Kyocera 1.0 4FL 0.060R WF SGS38109 | Carbide Endmill Kyotow.com
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- Stock: In Stock
- Model: ENDMILL
- Weight: 0.10kg
- Manufactured: In Japan
- Ships: Worldwide
- Item Code: SGS38109
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1. Product Overview
The Kyocera SGS38109 is a 4-flute solid carbide corner-radius endmill engineered for high-performance CNC milling operations. Featuring a 1.0" (25.400 mm) cutting diameter with a 0.06" (1.524 mm) corner radius, this tool is built on micro-grain tungsten carbide (0.8–1.0 μm) and finished with Uncoated (Bare Carbide) (WF grade). It delivers exceptional dimensional accuracy, superior surface finish, and extended tool life across a broad spectrum of workpiece materials.
Designed for modern machining centers, the SGS38109 combines an optimized 35° helix angle with precision-ground flutes to ensure efficient chip evacuation, minimal cutting forces, and reduced chatter—even in demanding applications such as mold & die, aerospace structural components, and precision medical device manufacturing.
2. ISO Designation Breakdown
The Kyocera catalog designation SGS-1.0-4F-0060-WF follows an internal classification system derived from ISO 1641 (solid ball-nosed and corner-radius endmills) and ANSI B94.19 standards:
| Position | Code | Meaning |
|---|---|---|
| 1–3 | SGS | Solid Carbide Endmill, General-Purpose / Semi-Finish Series |
| 4 | - | Separator |
| 5–7 | 1.0 | Nominal Cutting Diameter: 1.0" (25.400 mm) |
| 8 | - | Separator |
| 9–10 | 4F | Number of Flutes: 4 |
| 11 | - | Separator |
| 12–14 | 0060 | Corner Radius: 0.06" (1.524 mm) |
| 15 | - | Separator |
| 16–17 | WF | Grade / Coating: Wet Finish — Uncoated Micro-Grain Carbide |
3. Engineering Dimensions & Geometry
| Parameter | Inch | Metric | Tolerance |
|---|---|---|---|
| Cutting Diameter (D1) | 1.0" | Ø 25.400 mm | h6 (0 / -0.009 mm) |
| Corner Radius (R) | 0.06" | R 1.524 mm | ±0.005 mm |
| Overall Length (L) | 4.000" | 101.60 mm | ±0.50 mm |
| Flute Length (L1) | 2.000" | 50.80 mm | ±0.25 mm |
| Shank Diameter (D) | 1.0" | Ø 25.400 mm | h6 |
| Core Diameter (Dc) | 0.6500" | Ø 16.510 mm | ±0.02 mm |
| Neck Diameter (Dn) | 0.6175" | Ø 15.684 mm | ±0.02 mm |
| Helix Angle | — | 35° | ±1° |
| Number of Flutes (Z) | — | 4 | — |
| Radial Rake Angle (γf) | — | +5° | ±1° |
| Axial Rake Angle (γp) | — | +3° | ±1° |
| Corner Radius Tolerance | — | ±0.005 mm | — |
| Runout (peripheral) | — | ≤0.010 mm | — |
4. Grade Details — Key Grade Characteristics
Wet Finish — Uncoated Micro-Grain Carbide
| Property | Value / Description |
|---|---|
| Substrate | Micro-Grain Tungsten Carbide (0.8–1.0 μm) |
| Coating | Uncoated (Bare Carbide) |
| Hardness | HRA 92.0 |
| Transverse Rupture Strength | 3,800 MPa |
| Coating Color | Dark Gray |
| Max Operating Temperature | 600 °C |
- Maximum edge sharpness and keenness
- No coating delamination risk
- Superior surface finish on non-ferrous materials
- Optimal for wet coolant environments
- Excellent weld resistance on aluminum
5. Grade Comparison Matrix
| Attribute | WF (Uncoated) | TN (TiN) | TC (TiCN) |
|---|---|---|---|
| Hardness (HV) | 1,600 | 2,300 | 3,000 |
| Coef. of Friction | 0.45 | 0.35 | 0.30 |
| Tool Life (vs. WF) | 1.0× (baseline) | 2.0–3.0× | 3.0–5.0× |
| Best For | Non-ferrous, finish | General ferrous | Alloy & hardened steel |
