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Since its establishment in 1929, Tungaloy has been successfully developing and marketing superior grades for machining all types of materials, including CBN, Cermet, PCD, Ceramics and fine carbide grades with CVD and PVD coatings. Tungaloy is one of 4th largest CBN producer in the world.
A combination of cemented carbide, coating and post coating treatment produces a carbide grade. Only one of these components, the cemented carbide, is the necessary element of the grade, the others are optional. Cemented carbide is a composite material, comprising hard carbide particles that are cemented by a binding metal (usually cobalt).
A majority of cemented carbide inserts commercially available today are coated by a wear resistant coating, known as “coated cemented carbides”. There are also various surface treatment processes that may be applied to the rake face of the cemented carbide after the coating process. “Cemented carbide” may refer to both the substrate of a coated grade and an uncoated grade.
PremiumTec refers to a specific post-coating treatment process developed by Tungaloy. This surface treatment technology enhances the uniformity of the coated surfaces, while eliminating the by-products created during the coating process, which negatively affect the insert performance and shortens insert life. PremiumTec removes the inner tensile stresses created in the CVD coating due to the difference in thermal expansion coefficients between the substrate and coating layer. Droplets generated on the PVD coated insert surface can also be removed.
Application of PremiumTec, post surface treatment technologies considerably eliminates these unwanted defects, while increasing tool life and productivity.
PVD coatings were introduced during the late 1980s. With the use of advanced nano-technology, PVD coatings performed a gigantic step in overcoming complex problems that were impeding progress in the field.
Developments in science and technology brought a new class of wear-resistant nano layered coatings. These coatings are a combination of layers having a thickness of up to 50 nm (nanometers) and demonstrate significant increases in the strength of the coating compared to conventional methods.
Our premium grade for steel is Tungaloy’s CVD coated grade, T9215 for Accelerated Machining (high speed & high feed).
Tungaloy offers the T series chipbreakers (-TF, -TSF, -TM and -TH) for finishing, semi-finishing, medium and rough turning of steel. And the P series chipbreakers (-PF, -PSF and -PM) on our positive inserts for finishing, semi-finishing and medium turning for steel.
These chipbreakers, combined with Tungaloy’s PremiumTec treatment technology, delivers higher productivity, longer tool life, improved workpiece quality and more reliable performance. The chipbreakers generate less heat and prevent chips from welding on the cutting tools and components. Chips are broken down into smaller pieces to prevent them from tangling around the workpiece, facilitating more efficient removal from conveyor belts.
Cermet grades, such as NS9530 and GT9530 are some of the solutions for mirror-finish surface on steel.
In many turning applications, machinists tend to use inserts that are larger than actually required for the machining parameters being applied.
Tungaloy presents ISO-EcoTurn, the small sized insert series, which provide an economical advantage regarding cost per cutting edge.
Reduces about 40% in volume of insert and 20% in cost without reducing cutting conditions.
Select a Right hand anvil for a Right hand toolholder and a Left hand anvil for a Left hand toolholder.
Absolutely all popular grades, chipbreakers and geometries are available in the ISO-EcoTurn line.
CBN inserts are mainly used for machining hard materials in a hardness range from 55 to 62 RC. Conventional CBN inserts offer a wide range of brazed and flat tips that produce long and curled chips during the machining of hardened steel. Long chips can scratch the workpiece and damage the surface quality. Tungaloy offers a range of T-CBN inserts with chipbreakers that are ground on the CBN cutting edge to provide excellent chip control in medium to finishing applications with high surface quality. Tungaloy also offers Wiper technology on T-CBN inserts, which provides a superior surface roughness at a higher feed rate.
Please use StreamJetBar, carbide type boring bars. StreamJetBar reduces chattering and improves chip control in boring with a high overhang. BoreMeister, a boring bar with an anti-chatter mechanism, is also available.
The main advantage of premium CVD grades is the ability to work two to three times faster in cutting speed, from 100 m/min (330SFM) and up to 300 m/min (980SFM) , which is three times higher than any conventional carbide inserts. This dramatically increases productivity.
Tungaloy offers 3 new chipbreakers: -SF for finishing, -SM for medium and -SH for rough turning of stainless steel. All of which, together with the most advanced PremiumTec treatment technology, provide higher productivity, tool life and performance reliability. All 3 chipbreakers are also available in the ISO-EcoTurn line.
In addition, Tungaloy’s new chipbreakers: -HRF for finishing and -HRM for medium turning difficult-to-cut alloys, together with AlTiN PVD premium grades, provide Accelerated Machining at a high speed and feed.
