BARREL-SHAPED ENDMILLS

Quick Tool Selector Guide

Metric Catalog

SOLID
MULTI-MASTER ONE INSERT
CARBIDE
HEADS CUTTERS
ENDMILLS

w w w . i s c a r. c o m
 Barrel Shaped Endmills
Solid Carbide
Endmills

Solid Carbide
Oval-Shaped
Endmills for 3D Profiling

Solid Carbide Taper-Shaped

Endmills for 3D Profiling

Solid Carbide Lens-Shaped

Endmills for 3D Profiling

2 ISCAR
Multi-Master One Insert
Interchangeable Cutters
Carbide Heads

Oval-Shaped Taper Barrel-Shaped

Solid Carbide Heads Inserts with 2 Cutting Edges

Lens-Shaped Combined Barrel

Solid Carbide Heads and Lens-Shaped
Inserts with 2 Cutting Edges
 Barrel Shaped Endmills
Expanding the
Boundaries of Barrel
Endmill Applications
Endmills that feature a cutting edge being the Another advantage of this type of cutting
segment of a large-diameter arc were introduced edge versus ball-nose and toroidal cutters is
approximately 25 years ago. a significant increase in the distance between
As the cutting-edge shape of these endmills passes (a stepover or a stepdown, depending
is reminiscent of a barrel profile, terms such as on the direction of a cutter displacement after
“barrel milling cutters”, “barrel endmills” became every pass), at least four times more without the
common when referring to these types of degradation of the surface finish parameters. This
endmills. At first, the use of these implies that the number of passes and machining
barrel-shaped mills was limited time can be substatially reduced. Increasing the
to a few specific applications, distance between passes also improves tool life
such as machining 3D and therefore decreases tool cost per part.
surfaces of complex dies
and turbomachinery
The main consumers of “cutting barrels” are
components.
producers of aerospace, die and mold, medical,
However, advances
turbine and compressor components.
in 5-axis machining
Cutting tool companies have strengthened
and in CAM
their efforts to develop and manufacture more
systems have
advanced barrel endmill designs to meet
significantly
increased customer demands. Some of ISCAR’s
expanded the
latest product such as, barrel endmills,
boundaries of
MULTI-MASTER and one insert cutter
barrel endmill
families show good examples of this trend.
applications.
Traditionally,
ball-nose
and toroidal
cutters perform
these machining
operations.
The large-diameter
arc of the endmills
cutting edge provides
substantial reduction of
the cusp height generated
between passes machined by
a ball-nose or toroidal cutter.

4 ISCAR
 ISCAR’s program for barrel-shaped
cutters comprises tools in the
following design configuration:
• Solid carbide endmills.
• Assembled endmills that mount
MULTI-MASTER interchangeable
carbide heads, and indexable endmills.

These cutters differ in their

capabilities and field of application.
The figures and tables provide
general data that relate to the cutters.

accuracy

Solid
Carbide
Endmills

Multi-Master
Interchangeable
Carbide Heads
One Insert
Cutters

diameters

Table 1 - the Main Parameters of Barrel-Shaped Cutters

Parameters
Diameters Geometry
Type Range (mm) Barrel Lens Taper Number of Teeth
Solid Carbide Endmills 8-12 • • • 2-6
MM Cutters* 8-16 • • 2-6
One Insert Cutters 16-25 • • • 2
* MM cutters - MULTI-MASTER cutters

5
 Barrel Shaped Endmills
The Design
Concept Advantages
Solid carbide design ensures the highest MULTI-MASTER’s distinctive “no setup time”
tool accuracy. ISCAR offers oval and lens phenomenon, which enables the replacement
shaped solid carbide endmills in diameter of a worn head without removing the tool from
ranges of 8 - 12mm. the machine spindle, is effective in barrel tool
In addition, barrel endmills have been applications for semi-finish and finish
manufactured as interchangeable carbide heads milling operations.
with MULTI-MASTER threaded adaptations in the The one insert cutter design enables
diameter ranges of 8 - 16mm. cost-efficient increase of the cutter diameter
range of up to 25mm. According to this concept
barrel-shaped inserts are mounted on endmills.

