CMC 20.22

Inconel 722* - 380 Balance 15.0 - 6.5 - 0.04 0.55 0.2 0.6 2.4 30.0 - 5541 - NC16FeTi - NiCr16FeTi N07722
Inconel X-750* - 390 min 70.0 14.0-17.0 1.02) 5.0-9.0 - 0.062) 1.02) 0.52) 0.4-1.0 2.25-2.75 1.5 5542G 5582 - NC16FeTNb 2.4669 NiCr16FeTi N07750
Inconel 751** - - min 70.0 14.0-17.0 - 5.0-9.0 - 0.12) 0.52) 0.9-1.5 2-2.6 1.0 - - - - - - - N07751
Inconel 783* - - 26.0-30.0 2.5-3.5 3) 24-27.0 - 0.032) 0.52) 0.52) 5.0-6.0 0.1-0.4 3.5 - - - - - - R30783
Continued... Inconel HX - - Balance 20.5-23.0 0.5-2.5 17.0-20 8.0-10 0.05-1.15 1.02) 1.02) - - 1.0 - - - - 2.4665 - N06002
1) Balance
2) Maximum
3) Remainder
* These alloys can be hardened by an aging process.

120 121
192 193
Material Commercial Hardness Brinell HB Code Nominal composition approximate content in %
condition designation Ann. Aged
USA USA UK France Germany Germany Others
Ni Cr Co Fe Mo C Mn Si Al Ti Others SAE AMS BS ANFOR Werkst. Nr DIN 1706
Jethete M-252* - 320 55.3 19.0 10.0 2.5 - 0.15 - - 1.0 2.5 - - 5551 - - 2.4916 G-NiCr19Co N07252
MAR-M 246* - 270 59.5 9.0 10.0 - 2.5 0.15 - - 5.5 1.5 1.5 - - - - 2.4675 NiCo10W10Cr9AlTi -
MAR-M 421* - - 62.3 15.5 10.0 - 1.7 0.15 - - 4.25 1.75 1.75 - - - - - NiCr16Co10WAlTi -
MAR-M 432* - - 52.3 15.5 20.0 - - 0.15 - - 2.5 4.3 2.0 - - - - - NiCo20Cr16WAlTi -

MC S2.0.Z.AG
CMC 20.22
Nimocast 80* - - 69.9 20.0 2.0 5.0 - 0.1 - - 1.2 2.5 - - - 3146 NC 20 TA 2.4631 NiCr20TiAl -
Nimocast 90* - - 52.9 20.0 16.5 5.0 - 0.1 - - 1.3 2.4 - - - - NC 20 K17 TA 2.4632 NiCr20Co18Ti -
Nimonic 80A* - 350 Balance 18.0-21.0 2.01) 3.01) - 0.1 1.01) 1.01) 1.0-1.8 1.8-2.7 0.17 - - Hr 410,601 NC20TA 2.4631 NiCr20TiAk N07080
Aged or Nimonic 81* 200 - Balance 30.0 2.0 1.0 0.3 0.05 0.5 0.5 0.9 1.8 0.26 - - - - - - -
solution Nimonic 90* - 346 Balance 18.0-21.0 15.0-21.0 1.51) - 0.131) 1.01) 1.01) 1.0-2.0 2.0-3.0 0.391) - - Hr 2, 202 Nc20ATV 2.4632 NiCr20Co18Ti N07090
treated Nimonic 91 - - 27.0-30.0 19.0-21.0 1.01) - 0.11) 1.01) 1.01) 0.9-1.5 1.9-2.7 1.6 - - - - - - -
Nimonic 105* - 320 Balance 14.0-15.7 18.0-22.0 1.01) 4.5-5.5 0.121) 1.01) 1.01) 4.5-4.9 0.9-1.5 0.42) - - HR 3 NCKD20ATV 2.4634 NiCo20C15MoAlTi -
Nimonic 115* - 350 Balance 14.0-16.0 13.0-15.5 1.01) 3.0-5.0 0.12-0.2 1.01) 1.01) 4.5-5.5 3.5-4.5 0.42) - - HR4 NCK15ATD 2.4636 NiCo15Cr15MoAlTi -
Nimonic 901* - 350 42.5 12.5 1.01) Balance 5.75 0.11) 0.51) 0.41) 0.351) 2.9 0.62) 5660C 5661A - ZSNCDT42 2.4662 NiCr15MoTi N09901