The main advantages of high pressure coolant is the ability to improve chip control, reduce heat and extend insert life. Tungaloy’s TungTurn-Jet tool system is designed to supply the coolant directly into the cutting zone significantly maximizing productivity.
The high pressure coolant tooling is effective in machining sticky, gummy materials such as super alloys, stainless steel, titanium, and more.
The maximum LxD ratio for a steel shank is 3x, for a carbide shank it is 5x, and for BoreMeister, a boring bar with an anti-chatter mechanism, it is 10x.
See our latest General Catalog for recommended torques for all screw sizes.
Tungaloy offers several options for general grooving applications: the TungCut and TetraForce-Cut series offer a wide variety of grooving inserts for various widths and depths. The TetraMiniCut series is an economical solution for small widths and depths grooving close to the shoulder.
EasyMulti-Cut is the most efficient tool for deep face grooving operations offering improved productivity, excellent chip control and evacuation with adjustable blade system.
TetraForce-Cut and TetraMini-Cut are the most economical solutions which uses inserts with 4 cutting edges. Ground insert clamps into unique insert pocket and provides high rigidity as well as repeatability and economy.
For heavy duty grooving applications use Tungaloy’s TungHeavyGroove which features a unique dovetail structure to prevent insert movement during operations. Inserts are available in a width range of 10 – 25 mm (0.394″- 0.984″).
The first choice grade is AH7025, effective for a variety of applications. If you need good wear resistance in turning and grooving, use T9125. If you need a tougher grade with more impact resistance (Interrupted cuts), use GH130.
Use AH905 to machine high temperature alloys.
Use our secure clamping system “DuoJust-Cut”, which provides both front and back access to the insert screw, facilitating easier tool preparations in Swiss-type machines (as opposed to the conventional top clamping).
For bore diameters: 2 – 10 mm, use TinyMini-Turn inserts and toolholders.
TinyMini-Turn offers coolant through supply and precision cutting edges with a chip breaker for high productivity and surface quality.
Use the minimum possible overhang.
Work with a constant RPM.
Reduce the RPM if needed.
Reduce the insert width in order to decrease the cutting force.
TungTurn-Jet and Direct-TungJet tools are recommended for all coolant pressure levels 10 – 340 Bar (145 psi to 4930 psi) and all applications, as they deliver a repetitive and reliable coolant supply directly to the cutting edge at the exact point where it is needed, improving tool life and chip control. In addition, DirectJet does not require any extra coolant subassembly.
You can use TungModular system which can use same shanks of toolholders for different blades and inserts .
Thread milling produces threads with the circular ramping movement of a rotating tool.
The lateral movement of the tool in one revolution creates the thread pitch.
Tungaloy offers indexable ThreadMilling tools in multi-tooth design for high productivity, single-tooth for deep holes, and also solid carbide tools.
Interrupted cuts offer good chip control in long-chipping materials.
Lower cutting forces make it possible to thread in long overhangs and thin-walled components.
There is a risk of tap breakage on expensive parts; a thread mill can always be removed from the component completely.
Partial profile inserts do not cut the minor diameter (do not make calibration) while full profile inserts cut the minor diameter.
Performs complete thread profiling.
Recommended for mass production.
Suitable for a single profile only.
Root corner radius is only suitable for the relevant pitch.
One insert covers a wide range of pitches.
The partial profile insert has a smaller nose radius compared to the full profile inserts. This results in a weaker thread and a shorter tool life.
Additional operations to complete the outer/internal diameter is necessary.
Not recommended for mass production.
Flank infeed has better chip control and surface finish in most raw materials and applications.
Anvils for positive inclination angle are applicable when turning RH thread with RH holders or LH thread with LH tool holders.
Anvils for negative inclination are used when turning RH thread with LH holder or LH thread with RH tool holder.
Use AE Anvils for EX-RH and IN-LH Tool holders.
Use Al Anvils for IN-RH and EX-LH Tool holders.
Yes, it is possible. Remember: Lead = Pitch Multiplied by the No. of Starts.
When the depth of cut is too small, the chipbreaker becomes ineffective. Find the appropriate DOC in Tungaloy’s catalog for the insert currently in use and apply.
Select the correct infeed type:
Alternating flank infeed
TetraMini-Cut or DuoJust-Cut can thread the workpiece all the way closest to the flange wall without any interference.
The maximum LxD ratio for a steel shank is 2x, for a carbide reinforced steel shank (or “Tsuppari-ichibantype”) and carbide shank it is 3x.
