High-Efficiency Facemill MFPN - Kyocera

High-Efficiency Facemill 

MFPN 

Low cutting force and excellent fracture resistance 

1 

Economical 

2 

New design 

3 

Toughness 

4 

New chipbreaker 

5 

New grades 

BIG 

5 

5Mill Mill 

BIG 

5 

5Mill Mill 

Five Advantages of BIG Pentagon 

Roughing and general-purpose facemill with 

10-cornered pentagonal inserts 

Low cutting force due to helical cutting-edge 

design 

Fractures suppressed by double-edge position 

Chip evacuation improved by 3-dimensional 

chipbreaker 

Long tool life with PR12-Series MEGACOAT 

carbide inserts

1 

1 

2 

3 

Wiper edge 

BIG 

5 

5Mill Mill 

Economical 

New design 

Toughness 

Pioneering a new era 

Roughing and general-purpose facemill with 

10-cornered pentagonal inserts 

ap (mm) Depth of cut 

12 

10 

8 

6 

5 

4 

3 

2 

0.5 

Two-face restraint 

Major 

cutting edge 

BI 

Low cutting force due to helical cutting-edge 

5 

design 

MSRS 

Conventional 

0.06 0.1 0.2 0.3 0.4 0.5 0.6 

fz (mm/t) Feed per tooth 

+10° 

(A.R.) 

Main cutting edge 

No. 1 


High feed machining substantially improves efficiency 

NEW 


■Pentagonal double-sided tip excellent for 

constraining stability 

■10-cornered insert cuts cost per corner 

■Helical cutting-edge design with low 

cutting force reduces chattering 

■Helical cutting-edge design 

·High rake angle (A.R. Max. +10°) 

0.7 

Cutting edge 

angle 45° 

BI 

Principal force 

Feed force 

Back force 5M 

Fractures suppressed with double-edge position 

■Double-edge position 

·Major cutting edge makes chips thin, 

thereby reducing impact load at entrance 

and exit of workpiece 

Double-edge position 

Five Advantages of BIG Pentagon 

Main cutting edge 

No. 2 

Cutting force comparison (N) 

2000 

1600 

1200 

800 

400 

●Cutting force comparison 

0 

Highly stabilized accuracy due to two-face 

constraint facing the major cutting edge 

16% reduction in comparison 

with competitor A 

14% reduction in 

comparison with GM 

GM SM 

Competitor A Competitor B 

●Cutting conditions 

Workpiece :S50C 

Vc=150m/min, fz=0.1mm/t, apxae=5x105 mm, Machine :M/C(BT50) 

●Fracture resistance comparison 

PNMU1205ANER-GM 

(PR1225) 

Competitor C 

(PVD negative insert) 

Competitor D 

(PVD negative insert) 

No. of impacts 

0 5 10 15 20 

× 

× 

× 

× 

× 

× 

fz=0.5mm/t fz=0.6mm/t fz=0.7mm/t 


Workpiece :SCM440(38~42HS) 

Machine :BT50 M/C 

Vc=100m/min, fz=0.5~0.7mm/t, 

apxae=2x100mm (workpiece with 20mm width slot) 

0.5mm/t 

0.6mm/t 

0.7mm/t 

:No cracks 

× : Insert cracks

AT Hard 

ill 

High-Efficiency Facemill 


Milling-Facing PeNtagonal type 

5 

New grades 

G 

4 

New 

chipbreaker 

Long tool life with PR12-Series 

MEGACOAT carbide inserts 

■MEGACOAT 

·Long tool life and high-speed milling due to high hardness and 

high oxidation resistance 

●Wear comparison 

Flank wear [mm] 


Workpiece :SCM440H 

Vc=250m/min, fz =0.12mm/t 

apxae=2x85mm, Cutter Dia.:125mm 

Cut distance per 1 path:340mm 

3-dimensional chipbreaker 

improves chip evacuation 

■Smooth chip evacuation reduces chip-biting 

·3-types of chipbreakers enable coverage of a wide range 

of milling conditions 

Chipbreaker Applications Shape 

GM General 

SM 

GH 

0.30 

0.25 

0.20 

0.15 

0.10 

0.05 

0.00 

0 20 40 60 80 

Cutting time [min] 

Low cutting 

force 

Heavy 

milling 

ap (mm) Depth of cut 

6 

3 

1 

Competitor E 

Competitor F 

Competitor G 

PR1225 

SM 

Hardness(GPa) 

