For Gear, Spline & Rack Manufacturing

METRIC
Advanced Technologies for Gear, Spline and See it in action
Rack Manufacturing
The VARDEX Gear Milling Concept
• Advanced milling tools with multi-flute indexable carbide grade inserts for super fast machining.
• Offering a competitive alternative to the traditional Hob system.
• Tailor-made inserts and holders designed per customer application, with the exact required profile shape
(evolvent, involute or any other profile) to be transferred to the component.

New Clamping System

New stopper technology for

guaranteed radial and axial run out

Stoppers are pre-assembled on the toolholder

and remain intact when changing inserts

Gear Milling System Advantages

Super Fast Machining
• At least 50% less machining cycle time over other methods
• Carbide inserts with full profile designed for single pass machining
Long Tool Life
• Tough sub-micron grade coated inserts with up to 3 cutting edges
High Accuracy & Quality Machining
• No need for additional machining
• High quality surface finish
Economical Solution
• Absolute Price/Performance advantage over existing technology
High Precision Machining
• Gears: Up to Class 7 according to DIN 3962, or Class 11 according to ANSI 390.03
• Involute Splines: According to DIN 5480 or ANSI B92.1
• Straight sided Splines: According to ISO 14-1982
Simplified Machining
• Easy set-up and use on standard 3.5 axis CNC milling machines

2
 Major Applications

GEAR

The VARDEX Gear milling

tools are suitable for
machining both straight
and helical teeth covering
modules from 0.5-6.0mm
or DP 128.0-4.0.

SPLINE

The VARDEX Spline

milling tools are suitable
for machining both
involute or straight-
sided profiles, covering
modules from 0.5-6.0mm
or DP 48/96 - 4/8.

RACK

The VARDEX Rack milling

tools are suitable for
covering modules
from 0.5-6.0mm or
DP 128.0-4.0.

Gears, Splines and Racks can be machined with either Shell Mills, End Mills or Disc Mills.

End Mill Shell Mill Disc Mill U Style UT Style

3 Cutting Edges 1 Cutting Edge

3
Gear Milling Inserts

Circular Pitch

L L

IC IC

U Style - UT Style -
Module = Pitch / π 3 Cutting Edges 1 Cutting Edge
DP = 25.4 / Module

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VARDEX Gear Milling Machining Concept
Based on the required customer application, VARDEX designs and supplies tailor-made inserts to suit a
specific and single Module / DP as well as the exact number of teeth used on the component.
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Inserts for Gear, Rack and Spline Applications

ucriC

Insert Cutting
Application Module Diametrical Pitch (DP) L Toolholder Page
Size Edges
hctiP ral

GME5N 25W32-50-2U 215/...

0.5-1.0 26-52 1/4”U 11 3 5,9
Gear GMD12N D85-22-2U 215/...
GME5N 32W36-80-3U 215/...
GMS6N D42-16-3U 215/...
1.0-1.5 17-26 3/8"U 16 3 5,6,9
GMS7N D48-22-3U 215/...
GMD12N D90-22-3U 215/...
Rack 1.75-2.0 13-16 1/2"U 22 3 GMS7N D70-27-4U 215/... 7
3.0-3.5 7.5-9 1/2"UT 22 1 GMS6S D85-27-4UT 215/... 7
2.25-2.75 9.5-12 5/8"U 27 3 GMS6N D80-27-5U 215/... 8
3.5-6 4.5-7 5/8"UT 27 1 GMS5S D80-27-5UT 215/... 8
GME5N 25W32-50-2U 215/...
0.5-1.25 48/96; 40/80; 32/64; 24/48 1/4”U 11 3 5,9
GMD12N D85-22-2U 215/...
GME5N 32W36-80-3U 215/...
GMS6N D42-16-3U 215/...
Spline 1.5-2.0 20/40; 16/32 3/8"U 16 3 5,6,9
GMS7N D48-22-3U 215/...
GMD12N D90-22-3U 215/...
2.0-3.0 12/24; 10/20; 8/16 1/2"U 22 3 GMS7N D70-27-4U 215/... 7
4.0-5.0 6/12; 5/10 1/2"UT 22 1 GMS6S D85-27-4UT 215/... 7
3.0-4.0 8/16; 6/12 5/8"U 27 3 GMS6N D80-27-5U 215/... 8
5.0-8.0 5/10; 4/8 5/8"UT 27 1 GMS5S D80-27-5UT 215/... 8

