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Description
Indexable end mill Ø28 mm – 90° end mill for APKT 1604 inserts
Technical data and dimensions – Smoxh ST90 AP16, 25 mm Weldon shank
| Technical data | |
|---|---|
| Cutter diameter D | 28 mm |
| Shank diameter d | 25 mm, Weldon |
| Max. depth of cut a | 16 mm |
| Flute length l | 35 mm |
| Overall length L | 150 mm |
| Entering angle | 90 degrees |
| Number of inserts Z | 2 |
| Inserts | APKT 1604, e.g., APKT 160408 |
| Coolant supply | external |
| Insert screw | M4x9.5, Torx T15, 2.7 N·m |
| Manufacturer | Smoxh, Turkey (SM12967) |
Diameter28 mm
Depth of cutup to 16 mm
Inserts2 × APKT 1604
Coolant supplyexternally
Indexable end mill Ø28 mm The Smoxh ST90 AP16 cuts at a 90° angle with two 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 37 to 54 mm without a drill. When an edge becomes dull, index the insert and continue milling.
This is a shank-type end mill: the 25 mm Weldon shank has flats for the holder screw. The end mill does not rotate in the holder or pull out under load. With a length of 150 mm, extend the end mill from the holder only as far as the workpiece requires – every millimeter of overhang increases deflection. 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
Smoxh lists face milling, 90° shoulder milling, slotting, plunge milling, helical interpolation and contouring for APKT 1604 inserts. Each operation uses a different insert edge. The side edge, 16 mm long, forms the shoulder. The bottom edge smooths the floor and allows downward feeding. The drawings show cutter movement and the material being 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 19 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.
28 mm wide slot
The end mill travels through the material and cuts a 28 mm wide slot in a single pass. The full leading side of the cutter is engaged, and both inserts cut alternately. Use a smaller depth of cut than for shoulder milling and ensure effective chip evacuation.
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 37 to 54 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 28 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 28 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: 37 mm
The bottom insert edge extends approximately 9.54 mm inward from the cutter periphery. It therefore ends approximately 4.46 mm from the cutter axis (14 − 9.54 mm). A disc approximately 8.9 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 4.46 mm. Minimum hole diameter = 28 + 2 × 4.46 ≈ 37 mm. In a smaller hole, a core remains beneath the cutter and strikes the body.
Maximum flat-bottom hole diameter: 54 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 × 28 − 2 × 0.8 ≈ 54 mm. Make a larger hole in two steps: first use helical interpolation up to 54 mm, then enlarge it with circular passes.
Calculation: helical pitch for a 45 mm hole
Calculate the pitch along the cutter center path, not from the hole diameter. Path diameter = hole diameter 45 mm − cutter diameter 28 mm = 17 mm. One revolution covers a distance of 3.14 × 17 ≈ 53.4 mm. At a ramp angle of 2°, the pitch is 53.4 × 0.035 (tangent of 2°) ≈ 1.9 mm. A through hole in a 20 mm plate therefore requires approximately 11 revolutions. The pitch must not exceed 16 mm, which is the maximum insert depth of cut.
The shank is 25 mm in diameter, which is 3 mm smaller than the cutter, leaving 1.5 mm of clearance on each side. In a hole, the shank does not rub against the walls, and chips have room to escape. Hole depth is therefore limited by tool overhang and rigidity, rather than the 35 mm cutting section length.
▲
Axial entry only into a predrilled hole
The approximately 8.9 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 9 mm.
APKT 160408 inserts – material selection and replacement
The insert grade determines material suitability; the end mill remains the same
The ST90 AP16 D28 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.
| 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. Smoxh allows any ISO-compliant APKT 1604 insert in this end mill. To switch workpiece materials, simply change the insert without replacing the end mill.
Replacing and indexing the insert
The insert has two cutting edges. When one becomes dull, loosen the M4x9.5 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. Tighten the screw to the 2.7 N·m torque specified by Smoxh. 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 | 8–19 |
| M Stainless steel | 70–130 | 0.06–0.15 | 0.5–2.0 | 7–16 |
| K Cast iron | 150–280 | 0.10–0.25 | 1.0–5.0 | 11–19 |
| N Aluminum (K10 insert) | 300–600 | 0.10–0.25 | 1.0–6.0 | 11–19 |
| 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 28 mm) ≈ 1710 rpm. Feed rate = feed per tooth 0.10 mm × 2 inserts × 1710 rpm ≈ 340 mm/min. Enter these two values in the machine program. In aluminum, at 400 m/min, spindle speed increases to approx. 4550 rpm – check that the spindle can reach this speed.
Indexable end mill Ø28 mm The Smoxh ST90 AP16 replaces a cutter for 90° shoulders, slots and faces, as well as a cutter for holes. Helical interpolation produces flat-bottom holes from 37 to 54 mm. It uses two APKT 160408 inserts and has a 25 mm Weldon shank and external coolant. The maximum depth of cut is 16 mm.
Questions about the ST90 AP16 D28 indexable end mill
Inserts, tool holder, coolant
ISO APKT 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 M4x9.5 screw with a Torx T15 recess, tightened to 2.7 N·m.
A Weldon holder for a 25 mm shank. The holder's side screw presses against the shank flat – this system conforms to DIN 1835-B. The end mill does not rotate in the holder or pull out under load.
Externally: use the machine nozzles to direct coolant or compressed air onto the inserts. The stream should clear chips from the pocket and hole. Versions with through-tool coolant have the letter H in their designation.
Product accessories
Carbide insert APKT 160408 PDER FM H8320 Horn
Reference: 03503 In stock > 10 items
€5.26
€6.47 brutto
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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