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3-Flute DLC Coated Carbide End Mill| DuraEdge3 Alu

Kortools

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Ø1x3x4Dx50L

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Ø14x70x14Dx150L

Ø16x80x16Dx150L

Ø18x80x18Dx150L

Ø20x75x20Dx150L

Ø6x50x6Dx200L

Ø8x60x8Dx200L

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Ø12x70x12Dx200L

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Product description

DuraEdge3 Alu · 3-flute DLC-coated solid carbide end mill

For milling aluminium, aluminium alloys, zinc alloys and copper

DuraEdge3 Alu is a monolithic solid carbide end mill with three flutes and a DLC coating. Its flat end, helical cutting edges and U-shaped chip flutes form a tool for milling slots, pockets, flat surfaces and contours. It is intended for use on machining centres and CNC milling machines.

Select the size by cutting diameter, flute length, shank diameter and overall length. The four values in the size designation identify the particular version. Cutting diameter is not necessarily equal to shank diameter, and overall length does not mean the length of the cutting section.

1. Applications and milling operations

Operation	Tool application
Slot milling	Producing straight slots, keyways and U-shaped slots. Choose the cutting diameter for the width and geometry of the slot.
Pocket milling	Machining flat-bottomed pockets. Account for flute length and access of both the tool and holder to the pocket walls.
Side milling and contouring	Machining walls, steps and part outlines. The tool dimensions in the program should match the selected size.
Milling flat surfaces	Machining flat surfaces with a flat-end tool. Select cutting conditions for the material, workholding and type of pass.

The geometry is intended for the non-ferrous metals listed in the materials section. For slots and pockets, account for chip evacuation from the cutting area. The entry method and cutting conditions depend on the specific operation.

2. Construction and specifications

Parameter	Value
Tool type	Monolithic, flat-end shank milling cutter
Tool material	VHM — solid carbide
Number of flutes	3
Coating	DLC
Chip flute geometry	U-shaped design
Helix angle	45°
Shank type	Cylindrical
Cutting diameter	Ø1–20 mm, depending on size
Flute length	3–90 mm, depending on size
Shank diameter	Ø3–20 mm, depending on size
Overall length	50, 60, 75, 100, 150 or 200 mm, depending on size

These ranges describe the DuraEdge3 Alu family. Not every diameter is offered with every length and shank diameter. Check the exact combination in the selected size designation and its dimension card.

3. DLC coating and chip evacuation

The DLC coating reduces friction and the tendency of the machined metal to adhere to the tool surface. It is used on this geometry for machining aluminium and the other specified non-ferrous metals. Its performance also depends on the material, cutting load and machining conditions.

The U-shaped chip flutes support chip evacuation from the cutting zone. When planning an operation, also account for the space available for chips in the slot or pocket; tool geometry alone does not replace effective chip removal from the workpiece.

Surface quality and burr formation depend on the whole process. Relevant factors include alloy grade, cutting-edge condition, clamping stability and cutting conditions. Coating and geometry support tool performance, but do not establish a fixed tool life for every application.

4. Workpiece materials

Material	Application selection
Aluminium and aluminium alloys	The main application group for DuraEdge3 Alu. Select cutting conditions for the specific alloy and planned operation.
Zinc alloys	A material group within the tool application range. Account for alloy composition, part geometry and workholding.
Copper	A material within the tool application range. Select conditions for the workpiece material and required surface quality.

The Alu designation identifies the main application in aluminium. When considering another material, specify its exact grade and the operation; a DLC coating alone does not establish suitability for every material group.

5. How to read the size designation

Example: Ø6x18x6Dx50L. This identifies a cutting diameter of 6 mm, a flute length of 18 mm, a shank diameter of 6 mm and an overall length of 50 mm. All dimensions are in millimetres.

Designation element	Meaning	Value in the example
Ø6	Cutting diameter	6 mm
18	Flute length — cutting section	18 mm
6D	Cylindrical shank diameter	6 mm
50L	Overall tool length	50 mm

The order is the same throughout the family. D after a number identifies shank diameter, while L identifies overall length. Fractional sizes in the designation can use a decimal point: 1.5 means 1.5 mm.

Flute length and overall length are different dimensions. The value followed by L includes the whole tool, including the shank. It is not the permissible cutting depth or the tool overhang after mounting in the holder.

6. Choosing dimensions for the job

Select the cutting diameter. Compare it with the slot width, internal pocket radii or machined contour. This is the first value in the size designation.
Check flute length. The second value describes the cutting section. Consider it separately from overall length and the intended tool extension.
Match the shank to the holder. For example, an Ø3 cutting diameter can be paired with an Ø3 or Ø4 shank. Choose the holder and collet for the value followed by D, rather than cutting diameter alone.
Select the required overall length. Check access to the machining area and the position of the holder relative to the part and fixture. A longer version may also have a different flute length.
Compare all four values. The size designation, dimension card and tool data in the program should agree on cutting diameter, flute length, shank diameter and overall length.

The photograph on each dimension card is illustrative. Select the size from the stated dimensions, not from the proportions of the photograph. This is particularly relevant to short and long versions with the same cutting diameter.

7. Preparing the machining operation

Before running the program, check that the tool matches the selected size and that the shank is correctly clamped. Account for actual overhang, holder geometry and access within the part. Program data should correspond to the tool as mounted.

The tool can be used for dry machining of aluminium under suitable process conditions. Decide on cooling or lubrication for the specific alloy and operation, taking chip evacuation into account. The DLC designation alone does not determine the cooling method.

Selecting spindle speed, feed and depth of cut requires the material, cutting diameter, flute length, overhang and operation to be considered. Full-slot milling, side milling and surface finishing may need different conditions. An overall length of 150 or 200 mm does not mean that the same cutting load can be used as with a short version.

8. Frequently asked questions

How many flutes does DuraEdge3 Alu have?
It has three flutes. The tool is made from solid carbide, also designated VHM, and has a DLC coating.

Does an Ø3 cutter always have an Ø3 shank?
No. Shank diameter is the value followed by D. Check it separately from cutting diameter when selecting the tool.

Does 200L mean a flute length of 200 mm?
No. It means an overall tool length of 200 mm. Flute length is the second dimension in the designation and is shown separately on the card.

Is the DLC coating enough to select cutting conditions?
No. Material data, tool dimensions, actual overhang and the type of operation are also required. The coating is one of the tool characteristics.

How should I select a size when the photographs look similar?
Compare the complete designation: cutting Ø × flute length × D × L. The card gives the dimensions of the particular size, while the photograph illustrates the tool construction.