MC S2.0.Z.AG
Nimonic 263* - 275 Balance 19.0-21.0 19.0-21.0 0.71) 5.6-6.1 0.04-0.08 0.61) 0.41) 0.62) 1.9-2.4 0.32) - - HR10 NCK20D 2.4650 NiCr15Co19MoTi N07263

CMC 20.22
Nimonic PE16* - 250 42.0-43.0 15.5-17.5 2.01) Balance 2.8-3.8 0.04-0.06 0.21) 0.51) 1.1-1.3 1.1-1.3 0.62) - - HR207 NW11AC - NiFe33Cr17Mo -
Nimonic PK33* - 350 Balance 16.0-20.0 12.0-16.0 1.01) 5.0-9.0 0.071) 0.51) 0.51) 1.7-2.5 1.5-3.0 0.271) - - - NC19DUV - NiCr20Co16MoTi -
Rene 41 - - Balance 19.0 11.0 3.0 9.75 0.05 - - 1.6 3.5 0.007 - 5399 - NC19KDT 2.4973 NiCr19Co11MoTi N07041
Waspaloy - - Balance 18.0-21.0 12.0-15.0 2.01) 3.5-5.0 0.02-0.11) 1.01) 0.751) 1.2-1.6 2.75-3.25 0.6 - - - - 2.4654 - N07001
Waspaloy* - - 58.0b 19.0 13.5 2.01) 4.3 0.08 0.11) 0.151) 1.5 3.0 0.161) - 5544 - NC20K14 LW 2.4668 NiCr19Fe19NbMo
GMR 235* - 310 63.3 15.5 - 10.0 5.2 0.15 0.25 0.6 3.0 2.0 0.06 - - - - - - AISI: 686
MC S2.0.C.NS

GMR 235D* - - 4.5 15.5 - 4.5 5.0 0.15 - - 3.5 2.5 0.05 - - - - - NiCr16MoAl -
CMC 20.24

Cast or IN-100* - 350 61.6 12.5 18.5 - 3.2 0.07 1.2 0.5 5.0 4.75 - - 5397 HC204 NK15CAT LW 2.4674 NiCo15Cr10MoAlTi N13100
cast and Jessop G39* 130 - 67.5 19.5 - 5.0 3.0 0.5 - - - - 4.5 - - - - - NiCr20MoW -
aged Jessop G64* 220 - 60.7 11.0 - 2.0 3.0 0.15 - - 6.0 - 4.0 - - - - - NiCr11AlWNb -
Jessop G81* - 300 79.3 20.0 13.0 - - 0.05 - - 1.3 2.3 - - - - - - NiCr20Co18Ti -
MAR-M 200* - - 69.4 9.0 10.0 - - 0.15 - - 5.0 2.0 1.0 - - - NKW10CATaHf - NiW13Co10Cr9AlTi -
MC S3.0.Z.AG

Air Resist 13 - - - 21.0 Balance - - 0.45 - - 3.5 - 0.1 - - - - - - -

CMC 20.3

Air Resist 213 - - - 19.0 Balance - - 0.18 - - 3.5 - 0.1 - 5537C - KC20WN - CoCr20W15Ni -
Altemp S 816 - - 20.0 20.0 47.6 - 4.0 4.0 - - - - 0.4 - -5534 - - LW 2.4989 CoCr20Ni20W -
FSX 414 - - 10.0 29.0 Balance - - 0.25 - - - - - - - - - - - -
HS 25 - - 10.0 20.0 Balance - - 0.10 - - - - - 5537C 5759 - KC20WN LW 2.4964 CoCr20W15Ni AISI:670
HS 30 - - 16.0 24.0 51.4 1.0 6.0 - 0.6 0.6 - - 0.4 5380 - - - - CoCr26Ni14Mo R30030
MC S3.0.Z.AG

HS31 - - 10.0 25.0 Balance 1.5 - 0.50 - - - - 0.5 5382 ASTM A567 3146 KC25NW LW 2.4670 CoCr25NiW R30031
CMC 20.3

HS36 - - 10.0 18.0 53.1 2.0 - 15.0 1.5 - - - 0.4 - - - - - CoCr19W14NiB -

Jessop 832 - - 12.0 19.0 44.0 17.0 2.0 - 0.8 0.3 - - 3.5 - - - - - CoCr19Fe16NiMoVNb -
Jessop 834 - - 12.0 19.0 42.0 20.0 2.0 - - - - - 6.5 - - - - - CoCr19Fe20NiMoVNb -
Jessop 875 - - - 21.0 66.0 - - 11.0 - - - - 2.45 - - - - - CoCr21W11Nb -
MC S3.0.Z.AG