4
Toolholder - Weldon Shank for IC 1/4”U

D D2

L2 L3≤L1 D1
L1
L

Image for illustration

* LP will be
only,
supplied
final D2with
andthe
D1 inserts.
values will
Usebe
thesupplied
LP* for the
withmachine
the toolholder
set-up

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes

IC D1 D2 *L2 Insert Insert Stopper Stopper Stopper

L L1 D (max) (ref) (ref) Z Screw Torx Key Screw Key
1/4”U 3 GME5N 25W32-50-2U 215/... 116 50 25 30 32 8.0 5 SN2T HK2T 5LST SN5LTR K7T

Toolholder - Weldon Shank for IC 3/8”U

D D2

L2 L3≤L1 D1
L1
L

Image for illustration only, final D2 and D1 values will be supplied with the toolholder

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes

IC D1 D2 *L2 Insert Insert Stopper Stopper

L L1 D (max) (ref) (ref) Z Screw Torx+ Key Stopper Screw Key
3/8”U 3 GME5N 32W36-80-3U 215/... 151 80 32 35 36 10.0 5 SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8

Note: Customized toolholders are available upon request.

* L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only.
For an exact measurement, please use the Controller pre-settings.

5
Toolholder - Shell Mill for IC 3/8”U

D2 d(H6) D1 D2

L2
H

Image for illustration only, final D2 and D1 values will be supplied with the toolholder

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes
D1 D2 *L2 Insert Insert Stopper Stopper Holder
IC (max) (ref) d (H6) H (ref) Z Screw Torx + Key Stopper Screw Key Screw

3/8”U 3 GMS6N D42-16-3U 215/... 41 42 16 44.5 9.7 6 SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 M8x1.25x40

Toolholder - Shell Mill for IC 3/8”U

D2 d(H6) D1 D2

L2
H

Image for illustration only, final D2 and D1 values will be supplied with the toolholder

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes

IC D1 D2 *L2 Insert Insert Stopper Stopper Holder

(max) (ref) d (H6) H (ref) Z Screw Torx + Key Stopper Screw Key Screw
3/8”U 3 GMS7N D48-22-3U 215/... 47 48 22 48 10.0 7 SR3FIP8 KIP8 2TM1ST M3x7.5 KIP8 M10x1.5x35

Note: Customized toolholders are available upon request.

* L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only.
For an exact measurement, please use the Controller pre-settings.

6
Toolholder - Shell Mill for IC 1/2”U

D2 d(H6) D1 D2

L2
H

Image for illustration only, final D2 and D1 values will be supplied with the toolholder

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes
D1 D2 *L2 Insert Insert Stopper Stopper Holder
IC (max) (ref) d (H6) H (ref) Z Screw Torx + Key Stopper Screw Key Screw

1/2”U 3 GMS7N D70-27-4U 215/... 69 70 27 54 12.8 7 SR3FIP8 KIP8 2TM2ST M3x7.5 KIP8 M12x1.75x40

Toolholder - Shell Mill for IC 1/2” UT

D2 d(H6) D1 D2

H
L2

Image for illustration only, final D2 and D1 values will be supplied with the toolholder

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes

IC D1 D2 *L2 Insert Screw Insert Holder Screw

(max) (ref) d (H6) H (ref) Z Torx + Key
1/2”UT 1 GMS6S D85-27-4UT 215/... 83 85 27 50 9.9 6 SN4T HK4T M12x1.75x40

Note: Customized toolholders are available upon request.

* L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only.
For an exact measurement, please use the Controller pre-settings.

