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CoroMill® 331

Customer case, Thailand

IndustryGeneral engineering
MaterialHigh alloy steel, CMC 3.11 (P3.1.Z.AN)
OperationHalf side and face milling
MachineMazak
-73%
Cost per component

+279%
Productivity increase

Existing insert (H-PL 4240) New insert (E-M30 1130)
ToolL331.52-160S40FMN331.32-200Q40FM12.00
Insert N331.1A-08 45 08H-PL 4240N331.1A-08 45 08E-M30 1130
Dc160 (6.3)160 (6.3)
Zn1212
n, rpm 450350
vc m/min (ft/min)226 (741)176 (577)
hex mm (inch)0.017 (0.0007)0.078 (0.0031)
fz mm (inch)0.02 (0.001)0.09 (0.004)
vf, mm/min (in/min)108 (4)375 (15)
ap mm (inch)6 (0.236)6 (0.236)
ae mm (inch)40 (1.575)40 (1.575)
Tool change criteriaInsert breakdownInsert breakdown
Cut time (minutes)68.518
Tool life (components)1437.5

Result

The new E-M30 geometry offered a 279% increase in productivity and a substantial reduction of the cost per component.

Customer case, USA

ComponentFlow control ball valve (oil and gas)
MaterialM1.0.Z.AQ (316 SS)
OperationGrooving
MachineSpecial-purpose machine

Existing insert (H-PL S30T) New insert (L50 S30T)
ToolN331.32-152T38EM0.394 N331.32-152T38EM0.394
Insert N331.1A-08 45 08H-PL S30T N331.1A-08 45 08E-L50 S30T
DC152152
zn, (zeff)12 (6)12 (6)
n, rpm 11091109
vc m/min (ft/min)529 (1736)529 (1736)
hex mm (inch)0.036 (0.001)0.036 (0.001)
fz mm (inch)0.1 (0.004)0.1 (0.004)
vf, mm/min (in/min)658 (25.9)658 (25.9)
ap mm (inch)11.5 (0.453)11.5 (0.453)
ae mm (inch)5.5 (0.217)5.5 (0.217)
Time in cut / component, sec2.52.5
Tool life, components210260

Result

By replacing the H-PL geometry with the new L-50 geometry, tool life increased 24% with a considerably more reliable and predictable wear pattern.

Customer case, USA

ComponentAerospace nut tube coupling
MaterialS2.0.Z.AN (Inconel 625)
OperationGang milling
MachineHorizontal arbor mounted manual milling machine
67%
Increased tool life

Existing insert (H-PL S30T) New insert (L50 S30T)
ToolR331.52-127T38EM
L331.52-127T38EM
R331.52-127T38EM
L331.52-127T38EM
Insert N331.1A-08 45 08H-PL S30T N331.1A-08 45 08 L50 S30T
DC127127
zn, (zeff)10 (10)10 (10)
n, rpm 142142
vc m/min (ft/min)56.7 (186)56.7 (186)
hex mm (inch)0.051 (0.002)0.051 (0.002)
fz mm (inch)0.051 (0.002)0.051 (0.002)
vf, mm/min (in/min)72.95 (2.87)72.95 (2.87)
ap mm (inch)1.27 (0.050)1.27 (0.050)
ae mm (inch)16.26 (0.640)16.26 (0.640)
Time in cut / component, sec25.0 × 3 cuts indexed25.0 × 3 cuts indexed
Tool life, components120200

Result

The new L50 insert provided superior tool life and predictable, reliable tool wear. Less vibration and better surface finish were other appreciated improvements.

