1. Proper Care and Setting of ULTRA-MILL  Cutters

2. January 25, 20042 Introduction ULTRA-MILL  ULTRA-MILL  ULTRA-MILL  cartridges with diamond tips are recommended for milling non-ferrous materials such as, aluminum, carbon, graphite, plastics, composites, etc. When used properly ULTRA-MILL  cartridges will increase productivity through higher spindle speed and feed rates and also by extending tool life, decreasing the number of tool changes and increasing machine utilization. Normal machining practices, including the use of proper speeds and feeds should be adhered to at all times

3. January 25, 20043 Recommended Speeds & Feeds

4. January 25, 20044 Setting Use the same care practiced with carbide tools when measuring or setting- up. This care should include optical measurements when possible, and the avoidance of any contact of the tool’s cutting edges with the hard surfaces of micrometer anvils, gage blocks and any other inspection or set-up equipment. Machine set-up, including “touching off” must be done with a soft material (plastic or paper, etc.) between the tool and touch off plate. The following pages document setting an ULTRA-MILL using the preferred method with an Optical Pre-setter or a Surface Plate with an Indicator.

5. January 25, 20045 Storage When storing ULTRA-MILL  cutter with cartridges, cover the cartridges with the supplied boot. When storing cartridges, place them in their original containers. This will prevent the tools from contact with each other or any hard surfaces that could result in damaging the cutting edges.

6. January 25, 20046 Set-up Procedures Before installing new cartridges, check pockets and cartridges are clean and free of burrs.

7. January 25, 20047 Set-up Procedures Clean and stone bottom of cutter to eliminate burrs or dirt. Set cutter on surface plate or setting fixture.

8. January 25, 20048 Set-up Procedures Turn hex nuts down one full turn (CLW).

9. January 25, 20049 Set-up Procedures Install cartridges in body with 10-24 Button Head screws and snug (15-20 inch/pounds) with Torx wrench. Use Grade 8 or better screws as supplied by sp3.

10. January 25, 200410 Optical Set-up Procedures Set pre-setter to desired Set Height.

11. January 25, 200411 Contact Set-up Procedures Set dial indicator to desired Set Height. Requires indicator with.0001” resolution.

12. January 25, 200412 Optical Set-up Procedures Using ¼” wrench turn hex nut (CCLW) to adjust cartridges to.001” below Set Height.

13. January 25, 200413 Contact Set-up Procedures Using ¼” wrench turn hex nut (CCLW) to adjust cartridges to.001” below Set Height.

14. January 25, 200414 Optical Set-up Procedures Tighten Button Head screws to 45 inch/pounds +/- 2 in./lbs Torque Wrench Required

15. January 25, 200415 Contact Set-up Procedures Tighten Button Head screws to 45 inch/pounds +/- 2 in./lbs Torque Wrench Required

16. January 25, 200416 Optical Set-up Procedures Using ¼” wrench turn hex nut (CCLW) to adjust cartridges to proper Set Height. For best results all cutting edges should be within +\-.0001”. The closer the cutting edges are set the better the workpiece finish.

17. January 25, 200417 Contact Set-up Procedures Using ¼” wrench turn hex nut (CCLW) to adjust cartridges to proper Set Height. For best results all cutting edges should be within +\-.0001”. The closer the cutting edges are set the better the workpiece finish.

18. January 25, 200418 Set-up Procedures Verify all Button Head screws are set to the proper torque. Torque Wrench Required

19. January 25, 200419 is not responsible for any defects caused by improper use or setting of the ULTRA-MILL . Care should be taken when handling aluminum body cutters. Although the outside is very hard, it can be damaged from rough handling. Also PCD and TFd tipped cartridges have precision ground edges that can be damaged, so extreme caution should be taken when handling and setting. Proper handling and setting will result in best possible finishes and longest life. Please call 888-547-4156 with any questions regarding the use and care of ULTRA-MILL  components.