For Gear, Spline & Rack Manufacturing

INCH

Advanced Technologies for Gear, Spline and

Rack Manufacturing

See it in action

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 meth
methods
hod
o s
Carbide inserts with full profile designed for single
ingle pass
paass machining
machinin
ma
ng

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

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 straightsided 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
3 Cutting Edges

UT Style
1 Cutting Edge
3

Gear Milling Inserts

Circular Pitch
L

IC

IC

UT Style 1 Cutting Edge

U Style 3 Cutting Edges

Module = Pitch /
DP = 25.4 / Module

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.

Inserts for Gear, Rack and Spline Applications

Application

Module

Diametrical Pitch (DP)

Insert
Size

0.5-1.0

26-52

1/4U

11

Cutting
Edges

Toolholder

Page

GME5N 100W125-197-2U 215/...

Gear

5,9
GMD12N D335-100-2U 215/...
GME5N 125W142-315-3U 215/...

1.0-1.5

17-26

3/8"U

16

GMS7N D189-075-3U 215/...

5,6,9

GMD12N D354-100-3U 215/...

Rack

1.75-2.0

13-16

1/2"U

22

GMS7N D275-100-4U 215/...

3.0-3.5

7.5-9

1/2"UT

22

GMS6S D335-100-4UT 215/...

2.25-2.75

9.5-12

5/8"U

27

GMS6N D315-100-5U 215/...

3.5-6

4.5-7

5/8"UT

27

GMS5S D315-100-5UT 215/...

0.5-1.25

48/96; 40/80; 32/64; 24/48

1/4U

11

GME5N 100W125-197-2U 215/...

5,9
GMD12N D335-100-2U 215/...
GME5N 125W142-315-3U 215/...

Spline

1.5-2.0

20/40; 16/32

3/8"U

16

GMS7N D189-075-3U 215/...

5,6,9

GMD12N D354-100-3U 215/...

2.0-3.0

12/24; 10/20; 8/16

1/2"U

22

GMS7N D275-100-4U 215/...

4.0-5.0

6/12; 5/10

1/2"UT

22

GMS6S D335-100-4UT 215/...

3.0-4.0

8/16; 6/12

5/8"U

27

GMS6N D315-100-5U 215/...

5.0-8.0

5/10; 4/8

5/8"UT

27

GMS5S D315-100-5UT 215/...

Toolholder - Weldon Shank for IC 1/4U

D2

L2

D1

L3L1
L1

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

For Gear, Rack and Spline

Insert Insert
Cutting
Size Edges

Ordering Code

IC
1/4U

Spare Parts

GME5N 100W125-197-2U 215/...

No. of
Flutes

Dimensions inch
L

L1

4.65

1.97

1.00

D1
D2 *L2
(max) (ref) (ref)
1.18

1.25

.31

Insert
Screw
SN2T
(70036)

Insert
Torx Key
HK2T
(70227)

Stopper
5LST
(70013)

Stopper
Screw
SN5LTR
(72007)

Stopper
Key
K7T
(70026)

Toolholder - Weldon Shank for IC 3/8U

D
L2

L3L1

D2

D1

L1

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

For Gear, Rack and Spline

Insert Insert
Cutting
Size Edges

Ordering Code

IC
3/8U

Spare Parts

GME5N 125W142-315-3U 215/...

No. of
Flutes

Dimensions inch
L

L1

D1
(max)

D2
(ref)

*L2
(ref)

5.9

3.15

1.25

1.37

1.42

.39

Insert
Screw
SR3FIP8
(80973)

Insert
Torx+ Key
KIP8
(70231)

Stopper Stopper
Screw
2TM1ST M3x7.5
(70016) (70029)

Stopper
Key
KIP8
(70231)

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.

Toolholder - Shell Mill for IC 3/8U

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

Insert Insert
Cutting
Size Edges

Ordering Code

GMS7N D189-075-3U 215/...

No. of
Flutes

Dimensions inch
D1
(max)

IC
3/8U

Spare Parts

1.8

D2
(ref) d (H6)
1.89

.75

*L2
(ref)

1.89

.39

Insert
Insert
Stopper Stopper
Screw Torx + Key Stopper Screw
Key
SR3FIP8
KIP8
2TM1ST M3x7.5
KIP8
(80973) (70231)
(70016) (70029) (70231)

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.