| Edge Sharpness | ★★★★★ | ★★★★☆ | ★★★★☆ |
| Heat Resistance | ★★★☆☆ | ★★★★☆ | ★★★★★ |
| Cost Index | 1.0 | 1.15 | 1.25 |
6. Flute & Chip Evacuation Profile
Although endmills do not incorporate indexable-style chipbreakers, the SGS38109 features a precision-engineered flute profile that governs chip formation, evacuation, and cutting stability:
| Feature | Specification | Functional Benefit |
|---|---|---|
| Helix Angle | 35° | Progressive entry reduces impact shock; smooth chip flow along flute |
| Flute Form | Parabolic / constant helix | Maximized core strength with generous chip pocket volume |
| Edge Preparation | Micro-honed K-land (0.02–0.04 mm) | Prevents micro-chipping; enhances edge durability in interrupted cuts |
| Corner Radius Geometry | Tight-tolerance form grinding | Eliminates stress concentration; extends corner life vs. sharp corners |
| Surface Finish (Flute) | Ra 0.10–0.20 μm | Reduces chip adhesion; lower friction = less heat generation |
| Chip Space Ratio | 2.00× diameter | Adequate evacuation for 4-flute density without weakening core |
7. Recommended Applications & Workpiece Materials
The WF grade substrate and coating combination makes the SGS38109 particularly effective on the following material groups:
| Material Group | Examples | Machinability Rating | Recommended Grade |
|---|---|---|---|
| Carbon & Mild Steels | C45, 1045, A36, S275JR | ★★★★★ | TN, TC |
| Alloy Steels | 4140, 4340, 8620, 16MnCr5 | ★★★★☆ | TC (best), TN |
| Stainless Steels | 304, 316, 17-4PH, 420 | ★★★☆☆ | TC |
| Cast Irons | GG25, GGG40, Class 40 | ★★★★☆ | TN, TC |
| Aluminum & Alloys | 6061-T6, 7075-T6, 2024 | ★★★★★ | WF (best), TN |
| Copper & Brass | C36000, C11000, CuZn37 | ★★★★★ | WF |
| Titanium Alloys | Ti-6Al-4V, Ti-5Al-2.5Sn | ★★☆☆☆ | TC (light cuts) |
| Hardened Steels | H13, D2, 1.2344 (≤45 HRC) | ★★☆☆☆ | TC only |
8. Application Map by Operation
| Operation | Suitability | Notes / Parameter Guidance |
|---|---|---|
| Roughing | Not Recommended | Insufficient heat resistance; use TN or TC grade |
| Semi-Finishing | Limited | Low speeds only; excellent finish when parameters controlled |
| Finishing | Excellent | Maximum edge sharpness yields mirror surfaces |
| Profiling | Excellent | Optimal for non-ferrous profile milling |
| Slotting | Good | Wet coolant essential for chip evacuation |
| Pocketing | Good | Shallow depths preferred; excellent wall finish |
| 3D Contouring | Excellent | Smooth flutes reduce chatter on complex surfaces |
9. Recommended Cutting Conditions
All values are starting recommendations. Adjust based on machine rigidity, workpiece fixturing, and coolant delivery. Values shown for WF grade.
| Workpiece Material | Cutting Speed Vc (SFM) | Feed per Tooth fz (in) | Axial Depth ap | Radial Depth ae |
|---|---|---|---|---|
| Mild Steel (≤250 HB) | 80–110 | 0.003–0.005 | 1.0D–1.5D rough 0.2D–0.5D finish | 0.3D–0.5D rough 0.05D–0.1D finish |
| Alloy Steel (250–350 HB) | 60–85 | 0.002–0.004 | 0.5D–1.0D | 0.1D–0.3D |
| Stainless Steel (≤300 HB) | 50–70 | 0.002–0.003 | 0.5D–1.0D | 0.1D–0.3D |
| Cast Iron (≤260 HB) | 70–95 | 0.003–0.005 | 1.0D–1.5D | 0.3D–0.5D |
| Aluminum / Alloys | 300–450 | 0.005–0.010 | 1.0D–1.5D | 0.3D–0.5D |
Spindle Speed (RPM) formula: RPM = (SFM × 3.82) / Diameter(in). | Feed Rate (IPM) formula: IPM = RPM × fz × Z (flutes).