Jetalloy 209 - - 10.0 20.0 52.0 1.0 - 15.0 - - - 2.0 0.02 - 5772 - KC22WN - CoCr22W14Ni -
Co-based
CMC 20.3

L-251 - - 10.0 19.0 Balance 1.0 - - - - - 0.4 - - - - - - - -

M 203 - - 24.5 19.5 Balance 1.0 - 2.15 0.8 1.0 24.5 0.07 - - - - - - - -
M 204 - - 24.5 18.5 Balance 1.6 - - - 1.0 - 0.07 - - - - - - - -
M 205 - - 24.5 18.5 Balance 1.6 - 2.75 - - - 0.07 1.67 - - - - - - -
MAR-M 302 - - - 21.5 Balance - - 0.85 - - - - 9.0 CoCrW10TaZrB
MC S3.0.Z.AG

MAR-M 322 - - - 21.5 Balance 0.75 - - 0.1 0.1 0.75 1.0 6.75 CoCr22W9TaZrNb
CMC 20.3

MAR-M 509 - - 10.0 23.5 Balance - - - 0.1 0.1 0.2 0.6 4.0 3146-3 CoCr24Ni10WtaZrB
MAR-M 905 - - 20.0 20.0 Balance - - - - - 0.5 0.05 7.6
MAR-M 918 - - 20.0 20.0 Balance - - 0.05 - - - - - CoCr20Ni20Ta
Refreactaloy 70 - - 20.0 21.0 46.0 0.5 8.0 4.0 - - - - 0.08
V-36 - - 20.0 25.0 43.2 2.4 4.0 2.0 0.6 0.5 - - 2.29 CoCr25Ni20MoWNb
WI-52 - - 0.5 21.0 62.6 2.0 - 11.0 0.25 0.25 - - 2.45 - - - - - CoCr21Mo11W -
MC S3.0.Z.AG
CMC 20.3

Jessop X-40 - - 10.0 25.0 Balance 1.5 - 0.50 0.5 0.5 - - 0.5 - 5382 3156-2 - LW 2.4670 CoCr25NiW ASTM: A567
Jessop X-45 - - 10.5 25.5 Balance 2.0 - 0.25 - - - - 8.6 - - - - - - -
Jessop X-50 - - 20.5 25.5 40.3 4.0 - 12.0 - - - - 0.75 - - - - - - -
Jessop X-63 - - 10.0 25.0 57.6 1.0 6.0 - - - - - 0.45 - - - - - - -

Continued...
1) Maximum
* These alloys can be hardened by an aging process.

122
194 123
195
Material Commercial Hardness Brinell HB Code Nominal composition approximate content in %
condition designation Ann. Aged
USA USA UK France Germany Germany Others
Ni Cr Co Fe Mo C Mn Si Al Ti Others SAE AMS BS ANFOR Werkst. Nr DIN 1706

MC S3.0.Z.AG MC S3.0.Z.AG
Annealed J1650 - - 27.0 20.0 Balance - - 0.2 - - - 3.8 - - - - - - - -

CMC 20.3
or solution Haynes 25* - - 10.0 20.0 51.01) 3.02) - 0.1 1.5 0.42) - - 15.0 5537C 5759 - KC20WN LW 2.4964 CoCr20W15Ni R30605
treated Haynes 188* - - 22.0 22.0 39.01) 3.02) - 0.1 1.252) 0.35 - - 14.03 - 5772 - KC22WN - CoCr22W14Ni R30188
Undimet 188* - - 20.0-24.0 20.0-24.0 Balance 3.02) - 0.05-0.15 1.252) 0.2-0.5 - - 15.0 - - - - - - R30188
Undimet L-605* - - 9.0-11.0 19.0-21.0 Balance 3.02) - 0.05-0.15 1.0-2.0 0.42) - - 16.0 - - - - - - R30605

In aged HS6* - - 2.5 28.0 60.5 3.0 - 5.0 - - - - 1.0 - 5373 - - - - R30006

CMC 20.32
condition HS21* - - 3.0 27.0 Balance 1.0 5.0 - 0.6 0.6 - 0.25 - - 5385 3531 - - CoCr28Mo R30021
J1570* - 350 28.0 20.0 43.0 2.0 - 7.0 - - - - - - - - - - - -

Fe-based
quenched

MC SN.N.N.NN
CMC 05.3
and Greek Ascoloy - 300 2.0 12.0 - Balance - 0.19 - - - - 3.15 - 5508 - - - - S41880
tempered Jethete M 152** - 300 2.5 12.0 - Balance 1.7 0.15 - - - - 0.3 - 5718 - Z12 CND12 LW 1.4939 - -
martensitic
> 0.12%C

