Home > Products > Milling
 
 

With 80 years of experience, Safety is one of the largest suppliers of Milling Tools, offering dedicated technical support and flexible solutions for its broad range of standard and special indexable inserts. Safety designs, manufactures and markets technologically robust milling applications as well as advanced materials and engineered solutions for high-production, custom-machining systems.

Focusing on industry segments from automotive to die-and-mold, aerospace to energy production, Safety provides complete tooling solutions for increased productivity, effective use of resources and overall optimized metal cutting operations.

From the beginning, Safety partners with you to completely understand your unique tooling requirements, and global engineering, design, manufacturing and support resources ensures every project’s success.

SHOULDER MILLING CUTTERS

  • POLYMILL
  • COMPACT 90
  • ORBI-SAF

 

CONTOUR MILLING CUTTERS

  • AEROLONG
  • CT-SAF

 

FACE MILLING CUTTERS

  • AEROFINISH
  • PENTA 45
  • PENTA 60
  • PENTA High Feed
  • PENTA Heavy Duty
  • TETRA High Feed
  • QUADRI-SAF
  • QUADRI-SP
  • FORCE-SAF
  • FLASH-SAF

 

PROFILE MILLING CUTTERS

  • RD-SAF
  • TORO-SAF

 

BALL NOSE END MILLS

  • SR-SAF
  • SM-SAF
  • ARAF

 

PLUNG, SLOT & CHAMFER MILLING CUTTERS

  • PLUNG-SAF
  • RN-SAF
  • TE-SAF
  • GR-SAF

 

SPECIAL MILLING CUTTERS

  • BF-SAF
  • GEAR-SAF
  • BACK-SAF
  • THREE CUT MILLING DISC
  • GEAR TEETH CHAMFERING
Safety
Milling

HIGH FEED MILLING

At a time when cutting production cost is a priority, one solution that allows you to reduce your machining times considerably is high feed machining.
Carried out with existing machines, this combines a low cutting depth with a high feed per tooth. It offers an alternative to high speed machining (HSM) without any heavy investment.

Safety offers you 3 high feed milling cutters:
- Araf High Feed
- Orbi High Feed
- Penta High Feed
These cover diameters from 8 to 100 mm and can reach feeds per tooth of 2 to 3 mm.

 
High Feed
Milling
   
ARAF High Feed
Benefits:
Considerable reduction of pocket machining time in roughing
Milling with large overhangs using carbide shanks
Economical: using the existing shanks, you do not have to purchase any shanks
Long insert and shank service life
Characteristics:
Inserts from diameter 8 to 25 mm to machine with a maximum feed per tooth of 2 mm,
Cutting profile designed to reduce bending and vibrations of the tool
Inserts fitting on all ARAF milling cutters without modification of the shank
Available in grades VP5007, VP2003 & 5050
 
   
ORBI High Feed
Benefits:
Considerable reduction of your machining costs by at least halving the cycle time
No tool shank to replace
High precision of dimensions produced
Improved surface finish
Requires less power in roughing
Characteristics:
Sharp and precise inserts enabling machining with a feed per tooth of 1.5 mm maximum
Possibility of fitting on existing milling cutters after reworking of the shank
Large end mill and boring mill program from diameter 16 to 80 mm
Effective angle of 90° on the tool
Versatile geometry in grades VP5020 and VP5040 and with new submicrograin grade VP2003
 
   
PENTA High Feed
Benefits:
Reduction of machining time by a factor of 5 or 10
Saving on cutting edge cost
Long insert and shank service life
Highly resistant milling cutter shanks owing to the SILVER coating
A versatile and multi-functional tool for most materials to be machined
Very good operating safety with high stability during machining
Characteristics:
Milling cutters with a 19° entering angle enabling a feed per tooth of 3 mm maximum
Strong, stable PDMX 09 inserts with 5 cutting edges
Milling cutter shanks from diameter 32 to 100 mm
Also designed to perform ramping, helical interpolation or plunging operations
Two insert geometries available in grades VP5020, 2003 & 5050
 
   
TETRA High Feed High Feed milling cutter with positive four edged inserts !
High Feed Machining with Low Efforts
Good Performance in Contouring & Pocketing
4 Cutting Edges per Insert
ap Max 1mm
fzUpto 2mm
Axial Positive 10 Degree
Programming Radius 2mm
Equivalent Lead Angle 14 Degree
Tetra High Feed
Penta Heavy Duty – V560
The Power of PENTA. Times Two !
Heavy Roughing Face Mill
10 Cutting Edges
10mm Depth of Cut
100% Satisfaction    

The V560 allows operators to utilize the full power of machine tools, as well as securely perform heavy roughing operations. The V560 excels under difficult, full depth-of-cut machining conditions in forgings and beneath-casting scale.

FEATURES
Double-sided Penta design with 10 indexes per insert increases metal
removal rates and production capacity while using less horsepower
No cool down period required before indexing, allowing for more 
machine uptime
Secure insert retention for easier indexing… only three turns required
Patented ThruLok technology only requires a large, insert retention
screw that remains in the body
10 mm depth-of-cut capability allows operators to machine under the
tough outer layer of forge or cast workpieces, reducing insert wear
Insert edges are numbered for easy indexing
 

Diameter             : 100 - 315 mm
Max Depth of Cut : 10 mm
Entry angle          : 57°
Applications         : Heavy Roughing
Material               : Cast and Forged Steel, Stainless Steel, Cast Iron
 
 
Penta
Heavy Duty
   
Quadri SAF – V490
Reduce Cutter Inventory. Save Money. It’s Simple !
Multi Application Face Mill
One Cutter
Three Inserts Style
Endless Choices
V490 provides endless options to any of your general purpose, machining operations. V490 offers versatility ; the ability to consolidate multiple applications into one face mill which translates to cost savings.
FEATURES

