Kyocera Z4S PR1535 CEM04178 Square Endmill - Steel Machining

Product Overview

The Kyocera Z4S 6 mm × 30 mm Square Endmill (CEM04178) is a premium solid-carbide milling cutter engineered for high-performance CNC machining. Manufactured in Japan to exacting OEM standards, this 4-flute endmill combines a precision-ground substrate with an advanced PVD coating layer to deliver exceptional wear resistance, superior surface finish quality, and extended tool life in demanding production environments.

ISO Designation Breakdown

Engineering Dimensions & Geometry

Grade Details – Key Grade Characteristics

Grade PR1535 is a high-performance PVD-coated ultra-fine-grain carbide grade specifically developed for solid endmill applications in steels and stainless steels. The substrate combines a 0.6 μm WC grain size with a multi-layer TiAlN-based coating that provides outstanding thermal stability and oxidation resistance at elevated cutting temperatures.

• Coating: Multi-layer PVD TiAlN + TiN top layer (≈3.0 μm total thickness)
• Substrate: 12% Co, ultra-fine WC (0.6 μm)
• Hardness: 1,620 HV ( substrate ) / 3,200 HV ( coating )
• Transverse Rupture Strength: 3,800 MPa
• Max Operating Temperature: 850 °C
• Oxidation Onset: 1,050 °C

Grade Comparison Matrix

Chipbreaker Profile

Although solid endmills do not utilise indexable inserts, the Z4S series incorporates an engineered flute profile that functions analogously to a chipbreaker by controlling chip formation and evacuation:

• Flute Geometry: Variable-pitch asymmetric flute spacing to suppress chatter and harmonics
• Core Thickness: 62% of tool diameter for maximum rigidity at 5.0× L/D
• Edge Preparation: 0.02 mm honed land with micro-polished rake face to reduce built-up edge
• Helix Configuration: 38° right-hand helix with differential pitch (37° / 39° / 38° / 40°)
• Chip Pocket: Deep, polished flute valleys with surface roughness Ra ≤ 0.2 μm for efficient chip flow

Recommended Applications & Workpiece Materials

Application Map by Operation

Recommended Cutting Conditions

Parameters below are starting recommendations for grade PR1535 in medium-carbon steel (C45 / 1045). Adjust based on machine rigidity, coolant delivery, and workpiece fixturing.

Operating Guidelines

• Run-out Check: Verify tool run-out at the collet face is ≤ 0.01 mm TIR. Excessive run-out dramatically reduces tool life and surface quality.
• Entry Strategy: Avoid direct 90° plunge into solid material. Use a helical ramp entry with a maximum ramp angle of 2°–3° or employ a pre-drilled pilot hole.
• Coolant Concentration: When using water-miscible coolant, maintain a concentration of 8–10% and ensure delivery pressure ≥ 20 bar for through-tool systems.
• Chip Evacuation: At 5.0× L/D, chip evacuation is critical. Use air blast or high-pressure coolant to prevent chip re-cutting, especially in deep slotting.
• Tool Overhang: Minimise overhang to ≤ 3× tool diameter for optimal rigidity. For 5.0× L/D tools, use hydraulic or shrink-fit holders for best damping.
• Corner Wear Monitoring: Inspect the tool corner every 30–45 minutes of cutting time. Replace when flank wear land exceeds 0.15 mm or when chipping is visible.
• Speed & Feed Adjustment: Reduce cutting speed by 15% for stainless steels (304/316) and increase feed by 10% for cast iron to promote free chip breaking.

Toolholder Compatibility

The 6 mm shank diameter conforms to h6 tolerance, ensuring precise fit in standard precision collets and hydraulic chucks. Recommended holder systems:

• ER Collet Chuck: ER16 (for 4 mm) / ER25 (for 6 mm) with precision collet (≤ 0.01 mm run-out)
• Hydraulic Chuck: HSK-A63 or BT40 hydraulic holders for high-speed applications
• Shrink-Fit Holder: Induction shrink-fit system for maximum rigidity and balance (G2.5 @ 25,000 rpm)
• Milling Chuck: High-precision milling chucks (e.g., Kyocera MFH series) for heavy-duty roughing
• Taper Compatibility: BT40, BT50, HSK-A63, HSK-E40, DIN 69871

Packaging & Ordering Information

• Packaging: Each endmill is supplied in an individual sealed plastic tube with protective wax coating to prevent edge damage during transit.
• Minimum Order: No minimum order quantity. Bulk discounts available for quantities ≥ 50 pieces.
• Lead Time: In-stock items ship within 24–48 hours. Back-orders typically fulfilled within 5–7 business days.
• Warranty: 12-month manufacturer warranty against material and manufacturing defects under normal operating conditions.
• Storage: Store in original packaging at 15–25 °C with humidity ≤ 60% RH to preserve coating integrity.

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