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Description
Diameter100 mm
Depth of cutup to 16 mm
Inserts8 × APKT 1604
Coolant supplythrough the tool
Ø100 mm milling head – 90° for APKT 1604 inserts
Technical data and dimensions – Smoxh TK90 AP16, mounting bore 32 mm
| Technical data | |
|---|---|
| Head diameter D | 100 mm |
| Mounting bore d | 32 mm |
| Head height L | 50 mm |
| Max. depth of cut a | 16 mm |
| Entering angle | 90 degrees |
| Number of inserts Z | 8 |
| Inserts | APKT 1604, e.g., APKT 160408 |
| Coolant supply | internal (H) |
| Insert screw | M4x9.5, Torx T15, 3.0 N·m |
| Mounting screw | M16, 14 mm hex key |
| Manufacturer | Smoxh, Turkey (SM29217) |
Ø100 mm milling head Smoxh TK90 AP16 cuts at a 90° angle with eight APKT 1604 inserts. This milling head for metal face mills flat surfaces and mills square shoulders, slots, and pockets. It machines steel, stainless steel, and aluminum, and finishes hardened steel with a CBN insert. It removes up to 16 mm of material in one pass. The APKT 1604 insert has a 16.5 mm edge, so the head removes 6 mm more than TK90 AP10 heads. When an edge becomes dull, index the insert and continue machining.
This is an arbor-mounted milling head: instead of a shank, it has a 32 mm bore with a transverse slot. It fits onto a milling arbor, and the arbor's two drive keys engage the slot and transmit torque. An M16 screw clamps the milling head against the arbor face. Internal coolant, indicated by the letter H in the designation, flows through the arbor and screw to each of the 8 inserts.
APKT 1604 inserts – material selection and replacement
The insert grade determines the workpiece material; the milling head stays the same
The TK90 AP16 milling head accepts APKT 1604 inserts conforming to 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 corner radius of 0.8 mm.
The drawing shows top and side views of the APKT 160408 insert. The cutting edge is 16.5 mm long, and the insert is 9.54 mm wide and 4.76 mm thick. The long edge produces the shoulder wall, while the short edge at the corner smooths the floor. The 9.54 mm width also defines the area without cutting edges at the center of the milling head.
| Insert | Workpiece material | Notes |
|---|---|---|
| APKT 160408 PDER XM H6310 Horn | steel, stainless steel | PVD coating |
| APKT 1604 PDER K10 Horn | aluminum, nonferrous metals | grade K10 |
| APKT 160408 CBN Horn | hardened steel 50–57 HRC | dry finishing, one edge |
Horn is a Korean insert brand available in our store. Smoxh allows any ISO-compliant APKT 1604 insert in this milling head. To machine a different material, simply change the insert without replacing the milling head.
Replacing and indexing the insert
The drawing shows the milling head with two inserts removed from their pockets. Each insert is held by one M4x9.5 screw with a Torx T15 socket, threaded through the insert hole into the bottom of the pocket. Drawing numbers: 2 – milling head, 4 – insert, 5 – insert screw, 6 – Torx key.
The insert has two cutting edges. When one becomes dull, loosen the screw with a T15 key and rotate the insert by 180°. Before installation, remove chips from the pocket – a chip under the insert lifts it and causes runout. Tighten the screw to the 3.0 N·m torque specified by Smoxh. Replace all 8 inserts together so they cut at the same height. A CBN insert has only one edge – once it becomes dull, replace the insert with a new one.
Six operations with a 90° milling head
Face milling, shoulder milling, slotting, ramping, helical milling, plunge milling
Smoxh lists face milling, shoulder milling, slotting, plunge milling, and helical interpolation for milling heads using APKT 1604 inserts. Each operation uses a different insert edge. The side edge, 16 mm long, produces the wall. The bottom edge smooths the floor and allows downward cutting. The drawings show the milling head movement and the material removed.
Face milling
The milling head passes over the workpiece at a shallow depth of cut. The bottom insert edge with a short chamfer at the corner smooths the surface. One pass removes a strip up to approximately 70 mm wide, or 70 % of the diameter. This is how the milling head face mills end faces, ledges, and castings.
90° shoulder and contour
The side edge of the insert is parallel to the milling head axis. This produces a wall perpendicular to the floor. A shoulder height of up to 16 mm can be machined in one pass. A radius of 0.8 mm remains in the corner between the wall and floor, matching the insert corner radius.
100 mm wide slot
The head travels through the middle of the material and cuts a slot 100 mm wide in one pass. The full front of the head is engaged, with four inserts cutting at once. The forces change direction, so use a lower depth of cut and feed than for shoulder milling.
Ramping – angled entry
The milling head descends into the material along an inclined straight line while moving sideways. The bottom insert edge cuts downward, so a starter hole is not required. Smoxh does not specify a ramp angle – start with a small angle. At an angle of 1°, descending 3 mm requires approximately 172 mm of travel.
