1. Power Milling
With Greenleaf ®

2. Power Milling With Greenleaf ®
Heavy Milling Cutters
Powermill
Special Milling Cutters
Heavy Milling
Rail Milling
Crankshaft Milling
Camshaft Milling
Cutter Repair
Carbide Milling Grades
CVD PVD
GA G-910 G-9120
GA G-915
GA G-935
GA G-955

3. The basics of Milling with Greenleaf ® Milling cutters.

4. Milling 101 Hand of Cutters Right Hand Cutters Rotate Clockwise
Left Hand Cutters Rotate
Counter-Clockwise

5. Select Correct Cutter Diameter
Milling 101
Select Correct Cutter Diameter
1.5 Times Work Piece Width
WOC = 2/3 Cutter Diameter
Watch Machine Horsepower

6. Milling 101 Lead Angle Thins the Chip Uses Less Horsepower
Improved Tool Life

7. Lead Angles and Cutting Forces
Milling 101
Lead Angles and Cutting Forces
Less Force Into Part
More Force on Spindle
Less Force on Spindle
More Force Into Part

8. Lead Angle Effect on Chip Thickness
Milling 101
Lead Angle Effect on Chip Thickness
At 0° B = A
At 45° B = 70% of A

9. Milling 101 Cutter Pitch Coarse Pitch : Fine Pitch :
Better Chip Evacuation
Heavier IPT (MM/tooth)
Larger DOC
Fine Pitch :
More Teeth Engaged
Heavier IPM (MM/min)
Lighter DOC
A good guide is diameter (inches) + 2

10. Cutter Geometry Radial Rake
Milling 101
Cutter Geometry Radial Rake
Impacts Edge strength
Affects Cutting Forces

11. Cutter Geometry Axial Rake
Milling 101
Cutter Geometry Axial Rake
Directs Chip Flow
Caution with Fixturing

12. Cutter Geometry Negative vs. Positive
Milling 101
Cutter Geometry Negative vs. Positive
Strongest Geometry
Higher Feed Possible
Maximum Insert Usage
Higher Cutting Forces
Lower Cutting Forces
Better Chip Evacuation
Lower HP Consumption
Weaker Geometry

13. Cutter Geometry Double Negative
Milling 101
Cutter Geometry Double Negative
Negative Axial & Negative Radial
Advantages :
Strongest Shape
Cast Iron
Best Economy
Disadvantages :
Part/Machine Rigidity
Highest Forces
Chip Flow into Part

14. Cutter Geometry Double Positive
Milling 101
Cutter Geometry Double Positive
Positive Axial & Positive Radial
Advantages :
Milling Aluminum
Work Hardening Materials
Low HP
Disadvantages :
Fragile Cutting Edge
Pulling Forces
Not for Hardened Materials

15. Cutter Geometry Negative / Positive
Milling 101
Cutter Geometry Negative / Positive
Negative Radial & Positive Axial
Advantages :
Best General Purpose
Most Materials
Excellent Chip Ejection
Balanced Cutting Forces
Disadvantages :
Fewer Cutting Edges than Negative

16. Negative / Positive Best of Both Worlds
Milling 101
Negative / Positive Best of Both Worlds
Capable of Heavy Duty Milling
Works Best With Lead Angle Cutters
Powermill & High Shear Cutters

17. Do Not Exceed 2/3 of Edge Length (L)
Milling 101
Depth of Cut
Do Not Exceed 2/3 of Edge Length (L)

18. Milling Techniques Conventional (Up) Milling
Counteract Table Feed Backlash
Poor Chip Formation – Creates Heat
Work Hardening
Poor Insert Life - Flank Wear

19. Milling Techniques Climb (Down) Milling
Good Tool Life
Inserts must Survive Shock of Entry
Good Chip Formation
Watch Table Backlash!

