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Description
Indexable end mill Ø40 mm – 90° end mill for APKT 1604 inserts
Technical data and dimensions – Varel BAP 400R, 32 mm straight shank
| Technical data | |
|---|---|
| Cutter diameter D | 40 mm |
| Shank diameter d | 32 mm, plain straight shank |
| Max. depth of cut a | 16 mm |
| Length to shank L1 | 60 mm |
| Overall length L | 200 mm |
| Entering angle | 90 degrees |
| Number of inserts Z | 3 |
| Inserts | APKT 1604 and APMT 1604, e.g., APKT 160408 |
| Coolant supply | external |
| Insert screw | M4x9, Torx T15 |
| Manufacturer | Varel (BAP 400R C32-40-200) |
Diameter40 mm
Depth of cutup to 16 mm
Inserts3 × APKT 1604
Coolant supplyexternally
Indexable end mill Ø40 mm The Varel BAP 400R cuts at a 90° angle with three APKT 1604 inserts. It machines square shoulders, slots, pockets and faces in steel, cast iron and aluminum. It also enters solid material by helical interpolation and produces holes from 61 to 78 mm without a drill. When an edge becomes dull, index the insert and continue milling.
The 32 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 200 mm length provides access deep into the workpiece. With a long overhang, the end mill deflects more, so reduce the depth of cut and feed rate. The body has no coolant channel. Supply coolant or compressed air through the machine nozzles, directing the stream onto the inserts.
Six operations with a 90° end mill – from a flat surface to a hole
Face milling, shoulder milling, slotting, ramping, helical interpolation, plunge milling
The 90° end mill for APKT 1604 and APMT 1604 inserts performs face milling, 90° shoulder milling, slotting, plunge milling, helical interpolation, and contour milling. Each operation uses a different insert edge. The 16 mm long side edge forms the wall. The bottom edge smooths the floor and allows downward cutting. The drawings show cutter movement and the material removed.
Face milling
Feed the end mill across the workpiece at a shallow depth of cut. The bottom insert edge, with a short chamfer near the corner, smooths the surface. A single pass removes a strip up to approximately 27 mm wide, or about two-thirds of the diameter. This is sufficient for 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 16 mm of wall height. A 0.8 mm radius remains at the corner between the wall and floor, matching the insert corner radius.
40 mm wide slot
The end mill travels through solid material and cuts a 40 mm wide slot in a single pass. The full front of the cutter is engaged, and all three inserts cut in turn. 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, descending with each revolution. This produces a flat-bottom hole from 61 to 78 mm. Set the hole diameter in the machine program rather than by selecting a drill. This also provides smooth entry into a closed pocket.
Plunge milling
The end mill plunges axially downward, retracts, and steps sideways, much like a drill. Each plunge removes material only near the cutter periphery. Keep the stepover to approximately 9.4 mm: this is how far the insert extends inward from the periphery. The cutting force then acts mainly along the axis.
A hole without a drill – helical milling
Minimum and maximum hole diameters for a 40 mm end mill with a 0.8 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 40 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 gray disc at the cutter center is the area without cutting edges. The side view shows the cutter center path and pitch, which is the downward travel per revolution.
Minimum hole diameter: 61 mm
The bottom insert edge extends approximately 9.54 mm inward from the cutter periphery. It therefore ends approximately 10.46 mm from the cutter axis (20 − 9.54 mm). A disc approximately 20.9 mm in diameter without cutting edges remains at the cutter center. To remove all material there, the cutter center must follow a circle with a radius of at least 10.46 mm. Minimum hole diameter = 40 + 2 × 10.46 ≈ 61 mm. In a smaller hole, a core remains beneath the cutter and strikes the body.
Maximum flat-bottom hole diameter: 78 mm
The bottom is flat when the hole center lies beneath the straight section of the insert's bottom edge. This section ends at the corner, 0.8 mm short of the cutter circumference. Maximum hole diameter = 2 × 40 − 2 × 0.8 ≈ 78 mm. Make a larger hole in two steps: first use helical interpolation up to 78 mm, then enlarge it with circular passes.
Calculation: helical pitch for a 70 mm hole
Calculate the pitch along the cutter center path, not from the hole diameter. Path diameter = hole diameter 70 mm − cutter diameter 40 mm = 30 mm. One revolution covers a distance of 3.14 × 30 ≈ 94.2 mm. At a ramp angle of 2°, the pitch is 94.2 × 0.035 (tangent of 2°) ≈ 3.3 mm. A through hole in a 20 mm plate therefore requires approximately 6 revolutions. The pitch must not exceed 16 mm, which is the maximum insert depth of cut.