Customer case, India

ComponentLocomotive master rod
MaterialSteel CMC 2.2
OperationOil groove roughing with interpolation
MachineMazak, Nexus 5000-II

Existing insert (H-NL 1025) New insert (M30 1130)
ToolR331.35-063A25EM(Z6)R331.35-063A25EM(Z6)
Insert N331.1A-08 45 08H-NL 1025 N331.1A-08 45 08E-M30 1130
DC6363
zn, (zeff)6 (3)6 (3)
n, rpm 960960
vc m/min (ft/min)190 (623)190 (623)
hex mm (inch)0.015 (0.0006)0.015 (0.0006)
fz mm (inch)0.03 (0.001)0.03 (0.001)
vf, mm/min (in/min)58 (2.28)58 (2.28)
ap mm (inch)10 (0.394)10 (0.394)
ae mm (inch)3 (0.118)3 (0.118)
WearChippingFlank and thermal cracks
Tool life, components816

Result

Increased tool life with much more reliable and predictable tool wear. The cutting sound also improved significantly.

Customer case, France

ComponentHousing for tractor
MaterialCast iron FGL 300 (K2.2.C.UT)
OperationSide and face milling with interpolation
MachineHMC (HSK100)
Existing insert (M-KM 1020) New insert (M30 1020)
Tool203 24 0242 R 0114203 24 0242 R 0114
Insert N331.1A-08 45 08M-KM 1020 N331.1A-08 45 08 M30 1020
DC5050
zn, (zeff)6 (6, big overlap)6 (6, big overlap)
n, rpm 15611561
vc m/min (ft/min)245 (804)245 (804)
hex mm (inch)0.21 (0.008)0.21 (0.008)
fz mm (inch)0.21 (0.008)0.21 (0.008)
vf, mm/min (in/min)1965 (77.4)1965 (77.4)
ap mm (inch)10 (0.394)10 (0.394)
ae mm (inch)14 (0.551)14 (0.551)
Time in cut / component, min 0.840.84
Tool life, components3737

Result

The new M30 insert provided more controlled and less tool wear for the same number of components and less spindle load.

Customer case, Russia

Industry: Automotive
Component: Connecting rod cap
Material: Cast iron (K2.1.C.UT)
Operation: Mill full slot
Machine: Special arbor-mounted automatic milling machine
Coolant: Emulsion, 7%
33%
Increased tool life
  Existing insert (M-KM 3040) New insert (M30 1020)
Insert N331.1A-08 45 08M-KM3040 N331.1A-08 45 08 M30 1020
DC 125 125
zn (zeff) 16 (8) 16 (8)
Tool overhang Arbor-mounted Arbor-mounted
n, rpm 207 207
vc, m/min (ft/min) 81.5 (267) 81.5 (267)
hex mm (inch) 0.05 (0.002) 0.05 (0.002)
fz mm (inch) 0.12 (0.005) 0.12 (0.005)
vf, mm/min (in/min) 200 (7.87) 200 (7.87)
ap mm (inch) 6.0 (0.236) 6.0 (0.236)
ae mm (inch) 15 (0.591) 15 (0.591)
Time in cut/component (sec) 20.0 20.0
Spindle load NA NA
Tool life, components 3000 4000

Result

The new insert provided an improved, safe machining process with no cracks, less sound and with no vibration.

Oil groove finishing

Industry Automotive engine
Component: Connecting rod
Material: CrMo steel forging
Operation: Oil groove finishing
Machine: Vertical M/C
Coolant: Emulsion, 8%
  Existing insert (M-PM 4320) New insert (M30 4230)
Tool N331.32-080S27EM(Z6) N331.32-080S27EM(Z6)
Insert N331.1A-084508M-PM 4230 UVM3667-PMD-009  M30 4230
DC 80 (3.15) 80 (3.15)
zn 6 6
n, rpm 600 600
vc, m/min (ft/min) 150 (492) 150 (492)
fz mm (inch) 0.056 (0.002) 0.056 (0.002)
vf, mm/min (in/min) 100 (3.94) 100 (3.94)
ap mm (inch) 12 (0.472) 12 (0.472)
ae mm (inch) 2 pass 3+2.5 2 pass 3+2.5
Average flank wear, mm (inch) Less than 0.1 mm (0.004), even Less than 0.1 mm (0.004), even
Tool life (components) 15 components 15 components

Result

Existing M-PM shows slightly vibration-affected surface quality within specification. M30 however, shows good surface quality without vibration. M30 also proved much more light-cutting than the existing M-PM geometry.