Holder
Screw
3/8-24x1.5
(70264)

Toolholder - Shell Mill for IC 1/2U

D2

d(H6) D1

L2

D2

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

For Gear, Rack and Spline

Insert Insert
Cutting
Size Edges

Ordering Code

No. of
Flutes

Dimensions inch
D1
D2
d
(max) (ref) (H6)

IC
1/2U

Spare Parts

GMS7N D275-100-4U 215/...

2.7

*L2
(ref)

Insert
Screw

Insert
Torx + Key

Stopper

Stopper
Screw

Stopper
Key

Holder
Screw

.5

SR3FIP8
(80973)

KIP8
(70231)

2TM2ST
(70023)

M3x7.5
(70029)

KIP8
(70231)

1/2-20x1.5
(70224)

2.75 1.00 2.05

Toolholder - Shell Mill for IC 1/2 UT

D2

d(H6) D1

D2

L2

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

For Gear, Rack and Spline

Insert
Size

Insert
Cutting
Edges

Ordering Code

IC
1/2UT

Spare Parts

GMS6S D335-100-4UT 215/...

No. of
Flutes

Dimensions inch
D1
(max)

D2
(ref)

d (H6)

*L2
(ref)

Insert Screw

3.27

3.35

1.00

1.97

.40

SN4T
(70039)

Insert
Torx + Key
HK4T
(70241)

Holder Screw
1/2x20x1.5
(70224)

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.

Toolholder - Shell Mill for IC 5/8U

D2

D2

d(H6) D1

L2

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

For Gear, Rack and Spline

Insert Insert
Cutting
Size Edges

Ordering Code

GMS6N D315-100-5U 215/...

No. of
Flutes

Dimensions inch
*L2
(ref)

Insert
Screw

Insert
Torx + Key

3.15 1.00 2.36 .69

SN2T
(70036)

HK5T
(70229)

D1 D2
d
(max) (ref) (H6)

IC
5/8U

Spare Parts

3.1

Stopper Holder Screw

Stopper Stopper
Screw
Key
3ST
(70027)

SN3TM
(70236)

K3T
(70021)

1/2-20x1.5
(70224)

Toolholder - Shell Mill for IC 5/8UT

d(H6) D1

D2

D2

L2

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

For Gear, Rack and Spline

Insert
Size

Insert
Cutting
Edges

Ordering Code

IC
5/8UT

Spare Parts

GMS5S D315-100-5UT 215/...

No. of
Flutes

Dimensions inch
D1
(max)

D2
(ref)

d (H6)

*L2
(ref)

Insert Screw

3.07

3.15

1.00

1.97

.39

SN5TM
(70041)

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.

Insert
Torx + Key
HK5T
(70229)

Holder Screw
1/2-20x1.5
(70224)

Gear Milling Toolholder - Disc Mill for IC 1/4U

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

Insert
Size

Insert
Cutting
Edges

Ordering Code

No. of
Flutes

Dimensions inch

IC
1/4U

Spare Parts

D1
(max)

D2
(ref)

d (H6)

*L2
(ref)

3.3

3.35

1.00

.98

.49

12

GMD12N D335-100-2U 215/...

Insert
Screw
SN2T
(70036)

Insert
Torx + Key
HK2T
(70227)

Stopper Stopper
Screw Stopper Key
5LST
SN5LTR
K7T
(70013) (72007)
(70026)

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

d(H6)

D1

L2
D2

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

For Gear, Rack and Spline

Insert Insert
Cutting
Size Edges

Ordering Code

IC
3/8U

GMD12N D354-100-3U 215/...

Spare Parts
No. of
Flutes

Dimensions inch
D1
(max)

D2
(ref)

d (H6)

*L2
(ref)

3.5

3.54

1.00

.98

.49

12

Insert
Insert
Screw Torx + Key
SR3FIP8
KIP8
(80973) (70231)

Stopper
2TM2ST
(70023)

Stopper
Screw
M3x7.5
(70029)

Stopper
Key
KIP8
(70231)

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.

Vardex No.

