APKT1604PDSR-30: A Milling Insert for General Use
If you are looking for a milling insert that can handle a variety of materials and applications, you might want to consider APKT1604PDSR-30. This is a parallelogram-shaped insert with a 16 mm cutting edge length and a positive rake angle. It is designed for general use in milling operations, such as face milling, shoulder milling, slotting, ramping, and helical interpolation. In this article, we will explain what APKT1604PDSR-30 is, how to use it, how to maintain it, and where to buy it.
apkt1604pdsr-30
What is APKT1604PDSR-30?
APKT1604PDSR-30 is a milling insert that belongs to the APKT family of inserts from ISCAR, a leading manufacturer of cutting tools. The name of the insert indicates its shape, size, geometry, and grade. Here is what each letter and number means:
A: The shape of the insert is a parallelogram with an 85-degree included angle.
P: The rake angle of the insert is positive, which means it has a lower cutting force and a smoother chip flow.
K: The clearance angle of the insert is 11 degrees, which provides enough clearance for the cutting edge to avoid rubbing against the workpiece.
T: The tolerance class of the insert is T, which means it has a normal size tolerance and a normal hole tolerance.
1604: The size code of the insert is 1604, which means it has a 16 mm cutting edge length and a 9.45 mm inscribed circle diameter.
PDSR: The geometry code of the insert is PDSR, which means it has a right-hand cutting direction, a 1.78 mm corner radius, and an M chipbreaker. The M chipbreaker is suitable for medium machining conditions and provides good chip control and surface finish.
30: The grade code of the insert is 30, which means it is made of carbide with an AlTiN coating. The coating enhances the wear resistance and heat resistance of the insert, making it suitable for steel, stainless steel, cast iron, hard materials, non-ferrous metals, superalloys, and titanium.
Features and specifications of APKT1604PDSR-30
Here are some of the main features and specifications of APKT1604PDSR-30:
FeatureSpecification
ShapeParallelogram
Rake anglePositive
Clearance angle11 degrees
Tolerance classT
Cutting edge length16 mm
Inscribed circle diameter9.45 mm
Cutting directionRight-hand
Corner radius1.78 mm
ChipbreakerM
Grade30
MaterialCarbide
CoatingAlTiN
Workpiece materialsSteel, stainless steel, cast iron, hard materials, non-ferrous metals, superalloys, titanium
Milling operationsFace milling, shoulder milling, slotting, ramping, helical interpolation
Benefits and applications of APKT1604PDSR-30
APKT1604PDSR-30 is a versatile and reliable milling insert that offers several benefits and applications for different machining scenarios. Here are some of them:
It has a positive rake angle that reduces the cutting force and the power consumption, resulting in lower machining costs and higher productivity.
It has a parallelogram shape that provides four cutting edges per insert, increasing the tool life and the economy.
It has an AlTiN coating that improves the wear resistance and the heat resistance of the insert, enabling higher cutting speeds and longer tool life.
It has an M chipbreaker that ensures good chip control and surface finish, especially for medium machining conditions and interrupted cuts.
It can handle a wide range of workpiece materials, from steel to titanium, with good performance and quality.
It can perform various milling operations, such as face milling, shoulder milling, slotting, ramping, and helical interpolation, with high accuracy and efficiency.
How to use APKT1604PDSR-30?
To use APKT1604PDSR-30 effectively and safely, you need to follow some basic steps and guidelines. Here are some of them:
Choosing the right grade and cutting speed
The first step is to choose the right grade and cutting speed for the workpiece material and the machining condition. The grade 30 of APKT1604PDSR-30 is suitable for most materials, but you may need to adjust the cutting speed according to the hardness and the machinability of the material. Here is a table that shows the recommended cutting speeds for different materials:
MaterialCutting speed (m/min)
Steel (P)150-300
Stainless steel (M)100-200
Cast iron (K)200-400
Hard materials (H)50-100
Non-ferrous metals (N)300-600
Superalloys (S)50-150
Titanium (T)50-100
You can also use the following formula to calculate the cutting speed:
V = πDN/1000
Where:
V is the cutting speed in m/min
D is the diameter of the milling cutter in mm
N is the spindle speed in rpm
Setting up the milling machine and tool holder
The next step is to set up the milling machine and the tool holder for the insert. You need to make sure that the machine is clean and stable, and that the tool holder is compatible with the insert. For APKT1604PDSR-30, you can use a 90-degree milling cutter with a 22 mm diameter and a 27 mm height. The tool holder should have a screw clamping system and a coolant hole. Here is an example of a suitable tool holder for APKT1604PDSR-30:
You need to mount the insert on the tool holder with a torque wrench and a screwdriver, and tighten the screw to the recommended torque value of 2.5 Nm. You also need to align the insert with the tool axis and check the runout and balance of the tool.