40 

30 

20 

10 

GM 

TiC 

TiCN 

MEGACOAT 

TiN 

TiAlN 

(ref:carbide) 

0 200 400 600 800 1000 1200 

Oxidation temperature (˚C) 

GH 

MEGACOAT 

Insert grades Workpiece 

PR1225 

PR1210 

Steel / Stainless steel 

Cast iron / Titanium alloy 

0.06 0.1 0.2 0.3 0.4 0.5 0.6 0.7 

fz (mm/t) Feed per tooth 

2

3 

■MFPN45 

●Holder Dimension 

Bore Dia. Inch spec 

mm spec 

Coarse pitch 

Cross pitch 

Extra cross pitch 

Coarse pitch 

Cross pitch 


Description 

Stock 

E 

a 

No.of 

Insert 

ød 

b 

ød2 

ød1 

øD 

øD1 

45˚ 

6 

H 

E 

a 

Rake 

Angle(°) 

ød 

b 

ød1 

øD 

øD1 

Dimension(mm) 

45˚ 

6 

H 

A.R. R.R. 

max +10° 

Fig.1 Fig.2 Fig.3 

øD øD1 ød ød1 ød2 H E a b ød3 ød4 

E 

øD=63 -10° 

øD=80 -8° 

øD=100-250 -6° 

ød 

b 

ød2 

ød1 

øD 

øD1 

ød3 

ød4 

45˚ 

Shape Weight 

(kg) 

