Meet the latest edition to the Mill 4 family

5th October 2016
Posted By : Anna Flockett
Meet the latest edition to the Mill 4 family

The Mill 4 indexable milling cutters line from Kennametal is gaining an important new member. Adding a cutting tool designed for smaller machining centres, the Mill 4-11 offers the free cutting action of a single-sided insert at the low cost per edge of a double-sided.

Kennametal are staying positive with the latest addition to the Mill 4 family with unique insert geometry and extremely accurate pocket positioning, and the Mill 4-11 is also available in a variety of mounting options, with cutter diameters ranging from 16-80mm.

The Mill 4-11 accommodates 40-taper CAT and BT, HSK50, and similarly-sized spindles. Due to its free-cutting capabilities, it is suitable for successful metal removal in less-than-rigid setups and on light-duty machine tools, multitaskers and live-tool lathes.

Senior Global Product Manager for Indexable Milling, Tim Marshall said: “The Mill 4-11 enjoys the same strong insert design as its larger cousin, the Mill 4-15, but is 24 % shorter and 34% narrower. With an 11mm (0.433”) maximum cut length, this addresses the needs of those job shops and manufacturers producing smaller parts and part features while still offering high metal removal rates and excellent tool life.

Marshall continued: “What's unique about it is the step down is because of the insert design and precision, there´s very little mismatch between passes—for example, using a 63mm diameter tool (2.48”) and our SGE geometry, we were able to achieve less than 8µm (0.00003”) deviation between successive 6mm (0.236”) deep passes. One of our largest automotive customers completely eliminated a finishing operation on a steel alloy housing because of it, saving them many thousands of dollars annually.”

Director of Global Product Management for Indexable Milling, Scott Etling agreed and said: “The Mill 4-11 platform offers a full complement of grades and geometries. KCPM40 is our go-to grade for most steel applications and our newest KCSM40 is our first choice in aerospace and medical machining. Of course we have cast iron and aluminium grades and a variety of edge preps and corner radii up to 1.6mm (0.062”) as well. We´re very proud of this new offering.”

The Mill 4-11 is easy to use, as each insert is securely locked in place with a single M3 screw, and marked with a series of dimples to indicate geometry and insert style. Marshall recommends customers keep the tool clean and the screws lubricated with a small amount of grease, and said it´s a good idea to mount all of the inserts with the dimples or markings facing the same direction. “This improves accuracy during indexing, no matter whose cutting tools you´re using.”

The cutter has uneven pocket spacing designed to break up machine harmonics and reduce chatter. Because of its complex insert geometry and positive placement in the pocket, it has an effective radial rake angle between 1-11°, depending on the cutter diameter, and an axial rake angle of 3°, this despite the Mill 4-11´s double-sided design.

When taking cuts up to approximately 6.5mm (0.255”) axial engagement, the cutter is essentially ‘stepless’, although cuts up to 11mm deep (0.433”) are possible while still maintaining square, smooth walls.

Marshall added: “Best of all, it removes material quickly. We´ve performed extensive testing; time and again we beat the competition, in some cases by 35% greater metal removal rates and 40% or longer tool life. It´s quite simply a great addition to our portfolio.”


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