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Description
Indexable end mill Ø10 mm – 90° cutter for CCMT 0602 inserts
Technical data and dimensions – Varel AJU, 10 mm straight shank
| Technical data | |
|---|---|
| Cutter diameter D | 10 mm |
| Shank diameter d | 10 mm, plain straight shank |
| Max. depth of cut a | 6 mm |
| Length to shank L1 | 25 mm |
| Overall length L | 120 mm |
| Entering angle | 90 degrees |
| Number of inserts Z | 1 |
| Inserts | CCMT 0602, e.g., CCMT 060204 |
| Axial plunging | yes, the insert extends past the centerline |
| Coolant supply | external |
| Insert screw | M2.5x6, Torx T8 |
| Manufacturer | Varel (AJU C10-10-120) |
Diameter10 mm
Depth of cutup to 6 mm
Insert1 × CCMT 0602
Coolant supplyexternally
Indexable end mill Ø10 mm The Varel AJU cuts at a 90° angle with one CCMT 0602 insert. It machines square shoulders, slots, pockets and faces in steel and stainless steel. The catalog describes the AJU as a center-cutting end mill: the insert extends past the cutter centerline. The end mill can therefore plunge straight down into solid material at a low feed rate and produce holes up to 19 mm by helical interpolation. When the cutting edge becomes dull, index the insert and continue milling.
The 10 mm straight shank is smooth, without a flat. The catalog specifies a tolerance from −0.005 to −0.015 mm, making it suitable for a precision collet chuck or hydraulic chuck. The 120 mm length equals 12 cutter diameters. Extend the end mill from the holder only as far as the workpiece requires – at a diameter of 10 mm, every millimeter of overhang significantly increases deflection. The body has no coolant channel. Supply coolant or compressed air through the machine nozzles, directing the stream onto the insert.
Six operations with a 90° end mill – from a flat surface to a hole
Face milling, shoulder milling, slotting, ramping, helical interpolation, axial plunging
The 90° end mill with CCMT 0602 inserts performs face milling, 90° shoulder milling, slotting, ramping, helical interpolation and axial plunging. Each operation uses a different part of the insert. The side edge forms a shoulder up to 6 mm high. The corner with a 0.4 mm radius forms the floor. The bottom edge slopes away from the floor at 10° and cuts as the end mill feeds downward. The drawings show cutter movement and the material being removed.
Face milling
Move the end mill across the workpiece at a shallow depth of cut. The insert corner with a 0.4 mm radius forms the flat surface. The bottom edge slopes away from the surface at 10°, so it does not rub against it. A single pass removes a strip up to approx. 7 mm wide, or about two-thirds of the diameter. This is sufficient for small ledges, end faces and casting risers.
90° shoulder and contour
The side edge of the insert is parallel to the cutter axis, producing a wall perpendicular to the floor. A single pass can machine up to 6 mm of wall height. A 0.4 mm radius remains at the corner between the wall and floor, matching the insert corner radius.
10 mm wide slot
The end mill travels through solid material and cuts a 10 mm wide slot in a single pass. The full front of the cutter is engaged, and the single insert cuts at full engagement. Use a smaller depth of cut than for shoulder milling and ensure effective chip removal.
Ramping – angled entry
The end mill descends into the material along an inclined straight line while moving sideways. The bottom insert edge cuts downward, eliminating the need for a starter hole. This provides entry into a pocket or closed slot. At an angle of 3°, descending to a depth of 5 mm requires approximately 95 mm of travel.
Helical interpolation – a hole without a drill
The end mill follows a circular path and descends with each revolution. This enlarges the hole beyond 10 mm up to 19 mm. Set the hole diameter in the machine program rather than by selecting a drill size.
Axial plunging – 10 mm hole
The insert extends past the centerline, so it also cuts at the center of the end mill. The end mill plunges straight down into solid material and produces a 10 mm hole without predrilling. Set a low downward feed rate – only one insert cuts, and chips exit through the flute above it. Plunge no deeper than 6 mm per entry.
A hole without a drill – helical milling
Minimum and maximum hole diameters for a 10 mm end mill with a 0.4 mm insert corner radius
Helical milling is also known as helical interpolation. The end mill rotates about its own axis while the machine simultaneously moves it in a circle and downward. The path is shaped like a spring. A single 10 mm end mill can thus produce holes of various diameters.
The drawing shows the end mill in the smallest and largest holes, viewed from above. The insert extends past the cutter centerline, so there is no non-cutting zone at the center. The side view shows the path of the cutter center and the pitch, meaning the downward travel per revolution.
Minimum hole diameter: 10 mm
The insert is wider than the cutter radius: 6.35 mm versus 5 mm. Its bottom edge crosses the centerline and ends more than 1 mm beyond it. The end mill can therefore plunge directly into solid material, but only at a low feed rate. The minimum hole diameter equals the cutter diameter – 10 mm.
Maximum flat-bottom hole diameter: 19 mm
The CCMT insert is a 80° rhombus, while the shoulder must be machined at 90°. The bottom edge therefore slopes away from the floor at 10°, and only the corner leaves a flat bottom. In a 19 mm hole, the corner passes through the hole center, producing an entirely flat bottom. Maximum hole diameter = 2 × 10 − 2 × 0.4 ≈ 19 mm. In a smaller hole, a low cone less than 1 mm high remains at the center of the bottom. Make a larger hole in two steps: first use helical interpolation up to 19 mm, then enlarge it with circular passes.