Yes, it is possible by changing the anvil and infeed method.
DoTwistBall, TungForce-Rec, Tung-Tri, DoForce-Rec, DoTriple-Mill are our major product families for Accelerated Machining.
Generally, this term relates to the rake angles of an indexable milling cutter. Engineering ingenuity and advancement in powder metallurgy have resulted in the production of helical cutting edge inserts with a rake face that is “aggressively” inclined with respect to the insert cutting edge. This causes a significant increase in the positive rake angles (normal and axial) of a cutter carrying the inserts. The term “high positive” emphasizes this feature. Note: This definition reflects current, state of the art processes. As the production of tools with cemented carbide inserts does not deplete its own resources, we may assume that “high positive” of today will be considered as “normal” tomorrow.
Tungaloy offers electronic and printed catalogues that contain a description of the grade constituents (substrate and coating types), the range of cutting speeds and application ranges in accordance with ISO standards. Contact Tungaloy representatives in your region for details and assistance.
Most of the TungForce milling cutters introduced recently feature an inner channel for coolant supply to each insert directly through the cutter body.
It should be noted that the question has no definite answer and depends on several factors. However, in general, under the same MRR, increasing the feed coupled with reduced depth of cut is more favorable than the opposite combination (lesser feed with deeper cut) because this typically provides greater tool life.
If you know the application parameters, Tungaloy’s Tung-Navi , a computer aided search engine, can be a very effective tool. This free software can be accessed online or by downloading the Dr. Carbide App to any handheld device. If you require futher assistance with your tooling selection please contact a Tungaloy representative.
Use water soluble cutting fluid and decrease the cutting speed by 20%.
n = (Vc x 1000)/(3.14 x D), Vf = fz x Z x n,
For imperial stds:
n=SFM x 3.28 / D, Vf=Fz x Z x n.
Yes, ever since its first launch back in 1990, Tungaloy has successfully brought to market a wide variety of indexable milling cutters for High Feed applications. Our most popular indexable products for High Feed milling include DoFeed, DoFeedQuad, MillQuadFeed, MillFeed, as well as TungMeister tools and solid carbide end mills.
The most effective applications for High Feed machining are rough milling planes, pockets and cavities.
Although the depth of cut is limited to less than 2.5 mm, the extreme feed makes it a highly productive milling method.
Yes, DoFeedQuad and MillQuadFeed are ideal solutions for medium to heavy face milling of steel, cast iron, stainless steel, and heat resistant alloy.
DoFeed, MillFeed, MillQuadFeed
– MillQuadFeed has helical cutting edge inserts with a rake face that is “aggressively” inclined with respect to the insert cutting edge. Cutters have excellent chip flow thanks to the large gullets .
– DoFeed has been the go to product in many Aerospace companies for smaller diameters.
Tungaloy offers innovative and economical solutions for Slot Milling under the SlotMill Series :
TungMini-Slit – Slotting cutter ideal for thin slitting as well as cutting off.
TungThin-Slit, TungUniversal-Slot – Economical insert with 6 cutting corners.
TecTangential-Slot – Robust, tangential, 4 cutting edged insert.
Tungaloy’s SlotMill series covers widths from 1.6mm (0.063”) up to 25mm (1.00”) in standard tools and inserts.
The Slot Milling cutters differ in their mounting methods. They have either an arbor hole or shank type configuration.
SlotMill cutters have teeth on its face and periphery, and features a cutting face and sides for the simultaneous machining of the three surfaces: the bottom and the two sidewalls of the slot.
Side and face milling cutters can handle long, deep, open slots in a more efficient manner, and provide the best stability and productivity for this type of milling.
Down-milling. Make sure to use a firm stop in the direction of the tangential cutting forces to prevent them from forcing the workpiece down against the table.
The feed direction corresponds with the cutting forces, which means that rigidity and eliminating backlash are also important, since the cutter has a tendency to climb.
One TungMeister shank can carry heads with different profiles. These exchangeable heads drastically reduce tool change time.
TungMeister is a high-tech substitute for HSS and solid carbide milling cutters, ensures a reduction in tool disposal and allows for flexible combinations for various application needs.
The exchangeable head is simply screwed onto the dedicated shank.
During mounting, the head is screwed in by hand and then tightened with a wrench.
The head has two contact surfaces, which determine the heads location in the shank. The tapered surface ensures high concentricity, while the flange face surface secures the heads radial accuracy.
Tungaloy offers a wide range of TungMeister heads:
End milling heads of various shapes – 90°, 45°, 60° and more.