Multi-Master Interchangeable Carbide Heads

No Setup Time

Estimated Scallop when Milling with Barrel-Shaped Cutters

Oval-Shaped Solid Carbide Heads
Scallops Height (mm)
Diameter (mm) Radius (mm) 0.002 0.004 0.01 0.015
8 80 1.13 1.6 2.53 3.1
10 85 1.17 1.65 2.61 3.19
stepsize ap (mm)
12 75 1.1 1.55 2.45 3
16 75 1.1 1.55 2.45 3

Lens-Shaped Solid Carbide Heads

Scallops Height (mm)
Diameter (mm) Radius (mm) 0.002 0.004 0.01 0.015
8 16 0.51 0.72 1.13 1.39
10 20 0.57 0.8 1.26 1.55
stepsize ae (mm)
12 24 0.62 0.88 1.39 1.7
16 32 0.72 1.01 1.6 1.96

6 ISCAR
Solid Carbide Endmills

Estimated Scallop when Milling with Barrel-Shaped Cutters

Tapered-Shaped Endmills
Scallops Height (mm)
Diameter (mm) Radius (mm) 0.002 0.004 0.01 0.015
8 250 2 2.83 4.47 5.48
10 250 2 2.83 4.47 5.48 stepsize ap (mm)
12 250 2 2.83 4.47 5.48

Oval-Shaped Endmills
Scallops Height (mm)
Diameter (mm) Radius (mm) 0.002 0.004 0.01 0.015
8 90 1.2 1.7 2.68 3.29
10 85 1.17 1.65 2.61 3.19 stepsize ap (mm)
12 80 1.13 1.6 2.53 3.1

Lens-Shaped Endmills
Scallops Height (mm)
Diameter (mm) Radius (mm) 0.002 0.004 0.01 0.015
8 16 0.51 0.72 1.13 1.39
10 20 0.57 0.8 1.26 1.55 stepsize ae (mm)
12 25 0.63 0.89 1.41 1.73

7
 Barrel Shaped Endmills
One Insert Cutters

Estimated Scallop when Milling with Barrel-Shaped Cutters

HLB - Combined Barrel and Lens-Shaped Inserts With 2 Cutting Edges
Scallops Height (mm)
Barrel Lens Barrel Lens
Diameter (mm) Radius (mm) 0.25 0.4 0.5 1 1.5 0.5 0.75 1 1.5 2
16 16 32 0.5 1.25 1.95 7.8 17.6 1 2.2 3.9 7.8 15.6
stepsize
20 20 40 0.4 1 1.56 6.25 14.1 0.4 1 1.56 6.25 12.5
ap/ae (mm)
25 25 50 0.3 0.8 1.25 5 11.25 0.3 0.8 1.25 5 11.25

HCT - Taper Barrel-Shaped Inserts With 2 Cutting Edges

Scallops Height (mm)
Diameter (mm) Radius (mm) 0.6 1.2 1.8 2.4
16 45 1 4 9 16
20 60 0.75 3 6.75 12 stepsize ap (mm)
25 75 0.6 2.4 5.4 9.6

8 ISCAR
 oval-shaped lens-shaped
taper-shaped

R ae h
scallop height

ap

h
scallop height

β=34˚-46˚
β=0º-20º

R ap

R
β=0°-10°
ap

R ae

A scallop height can be calculated as a function of ap/ae

and R by use of the equation in the table below
Insert/Application H

milling by bottom edge 0.5x(2xR−√((2xR)2−ae2) )

HLB
milling by peripheral edge
0.5x(2xR−√((2xR)2−ap2) )
HCT milling by taper edge
R-radius of appropriate (botton or peripheral) cutting edge

Recomended Range for Milling by use of Barrel-Shaped Inserts

Insert Angle β, Working Range
HLB - Barrel 0°-20°
HLB - Lens 0°-10°
HCT - Taper 34°-46°

9
 Barrel Shaped Endmills
APMX
EOB
Solid Carbide Oval-Shaped PRFA
DCONMS
(Barrel) Endmills for 3D Profiling
RE
PRFRAD
0.02
OAL

Dimensions Tough 1 Hard

IC902

IC602
IC08
Designation DCONMS RE PRFRAD APMX PRFA NOF(1) OAL Shank(2)
EOB-R1R90A24/7-4C08-63 8.00 1.00 90.00 24.50 14.88 4 63.00 C •
EOB-R2R90A20/7-4C08-63 8.00 2.00 90.00 21.50 12.18 4 63.00 C •
EOB-AL-R2R85A20/9-4C10-72 10.00 2.00 85.00 21.00 18.68 4 72.00 C •
EOB-R2R85A24/8-4C10-72 10.00 2.00 85.00 24.50 15.46 4 72.00 C •
EOB-R3R85A21/6-4C10-72 10.00 3.00 85.00 21.30 12.62 4 72.00 C •
EOB-R2R80A27/9-4C12-83 12.00 2.00 80.00 27.10 18.38 4 83.00 C •
EOB-AL-R3R85A24/8-4C12-83 12.00 3.00 85.00 25.00 16.12 4 83.00 C •
EOB-R3R80A24/8-4C12-83 12.00 3.00 80.00 24.50 15.98 4 83.00 C •
EOB-R4R80A21/6-8C12-83 12.00 4.00 80.00 21.50 13.10 8 83.00 C •
EOB-R4R80A21/7-4C12-83 12.00 4.00 80.00 21.50 13.10 4 83.00 C •
(1) Number of flutes
(2) C-Cylindrical