20. Milling Techniques Cutter Positioning
Can Cause Vibration
Cutter On Center

21. Milling Techniques Cutter Positioning
Helps Eliminate Vibration
Climb Mill If Possible
Keep 2 Teeth in Cut
1/4 - 1/3 Cutter Overhang
Slightly Off Center

22. Milling Techniques Angle of Entry
Positive Angle of Entry
Contact at Weak Section of Insert
Poor Impact Resistance
E2 > 90°

23. Milling Techniques Angle of Entry
Negative Angle of Entry
Contact at Strong Section of Insert
Best Impact Resistance
E1 < 90°

24. Milling Techniques Angle of Entry

25. Milling Through Interruptions
Use a Lead Angle Cutter
Use a Strong Carbide Grade
Use Medium to Fine Pitch Cutter
Use Lighter Feed Rate

26. Milling Techniques Surface Finish
Radii Leave “Tracks”
Radius Size Determines Finish

27. Milling Techniques Surface Finish
Milling Inserts Have Flats
“Wiping Effect” Improves Finish

28. Milling 101 Common Terms English Metric Surface Feet Per Min.
Revolutions Per Min.
Number Of Teeth
Feed Per Tooth
Feed Per Revolution
Feed Per Minute 
SFM
RPM T
FPT (IPT)
FPR (IPR)
IPM
3.1416
Surface Meters Per Min.
Revolutions Per Minute
Number Of Teeth
Feed Per Tooth
Feed Per Revolution
Feed Per Minute 
M/Min
RPM Z
FPT
(MM/Tooth)
FPR (MM/Rev)
MM/Min
3.1416

29. Milling 101
Select a cutter that is 1.5 times work piece width where possible.
Select a cutter with Negative radial/Positive axial geometry in most cases.
Select a cutter with a fairly course pitch for most materials.
Use a cutter with a lead angle to reduce cutting forces.
Climb (down) mill where possible.
Position the cutter with a negative angle of entry with 1/4th - 1/3rd overhang condition.
Do not exceed 2/3rd cutting edge length on your depth of cut.

30. Questions?

31. Powermill®

32. Powermill® When should you consider a Powermill®?
When removing forging scale in heavy-duty cutting with severe interruptions and uneven surfaces is required.
When large DOC and high MRR are crucial for productivity.
When versatility and durability is required.
When cost is a consideration.
When horsepower is a concern, the LNES sinusoidal insert can be used to reduce HP consumption by approximately 30%.

33. Powermill® M402LN-A: 2° Lead, Neg-Neg
Diameter range: 4” (100MM)-12” (315 MM)”
M400LNP-A: 0° Lead, Neg-Pos
Diameter range: 4” (100MM)-12” (315 MM)”
M430LNP-A: 30° Lead, Neg-Pos
C430LNP-H: 30° Lead, Neg-Pos (Heavy Duty)
C430LNP-W: 30° Lead, Neg-Pos (Finishing)
Diameter range: 4” (100MM)-12” (315 MM)” 33

34. Note: Tune up kit available
Powermill®
M402LN-A: 2° Lead, Neg-Neg
Negative Radial, Negative Axial
Diameter Range: 4” (100MM) – 12” (315 MM)
Max. DOC Range: .68” (17.3MM) ” (26.9MM)
Advantages :
Strongest Shape
Cast Iron
Best Economy
LNES insert for lower HP machines.
Disadvantages :
Part/Machine Rigidity
Highest Forces
Chip Flow into Part
Note: Tune up kit available 34

35. Note: Tune up kit available
Powermill®
M400LNP-A: 0° Lead, Neg-Pos
Negative Radial & Positive Axial
Diameter Range: 4” (100MM) - 12” (315 MM)
Max. DOC Range: .68” (17.3MM) – 1.06” (26.9MM)
Advantages :
Best General Purpose
Most Materials
Excellent Chip Ejection
Balanced Cutting Forces
Disadvantages :
Fewer Cutting Edges than Negative
Note: Tune up kit available 35

36. Powermill® M430LNP-A: 30° Lead, Neg-Pos
C430LNP-H: 30° Lead, Neg-Pos (Heavy Duty)
C430LNP-W: 30° Lead, Neg-Pos (Finishing)
Diameter range: 4” (100MM)-12” (315 MM)
Max. DOC Range: .50” (12.7MM) - .88” (22.3MM)
Advantages :
Best General Purpose
Most Materials
Excellent Chip Ejection
Balanced Cutting Forces
Chip thinning
Disadvantages :
Fewer Cutting Edges than Negative
Lower maximum depth of cut than 0° lead cutter
Note: Tune up kit available 36

37. Powermill® 37 Hardened Anvils and Back-up Plates Protect Cutter Body
Maintain Accuracy R/C
Front Wedge Design
Maximum Security & Insert Rigidity
Hard Faced for Durability
Interchangeable Components
Multiple Applications
2o & 30o Anvils fit Left and Right Hand Cutters 37