MFPN 45080R-5T 

45100R-6T 

45125R-7T 

● 

● 

● 

5 

6 

7 

80 

100 

125 

93 

113 

138 

25.4 

31.75 

38.1 

22 

48 

58 

13 

- 

50 

27 

32 

36 

6 

8 

10 

9.5 

12.7 

15.9 

- - 

Fig.1 

Fig.2 

1.1 

1.4 

2.6 

45160R-8T 

45200R-10T 

45250R-12T 

● 

● 

● 

8 

10 

12 

160 

200 

250 

173 

213 

263 

50.8 

47.625 

72 

110 101.6 

63 

38 

40 

11 

14 

19.1 

25.4 18 26 Fig.3 

4.0 

6.7 

9.4 


45100R-8T 

45125R-10T 

● 

● 

● 

6 

8 

10 

80 

100 

125 

93 

113 

138 

25.4 

31.75 

38.1 

22 

48 

58 

13 

- 

50 

27 

32 

36 

6 

8 

10 

9.5 

12.7 

15.9 

- - 

Fig.1 

Fig.2 

1.1 

1.4 

2.7 

45160R-12T 

45200R-14T 

45250R-16T 

● 

● 

● 

12 

14 

16 

160 

200 

250 

173 

213 

263 

50.8 

47.625 

72 

110 101.6 

63 

38 

40 

11 

14 

19.1 

25.4 18 26 Fig.3 

4.0 

6.9 

9.6 


45100R-10T 

45125R-13T 

● 

● 

● 

8 

10 

13 

80 

100 

125 

93 

113 

138 

25.4 

31.75 

38.1 

22 

48 

58 

13 

- 

50 

27 

32 

36 

6 

8 

10 

9.5 

12.7 

15.9 

- - 

Fig.1 

Fig.2 

1.1 

1.3 

2.7 

45160R-16T 

45200R-18T 

45250R-20T 

● 

● 

● 

16 

18 

20 

160 

200 

250 

173 

213 

263 

50.8 

47.625 

72 

110 101.6 

63 

38 

40 

11 

14 

19.1 

25.4 18 26 Fig.3 

4.0 

6.9 

9.6 

MFPN 45063R-4T-M 

45080R-5T-M 

45100R-6T-M 

45125R-7T-M 

45160R-8T-M 

45200R-10T-M 

45250R-12T-M 

● 

● 

● 

● 

● 

● 

● 

4 

5 

6 

7 

8 

10 

12 

63 

80 

100 

125 

160 

200 

250 

76 

93 

113 

138 

173 

213 

263 

22 

27 

32 

40 

60 

19 

22 

48 

58 

68 

110 

11 

13 

- 

66.7 

101.6 

40 

50 

63 

21 

24 

30 

32 

40 

6.3 

7 

8 

9 

14 

10.4 

12.4 

14.4 

16.4 

25.7 

- 

14 

18 

- 

20 

26 

Fig.1 

Fig.2 

Fig.3 

0.5 

1.1 

1.4 

2.6 

3.8 

6.4 

9.1 


45080R-6T-M 

45100R-8T-M 

45125R-10T-M 

45160R-12T-M 

45200R-14T-M 

45250R-16T-M 

● 

● 

● 

● 

● 

● 

● 

5 

6 

8 

10 

12 

14 

16 

63 

80 

100 

125 

160 

200 

250 

76 

93 

113 

138 

173 

213 

263 

22 

27 

32 

40 

60 

19 

22 

48 

58 

68 

110 

11 

13 

- 

66.7 

101.6 

40 

50 

63 

21 

24 

30 

32 

40 

6.3 

7 

8 

9 

14 

10.4 

12.4 

14.4 

16.4 

25.7 

- 

14 

18 

- 

20 

26 

Fig.1 

Fig.2 

Fig.3 

0.5 

1.0 

1.4 

2.5 

3.8 

6.5 

9.1 


45080R-8T-M 

45100R-10T-M 

45125R-13T-M 

45160R-16T-M 

45200R-18T-M 

45250R-20T-M 

● 

● 

● 

● 

● 

● 

● 

6 

8 

10 

13 

16 

18 

20 

63 

80 

100 

125 

160 

200 

250 

76 

93 

113 

138 

173 

213 

263 

22 

27 

32 

40 

60 

19 

22 

48 

58 

68 

110 

11 

13 

- 

- 

66.7 

101.6 

40 

50 

63 

21 

24 

30 

32 

40 

6.3 

7 

8 

9 

14 

10.4 

12.4 

14.4 

16.4 

25.7 

- 

14 

18 

- 

20 

26 

Fig.1 

Fig.2 

Fig.3 

0.5 

1.1 

1.3 

2.6 

3.9 

6.6 

9.3 

6 

H 

Shim 

Yes 

- 

- 

Yes 

- 

- 

●:Std. Stock

■Spare Parts 

●Spare parts (mm / inch common spec) 

Coarse pitch 

Cross pitch 


MP-1 

Description 

Clamp 

Screw 

Wrench 

TT DTM 

Spare Parts 

Shim Shim Screw Wrench 

Anti-seize 

Compound 

MP-1 

Arbar 

Clamp Screw 


HH10x30 

MFPN 45080R-5T-(M) SB-50140TR TT-15 MFPN-45 SPW-7050 LW-5 HH12x40 

MFPN 45100R-6T-(M) 

45250R-12T-(M) 

for Insert Clamp 

Recommended torque is 

4.2 Nm. 

- 

for Shim Clamp 


6.0 Nm. 

MP-1 

- 


HH10x30 

MFPN 45080R-6T-(M) SB-50140TR TT-15 HH12x40 

MFPN 45100R-8T-(M) for Insert Clamp 

- - - - MP-1 


- 

45250R-16T-(M) 

4.2 Nm. 


HH10x30 

MFPN 45080R-8T-(M) SB-40140TRN - DTM-15 HH12x40 

MFPN 45100R-10T-(M) 

for Insert Clamp 

- - - MP-1 

45250R-20T-(M) 


3.5 Nm. 

- 

~ 

~ 

~ 

∙Coat Anti-seize Compound (MP-1) thinly on portion of taper and thread when insert is fixed. 

■Insert description Classification of usage P 

●Milling Inserts (with hole) ★ Roughing / 1st Choice 

Roughing / 2nd Choice 

■ Finishing / 1st Choice 

Finishing / 2nd Choice 

Shape 

Handled insert indicates Right-Hand 

General 

Low cutting force 

Tough Edge (for heavy milling) 

Z 

Z 

Z 

X 

X 

X 

A 

A 

A 

T 

T 

T 

Ød 

Ød 

Ød 

(Hardened material is applicable only under 

45HRC) 

Description 

PNMU 1205ANER-GM 

Steel ★ 

Die Steel ★ 

M Stainless Steel ★ 

K 

Gray Cast Iron 

Nodular Cast Iron 

★ 

★ 

N Non-ferrous Material 

S 

Heat-resistant Alloy 

Titanium alloy 

★ 

★ 

H Hardened material 

Dimension(mm) MEGACOAT 

A T ød X Z PR1225 PR1210 

17.88 5.56 

● ● 

PNMU 1205ANER-SM 6.2 2.0 2.0 ● ● 

PNMU 1205ANER-GH 17.98 6.17 ● ● 

●Reference for selecting a facemill and insert suitable for each milling purpose 

Milling Purpose 

General milling for steel and alloy steel 

Steel and alloy steel (to prevent chattering due to low rigidity 

machine or poor clamping power) 