10 ISCAR
 LF
APMX

MM EOB DCONMS PRFA

Interchangeable Oval-Shaped
RE
(Barrel) Solid Carbide PRFRAD
Heads for 3D Profiling 0.02 THSZMS

Dimensions

IC908
Designation PRFRAD RE APMX PRFA THSZMS NOF(1) DCONMS LF
MM EOB08R1.5R80A13-4T05 80.00 1.50 14.20 24.00 T05 4 8.00 18.00 •
MM EOB08R1.5R80A13-6T05 80.00 1.50 14.10 24.00 T08 6 8.00 18.00 •
MM EOB10R2.0R85A16-4T06 85.00 2.00 16.50 24.00 T06 4 10.00 22.00 •
MM EOB10R2.0R85A16-6T06 85.00 2.00 16.50 24.00 T06 6 22.00 22.00 •
MM EOB12R2.0R75A21-4T08 75.00 2.00 21.30 24.00 T08 4 12.00 27.00 •
MM EOB12R2.0R75A21-6T08 75.00 2.00 21.30 24.00 T08 6 27.00 27.00 •
MM EOB16R3.0R75A26-4T10 75.00 3.00 27.00 24.00 T10 4 16.00 33.50 •
MM EOB16R3.0R75A26-6T10 75.00 3.00 27.00 24.00 T10 6 33.50 33.50 •
(1) Number of flutes

LF
APMX

MM EOBA DCONMS PRFA

Interchangeable Oval-Shaped
RE
(Barrel) Solid Carbide Heads PRFRAD
for 3D Aluminum Profiling 0.02 THSZMS

Dimensions

Designation PRFRAD RE APMX PRFA THSZMS NOF(1) DCONMS LF IC08

MM EOBA08R1.5R80A13-4T05 80.00 1.50 14.20 24.00 T05 4 8.00 18.00 •
MM EOBA10R2.0R85A16-4T06 85.00 2.00 16.50 24.00 T06 4 10.00 22.00 •
MM EOBA12R2.0R75A21-4T 75.00 2.00 21.30 24.00 T08 4 12.00 27.00 •
MM EOBA16R3.0R75A26-4T10 75.00 3.00 27.00 24.00 T10 4 16.00 33.50 •
(1) Number of flutes

11
 Barrel Shaped Endmills
APMX

BSR
0.02
DC DCONMS
ELB
Solid Carbide Lens-Shaped
RE
(Barrel) Endmills for 3D Profiling LU
OAL

Dimensions

IC902
Designation DC BSR RE LU APMX DCONMS NOF(1) OAL Shank(2)
ELB-R0.75R16A5-6C8-63 8.00 15.00 0.75 5.00 1.10 8.00 6 63.00 C •
ELB-R1R20A7-6C10-72 10.00 20.00 1.00 7.00 1.43 10.00 6 72.00 C •
ELB-R1R25A9-6C12-83 12.00 25.00 1.00 9.00 1.53 12.00 6 83.00 C •
(1) Number of flutes
(2) C-Cylindrical

LF
LU THSZMS
APMX

MM ELB
Interchangeable Lens-Shaped DC DCONMS
BSR
(Barrel) Solid Carbide 0.02
Heads for 3D Profiling
RE

Dimensions

IC908
Designation DC BSR RE LU APMX THSZMS DCONMS NOF(1) LF
MM ELB08R16A05-4T05 8.00 16.00 0.50 5.50 0.90 T05 8.00 4 10.00 •
MM ELB10R20A07-4T06 10.00 20.00 1.00 7.50 1.42 T06 10.00 4 13.00 •
MM ELB12R24A09-4T08 12.00 24.00 1.00 9.00 1.55 T08 12.00 4 16.50 •
MM ELB16R32A12-4T10 16.00 32.00 1.00 12.00 1.80 T10 16.00 4 20.50 •
(1) Number of flutes

LF
LU THSZMS
APMX

MM ELBA
Interchangeable Lens-Shaped DC DCONMS
(Barrel) Solid Carbide Heads BSR
0.02
for 3D Aluminum Profiling
RE