The shank diameter is 32 mm, which is 8 mm smaller than the cutter diameter, leaving 4 mm clearance on each side. The shank does not rub against the hole walls, and chips have room to escape. Hole depth is therefore limited by tool overhang from the holder and rigidity, rather than the 60 mm length up to the shank.
▲
Axial entry only into a predrilled hole
The approximately 20.9 mm area at the cutter center has no cutting edges. Plunging straight down into solid material causes the core to bear against the body and overload the inserts. Enter solid material by ramping or helical interpolation. Axial entry is possible only into a previously drilled hole on the same axis, with a diameter of at least 21 mm.
APKT 160408 inserts – material selection and replacement
The insert grade determines material suitability; the end mill remains the same
The BAP 400R C32-40-200 end mill accepts APKT 1604 inserts in accordance with ISO 1832. The letter A denotes a 85° parallelogram, in practice a rectangular insert. P denotes a 11° clearance angle: the insert has positive geometry and cuts freely. The number 16 indicates the cutting edge length in millimeters, and 04 the insert thickness. The final digits 08 indicate a 0.8 mm corner radius.
The catalog specifies APMT 1604 inserts for this end mill. An APKT insert of the same size has the same shape and differs only in tolerance class: K is more precise than M. Both fit the same insert pocket.
| Insert | Workpiece material | Notes |
|---|---|---|
| APKT 160408 PDER XM H6310 Horn | steel, stainless steel | PVD coating |
| APKT 1604 PDER K10 Horn | aluminum, nonferrous metals, gray cast iron | grade K10 |
| APKT 160408 CBN Horn | hardened steel | finishing, one cutting edge |
Horn is a Korean insert brand available in our store. Select the insert grade for the workpiece material; the end mill remains the same.
Replacing and indexing the insert
The insert has two cutting edges. When one becomes dull, loosen the M4x9 screw with a Torx T15 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 all inserts together so they cut at the same height. The CBN insert has only one cutting edge – replace the insert with a new one when it becomes dull.
Cutting data – starting values for APKT inserts
Speed, feed per tooth, and depth by material group
The table provides conservative starting values for milling a 90° shoulder with APKT inserts. Start at the lower limit and increase the values while monitoring chips and spindle operation. Reduce the feed rate for slotting, ramping and helical interpolation. Use CBN inserts dry and only for finishing – coolant causes edge chipping.
| 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 | 12–28 |
| M Stainless steel | 70–130 | 0.06–0.15 | 0.5–2.0 | 10–24 |
| K Cast iron | 150–280 | 0.10–0.25 | 1.0–5.0 | 16–28 |
| N Aluminum (K10 insert) | 300–600 | 0.10–0.25 | 1.0–6.0 | 16–28 |
| H Hardened steel 50–57 HRC (CBN insert) | 100–170 | 0.04–0.08 | up to 0.5 | up to 0.2 |
Spindle speed and feed rate calculation – steel, 150 m/min
Spindle speed = 1000 × cutting speed 150 m/min ÷ (3.14 × cutter diameter 40 mm) ≈ 1190 rpm. Feed rate = feed per tooth 0.10 mm × 3 inserts × 1190 rpm ≈ 360 mm/min. Enter these two values in the machine program. In aluminum, at 400 m/min, spindle speed increases to approx. 3180 rpm – check that the spindle can reach this speed.
Indexable end mill Ø40 mm The Varel BAP 400R replaces a cutter for 90° shoulders, slots and faces, as well as a cutter for holes. Helical interpolation produces flat-bottom holes from 61 to 78 mm. It uses three APKT 160408 inserts and has a 32 mm straight shank and external coolant. The maximum depth of cut is 16 mm.
Questions about the BAP 400R C32-40-200 indexable end mill
Inserts, tool holder, coolant
ISO APKT 1604 and APMT 1604 inserts, e.g., APKT 160408 with a 0.8 mm corner radius. Grade H6310 from the Korean brand Horn is suitable for steel and stainless steel, K10 for aluminum and cast iron, and a CBN insert for hardened steel. The insert is secured with an M4x9 screw with a Torx T15 recess.
A collet chuck with a 32 mm collet or a hydraulic chuck for a 32 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 inserts. The stream should clear chips from the pocket and hole. The BAP series catalog does not list a version with a coolant channel.
Product accessories
Carbide insert APKT 160408 PDER XM H6310 Horn
Reference: 10358 In stock > 10 items
€4.08
€5.02 brutto
Carbide insert APKT 1604 PDER K10 Horn
Reference: 0000012671 In stock > 10 items
€5.53
€6.80 brutto
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| Courier GLS | Cash on delivery | 17,26 zł gross | Lead time 1 working day |
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