38. Powermill® 38

39. Powermill®
Inserts
Approximately equal width and thickness adds strength needed to handle large depths of cut and heavy interrupted cuts.
Insert design allows for high strength while using minimal carbide to reduce cost.
Performance with high metal removal rates.
Productive Greenleaf carbide grades. 39

40. Powermill® Inserts Insert Cutter LNE-335 LNE-335F LNE-34.57 LNE-34.57F
2° lead Neg-Neg
LNES-335
LNES-34.57
2° lead Neg-Neg
LNP-335R/L LNP R/L
LNP-34.57R/L LNP R/L
LNP RW/LW
0° lead Neg-Pos
30° lead Neg-Pos
YCE
30° lead Neg-Pos
Finishing 40

41. Powermill®
Test Data 41

42. Powermill®
Test Data
Powermill ® Milling Cutter - M430LNP12A
Material BHN Steel Forging
Cutter dia (301.1 mm)
Grade – G-955
Speed SFM (122 M/Min)
Feed (0.33 mm) per Tooth
WOC (203.2 mm)
DOC (10.2 mm)
MRR Cu In / Min (2000 cu cm/min)
Required HP - 153
Resulted in an order for (4) 12” cutters and a blanket order for 23,000 inserts 42

43. Powermill®
Test Data
Prior – Competitor Button Cutter
Material – Alloy Steel unknown hardness
Cutter dia. – 8.0 (203 mm)
Insert/Grade – RNMA-84 SF30
Speed SFM (112 M/Min)
Feed (0.45 mm) per Insert
.0134 (.34 mm) ACT
WOC – 5.25 (134.1 mm)
DOC (7.62 mm) Maximum
MRR - 40 Cu In / Min (655 cu cm/min)
Required HP - 50
Powermill Milling Cutter - C430LNP10H
Material – Alloy Steel unknown hardness
Cutter dia (254 mm)
Insert/Grade – LNP-44.57R GA-5036
Speed SFM (165 M/Min)
Feed (0.28 mm) per Insert
WOC – 6.5 (165.1 mm)
DOC (15.2 mm)
MRR - 90 Cu In / Min (1475 cu cm/min)
Required HP - 112
3X increase in speed and 2X increase in DOC with 225% increase in MRR resulted in order 43

44. Powermill®
Test Data 44

45. Powermill® Beware of Required Horsepower Required HP - 93
Powermill ® Milling Cutter - M430LNP04A
Material – P BHN
Cutter dia. – 4.0” (102 mm)
Speed – 400 SFM (122 M/Min)
Feed ” (0.51 mm)/Insert
WOC – 3” (203.2 mm)
DOC - .50” (12.7 mm)
MRR – 46.5 Cu In / Min (762 Cu Cm/Min)
Powermill ® Milling Cutter - M430LNP12A
Material – P BHN
Cutter dia. – 12” (305 mm)
Speed – 400 SFM (122 M/Min)
Feed ” (0.51 mm)/Insert
WOC – 9” (203.2 mm)
DOC - .50” (12.7 mm)
MRR – 140 Cu In / Min (2285 Cu Cm/Min)
Required HP - 93
Required HP - 279

46. Powermill®
Powermill ® cutters have the versatility to get the job done.
Powermill ® cutters are standard and most are in stock.
Productive carbide grades available for many materials.
Capable of very high metal removal rates.
DOC range from .50 max to 1.06 max depending on cutter and hardware.
Be sure to calculate horsepower and ensure the machine has the capability to run the cutter.
Consider the Powermill ® before going to a special cutter.

47. Questions?

48. Special Milling Cutters

49. Special Milling Cutters
Advantages
Custom built milling cutters optimized for the application at hand.
If the application permits, most cutters can be designed for high speed milling and high metal removal rates.
Most cutters are designed with replaceable hardened components.
Productive carbide grades available for most applications.
Tune up kits available
In event of a major crash, we can re-work Greenleaf ® special cutters to as new condition.