Profile milling heads, ball nose, toroidal, concave radii and others.
Heads for high-feed milling;
Slot and groove milling heads for milling grooves for retaining or O-rings, T-slot and more.
Thread milling heads; and
Center and spot drilling heads.
The accuracy of the end mill heads have the following tolerance limits: e8 tolerance for multi flute heads that are produced from blanks and h9 tolerance for economy type heads.
The precision heads for finish profiling are made with tolerance limits for diameter h7 and the heads for milling aluminum, h6.
The diametric tolerance for the cylindrical cutting area of the heads for chamfering, spot drilling, and countersinking is h10.
No , do not apply lubricants to the TungMeister S-thread connection.
One of the main advantages of the face contact is high repeatability, which ensures a close tolerance for the head overhang with respect to the contact face of a shank. The overhang limits are ±0.02 mm (0.0008″ ) for the majority of the end milling heads.
Face milling is the most common milling operation and can be performed using a wide range of different tools.
Cutters with a 45º entering angle are most frequently used, but round insert cutters, feed mill cutters, square shoulder cutters and side and face mills are also used for certain conditions.
Reduce vibrations on long overhangs due equal distribution of cutting forces in vertical and Horizontal directions.
Chip thinning effect allows increased productivity.
– Strongest cutting edge.
– Especially suitable for heat-resistant alloys.
– Smooth cutting action.
DoOcto / DoQuad
Excellent surface finishes can be achieved with standard inserts in combination with one or more wiper inserts. Wiper inserts work most efficiently at a high feed per revolution, in larger diameter cutters with extra close pitch and adjustable mechanism.
Yes, all our main lines have wiper inserts for better surface quality.
Tungaloy offers the NMS cutter range for finishing operations. This cutter is capable of providing a sub-micron quality of surface finish so that it can even make an excellent replacement for some of the grinding operations.
During shoulder milling operations, the cutter generates two faces simultaneously, which requires peripheral milling in combination with face milling.
Achieving a true, 90º degree shoulder is one of the most important requirements.
The Tung-Tri line with economical, super positive, triangular Inserts with 3 cutting edges for 90° shouldering.
DoForceTri shoulder milling cutters with double-sided triangular inserts with 6 cutting edges.
– TungTriShred line with triangular shred inserts with 3 cutting edges
– DoRec line with tough, double sided inserts with 4 edges
– TecMill line with tangential clamped insert with 4 edges
– TungRec and TungQuad lines for smaller diameters with 2 and 4 cutting edge respectively
Tungaloy produces all types of cutters; bore type, shank type, extended flute, modular, solid carbide and multi-functional.
Yes, TungForce-Rec provides outstanding cutting performance, exceeding the ability of solid carbide endmills in machining small pockets and slots.
Tungaloy’s first choice is the Tung-Tri line with a super positive rake face design for low cutting resistance plus helical cutting edges for smooth cutting and excellent wall straightness.
For more deeper shouldering use extended flute, and see extended flute section in FAQ.
Extended flute cutters are also known as “porcupine” or “long-edge” cutters, also called COB cutters.
The cutting length of an extended flute cutter consists of a set of indexable inserts that are placed gradually with a mutual offset of one another.
Extended flute cutters are generally used for milling deeper shoulders and trimming operations.
Tungaloy’s extended flute cutters are suitable for cost-effective machining.
Tungaloy’s extended flute mills use splitter inserts to improve performance during roughing operations and reduce power consumption.
Yes. The TungTri-Shred line uses triangular shred inserts with 3 symmetrical cutting edges.
Wave shredded cutting edge splits the chips, reduces vibration and cutting forces in heavy machining.
Yes. There are solutions that ensure this type of machining.
TungTri’s economical 3 cutting edged wiper inserts with helical cutting edges are well-balanced, designed especially for semi-finish milling.
The TungTri-Shred line uses inserts with a straight, high positive cutting edge for finishing and semi-finishing applications.
Tungaloy’s TecMill line for roughing with tangential clamped insert with 4 edges.
Yes, a modular extended flute cutter in the Tung-Tri line offers a smart connection for milling length flexibility.
The various cutting tool material grades and geometries available allow the tools to be optimally matched to the respective application.
AH3135 for steel and stainless steel
AH120 and T1215 for cast iron
KS05F for non ferrous materials
Profile milling is multi-axis milling of convex and concave shapes in two and three dimensions.
The primary industry using profile milling is Die and Mold followed by the Aerospace industry. In addition, almost every industry requires profile milling tools in a varying degree.