Full slotting with interpolation

ComponentValve body (oil and gas)
MaterialCMC 02.2 (P2.5.Z.HT)
OperationFull slotting with interpolation
MachineHYUNDAI03
+195%
Productivity

-500 HRS
Machine time
Competitor CoroMill® 331
ToolTMR331.35-520743
Insert L331.1A-08 45 30H-WL 1030
DC mm (inch)80 (3.15)86 (3.4)
zeff44
n, rpm 500650
vc m/min (ft/min)175 (574)175 (574)
fz mm/z (in/z)0.1 (0.0039)0.2 (0.0079)
vf, mm/min (in/min)200 (7.874)520 (20.472)
ap mm (inch)1 (0.039)10 (0.394)
ae mm (inch)80 (3.150)60 (2.362)
Cycle time, min3010
Results
Tool life, components44
Tool life, m (feet)12 (39.37)20.8 (68.24)
Tool life, min12040

Boss milling

ComponentTurbine support case
MaterialCMC 20.22 (S2.0.Z.AG)
OperationBoss milling (interpolation)
MachineChiron
+166%
Productivity

-382 HRS
Machine time
Competitor CoroMill®331
ToolR331.35-050A20CM060
Insert N331.1A-043505H-PL S30T
DC mm (inch)50 (2.0)50 (2.0)
zn4 (zeff2)6 (zeff3)
n, rpm 255255
vc m/min (ft/min)40 (131)40 (131)
hex mm (inch)0.01 (0.0004)0.02 (0.0008)
fz mm/z (in/z)0.01 (0.0004)0.02 (0.0008)
vf, mm/min (in/min)7 (0.276)18 (0.709)
ap mm (inch)1 (0.039)1 (0.039)
ae mm (inch)6 (0.236)6 (0.236)
Cycle time, min346118
Results
Tool life, components0.090.25
Tool life, m (feet)0.04 (0.131)0.11 (0.361)
Tool life, min29.529.41

Deep grooving

ComponentAircraft frame
MaterialCMC 23.22 (S4.3.Z.AG)
OperationDeep grooving
MachineGidding & Lewis
+826%
Productivity

-76 HRS
Machine time
Competitor CoroMill® 331
ToolN331.32-203T51FMB
Insert R331.1A-084530H-WL 1030
DC mm (inch)203 (8.0)203 (8.0)
zn18 (zeff6)16 (zeff8)
n, rpm 7372
vc m/min (ft/min)46 (151)46 (151)
fz mm/z (in/z)0.051 (0.002)0.127 (0.005)
vf, mm/min (in/min)22.25 (0.876)72.77 (2.865)
ap mm (inch)7.62 (0.300)13.46 (0.530)
ae mm (inch)12.7 (0.500)12.7 (0.500)
Cycle time, min37.56.5
Results
Tool life, components0.58
Tool life, m (feet)0.42 (1.37)3.78 (12.41)
Tool life, min18.7552

Half side and face milling

ComponentGeneral engineering
MaterialCMC 01.3 (P1.3.Z.AN)
OperationHalf side and face milling
MachineHeller MCH350
+569%
Productivity

-394 HRS
Machine time
Competitor CoroMill®​ 331
ToolR331.32-125Q32 KM 15
Insert N331.1A-115008M-PM4230
DC mm (inch)125 (5.0)125 (5.0)
zn10 (zeff10)8 (zeff8)
n, rpm 530790
vc m/min (ft/min)208 (682)310 (1017)
hex mm (inch)0.05 (0.0020)0.12 (0.0047)
fz mm/z (in/z)0.08 (0.0031)0.18 (0.0071)
v​f, mm/min (in/min)424 (16.693)1138 (44.803)
ap mm (inch)5 (0.197)8 (0.315)
ae mm (inch)12 (0.472)15 (0.591)
Cycle time, min33.965.01
Results
Tool life, components812
Tool life, m (feet)115.12 (377.69)68.42 (224.47)
Tool life, min271.6860.12

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