Dimensions
IC08

Designation DC BSR RE LU APMX THSZMS DCONMS NOF(1) LF

MM ELBA08R16A05-4T05 08 8.00 16.00 0.50 5.50 0.90 T05 8.00 4 10.00 •
MM ELBA10R20A07-4T06 10.00 20.00 1.00 7.50 1.42 T06 10.00 4 13.00 •
MM ELBA12R24A09-4T08 08 12.00 24.00 1.00 9.00 1.55 T08 12.00 4 16.50 •
MM ELBA16R32A12-4T10 16.00 32.00 1.00 12.00 1.80 T10 16.00 4 20.50 •
(1) Number of flutes

12 ISCAR
 APMX
RE_2
PRFRAD
0.02
RE
ETB TFBA
Solid Carbide Taper-Shaped DCONMS
(Barrel) Endmills for 3D Profiling
OAL

Dimensions

IC902
Designation PRFRAD RE_2 RE APMX TFBA DCONMS NOF(1) OAL Shank(2)
ETB-R1R250A10/20-4C08-63 250.00 4.00 1.00 10.00 40.00 8.00 4 63.00 C •
ETB-R2R250A11/20-4C10-72 250.00 5.00 2.00 11.00 40.00 10.00 4 72.00 C •
ETB-R3R250A12/20-4C12-83 250.00 6.00 3.00 12.00 40.00 12.00 4 83.00 C •
(1) Number of flutes
(2) C-Cylindrical

13
 Barrel Shaped Endmills
Table 2 - Recommended Cutting Parameters to Start
Tensile Strength Hardness Material Cutting Parameter Range
ISO

Material Condition (N/mm2) HB No. vc (m/min) fz (mm/t)

<0.25% C annealed 420 125 1 210-300 0.005-0.01xD**
non-alloy ≥0.25% C annealed 650 190 2 200-250 0.005-0.01xD
steel and cast
<0.55% C quenched and tempered 850 250 3 160-240 0.004-0.009xD
steel, free
cutting steel annealed 750 220 4 160-240 0.003-0.008xD
≥0.55% C
quenched and tempered 1000 300 5 140-200 0.004-0.009xD
annealed 600 200 6 160-240 0.003-0.008xD
low alloy and cast steel
P 930 275 7 120-200 0.003-0.008xD
(less than 5% of
quenched and tempered 1000 300 8 130-200 0.003-0.008xD
alloying elements)
1200 350 9 140-200 0.003-0.008xD
high alloyed steel, cast annealed 680 200 10 130-200 0.003-0.008xD
steel and tool steel quenched and tempered 1100 325 11 70-130 0.002-0.007xD
stainless steel and ferritic / martensitic 680 200 12 80-175 0.002-0.007xD
cast steel martensitic 820 240 13 60-165 0.002-0.007xD
stainless steel and
M austenitic, duplex 600 180 14 60-110 0.002-0.007xD
cast steel
ferritic / pearlitic 180 15 150-275 0.005-0.01xD
gray cast iron (GG)
pearlitic / martensitic 260 16 150-265 0.005-0.01xD
ferritic 160 17 150-200 0.005-0.01xD
K nodular cast iron (GGG)
pearlitic 250 18 90-150 0.004-0.009xD
ferritic 130 19 150-200 0.005-0.01xD
malleable cast iron
pearlitic 230 20 90-150 0.004-0.009xD
annealed 200 31 20-45 0.002-0.004xD
Fe based
high hardened 280 32 20-35 0.002-0.004xD
temperature annealed 250 33 20-35 0.002-0.004xD
Ni or Co
S alloys hardened 350 34 20-35 0.002-0.004xD
based
cast 320 35 60-90 0.002-0.004xD
pure 400 190 36 60-90 0.002-0.004xD
titanium alloys
alpha+beta alloys, hardened 1050 310 37 60-90 0.002-0.004xD
hardened 55 HRC 38 40-80 0.001-0.003xD
hardened steel
hardened 60 HRC 39
H
chilled cast iron cast 400 40 40-80 0.001-0.003xD
cast iron hardened 55 HRC 41 40-80 0.001-0.003xD
* Recommended amount of material engagement should not exceed 0.3mm
** D - nominal diameter of solid carbide endmill (MM head)

14 ISCAR
HLB-QF PRFRAD
Combined Barrel and
Lens-shaped Inserts with APMX
2 Cutting Edges
BSR 10.5˚ S1

DC RE

Dimensions

IC908
Designation DC APMX S1 RE BSR PRFRAD
HLB D160-QF 16.00 7.00 3.37 1.50 32.00 16.00 •
HLB D200-QF 20.00 9.00 4.65 2.00 40.00 20.00 •
HLB D250-QF 25.00 11.00 5.40 2.50 50.00 25.00 •
• For machining recommendations, see table 3