50. Special Milling Cutters
Test
Data

51. Special Milling Cutters
24” (610mm) Dia.
30o Lead High Shear Mill
High Speed Milling with grades
GA-5125, G-9120 51

52. Special Milling Cutters MRR–107 Cu In/Min (1180 Cu Cm/ Min
24” (610mm) Dia.
30o Lead High Shear Mill
Special Milling Cutter
Material BHN Steel Forging
Cutter dia. - 24” (301.1 mm)
Insert – GA-5125
Speed SFM (127 M/Min)
Feed ” (0.19 mm) per Insert
WOC - 18” (203.2 mm)
DOC - .50” (12.7 mm)
MRR–107 Cu In/Min (1180 Cu Cm/ Min
Required HP - 133

53. Special Milling Cutters MRR-144 Cu In/Min (2360 Cu Cm/Min)
24” (610mm) Dia.
30o Lead High Shear Mill
Special Milling Cutter
Material BHN Steel Forging
Cutter dia. - 24” (301.1 mm)
Insert – G-9120
Speed SFM (127 M/Min)
Feed ” (0.26 mm) per Insert
WOC - 18” (457.2 mm)
DOC - .50” (12.7 mm)
MRR-144 Cu In/Min (2360 Cu Cm/Min)
Required HP - 180
35% increase in feed equated to a 35% increase in MRR over GA-5125 with 30 minute time savings per block!

54. Special Milling Cutters
12” (305MM) Dia.
30o Lead High Shear Mill
High Speed Milling with grade G-955

55. Special Milling Cutters MRR - 122 Cu In / Min (2000 Cu Cm/Min)
12” (305MM) Dia.
30o Lead High Shear Mill
High Speed Milling with grade G-955
Special Milling Cutter
Material BHN Steel Forging
Cutter dia (301.1 mm)
Insert G-955
Speed SFM (122 M/Min)
Feed (0.33 mm) per Insert
WOC (203.2 mm)
DOC (10.2 mm)
MRR Cu In / Min (2000 Cu Cm/Min)
Required HP - 153

56. Special Milling Cutters
6” (152.4MM) Dia.
90o Lead High Shear Mill
High Speed Milling with grade G-935

57. Special Milling Cutters MRR - 29 Cu In / Min (475 Cu Cm/Min)
6” (152.4MM) Dia.
90o Lead High Shear Mill
High Speed Milling with grade G-935
Special Milling Cutter
Material Steel 350 BHN
Cutter dia. - 6” (301.1 mm)
Insert – TPEN-53P12R G-935
Speed SFM (145 M/Min)
Feed ” (0.10 mm) per Insert
WOC - 4.5” (114 mm)
DOC - .50” (12.7 mm)
MRR - 29 Cu In / Min (475 Cu Cm/Min)
Required HP - 36

58. Special Milling Cutters Special Switch Point Rail Milling Cutter
9.0” (228 MM) Dia.
Special Switch Point Rail Milling Cutter
High Speed Milling with grade GA-5125

59. Special Milling Cutters
9.0” (228 MM) Dia.
Special Switch Point Rail Milling Cutter
High Speed Milling with grade GA-5125
Special Milling Cutter
Material - Manganese Steel 400 BHN
Cutter dia. – 9.0” (229 mm)
Insert – RPGN-84 GA-5125
SPGN-643 GA-5125
Speed SFM (152.5 M/Min)
Feed ” (0.32 mm) per Insert
WOC – .75” (19 mm)
DOC - Varies
LOC – 39 Feet (11.9 Meter)
See customer testimonial

60. Special Milling Cutters A page from the customers
justification report
Several grades of carbide from three
different manufacturers, Ingersoll,
AGI / VR Wesson and Greenleaf ® have
been run in these tools trying to improve
performance. The best performance
achieved was from Greenleaf with their
GA-5125 grade carbide inserts
In almost every case where a catastrophic
Insert failure has occurred, we were able to
replace the wedges, wedge screws and
or back-up plates, and have the tool back
in service in less than a couple of hours.

61. Special Milling Cutters
Another page from the
customers justification
report.

62. Special Milling Cutters Special Rail Milling Cutter
9.5” (241 MM) Dia.
Special Rail Milling Cutter
High Speed Milling with grade GA-5125

63. Special Milling Cutters Special Rail Milling Cutter
9.5” (241 MM) Dia.
Special Rail Milling Cutter
High Speed Milling with grade GA-5125
Special Milling Cutter
Material - Manganese Steel 375 BHN
Cutter dia. – 9.5” (301.1 mm)
Insert – SNGN-643 GA-5125
GA-5125
GA-5125
Speed SFM (152.5 M/Min)
Feed ” (0.76 mm) per Insert
to obtain .018 (0.46 mm) ACT
WOC – 3.5” (89 mm)
DOC - .08” (2 mm)
Required HP - 48

64. Special Milling Cutters Special Flair Rail Milling Cutter
25 degree
Special Flair Rail Milling Cutter
Cutter uses 72 inserts!