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Adjusting the cutting parameters and feed rate
The final step is to adjust the cutting parameters and feed rate for the milling operation. The cutting parameters include the depth of cut, the width of cut, and the angle of entry. The feed rate is the distance that the tool moves per revolution of the spindle. You need to choose the optimal values for these parameters based on the material, the operation, and the desired surface finish. Here is a table that shows some general guidelines for these parameters:
OperationDepth of cut (mm)Width of cut (%)Angle of entry (degrees)Feed rate (mm/tooth)
Face milling1-550-100900.1-0.3
Shoulder milling1-510-50900.1-0.3
Slotting1-51000-150.05-0.2
Ramping1-510-501-100.05-0.2
Helical interpolation1-510-501-100.05-0.2
You can also use the following formula to calculate the feed rate:
F = fz x z x N
Where:
F is the feed rate in mm/min
fz is the feed per tooth in mm/tooth
z is the number of teeth on the milling cutter
N is the spindle speed in rpm
How to maintain and replace APKT1604PDSR-30?
To ensure the best performance and quality of APKT1604PDSR-30, you need to maintain and replace it regularly and properly. Here are some tips and tricks for doing so:
Checking the insert condition and wear patterns
You need to check the insert condition and wear patterns after every machining cycle or when you notice a change in the cutting sound, force, or quality. You need to look for signs of wear, such as flank wear, crater wear, notch wear, chipping, thermal cracking, or built-up edge. You can use a magnifying glass or a microscope to inspect the insert more closely. Here is a table that shows some common wear patterns and their causes:
Wear patternCause
Flank wearNormal wear due to friction between the insert and the workpiece.
Crater wearWear due to diffusion and abrasion on the rake face of the insert.
Notch wearWear due to mechanical stress and thermal shock on the corner of the insert.
ChippingDamage due to impact or vibration on the cutting edge of the insert.
Thermal crackingCracks due to thermal cycling and stress on the insert surface.
Built-up edgeMaterial accumulation on the cutting edge of the insert due to adhesion and welding.
You need to measure the wear width and depth of the insert with a caliper or a micrometer, and compare them with the maximum allowable values for the material and the operation. You can use the following table as a reference:
MaterialOperationMaximum flank wear width (mm)Maximum crater wear depth (mm)
Steel (P)Face milling0.30.15
Steel (P)Shoulder milling0.250.1
Steel (P)Slotting0.20.05
Stainless steel (M)Face milling0.250.1
Stainless steel (M)Shoulder milling0.20.05
Stainless steel (M)Slotting0.150.03
Cast iron (K)Face milling0.40.2
Cast iron (K)Shoulder milling0.30.15
Cast iron (K)Slotting0.250.1
Hard materials (H)Face milling0.150.05
Hard materials (H)Shoulder milling0.10.03
Hard materials (H)Slotting0.050.01
Non-ferrous metals (N)Face milling0.30.15
Non-ferrous metals (N)Shoulder milling0.250.20.1
Non-ferrous metals (N)Slotting0.150.05
Superalloys (S)Face milling0.20.1
Superalloys (S)Shoulder milling0.150.1
Superalloys (S)Slotting0.050.03
Titanium (T)Face milling0.150.05
Titanium (T)Shoulder milling0.10.05
Titanium (T)Slotting0.030.01
If the wear width or depth exceeds the maximum values, you need to replace the insert with a new one. You can also use a wear indicator tool to measure the wear more accurately.
Cleaning and storing the inserts and tools
You need to clean and store the inserts and tools properly after each use. You need to remove the chips and dust from the insert and the tool holder with a brush or an air jet. You need to avoid using any solvents or abrasives that might damage the coating or the substrate of the insert. You need to store the inserts and tools in a dry and cool place, away from moisture, heat, and corrosion. You need to use the original packaging or a suitable container to protect the inserts and tools from physical damage or contamination.
Replacing the inserts and disposing of the used ones
You need to replace the inserts and dispose of the used ones in a safe and responsible manner. You need to use a torque wrench and a screwdriver to loosen the screw and remove the insert from the tool holder. You need to wear gloves and eye protection when handling the inserts, as they may be hot, sharp, or contaminated. You need to place the used inserts in a separate bin or bag, and label them as hazardous waste. You need to follow the local regulations and guidelines for disposing of the used inserts, or contact your supplier for recycling options.