Fe-based Crucible A286* - 250 25.0 14.0 - Balance 1.3 0.05 1.3 0.5 0.2 2.1 - J467 5525 HR5152 Z06 NCT25 LW 1.4980 - ASTM: 368
MC M1.O.Z.PH

precipi- Discaloy 24* - 280 26.0 13.5 - Balance 2.7 0.04 0.9 0.8 0.1 1.7 - (J467) 5733 - Z3 NCT25 LW 1.4943 - S66220
CMC 05.4

tation Discaloy 16-25-6* - 290 25.0 16.0 - Balance 6.0 0.12 1.35 0.7 - 0.3 0.4 - 5725 - Z3 NCT25 - - -
hardened Unitemp 212* - 280 25.0 16.0 - Balance - 0.08 0.05 0.15 0.15 4.0 0.5 - - - - - - -
steels Incoloy A-286 - 280 25.5 15.0 - Balance 1.25 - - - - 2.1 - 5525 5726 HR 51-2 Z 3 NCT 25 1.4980 X5NiCrTi2615 S66286
665B* - 280 26.0 13.5 - Balance 1.5 0.08 - - - 2.85 - J467 5543 - - 1.4943 - S66545
19-9-DL* - 250 9.0 18.5 - Balance 1.4 0.3 1.5 0.6 - 0.25 1.75 - 5526 - - LW 1.4984 - S63198
MC P3.3.Z.AN MC P5.0.Z.PH

17-4-PH* - 250 4.0 16.5 - Balance - 0.7 1.0 1.0 - - 3.57 J467 5604 - - 1.4542 XCrNiCuNb174 S17400
CMC 05.4

Udimar 250* - - 17.0-19.0 - 7.0-8.5 Balance 4.6-5.1 0.032) 0.12) 0.12) 0.05-0.15 0.3-0.5 0.022) - - - - - - K92890
CMC 05.4

Udimar 300* - - 18.0-19.0 - 8.0-9.5 Balance 4.6-5.2 0.032) 0.12) 0.12) 0.05-0.15 0.55-0.8 0.022) - - - - - - K93120

Annealed Incoloy 800** 184 - 30-35.0 19-23.0 - min 39.5 - 0.12) - - 0.15-0.6 0.15-0.6 - - - - - 1.4876 X10NiCrAlTi3220 N08800
MC S1.0.U.AN
CMC 20.11

or solution Incoloy 803 - - 32-37.0 25-29.0 - Balance - 0.06-0.1 1.52) 1.02) 0.15-0.6 0.15-0.6 - - - - - - - S35045
treated Incoloy DS** 180 - 34.5-41 17-19.0 Balance - 0.01 0.8-1.5 1.9-2.6 - 0.2 0.5 - - - - 1.4864 X12NiCrSi3616 -
Sanicro 30** 150 - 34.0 22.0 - Balance - 0.03 0.55 0.55 0.3 0.5 0.1 - - - - 1.4558 X2NiCrAlTi3220 -
Nilo 36 - - 36.0 0.25 - Balance - 0.05 0.50 0.25 0.10 0.10 0.14 - - - - 1.3912 - K93600
Nilo 42 - - 42.0 0.25 1.0 Balance - 0.005 0.8 0.03 0.15 - - - - - A54-301 1.3917 K94100
Aged or
MC S1.0.U.AG

Haynes 556* - 260 20.0 22.0 18.0 31.01) 3.0 0.1 1.0 0.4 0.2 - 3.34 - 5877 - - - - R30556
CMC 20.12

solution Multimet 155* - 260 20.0 21.0 20.0 30.01) 3.0 0.12 1.5 1.02) - - 3.65 - 5769 - - 1.4971 X12CrCoNi2120 R30155
treated and N155* - 260 20.0 21.0 20.0 Balance 3.0 0.15 1.5 0.5 - - 1.0 - 5768 - - 1.4971 X12CrCoNi2120 R30155
aged N156* - 260 33.0 17.0 24.0 Balance 3.0 0.33 - - - - - - - - - - - -
S 590* - 270 20.0 21.0 20.0 Balance 4.0 0.43 - - - - - - 5770 - - 1.4977 X40CoCrNi2020 R30590

1) Balance
2) Maximum
* These alloys can be hardened by an aging process.
** These alloys cannot be hardened by an aging process.

124
196 125
197
Notes Notes

198 199
Notes

200