Helical interpolation – a hole without a drill
The milling head follows a circular path and descends with each revolution. This produces a flat-bottom hole from 181 to 198 mm in diameter. Set the hole diameter in the machine program. This also provides smooth entry into a closed pocket.
Plunge milling
The milling head plunges axially downward, retracts, and steps sideways. Each plunge removes material only at the periphery. Keep the lateral stepover to approximately 9.5 mm or less – this is how far the insert extends inward from the periphery. The force then acts mainly along the axis.
Helically milled hole: from 181 to 198 mm
The bottom insert edge extends approximately 9.54 mm inward from the milling head periphery. It therefore ends 40.46 mm from the axis (50 − 9.54 mm). A 80.9 mm circular area without cutting edges remains at the center of the face. Minimum hole diameter = 100 + 2 × 40.46 ≈ 181 mm – in a smaller hole, a core remains beneath the milling head. Maximum flat-bottom hole diameter = 2 × 100 − 2 × 0.8 ≈ 198 mm.
Calculation: helical pitch for a 190 mm hole
Calculate the pitch along the path of the head center, not from the hole diameter. Path diameter = hole diameter 190 mm − head diameter 100 mm = 90 mm. One revolution covers a distance of 3.14 × 90 ≈ 282.7 mm. At a ramp angle of 1°, the pitch is 282.7 × 0.0175 (tangent of 1°) ≈ 4.9 mm per revolution. The 1° angle is an example – Smoxh does not specify it. The pitch must not exceed 16 mm, the maximum depth of cut of the insert. For steel, the cutting data table specifies a depth of up to 4 mm, so a pitch of 4.9 mm is too large for this material. Reduce the angle to approx. 0.8° to bring the pitch down to 4 mm.
▲
The milling head cannot drill
The 80.9 mm circular area at the center of the face has no cutting edges. When plunging straight down into solid material, the core will contact the body and overload the inserts. Enter solid material by ramping or along a helical path. Axial entry is only possible over a hole at least 81 mm in diameter.
Cutting data – starting values for 8 inserts
Cutting speed, feed per tooth, spindle speed, and feed rate for a 100 mm milling head
The table provides conservative starting values for milling a 90° shoulder with APKT inserts. Spindle speed and feed rate are calculated for a diameter of 100 mm and 8 inserts. Start with these values and increase them while monitoring the chips and spindle operation. Reduce the feed when slotting, ramping, and helical milling. Use a CBN insert dry and for finishing only: turn off through-coolant, as the fluid causes edge chipping.
| Workpiece material | Insert | Cutting speed vc [m/min] | Feed per tooth fz [mm] | Spindle speed [rpm] | Feed rate [mm/min] | Max. depth of cut ap [mm] |
|---|---|---|---|---|---|---|
| P Structural and alloy steel | H6310 | 150 (130–200) | 0.10 (0.10–0.20) | 480 | 380 | 4 |
| M Stainless steel | H6310 | 90 (70–130) | 0.08 (0.06–0.15) | 290 | 180 | 2 |
| N Aluminum | K10 | 400 (300–600) | 0.10 (0.10–0.25) | 1270 | 1020 | 6 |
| H Hardened steel 50–57 HRC | CBN | 120 (100–170) | 0.04 (0.02–0.08) | 380 | 120 | 0.5 |
Spindle speed and feed rate calculation – steel, 150 m/min
Spindle speed = 1000 × cutting speed 150 m/min ÷ (3.14 × milling head diameter 100 mm) ≈ 480 rpm. Feed rate = feed per tooth 0.10 mm × 8 inserts × 480 rpm ≈ 380 mm/min. Enter these two values in the machine program. In aluminum, at 400 m/min, the spindle speed rises to approximately 1270 rpm.
Ø100 mm milling head Smoxh TK90 AP16 face mills and mills 90° shoulders, slots, and pockets in steel, stainless steel, aluminum, and hardened steel. It mills holes from 181 to 198 mm by helical interpolation. It uses eight APKT 160408 inserts, mounts on a face mill arbor with a 32 mm pilot, and has through-coolant. The maximum depth of cut is 16 mm.
Questions about the TK90 AP16 D100 milling head
Arbor, inserts, coolant, holes
A drive-key arbor with a 32 mm pilot and two 14 mm drive keys, such as SK40 conforming to DIN 69871-A (7369 40-32-60) or BT40 conforming to MAS 403-BT. The keys engage the transverse slot in the milling head and transmit torque. An M16 screw threaded into the arbor pilot clamps the milling head.
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 a CBN insert for hardened steel. Each insert is secured with an M4x9.5 screw with a Torx T15 recess, tightened to 3.0 N·m.
Coolant flows through the center of the arbor and the hole in the STV-C M16 mounting screw. From the chamber behind the screw, 8 channels direct it to each insert. The coolant system works when the spindle and arbor provide a through-coolant supply.
Approximately 181 mm. In a smaller hole, a core remains beneath the center of the face because the 80.9 mm circular area at the center of the milling head has no cutting edges. The largest flat-bottom hole produced in a single helical path is 198 mm in diameter.
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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