Calculation: helical pitch for a 15 mm hole
Calculate the pitch along the cutter center path, not from the hole diameter. Path diameter = hole diameter 15 mm − cutter diameter 10 mm = 5 mm. One revolution covers a distance of 3.14 × 5 ≈ 15.7 mm. At a ramp angle of 2°, the pitch is 15.7 × 0.035 (tangent of 2°) ≈ 0.5 mm. A through hole in a 20 mm plate therefore requires approximately 40 revolutions. The pitch must not exceed 6 mm, which is the maximum insert depth of cut.
The shank has the same nominal diameter as the cutter, 10 mm. The catalog specifies a cutter tolerance from −0.03 to −0.08 mm and a shank tolerance from −0.005 to −0.015 mm, so the shank can be a few hundredths of a millimeter larger. In a hole deeper than 25 mm, designated L1, the shank will rub against the wall.
▲
Axial plunging – low feed rate
When plunging straight down, only the bottom edge of a single insert cuts. Set a lower downward feed rate than for side milling. Plunge no deeper than 6 mm per entry – this is the maximum depth of cut.
CCMT 060204 inserts – material selection and replacement
The insert grade determines material suitability; the end mill remains the same
The AJU C10-10-120 end mill accepts CCMT 0602 inserts in accordance with ISO 1832. The first letter C denotes a 80° rhombus. The second C denotes a 7° clearance angle: the insert has positive geometry, is single-sided and cuts freely. M denotes the medium tolerance class, and T denotes a hole with a recess for the screw head and a chip breaker on one side. The number 06 indicates an edge length of approx. 6.4 mm, 02 indicates a thickness of 2.38 mm, and the final digits 04 indicate a 0.4 mm corner radius.
| Insert | Workpiece material | Notes |
|---|---|---|
| CCMT 060204 H6310 Horn | steel, stainless steel | PVD coating, 0.4 mm corner radius |
| CCMT 060202 H6310 Horn | steel, stainless steel | 0.2 mm corner radius, light finishing |
Horn is a Korean insert brand available in our store. An insert with a 0.2 mm corner radius leaves a smaller radius at the shoulder corner, while a 0.4 mm corner radius provides greater strength. Select the insert grade for the workpiece material while keeping the same end mill.
Replacing and indexing the insert
The CCMT insert has four edges, two of which are cutting edges – at the acute 80° corners. When one becomes dull, loosen the M2.5x6 screw with a Torx T8 key and rotate the insert by 180°. Before installing it, clean chips from the insert seat – a chip beneath the insert lifts it and causes runout. The catalog does not specify a tightening torque – use the value from the insert manufacturer's data sheet. Replace the insert when both cutting edges become dull.
Cutting data – starting values for CCMT inserts
Speed, feed per tooth, and depth by material group
The table provides conservative starting values for milling a 90° shoulder. The end mill has a diameter of 10 mm and a length of 12 diameters, so start at the lower limits for feed rate and depth of cut. Increase them while monitoring chips and spindle operation. Reduce the feed rate for slotting, ramping and helical interpolation.
| Workpiece material | Cutting speed vc [m/min] | Feed per tooth fz [mm] | Depth ap [mm] | Width ae [mm] |
|---|---|---|---|---|
| P Structural and alloy steel | 130–200 | 0.10–0.20 | 1.0–4.0 | 3–7 |
| M Stainless steel | 70–130 | 0.06–0.15 | 0.5–2.0 | 2–6 |
Spindle speed and feed rate calculation – steel, 150 m/min
Spindle speed = 1000 × cutting speed 150 m/min ÷ (3.14 × cutter diameter 10 mm) ≈ 4770 rpm. Feed rate = feed per tooth 0.10 mm × 1 insert × 4770 rpm ≈ 480 mm/min. Enter these two values in the machine program. At a diameter of 10 mm, spindle speed is high even in steel – check that the spindle can reach it.
Indexable end mill Ø10 mm Varel AJU replaces cutters for 90° shoulders, slots and faces, as well as a cutter for holes. It plunges axially into solid material at a low feed rate and enlarges holes to 19 mm by helical interpolation. It uses one CCMT 060204 insert, has a 10 mm straight shank and uses external coolant. The maximum depth of cut is 6 mm.
Questions about the AJU C10-10-120 indexable end mill
Inserts, axial plunging, tool holder, coolant
ISO CCMT 0602 inserts, e.g., CCMT 060204 with a 0.4 mm corner radius. Grade H6310 from the Korean brand Horn is suitable for steel and stainless steel. The insert is secured with an M2.5x6 screw with a Torx T8 recess.
Yes – the insert extends past the cutter axis, so the cutter makes a 10 mm hole without predrilling. Set the plunge feed lower than the side milling feed and plunge no more than 6 mm per entry. A low cone, less than 1 mm high, remains at the center of the bottom.
A collet chuck with a 10 mm collet or a hydraulic chuck for a 10 mm shank. Both clamp the smooth shank around its entire circumference. Extend the end mill from the holder only as far as the machining depth requires.
Externally: use the machine nozzles to direct coolant or compressed air onto the insert. The stream should clear chips from the pocket and hole. The AJU series catalog does not list a version with a coolant channel.
Product accessories
Carbide insert CCMT 060202 H6310 Horn
Reference: 0000006504 In stock > 10 items
€3.16
€3.88 brutto
Carbide insert CCMT 060204 H6310 Horn
Reference: 0000005754 In stock > 10 items
€3.16
€3.88 brutto
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