HCT-QF
Taper Barrel-Shaped Inserts
with 2 Cutting Edges
PRFRAD APMX

RE S1
DC

Dimensions

IC908
Designation DC APMX S1 RE PRFRAD
HCT D160-QF 16.00 8.50 3.37 1.60 45.00 •
HCT D200-QF 20.00 10.50 4.65 2.00 60.00 •
HCT D250-QF 25.00 12.50 5.40 2.50 75.00 •
• For machining recommendations, see table 3

15
 Barrel Shaped Endmills
Table 3 - average cutting data when milling with barrel-shaped inserts
Material Group No. Typical
Representstive Feed fz (mm/t) Deph of Cut (mm)

Carbide Grade
Hardness, HB

DIN W.-Nr.
ae ae ap

AISI/SAE/

Coolant
Cutting

ASTM
Speed vc0 HCT HLB HLB HCT HLB HLB
ISO

Material (mm/min) Taper Barrel Lens Taper Barrel Lens

non-alloy steel
and cast steel, 1-5 130-180 1020 1.0402 IC908 500-600 0.1-0.2 0.12-0.25 0.15-0.3 0.1 0.1 0.1 Dry
free cutting steel

low alloy and 6-8 260-300 4340 1.6582 IC908 500-600 0.1-0.2 0.12-0.25 0.15-0.3 0.1 0.1 0.1 Dry
cast steel
(less than 5% 35-42**
P of alloying 9 3135 1.5710 IC908 400-500 0.1-0.2 0.12-0.25 0.15-0.3 0.1 0.1 0.1 Dry
HRC
elements)
high alloyed
steel, cast steel 10-11 200-220 H13 1.2344 IC908 500-600 0.1-0.2 0.12-0.25 0.15-0.3 0.1 0.1 0.1 Dry
and tool steel
stainless steel
12-13 200 420 1.4021 IC908 500-600 0.1-0.2 0.12-0.25 0.15-0.3 0.1 0.1 0.1 Dry
and cast steel
stainless steel
M 14 200 304L 1.4306 IC908 400-500 0.1-0.2 0.12-0.32 0.15-0.3 0.1 0.1 0.1 Wet
and cast steel
gray cast 0.6025
15-16 250 Class 40 IC908 600-700 0.15-0.3 0.2-0.35 0.25-0.4 0.125 0.125 0.125
iron (GG) (GG25)
K Dry
nodular cast Class 0.7050
17-18 200 IC908 500-600 0.15-0.3 0.2-0.35 0.25-0.4 0.125 0.125 0.125
iron (GGG) 65-45-12 (GGG50)

Inconel
high temperature 33-35 340
718
2.4668 25-35 0.05-0.1 0.07-0.13 0.1-0.2 0.1 0.1 0.1
S alloys and IC908 Wet
titanium 35-40 AMS 3.7165
36-37 40-60 0.06-0.1 0.07-0.13 0.1-0.2 0.1 0.1 0.1
HRC R56400 (Ti6Al4V ELI)
45-49
HARDOX 450 plate 200-300 0.05-0.1 0.1-0.15 0.15-0.2 0.075 0.075 0.075
HRC
H hardened steel 38 IC908 Dry
58-62
D2 1.2379 180-250 0.05-0.1 0.1-0.15 0.15-0.2 0.05 0.05 0.05
HRC
* ISCAR material group in accordance with VDI 3323 standard
** Quenched and tempered
For machining in unstable conditions, the recommended cutting data should be reduced by 20-30%

16 ISCAR
 Cutting speed vc depends on the tool overhang H.
The cutting speed can be calculated as follows:

vc=vc0*kH

Where:
vc0 - cutting speed as recommended in table 3
kH - overhang factor in table 4

Table 4 - Overhang Factor KH

H/d* Low Then 3 Over 3 Up to 5 Over 5 Up to 6 Over 6 Up to 7 Over 7
kH 1 0.8 0.7 0.6 0.5
d* - nominal tool diameter

17 17
 Barrel Shaped Endmills
Parameters for CNC Programing of Profile
Cutters by Use of a CAM System
Select a barrel tool configuration and define its dimensions as shown below:

• Oval (Barrel) Shaped

OAL

APMX
PRERAD

RE

• Taper Shaped

OAL

TFBA

RE2

PRFRAD APMX
RE

• Lens Shaped

OAL

LU

APMX BSR
RE
D

18 ISCAR
19
BARREL-SHAPED ENDMILLS
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