Productivity oriented (Running cost decrease) (Over ap=4 mm, 

over fz=0.35 mm/t) 

Genral milling for stainless steel 

Stainless steel (to prevent chattering due to low rigidity 

machine or poor clamping power) 

Cast iron (for processing efficiency improvement) 

Cast iron (Over ap=4 mm, over fz=0.35 mm/t) 

Coarse 

pitch 

Facemill-type Chipbreaker 

Cross pitch 

Extra cross 

pitch 

●:Std. Stock 

GM SM GH 

4

5 

■Case studies 

·Construction machine part 

·Vc=170m/min 

·apxae=4x10mm 

·fz=0.3mm/t 

·Vf=1350mm/min 

·DRY 

·Cutter 

MFPN45125R-10T 

(10 edges) 

·Insert 


(PR1225) 


(PR1225) 

Competitor H 

SS400 

Face milling (with meltdown surface) 

1500 

·MFPN facemill enables stable milling due to reduced chip-biting and 

edge cracks 

·MFPN facemill, no chattering, showed 3 times longer tool life than 

competitor 

·Construction machine part 

·Vc=175m/min 

·apxae=1.5x100mm 

·fz=0.19mm/t 


·DRY 

·Cutter 


(12 edges) 

·Insert 


(PR1225) 


(PR1225) 

Competitor J 

3pcs/edge 

Alloy steel 

Total D.O.C.:15mm 

2pcs/edge 

1pcs/edge 

1pcs/edge 

100 

200 

3 times 

longer tool life 

Evaluation by the user 

·MFPN facemill showed 2 times longer tool life than competitor 

·Competitor caused cracks by chip-biting. MFPN facemill had no 

cracks and allowed stable milling 

·MFPN facemill enabled twice the table feed rate compared with the 

competitor. Milling efficiency improved two-fold. 

100 

ø400 

2 times 



·Pipe 

·Vc=180m/min 


·fz=0.44mm/t 


·DRY 

·Cutter 


(10 edges) 

·Insert 


(PR1210) 


(PR1210) 

Competitor I 

FCD450 

ø3000 

·MFPN facemill showed 1.5 times longer tool life than the competitor 

·High feed rate of MFPN allowed 1.3 times higher milling efficiency 

compared to the competitor 

·Press die 

·Vc=130m/min 


·fz=0.15mm/t 


·DRY 

·Cutter 


(12 edges) 

·Insert 


(PR1210) 


(PR1225) 

Competitor K 

FCD600 

Face milling 

3pcs/edge 

2pcs/edge 

Cutting time 

128 minutes 

3000 

Cutting time 

167 minutes 

80 

2000 

1.5 times 



·Highly stable milling into the entrance of workpiece and less vibration 

than the competitor 

·Cleanly curled chips which barely cause chip-biting 

·Cutting speed has been changed Vc=110 m/min of conventional 

competitor's to Vc=130 m/min, thereby the milling efficiency of 

MFPN increased 1.2 times 

300 

Milling efficiency 

increased 1.2 times 

Evaluation by the user

■Case studies 

·Plate 

·Vc=230m/min 


·fz=0.19mm/t 


·DRY 

·Cutter 


(12 edges) 

·Insert 

PNMU1205ANER-SM 

(PR1225) 


(PR1225) 

Competitor L 

(for roughing) 

SS400 

2000 

·MFPN facemill causes no vibration, enabling stable milling, even 

though the number of cutting edges of facemill has been increased 

by 4 and the feed per tooth has been increased by 1.3 times 

·Does not generate much heat after milling and obtains the lustrous 

surface finish without burrs 

·Milling efficiency increased 2.6 times with the high cutting conditions 

·Plate 

·Vc=180m/min 


·fz=0.15mm/t 


·DRY 

·Cutter 


(10 edges) 

·Insert 


(PR1225) 

[Conventional] 

Vc=140m/min 

apxae=3x80mm 

fz=0.11mm/t 

(Vf=230mm/min) 

Cutting time 7.3 

minutes 

(4 passes) 

Cutting time 19 minutes 

(4 passes) 