7
Toolholder - Shell Mill for IC 5/8”U

D2 d(H6) D1 D2

L2 H

Image for illustration only, final D2 and D1 values will be supplied with the toolholder

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes
D1 D2 *L2 Insert Insert Stopper Stopper Stopper Holder
IC (max) (ref) d (H6) H (ref) Z Screw Torx + Key Screw Key Screw

5/8”U 3 GMS6N D80-27-5U 215/... 79 80 27 62 17.5 6 SN2T HK5T 3ST SN3TM K3T M12x1.75x40

Toolholder - Shell Mill for IC 5/8”UT

D2 d(H6) D1 D2

L2 H

Image for illustration only, final D2 and D1 values will be supplied with the toolholder

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes

IC D1 D2 *L2 Insert Screw Insert Holder Screw

(max) (ref) d (H6) H (ref) Z Torx + Key
5/8”UT 1 GMS5S D80-27-5UT 215/... 89 80 27 25 12.5 5 SN5TM HK5T M12x1.75x40

Note: Customized toolholders are available upon request.

* L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only.
For an exact measurement, please use the Controller pre-settings.

8
Gear Milling Toolholder - Disc Mill for IC 1/4”U
d(H6)

D1

L2 D2
H

Image for illustration only, final D2 and D1 values will be supplied with the toolholder

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes
D1 D2 *L2 Insert Insert Stopper
IC (max) (ref) d (H6) H (ref) Z Screw Torx + Key Stopper Screw Stopper Key
1/4”U 3 GMD12N D85-22-2U 215/... 84 85 22 25 12.5 12 SN2T HK2T 5LST SN5LTR K7T

Gear Milling Toolholder - Disc Mill for IC 3/8”U

d(H6)

D1

L2
H D2

Image for illustration only, final D2 and D1 values will be supplied with the toolholder

For Gear, Rack and Spline Spare Parts

Insert Insert No. of
Cutting Ordering Code Dimensions (mm)
Size Edges Flutes

IC D1 D2 *L2 Insert Insert Stopper Stopper Stopper

(max) (ref) d (H6) H (ref) Z Screw Torx + Key Screw Key
3/8”U 3 GMD12N D90-22-3U 215/... 89 90 22 25 12.5 12 SR3FIP8 KIP8 2TM2ST M3x7.5 KIP8

Note: Customized toolholders are available upon request.

* L2 is measured from the center of the profile to the end of the toolholder. The L2 value is for reference purposes only.
For an exact measurement, please use the Controller pre-settings.

9
Recommended Grades, Cutting Speeds Vc [m/min] and Feed f [mm/tooth]

Vardex No.
Vc [m/min]
Material Hardness Feed f
Group Material Brinell HB VBX [mm/tooth]
1 Low carbon (C=0.1-0.25%) 125 100-210 0.20-0.32
2 Unalloyed steel Medium carbon (C=0.25-0.55%) 150 100-180 0.20-0.32
3 High Carbon (C=0.55-0.85%) 170 100-170 0.15-0.23
4 Non hardened 180 60-90 0.17-0.28

P
Low alloy steel
5 Hardened 275 80-150 0.15-0.28
(alloying elements≤5%)
Steel 6 Hardened 350 70-140 0.15-0.25
7 High alloy steel Annealed 200 60-130 0.15-0.22
8 (alloying elements>5%) Hardened 325 70-110 0.13-0.21
9 Low alloy (alloying elements <5%) 200 100-170 0.15-0.22
Cast steel
10 High alloy (alloying elements >5%) 225 70-120 0.12-0.22
11 Stainless steel Non hardened 200 100-170 0.15-0.22
12 Ferritic Hardened 330 100-170 0.16-0.23
13 Stainless steel Austenitic 180 70-140 0.15-0.25
M
Stainless
14 Austenitic
15 Stainless steel
Super Austenitic
Non hardened
200
200
70-140
70-140
0.12-0.20
0.16-0.24
Steel
16 Cast Ferritic Hardened 330 70-140 0.12-0.20
17 Stainless steel Austenitic 200 70-120 0.15-0.22
18 Cast austenitic Hardened 330 70-120 0.12-0.20
28 Malleable Ferritic (short chips) 130 60-130 0.16-0.24
29 Cast iron Pearlitic (long chips) 230 60-120 0.15-0.22