65. Special Milling Cutters Special Flair Rail Milling Cutter
25 degree
Special Flair Rail Milling Cutter
50% increase in speed, 90% increase in feed. Resulted in order of more geometries!
Required HP - 143

66. Special Milling Cutters Examples of Tools for the Rail industry

67. Special Milling Cutters
Camshaft and Crankshaft Milling 67

68. Special Milling Cutters
Camshaft and Crankshaft Milling
Design
OD Segments
64” (1625 MM) diameter cutter 68

69. Special Milling Cutters
Camshaft and Crankshaft Milling
Design
(120) Inserts SNGN-643
(48) Inserts RNGN-84
12 segments per cutter
168 total inserts/load 69

70. Special Milling Cutters
Crankshaft Milling Cutter supplied by Greenleaf ®
Locomotive and Marine Diesel Engines
Power Generation
Automotive
(120) Inserts SNGN-643
(48) Inserts RNGN-84 70

71. Special Milling Cutters
Camshaft and Crankshaft Milling
Customers' existing
Cutter 71

72. Special Milling Cutters
Crankshaft Milling Cutter supplied by Greenleaf ®
Segments allow inexpensive repairs
Qualified mounting allows you to replace one segment or all
3.425 (87 MM) Width of Cut
22.44” (570 MM) I.D. 72

73. Special Milling Cutters 64 inserts total/cutter load
Camshaft and Crankshaft Milling
Design
ID Segments
8 Segments per cutter
64 inserts total/cutter load 73

74. Special Milling Cutters 72 Total Inserts, (24) Effective
Crankshaft Milling Cutter supplied by Greenleaf ®
Cam Shaft Mill
Cutter Dia: 16.0” (406.4 mm)
Cutting width: .81” (20.6 mm)
72 Total Inserts, (24) Effective 74

75. Special Milling Cutters Cam Shaft, 4140 Steel Forging
Insert Grade GA-5036
Original Tool Life:
Slotting Cutter:
18 parts per index
New Tool Life:
85 parts per index 75

76. Cutter Repair
We refurbish and repair damaged Greenleaf ® special Tooling.

77. Special Milling Cutters
Advantages
Custom built milling cutters optimized for the application at hand.
If the application permits, most cutters can be designed for high speed milling and high metal removal rates.
Most cutters are designed with replaceable hardened components.
Productive carbide grades available for most applications.
Tune up kits available
In event of a major crash, we can re-work Greenleaf ® special cutters to as new condition.

78. Questions?

79. Greenleaf ® Carbide Grades for Milling
Greenleaf ® Corporation is an industry pioneer in
coated carbide technology.
Selecting the best carbide grade for the application is critical to the success and productivity of any milling operation. 79

80. Greenleaf ® Carbide Grades for Milling
UNCOATED
G-53 General Purpose Milling
Steel and Steel Alloys
Good Toughness and Wear Resistance
High Shear, Powermill
G-53
G-60 Finish Milling Grade for Steels
Finish Wiper Inserts
Powermill
G-60 80

81. Greenleaf ® Carbide Grades for Milling
MT-CVD COATED
GA-5036 High Performance Steel Milling
Heavy or Light Duty at High Speed
Hushcut, High Shear, Powermill, Screw-on, Excelerator
GA-5125 High Performance Manganese Steel Milling Grade
High Speeds and Moderate Feeds
Special Applications 81

82. Greenleaf ® Carbide Grades for Milling
MT-CVD COATED
GA-5040 Tough Grade for Milling most Materials
Severe Applications, Low Speeds
Hushcut, High Shear, Powermill, Screw-on, Excelerator
GA-5023 High Performance Cast Iron Milling
Special Applications 82

83. Greenleaf ® Carbide Grades for Milling
PVD COATED
G-910 High Temp Alloys, Primarily Titanium at Moderate Speeds
High Shear
G-915 High Temps, Stainless & Carbon Steels
at Moderate Speeds Tough, Abrasion Resistant
Hushcut, High Shear, Screw-on, Excelerator
G-935 Tough, Higher Speed Steel Milling
Screw-on 83

84. Greenleaf ® Carbide Grades for Milling
PVD COATED
G-955 Rough Steel Forgings, tool steels.
Tough, High speed steel Milling
Special Applications
G-9120 Tough, Higher Speed Steel Milling
Rough Steel Forgings, tool steels
Improvement over G955 in most apps
Special Applications 84

85. Questions?

86. Thank You!