Proper Care and Setting of ULTRA-Proper Care and Setting of ULTRA-MILLMILL Cutters Cutters

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IntroductionIntroduction

ULTRA-MILLULTRA-MILL cartridges with diamond tips are recommended for milling non-ferrous materials such as, aluminum, carbon, graphite, plastics, composites, etc. When used properly ULTRA-MILLULTRA-MILL cartridges will increase productivity through higher spindle speed and feed rates and also by extending tool life, decreasing the number of tool changes and increasing machine utilization. Normal machining practices, including the use of proper speeds and feeds should be adhered to at all times

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Recommended Recommended Speeds & FeedsSpeeds & Feeds

Aluminum 800 6000 0.004 0.015< 12% Silicon

Aluminum 800 4000 0.005 0.012> 12% Silicon

Metal Matrix Composites 2000 3000 0.005 0.015

Copper Alloys, 2000 3300 0.002 0.008

Brass, Bronze, Lead, Zinc 500 1500 0.002 0.006

Unfilled Plastics, Graphite, Carbon 2000 4000 0.003 0.008

Reinforced Plastics, Composite materials 2000 4000 0.003 0.01

Green Ceramics 200 900 0.002 0.006

Wood 3000 9000 0.004 0.015

Feed (in./tooth)Material

Non- Ferrous Metals

Non- Metallic Materials

Speed (SFPM)

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SettingSetting

Use the same care practiced with carbide tools when measuring or setting-up. This care should include optical measurements when possible, and the avoidance of any contact of the tool’s cutting edges with the hard surfaces of micrometer anvils, gage blocks and any other inspection or set-up equipment. Machine set-up, including “touching off” must be done with a soft material (plastic or paper, etc.) between the tool and touch off plate.

The following pages document setting an ULTRA-MILL using the preferred method with an Optical Pre-setter or a Surface Plate with an Indicator.

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StorageStorageWhen storing ULTRA-MILL cutter with cartridges, cover the cartridges with the supplied boot. When storing cartridges, place them in their original containers. This will prevent the tools from contact with each other or any hard surfaces that could result in damaging the cutting edges.

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Set-up ProceduresSet-up Procedures

Before installing new cartridges, check pockets and cartridges are clean and free of burrs.

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Set-up ProceduresSet-up Procedures

Clean and stone bottom of cutter to eliminate burrs or dirt. Set cutter on surface plate or setting fixture.

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Set-up ProceduresSet-up Procedures

Turn hex nuts down one full turn (CLW).

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Set-up ProceduresSet-up Procedures

Install cartridges in body with 10-24 Button Head screws and snug (15-20 inch/pounds) with Torx wrench.

Use Grade 8 or better screws as supplied by sp3.

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OpticalOpticalSet-up ProceduresSet-up Procedures

Set pre-setter to desired Set Height.

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ContactContactSet-up ProceduresSet-up Procedures

Set dial indicator to desired Set Height.

Requires indicator with .0001” resolution.

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OpticalOpticalSet-up ProceduresSet-up Procedures

Using ¼” wrench turn hex nut (CCLW) to adjust cartridges to .001”

below Set Height.

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ContactContactSet-up ProceduresSet-up Procedures

Using ¼” wrench turn hex nut (CCLW) to adjust cartridges to .001”

below Set Height.

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OpticalOpticalSet-up ProceduresSet-up Procedures

Tighten Button Head screws to 45 inch/pounds +/- 2 in./lbs

Torque Wrench Required

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ContactContactSet-up ProceduresSet-up Procedures

Tighten Button Head screws to 45 inch/pounds +/- 2 in./lbs

Torque Wrench Required

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OpticalOpticalSet-up ProceduresSet-up Procedures

Using ¼” wrench turn hex nut (CCLW) to adjust cartridges to proper Set Height. For best results all cutting edges should be within +\-.0001”.

The closer the cutting edges are set the better the workpiece finish.

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ContactContactSet-up ProceduresSet-up Procedures

Using ¼” wrench turn hex nut (CCLW) to adjust cartridges to proper Set

Height. For best results all cutting edges should be within +\-.0001”.

The closer the cutting edges are set the better the workpiece finish.

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Set-up ProceduresSet-up Procedures

Verify all Button Head screws are set to the proper torque.

Torque Wrench Required

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is not responsible for any defects caused by improper use or setting of the ULTRA-MILL. Care should be taken when handling aluminum body cutters. Although the outside is very hard, it can be damaged from rough handling. Also PCD and TFd tipped cartridges have precision ground edges that can be damaged, so extreme caution should be taken when handling and setting.

Proper handling and setting will result in best possible finishes and longest life.

Please call 888-547-4156 with any questions regarding the use and care of ULTRA-MILL components.