SCM415 

300 

80 




·Even if the cutting speed and feed rate are raised up to the level of the 

conventional tool, the tool life of MFPN remains unchanged and milling 

efficiency increases by 2.6 times 

·MFPN vibrates less right at entrance and exit on workpiece with reduced 

cutting sound 

400 


· Shaft (End face milling) 

·Vc=140m/min 


·fz=0.19mm/t 


·DRY 

·Cutter 


(6 edges) 

·Insert 


(PR1225) 

Alloy steel 

End face milling 

·Although the conventional tool causes chattering, MFPN facemill 

suppresses chattering, enabling stable milling 

·Even if the feed rate is raised to 1.9 times, the insert wears less and 

there is no cracks on the insert 

·Both the milling efficiency and the tool life have been improved 

·Case 

·Vc=90m/min 


·fz=0.19mm/t 


·DRY 

·Cutter 


(6 edges) 

·Insert 


(PR1225) 


(PR1225) 

Competitor M 

(for roughing) 

SUS304 

500 

800 

1.5pcs/edge 

1pcs/edge 

ø90 


·Even when the cutting depth, cutting speed and feed rate cannot be 

raised due to the low rigidity of a workpiece, MFPN facemill enables 

stable milling without chattering and also has an improved tool life of 

1.5 times 

600 




6

■Precautions for use (How to mount an insert) 

1.Be sure to remove dust and chips from the insert mounting pocket. 

2.After applying anti-seize compound on portion of taper and thead, while pressing the insert against the constraint 

surfaces, put the screw into the hole of the insert and tighten the screw with appropriate torque. See Fig. 1 and Fig. 2. 

Recommended tightening torque → The torque for coarse pitch and cross pitch (using M5 screw) is 4.2 Nm. 

The torque for extra cross pitch (using M4 screw) is 3.5 Nm. 

3.After tightening the screw, make sure that there is no clearance between the insert seat surface and the bearing surface of 

the holder and between the insert side surfaces and the constraint surface of the holder. 

4.To change the cutting edge of the insert, turn the insert counterclockwise (see Fig. 3). Insert corner identification number is 

stamped on the top surface of insert except SM chipbreaker(Fig. 4). 

To protect the wiper edge, use the corners of insert in the sequence of corner numbers. 

Constraint 

surface 

■ Recommended conditions 

Work Piece Material 

Insert 

Grade 

Cutting Speed 

(m/min) 

Chipbreaker 

fz(mm/t) Feed per tooth 

0.06 0.1 0.2 0.3 0.4 0.5 0.6 0.7 

Carbon Steel 

SxxC 

PR1225 120~180~250 

GM★ 

SM 0.06 

0.1 

● 0.12 

● 0.2 

0.25 

0.4 

GH 0.2 

● 0.4 0.7 

Alloy Steel 

SCM 

PR1225 100~160~220 

GM★ 

SM 0.06 

0.1 ● 0.2 

● 0.12 

0.25 

0.4 

GH 0.2 ● 0.4 

0.6 

Die Steel 

SKD/NAK 

PR1225 80~140~180 

GM★ 

SM 0.06 

0.1 

● 0.1 

● 0.2 

0.2 

0.35 

GH 0.2 ● 0.35 0.5 

Stainless Steel 

SUS304 PR1225 100~150~200 

GM 

SM★ 0.06 

0.1 ● 0.2 

● 0.12 

0.25 

0.4 

Gray Cast Iron 

FC 

PR1210 120~180~250 

GM★ 

SM 0.06 

0.1 ● 0.2 

● 0.12 0.25 

0.4 

GH 0.2 

● 0.4 0.7 0.7 

Nodular Cast Iron 

FCD 

PR1210 100~150~200 

GM★ 

SM 0.06 

0.1 

● 0.1 

● 0.2 

0.2 

0.35 

GH 0.2 ● 0.35 0.5 

Titanium Alloy PR1210 30~50~70 SM★ 0.06 ● 0.08 0.15 

Cutter Specifications 

Coarse pitch (with shim) 

Cross pitch (without shim) 

(For GH chipbreaker, recommend under fz=0.4 

mm/t.) 

Extra cross pitch (without shim) 

The use of the GH breaker is not recommended. 

Side surface 

of insert 

Fig.1 Fig.2 Fig.3 Fig.4 

Top surface 

of insert 

Insert corner 

identication number 

❋The bold-faced number indicates a center value of recommended condition. ★:1st Recommendation :2nd Recommendation

High-Efficiency Facemill MFPN - Kyocera

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