Round indexable inserts and ball nose end mills in solid carbide tools or indexable type tools.
When using a ball nose end mill, the most critical area of the cutting edge is the tool center, where the cutting speed is close to zero, which is unfavorable for the cutting process.
Chip evacuation at the tool center is critical, due to the narrow space at the chisel edge.
We recommend tilting the spindle or the workpiece 10 to 15 degrees, which moves the cutting zone away from the tool center.
The minimum cutting speed will be higher.
Improved tool life and chip formation.
Better surface finish.
Tungaloy’s DoTwistBall line with twisted, high positive angled inserts which fit into a unique pocket shape ensuring high stability and accuracy of insert positioning.
An additional advantage is the 120º edge which allows ramp down operations on all 4 cutting edges.
– Solid Carbide Ball Nose Endmills
– TungMeister ball nose heads
Yes, Tungaloy has been producing gear milling solutions for many years.
Tungaloy’s SlotMill series covers widths from 1.6 mm up to 25 mm in standard tools and inserts.
The module ranges available for gear milling cutters are
|Roughing||M10 – M32||M6.5 – M60|
|Finishing||M5 – M25||M5 – M20|
Our finishing cutter can guarantee “CLASS 7～8 DIN” (ANSI 1-2) accuracy.
– Solid carbide small diameter drills from 0.1mm up to 3 mm (0.004″ up to 0.118″); L/D = 5-15
– Solid carbide drills with and without coolant from 3 mm up to 20 mm (0.118″ up to 0.781″); L/D=2-8
– Drillmeister – indexable head drill from D6 mm up to 25.9 mm (0.236″ up to 1.020″) ; L/D = 5 -10
– TungDrillTwisted indexable insert drills from 12.5 mm up to 54 mm (0.5″ up to 2.125″); L/D = 2 – 5
– TungSixDrill indexable insert drills from 20 mm up to 54 mm (0.812″ up to 2.00″); L/D = 2 – 4
– TungDrillBig series, Body, L/D=2.5, dia=55 – 80mm (2.25″ up to 3.157″), diameter adjustable with setting plates. The same inserts can be used for TungDrillTwisted and TungSixDrill.
This depends on the diameter. For example, the minimal flow rate for a 6 mm (0.236″) DrillMeister is 5 liters per minute (1.32GPM); for a 20 mm (0.787″) use 18 liters per minute (4.75GPM)
This depends on the diameter and tool length. For example, the minimal pressure for a 6 mm (0.236″) DrillMeister on 8xD is 12 bar (174psi); for 25 mm (1.00″) DrillMeister on 12xD is 4.5 bar (65 psi)
With a stable set-up, the deviation may vary from 0.03 (0.001″) mm to 0.2 mm (0.008″) for each 100 mm (4″) of drilling depth. Important: Achieved results may vary due to tool length, machine, fixture, adaptation, etc.
No, the DrillMeister family is not designed for boring operations. The tool and insert may fail.
The recommended adapter is the one that is most suited for the tool’s shank. For example, if the shank is round, the most accurate adapter would be the HYDRO type.
The exit for the materials should not be more than 2-3 mm (0.08 – 0.118″) than the diameter edge of the insert.
Normally it is not necessary. Pre-drill a pilot hole only when the length-to-diameter ratio is 8 or above.
Yes. In this case, the maximum drilling depth will be 3xD. Lower the feed rate by 20%.
It is possible, only if the pilot hole is smaller than 1/4 of the final working diameter.
TungSix-Drill is the world’s leading indexable drill with 6 cutting edges.
Stronger central cutting edge due the obtuse angle relief
Economical 6 cornered drilling inserts for cost reduction
Stable cutting even with highly interrupted machining
Yes, TungSix-Drill provides a similar chip shape compared to positive type inserts due to its higher rake angles.
Use DS chip breaker for stainless and low carbon steel.
Yes, DeepTri-Drill is a high productivity, indexable deep drilling line.
Standard gundrill sizes are for drilling depths: 10xD, 15xD, and 25xD. A longer gundrill up to 2.5 meters or 8 feet is also available on request.
Unique triangular insert with splitters. Splitting the chips is essential for chip evacuation suitable for most workpiece materials.
An accurate diameter of IT10 is assured throughout the hole due to 2 guiding pads, which also assures high straightness and excellent surface finish.
Yes, all types of DeepTri-Drill inserts and some pads can also be mounted on BTA heads and gundrills.
Yes, but check Tungaloy’s General Catalog for the recommended coolant pressure and amount.