10. Operating Guidelines
- Runout Control: Maintain toolholder runout ≤0.01 mm at the tool tip. Excessive runout causes uneven flute loading and premature corner wear.
- Coolant Strategy: Flood coolant or high-pressure through-spindle (70+ bar) recommended for chip evacuation. Avoid dry cutting on ferrous materials.
- Ramp Entry: Use helical ramp entry at 1–2° angle or pre-drill pilot hole. Avoid plunging directly into solid material.
- Step-Over Strategy: For finishing, use 5–10% radial step-over (ae = 0.05–0.10 × D) to achieve mirror surface finishes.
- Corner Radius Benefit: The 0.06" corner radius distributes cutting forces over a larger arc, increasing corner life 3–5× compared to sharp-corner endmills.
- Tool Life Monitoring: Inspect flank wear (VB) every 30 min of cutting time. Retire tool when VB exceeds 0.15 mm or corner radius shows visible chipping.
- Vibration Damping: Keep tool overhang (stick-out) to minimum practical length. If overhang exceeds 4× diameter, reduce speeds and feeds by 20–30%.
11. Toolholder Compatibility
| Holder Type | Recommended Model / Size | Advantages |
|---|---|---|
| Hydraulic Chuck | HydroForce HPH-32 | Best runout <0.003 mm; vibration damping |
| Shrink Fit | SFG-32-100 | Maximum grip; ideal for high-speed finishing |
| Collet Chuck | ER32 Precision | Good versatility; ensure <0.01 mm runout |
| Milling Arbor | MAS-BT50-SM32-105 | Heavy-duty roughing; BT50 taper stability |
| Weldon Holder | Weldon 1.0" Flat | Positive drive; secure side-lock for slotting |
12. Packaging & Ordering Information
| Item | Details |
|---|---|
| Manufacturer Part Number | SGS38109 |
| Brand | Kyocera Precision Tools (Japan) |
| Country of Manufacture | Japan |
| Packaging Type | Individual plastic tube with protective end caps; anti-corrosion VCI paper |
| Quantity per Pack | 1 piece |
| Minimum Order Quantity | 1 piece (bulk discounts available for 10+ units) |
| Warranty | Full manufacturer defect warranty — 12 months from date of purchase |
| Certifications | ISO 9001:2015 (Manufacturing), ISO 1641 (Tool Geometry Standard) |
| Storage Recommendation | Store in original packaging at 15–25 °C, humidity <60% RH |
13. Catalog Meta Data
| Meta Field | Value |
|---|---|
| Product Family | SGS Series — Solid Carbide Corner-Radius Endmills |
| Tool Category | Rotating Tool / Milling Cutter |
| Tool Sub-Category | 4-Flute Corner-Radius Endmill |
| Primary Application | Semi-finishing to finishing of contoured surfaces, pockets, and profiles |
| Secondary Application | Light roughing in stable setups; slotting up to 1×D depth |
| Compatible Machines | 3-axis to 5-axis CNC machining centers; high-speed machining (HSM) centers |
| Industry Verticals | Aerospace, Automotive, Mold & Die, Medical Device, General Engineering |
| Date Added to Catalog | 2026-05-23 |
| Last Specification Update | 2026-07-15 |
| Replacement / Successor | None — current active catalog item |
All technical data and recommendations are provided as general guidance. Always verify parameters against your specific machine, fixture, and material batch before production runs. Kyocera and Kyotow.com disclaim liability for tool failure arising from improper application or operating conditions outside stated ranges.
✓ Genuine Kyocera Product
| Manufacturer | Kyocera Corporation |
|---|---|
| Status | Verified Original Product |
| Quality Assurance | Guaranteed Genuine Kyocera Components |
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- Confirm dimensions, geometry, coating, and grade using the official Kyocera item code.
- Technical datasheets are available upon request.
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Please verify machine compatibility, insert geometry, coating, and application grade before placing your order.
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Kyotowは日本の国内流通ネットワークから京セラ正規品を直接仕入れることで、欧米の現地代理店による大幅な上乗せ価格や営業コスト、中間マージンを完全に排除しています。その構造的メリットを、お客様の加工現場へ100%還元いたします。
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