Where to buy APKT1604PDSR-30?
If you are interested in buying APKT1604PDSR-30, you have several options to choose from. Here are some of them:
Online sources and suppliers of APKT1604PDSR-30
One of the easiest and fastest ways to buy APKT1604PDSR-30 is to order it online from various sources and suppliers. You can browse through different websites and catalogs, compare prices and features, read reviews and ratings, and place your order with a few clicks. Some of the online sources and suppliers of APKT1604PDSR-30 are:
[ISCAR]: This is the official website of ISCAR, the manufacturer of APKT1604PDSR-30. You can find detailed information about the insert, its features, specifications, grades, geometries, applications, and more. You can also use their online tools, such as e-catalogs, product selectors, machining calculators, technical guides, etc., to help you choose the right insert for your needs. You can also contact their customer service or sales representatives for any inquiries or orders.
[Amazon]: This is one of the largest online marketplaces in the world, where you can find almost anything you need, including APKT1604PDSR-30. You can search for the insert by its name or code, filter by price, rating, availability, etc., and read customer reviews and feedback. You can also benefit from their fast delivery, free shipping, easy returns, and customer support.
[eBay]: This is another popular online platform where you can buy and sell various items, including APKT1604PDSR-30. You can bid for the insert in an auction format, or buy it at a fixed price. You can also check the seller's reputation, feedback, location, etc., before making a purchase. You can also use their secure payment methods, buyer protection program, and customer service.
Offline sources and distributors of APKT1604PDSR-30
If you prefer to buy APKT1604PDSR-30 in person, you can also visit some offline sources and distributors near you. You can see and touch the insert yourself, ask questions and advice from experts, negotiate prices and discounts, etc. Some of the offline sources and distributors of APKT1604PDSR-30 are:
[MSC Industrial Supply]: This is one of the leading distributors of metalworking and maintenance products in North America. They have over 1.5 million products in stock, including APKT1604PDSR-30. They have more than 100 branches across the US and Canada, where you can visit their showrooms, talk to their sales associates, or pick up your order.
[Grainger]: This is another major supplier of industrial products and services in North America. They have over 1 million products available online and over 250 local branches, where you can find APKT1604PDSR-30 and other milling inserts. They also offer technical support, inventory management, and online ordering services.
[Local hardware stores]: You can also check your local hardware stores for APKT1604PDSR-30 and other cutting tools. You may find some good deals and discounts, as well as friendly and helpful staff. However, you may not find the exact insert you need, or the quality and variety may be limited.
Conclusion
APKT1604PDSR-30 is a milling insert that can handle a variety of materials and applications. It has a positive rake angle, a parallelogram shape, an AlTiN coating, and an M chipbreaker. It can perform face milling, shoulder milling, slotting, ramping, and helical interpolation with high accuracy and efficiency. To use it properly, you need to choose the right grade and cutting speed, set up the milling machine and tool holder, adjust the cutting parameters and feed rate, check the insert condition and wear patterns, clean and store the inserts and tools, replace the inserts and dispose of the used ones, and buy the inserts from reliable sources and suppliers. By following these steps and guidelines, you can get the best performance and quality from APKT1604PDSR-30.
FAQs
Here are some frequently asked questions about APKT1604PDSR-30:
Q: What is the difference between APKT1604PDSR-30 and APKT1604PDR-76?
A: The main difference is in the geometry code. The PDR-76 has a left-hand cutting direction, a 0.76 mm corner radius, and an F chipbreaker. The F chipbreaker is suitable for fine machining conditions and provides excellent surface finish and chip control.
Q: How many inserts can I use on a 90-degree milling cutter with a 22 mm diameter?
A: You can use two inserts on each side of the milling cutter, for a total of four inserts.
Q: How can I prevent built-up edge on APKT1604PDSR-30?
A: You can prevent built-up edge by using a sufficient amount of coolant, increasing the cutting speed, reducing the feed rate, or using a sharper insert geometry.
Q: How can I improve the surface finish with APKT1604PDSR-30?
A: You can improve the surface finish by using a smaller corner radius, reducing the depth of cut, increasing the feed rate, or using a finer insert geometry.
Q: How can I extend the tool life of APKT1604PDSR-30?
A: You can extend the tool life by using a lower cutting speed, increasing the depth of cut, reducing the feed rate, or using a tougher insert grade.
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