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The Exacta-Set Milling System

About the Exacta-Set

After many years of observing and studying the offerings in the marketplace for PCD milling cutters and with our own experience with monoblock options, we have developed what we believe is the best option that provides a sensible combination of durability, stability, and simplicity as a platform for cartridge style PCD milling. 

We have the ability to successfully provide for all of your tooling needs from start to finish with regard to PCD Milling, PCD Drilling, PCD Reaming, PCD Insert Tools, and PCD Inserts.

 

Rectangle 1-1

 

Exacta-Set - Imperial Range

The Milling Programme

PART NO.

SIZE

PILOT

PILOT HIGHT

KEY WAY WIDTH

SET HIGHT

COOLANT METHOD

NO. OF STATIONS

BODY MATERIAL

414-50.8.12.7

2.00"

0.50"

0.57"

0.25"

2.00"

Screw

6

Steel

414-63.5.19.05

2.50"

0.75"

0.75"

0.31"

2.00"

Screw

8

Steel

414-76.2.25.4

3.00"

1.00"

0.75"

0.38"

2.00"

Screw

10

Aluminum 

414-101.4.31.75

4.00"

1.25"

0.75"

0.50"

2.00"

Screw

12

Aluminum 

414-127.0.38.1

5.00"

1.50"

1.00"

0.63"

2.375"

Plate

16

Aluminum 

414-152.4.38.1

6.00"

1.50"

1.00"

0.63"

2.375"

Plate

20

Aluminum 

414-203.2.63.5

8.00"

2.50"

1.25"

1.00"

2.375"

Plate

24

Aluminum 

414-254.0.63.5

10.00"

2.50"

1.25"

1.00"

2.375"

Plate

28

Aluminum 

414-304.8.63.5

12.00"

2.50"

1.25"

1.00"

2.375"

Plate

36

Aluminum 

 

Through Coolant Accessories

MILLING CUTTER SIZE

SHOWER SCREW PART NUMBER

SHOWER PLATE PART NUMBER

SHOWER SCREW THREAD

BODY MATERIAL

2.00 414-50.8-SS N/A 1/4 x 28 Steel
2.50 414-63.5-SS N/A 3/9 x 24 Steel
3.00 414-76.2-SS N/A 1/2 x 20 Steel
4.00 414-101.4-SS N/A 5/8 x 18 Steel
5.00 414-127.0-SS 414-127.0.CP 3/4 x 16 Steel Screw + Aluminum Plate*
6.00 414.152.4-SS 414-152.4.CP 3/4 x 16 Steel Screw + Aluminum Plate*
8.00 N/A 414-203.2.CP N/A Aluminum
10.00 N/A

414-254.0.CP

N/A Aluminum
12.00 N/A 414-304.8.CP N/A Aluminum

 

Exacta-Set - Hybrid Range

The Milling Programme

PART NO.

SIZE

PILOT

PILOT HIGHT

KEY WAY WIDTH

SET HIGHT

COOLANT METHOD

NO. OF STATIONS

BODY MATERIAL

414-80.025.4

80mm

25.4mm

22mm

9.5mm

50mm

Screw

10

Aluminum 

414-100.0.31.75

100mm

31.75mm

30mm

12.7mm

50mm

Screw

12

Aluminum 

414-125.0.38.1

125mm

38.1mm

34mm

15.9mm

63mm

Plate

16

Aluminum 

414-160.038.1

160mm

38.1mm

34mm

15.9mm

63mm

Plate

20

Aluminum 

 

Through Coolant Accessories

MILLING CUTTER SIZE

SHOWER SCREW PART NUMBER

SHOWER PLATE PART NUMBER

SHOWER SCREW THREAD

BODY MATERIAL

80mm 414-80.0-SS N/A

M12 x 1.75

Steel
100mm 414-100.0-SS N/A M16 x 2.0 Steel
125mm 414-12.0-SS 414-125.0.CP M20 x 2.5 Steel Screw + Aluminum Plate*
160mm 414-160.0-SS 414-125.0-CP M20 x 2.5 Steel Screw + Aluminum Plate*

 

Exacta-Set - Metric Range

Through Coolant Accessories

MILLING CUTTER SIZE

SHOWER SCREW PART NUMBER

SHOWER PLATE PART NUMBER

SHOWER SCREW THREAD

BODY MATERIAL

50mm 414-50.0-SS N/A M8 x 1.25 Steel
63mm 414.63.0-SS N/A M10 x 1.5 Steel
80mm 414.80.0-SS N/A M12 x 1.75 Steel
100mm 414.100.0-SS N/A M16 x 2.0 Steel
125mm 414.125.0-SS 414.125.0.CP M20 x 2.5 Steel Screw + Aluminum Plate*
160mm 4140.160.0-SS 414.160.0.CP M20 x 2.5 Steel Screw + Aluminum Plate*
200mm N/A 414.200.0.CP N/A Aluminum
250mm N/A 414-2250.0.CP N/A Aluminum
300mm N/A 414-300.0.CP N/A Aluminum
 
Hardware

 

PART NO.