K
Cast Iron
30
31
Grey cast iron
Low tensile strength
High tensile strength
180
260
60-130
60-100
0.15-0.22
0.15-0.22
32 Ferritic 160 60-125 0.10-0.20
Nodular SG iron
33 Pearlitic 260 50-90 0.15-0.22
34 Aluminium alloys Non aging 60 100-250 0.30-0.50
35 Wrought Aged 100 100-180 0.28-0.50

N(K)
Non-Ferrous
36
37
Aluminium alloys
Cast
Cast & aged
75
90
150-400
150-280
0.28-0.50
0.25-0.40
Metals 38 Aluminium alloys Cast Si 13-22% 130 80-150 0.28-0.50
39 Copper and Brass 90 120-210 0.30-0.50
40 Copper alloys Bronze and non leaded copper 100 120-210 0.28-0.50
19 Annealed (Iron based ) 200 20-45 0.09-0.15

S(M)
Heat
20 High temperature
21 alloys
Aged (Iron based)
Annealed (Nickel or Cobalt based)
280
250
20-30
15-20
0.07-0.13
0.08-0.15

Resistant 22 Aged (Nickel or Cobalt based) 350 10-15 0.08-0.15

Material 23 Pure 99.5 Ti 400Rm 70-140 0.07-0.13
Titanium alloys
24 α+β alloys 1050Rm 20-50 0.07-0.13

H(K)
Hardened
25
Extra hard steel Hardened & tempered
45-50HRc 15-45 0.05-0.12

26 51-60HRc* 15-40 0.05-0.12

Material
* Note: Special tools, which are not listed in this catalog, are required for extra hard steel (51-60HRc).

Grades U Style UT Style

Grade Application
TiCN coated carbide grade.
VBX Excellent grade for general use.

Other grades are available upon request.

10
 Distributor Name

ENQUIRY No.
NEUMO Ehrenberg Group

Request Form*
* Please submit a completed version of this form with each request (a drawing is recommended).
For Rack, Straight Spline, Worm or other special forms, a drawing must be supplied with all relevant dimensions!
Basic Dimensions R (D2/2)

1 | Gear / Spline Standard

2 | Class of Accuracy
3 | Module (M) / Diametrical Pitch (DP)
4 | Number of Teeth
Limitation
5 | Pressure Angle
6 | Helix Angle Tool Radius (R) < Tool Exit Limitation
7 | Direction of Helix (RH/LH) R (D2/2)
8 | Pitch Diameter (REF)
9 | Major Diameter Max: Min:
10 | Minor Diameter Max: Min:
11 | Form Diameter (For Spline only)
Exit Arc
12 | Fillet Radius
13 | Root Type (For Spline only) Fillet Root Flat Root
Tool Radius (R) < Exit Arc
One of the following must be supplied:
14a | Measurement Over Pins Ø: Max: Min:
14b | Tangent Length Over (N) Teeth N: Max: Min:
14c | Actual - Tooth Thickness Max: Min:

Additional Information
15 | For Tool Exit Limitation, a detailed component drawing must be supplied!
16 | Exit Arc Radius (R)
17 | Material Hardness (During machining) Pin Diameter

18 | Material Designation

Pressure Angle
Involute
Flat Root Spline
er
et
iam
)D
de
t si
Ou

er
iamet
r(

oot) D
aj o

(R
Minor
M

Form Diameter Fillet Radius Measurement

Pi t c Over Pins
hD
iam
e te
r

Fillet Root Spline Involute

Tooth Thickness

Fillet Radius

Form Diameter Fillet Radius

Tangent length over
(N) teeth
For Gear, Spline & Rack Manufacturing

Visit VARGUS

221-01164
METRIC EE
VARGUS Ltd. [email protected] www.vargus.com 07/2013
EDITION 03