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CoroMill® 390

Performance: Lightweight CoroMill® 390 produced with additive manufacturing

A small reduction in distance and mass between the cutting edges and the Silent Tools™ damper enables an increased depth of cut, and in doing so, a significant productivity increase when working with long overhangs.


+200%
INCREASED PRODUCTIVITY

Workpiece materialP2.5.Z.HT, hardness 290 HB
OperationFace milling with large radial cutter engagements (80–100% of cutter diameter)
MachineOKUMA MA550-VB
AdapterC5-Q22D-048-220
Conventional CoroMill® 390 Lightweight CoroMill® 390
Tool materialSteelTitanium alloy
Tool diameter, mm5050
Weight, g (oz)317 (11.2)66 (2.33)
InsertR390-11T308M-PM 1130R390-11T308M-PM 1130
zn33
n rpm1,2731,273
vc m/min (ft/min)200 (656)200 (656)
vf mm/min (in/min)573 (22.6)573 (22.6)
fz mm/z (in/z)0.15 (0.006)0.15 (0.006)
ap mm (inch)1.5 (0.059)4.5 (0.177)
ae mm (inch)50 (1.97)50 (1.97)
MRR cm3/min (in3/min)43 (2.62)129 (7.87)
Result: 200% increased productivity

Performance: Slot milling in steel

​A subcontractor’s productivity was limited by its end mill, as the two-insert
cutter could only manage a 2 mm (0.079 inch) cutting depth. After switching to a CoroMill® 390 cutter with three size 07 inserts, the cutting depth could be increased to 3 mm (0.118 inch). As a bonus, the burr formation caused by the previous tool was nowhere to be seen when milling with the new cutter. The overall verdict: a double win for CoroMill® 390, with increased productivity and tool life.


+225%
PRODUCTIVITY

​Workpiece material​P2.1.Z.AN
Operation​Slot milling
Tool​R390-012A12-07M
Existing solution
​Insert​390R-070204M-PM 1130
vc m/min (ft/min)​200 (656.166)​150 (492.125)
vf mm/min (in/min)​900 (35.433)​600 (23.622)
hex mm (inch)​0.1 (0.004)​0.1 (0.004)
ap mm (inch)​3 (1.118)​2 (0.079)
ae mm (inch)​12 (0.472)​12 (0.472)
​Result
Time in cut, min3.765.5

Performance: CoroMill® 390 with size 07 inserts

​To achieve acceptable component quality, maximum cutting depth was restricted in this application. After switching to the CoroMill® 390 cutter with size 07 inserts, the cutting depth could be increased, generating higher productivity. With GC1130 inserts, the tool life was improved by 47%, significantly reducing cost per component.


+47%
TOOL LIFE

Component​Die and mold
​Workpiece material​P2.5.Z.HT
Operation​Slot and pocket milling
GC1130 ​Existing solution
ToolR390-012A12-07M
​Insert​390R-070204M-PM 1130
zn​3​3
n rpm​4,005​3,979
vc m/min (ft/min)​151 (495)​150 (492)
vf mm/min (in/min)​853 (33.583)​900 (35.433)
fz mm (inch)0.07 (0.003)​0.075 (0.003)
ap mm (inch)​1.5 (0.059)​1 (0.039)
ae mm (inch)​12 (0.472)12 (0.472)
​Result
Tool life44 minutes30 minutes

Performance: Slot and shoulder milling with long overhangs

Unstable conditions with long overhangs, combined with a forged surface and coolant, were causing some challenges for the insert tool life in this application. Surface quality issues, caused by flaking of the coating, limited insert tool life. By exchanging the existing solution with GC1130 inserts, flaking was significantly reduced and 57% more components could be machined.


+57%
TOOL LIFE

Component​Rear spindle
​Workpiece material​P2.5.Z.HT
Operation​Slot and pocket milling
GC1130 ​Existing solution
ToolR390-020A20-11M
​Insert​R390-11 T3 08M-PM 1130
zn​33
n rpm​2,4002,400
vc m/min (ft/min)​151 (495)151 (495)
vf mm/min (in/min)​864 (34.016)​864 (34.016)
fz mm (inch)0.12 (0.005)0.12 (0.005)
ap mm (inch)3.5 (0.138)​3.5 (0.138)
ae mm (inch)20 (0.787)20 (0.787)
​Result
Tool life ​440 components ​280 components

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