Recommended Grades, Cutting Speeds Vc [ft/min] and Feed f [inch/tooth]

Material
Group

Vc [ft/min]

1
2

Unalloyed steel

3
4

170

328 - 558

.0060 - .0090

Hardened

350

230 - 459

.0060 -.0098

Annealed

200

197 - 426

.0060 - .0087

Hardened

325

227 - 361

.0051 - .0083

15
16
17
18
28
29
30
31
32
33

Low alloy steel

(alloying elements5%)
High alloy steel
(alloying elements>5%)

Low alloy (alloying elements <5%)

200

328 - 558

.0060 - .0087

High alloy (alloying elements >5%)

225

230 - 394

.0047 - .0087

Stainless steel
Ferritic

Non hardened

200

328 - 558

.0060 - .0087

Hardened

330

328 - 558

.0063 - .0091

Stainless steel
Austenitic

Austenitic

180

230 - 460

.0060 - .0098

Cast steel

Super Austenitic

200

230 - 460

.0047 - .0079

Stainless steel
Cast Ferritic

Non hardened

200

230 - 460

.0063 - .0094

Hardened

330

230 - 460

.0047 - .0079

Stainless steel
Cast austenitic

Austenitic

200

230 - 394

.0060 - .0087

Hardened

330

230 - 394

.0047 - .0079

Malleable
Cast iron

Ferritic (short chips)

130

197 - 426

.0063 - .0095

Pearlitic (long chips)

230

197 - 394

.0060 - .0087

Low tensile strength

180

197 - 426

.0060 - .0087

High tensile strength

260

197 - 328

.0060 - .0087

Ferritic

160

197 - 410

.0039 - .0079

Pearlitic

Grey cast iron

Nodular SG iron

260

164 - 295

.0060 - .0087

34 Aluminium alloys
35 Wrought

Non aging

60

328 - 820

.0118 - .0197

Aged

100

328 - 590

.011 - .0197

36

Cast

75

492 - 1312

.011 - .0197

Cast & aged

90

492 - 918

.0098 - .0157

37

Aluminium alloys

Non-Ferrous
38 Aluminium alloys
Metals

Cast Si 13-22%

130

262 - 492

.011 - .0197

39 Copper and
40 Copper alloys

Brass

90

394 - 689

.0118 - .0197

Bronze and non leaded copper

100

394 - 689

.011 - .0197

19

Annealed (Iron based )

200

66 - 148

.0035 - .0059

20

High temperature
21 alloys

Aged (Iron based)

280

66 - 98

.0028 - .0051

Annealed (Nickel or Cobalt based)

250

49 - 66

.0031 - .0059

22

Aged (Nickel or Cobalt based)

350

33 - 49

.0031 - .0059

Pure 99.5 Ti

400Rm

230 - 459

.0028 - .0051

+ alloys

1050Rm

66 - 164

.0028 - .0051

45-50HRc

49 - 148

.002 - .0047

51-55HRc*

49 - 131

.002 - .0047

23
24

H(K)

High Carbon (C=0.55-0.85%)

.0067 - .011

14

Heat
Resistant
Material

.0079 - .0126

.0060 - .011

13

S(M)

.0079 - .0126

328 - 590
197 - 295

12

N(K)

328 - 689

150

262 - 492

11

Cast Iron

125

Medium carbon (C=0.25-0.55%)

275

10

Low carbon (C=0.1-0.25%)

180

Titanium alloys

25
Extra hard steel

Hardened
Material

Hardened & tempered

26

* Note: Special tools, which are not listed in this catalog, are required for extra hard steel (51-55HRc).

Grades
Grade

VBX

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

Other grades are available upon request.

10

Feed f
[inch/tooth]

Non hardened

Stainless
Steel

VBX

Hardened

Steel

Hardness
Brinell HB

Material

U Style

UT Style

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

Max:

Min:

14b | Tangent Length Over (N) Teeth

N:

Max:

Min:

Max:

Min:

14c | Actual - Tooth Thickness

Additional Information
15 | For Tool Exit Limitation, a detailed component drawing must be supplied!

Pin Diameter

16 | Exit Arc Radius (R)

17 | Material Hardness (During machining)
Pressure Angle

er

18 | Material Designation

iam

et

Involute

aj o

r(
Ou

t si

de
)D

Flat Root Spline

Form Diameter

Fillet Root Spline

(R
Minor

Pi tc

Fillet Radius

Involute

Tooth Thickness

Fillet Radius

Form Diameter

Fillet Radius

o o t) D

Tangent length over

(N) teeth

hD

iamet

er

Measurement
Over Pins
iam

e te

For Gear, Spline & Rack Manufacturing

Visit VARGUS

Vargus USA
1149 Barberry Drive
Janesville, WI 53545 U.S.A

Tel: +1-800-828-8765
+1-608-756-4930
Fax:+1-608-741-7125

sales@vargususa.com
www.vargususa.com

221-01321
INCH EA
03/2015
EDITION 02/213