SIZE

MHC-001

Adjusting Nut Post -2.00 or 50mm Set Height Milling Cutter

MHC-002

7mm Hexagon Adjustment Nit

MHC-003

Shim Plate

MHC-004

Shim plate retaining screw M3X8

MHC-005

Cartridge Clamp Screw M4X12

MHC-006

Coolant Plate Machine Screw, M4X30

 

 

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Aluminium Body available for most sizes.

Lightweight - easier on spindle acceleration and deceleration. 
Absorbs much of the shock with a machine crash - acts like a fuse.
Anodize hard-coat surface has 70 Rc hardness.
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Fully Adjustable Axially.

Provides the best surface finish for a milling cutter.
Provides the best opportunity for longest tool life.
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Chip Deflection.

Chip Deflection build into the cutter body to keep cost out of the cartridge.

The cutting forces help drive the cartridge into the pocket providing the best stability for the cartridge while in the cut.

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Ground & Laser.

Ground and laser edge options to provide the best quality cut for the application.

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Depth of Cut.

Depth of Cut range from 5mm to 13mm.

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Five basic cartridge geometries.

Five basic cartridge geometries available with multiple nose preparations and wiper configurations to solve most any milling challenges.

 

Application Details

Recommended Cutting Data

MATERIAL

SURFACE SPEED (M/MIN)

SURFACE SPEED (FT/MIN)

FEED PER TOOTH (MM/TOOTH)

FEED PER TOOTH (IN/TOOTH)

AL LESS THAN 8% SILICON CONTENT        

Low (thin Part or fixture issues)

600 1950 0.05 to 0.1 0.002 to 0.004

Starting

1250 4100 0.15 to 2.0 0.006 to 0.008

Progressive

3050 10 000 0.15 to 2.0 0.006 to 0.008 
AL 8-10% SILICON CONTENT        

Low (thin Part or fixture issues)

600 1000 0.05 to 0.1 0.002 to 0.004

Starting

900 1500 0.15 to 2.0 0.006 to 0.008

Progressive

1850 1950

0.15 to 2.0

0.006 to 0.008
AL GREATER THAN 8% SILICON CONTENT        

Low (thin Part or fixture issues)

300 980 0.05 to 0.1 0.002 to 0.004

Starting

450 1500 0.15 to 2.0 0.006 to 0.008

Progressive

600

1950 0.15 to 2.0

0.006 to 0.008

COPPER - BRONZE - ZINC        

Low (thin Part or fixture issues)

300 980 0.025 to 0.05

0.001 to 0.002

Starting

450 1500 0.05 to 0.075 0.002 to 0.003

Progressive

750 2460 0.10 to 0.15 0.004 to 0.006
GREEN CARBIDE AND GREEN CERAMIC        

Low (thin Part or fixture issues)

150 490 0.05 to 0.1 0.002 to 0.004

Starting

300 980 0.01 to 0.15 0.004 to 0.006

Progressive

450 1470 0.15 to 0.2 0.006 to 0.008
CARBON FIBER COMPOSITES        

Low (thin Part or fixture issues)

450 1480 0.05 to 0.075 0.002 to 0.003

Starting

750 2450 0.075 to 0.1 0.003 to 0.004

Progressive

1500 4900 0.1 to 0.13 0.004 to 0.05

 

Exacta-Set Milling Cutter Assembly Adjusting Process

  1. Lead new cartridge into pocket and snug the Cartridge Mounting Screw using a T20 Torx Wrench. 

  2. Raise the cartridges using the 7mm Axial Adjusting nut and a 7mm Open Wrench to within 0.025mm (0.0010") of the Final Set Height. 

  3. Torque the Cartridge Mounting Screw to 45 in/Ibs or 5.0 Nm using a pre-set torque wrench fitted with a T20 Torx bit.

  4. Raise the cartridges using the 7mm Acial Adjusting Nut and a 7mm Open End Wrench to the Final Set height for the milling cutter assembly to +/-0.003mm (+/_0.001").*

*If the cartridge is adjusting too far above the final set hight, loosen the Cartridge Mounting Screw and lower the cartridge to re-start the MIlling Cutter Assembly Adjustment Process