Adaptable to any type of operation… one face mill, three insert styles:

Octagon    : Effective low cutting force milling with eight indexes
Square      : 90˚ shoulder machining with depth-of-cut up to 12 mm
                    or 15 mm
Round       : Rough facemilling or shallow profile machining
Secure insert retention and precise indexing
Universal insert pocket
Easy to program. Same height and diameter dimension with three
 

Insert styles
 

Insert Size 12 mm : Diameter 32 - 160 mm
Insert Size 15 mm : Diameter 50 - 100 mm
Mounting Type      : Shell Mill and Weldon End Mill
Application            : Facemilling, Shoulder Milling and Profiling
Material                : Steel, Stainless Steel, Cast Iron

 
Quadri
SAF
   
Compact 90 – High Performance Endmilling Solution
Compact Milling Cutters with Multi Corner Inserts

What is the main use of an endmill? It is to productively machine surfaces, shoulders and slots. In most cases this operation is simple, with straight horizontal feed without ramping.

With up to six cutting edges and a new double sided insert design COMPACT 90 is the best choice for this task. The COMPACT 90 provides a multi-edge endmilling solution down to 12 mm diameter.

The innovative concept delivers higher feeds, preserves tight tolerances and at the same time simplifies your selection for multiple milling operations with one economical solution.

 

AVAILABLE WITH THE NEW 5050 GRADE !

The new super tough universal 5050 grade exhibits top performance in roughing of steel and stainless steel. It has been developed for the most demanding operations, in particular for 90° shoulder milling. It also provides an excellent solution to high volume removing in titanium machining.
COMPACT 90 FEATURES AND BENEFITS
Increased feed per tooth, thanks to the strong double sided insert design
Superior tolerance of 90° shoulder through better insert positioning
Low cost per edge and low total cost of machining
Excellent capabilities to work with long overhangs
Reduced inventory owing to simple insert geometry and grade choice
INNOVATIVE INSERT DESIGN
Robust double sided design
Multicorner shape in compact size
Sharp short cutting edge that prevents vibration and chatter
Insert edge located above the seating surface providing more positive cutting action

COMPACT CPE4
Diameter: From 12 mm up to 20 mm
Maximum depth of cut: 2 mm
COMPACT CPW4
Diameter: From 20 mm up to 50 mm
Maximum depth of cut: 3.5 mm
COMPACT CPW6
Diameter: From 25 mm up to 80 mm
Maximum depth of cut: 5 mm

Aplication : Endmilling, slotting, facemilling, vertical wall machining
Material    : All materials

 
Compact 90
   
SM SAF – High Performance Profiling Solution Ball Nose High Productivity with Sidelok Technology !

Profile milling performance with unique 3 teeth solution.
SM cutters present the unique Safety solution with 3 inserts for ball nose machining as compared to 2 inserts for conventional ball nose cutters.
Increased number of teeth is achieved by using SideLokTM, the innovative clamping system by Safety
The SM gives up to 50% feed rate increase in semi-finishing profile milling operations compared to the traditional 2 teeth cutters
The insert exchange downtime is also reduced, as the clamping procedure does not require any removal of screws from the body
SM inserts are fully periphery ground. The design of the insert seat with SideLokTM clamping ensures excellent insert positioning and hence very low runout and narrow tolerance for external diameter of the sphere
SM cutters are true center cutting by the single edge crossing the tool axis. Transition to 3 edge cutting starts already outside 1/3 of Dc max and takes place without any mismatch. In result SM becomes an alternative for Solid Carbide and exchangeable head cutters in most of applications
Thanks to rigid robust design and stable SideLokTM insert clamping SM cutters present a universal solution regardless of the application, whenever profile milling is used: D&M, aerospace, energy and general engineering
The insert program contains all modern PVD coated grades for wide range of the Die&Mold materials with different hardness level, as well as for steels, stainless steels and exotic heat resistant and Titanium alloys
SM SAF
   
Force SAF – with SideLok Technology
Diameters                   : 80 mm to 250 mm
Max. Depth of Cut       : 6 mm
Corner Configurations  : 0.4 mm to 1.6 mm
Lead Angle                  : 60°
Applications                 : Rough and finish
Wiper Inserts               : Available
Materials                     : Cast iron, CGI, ductile and nodular irons
 
VForce
   
Flash SAF – high speed milling cutters for Aluminium

Diameters                  : 50 mm to 315 mm
Max. depth of cut        : 10 mm
Geometry                   : pos/pos
Corner configurations  : r 0.4 mm, r 0.8 mm, ch 0.8x45°
Lead angle                 : 90°
Applications                :rough & finish aluminum & non-ferrous, finish cast iron
Wiper inserts              : available
Materials                    : aluminum, non-ferrous, bi-metal,cast iron
 
VFlash
   
BF SAF – Burr Free Milling Cutter

No burrs - Outstanding surface finish quality !
Each BF milling cutter is designed to fully meet your needs !

Facing:
Aluminum, Steel, Cast Iron, Bimetal

Gains:
Facing with no deburring
Full control of the quality parameters of the parts
Outstanding surface quality
No insert adjustment
Reduction of the cost-per-part of 30%
66% reduction in set-up time
High-feed machining with a reduced number of teeth
Performance:
Finish milling of the combustion face on an aluminum cylinder head (AS7G07Y39)
Frequency: 50,000 cycles
Surface quality obtained on the 50,000th part: W=0.987 µm; Rz=1.325 µm; Rmax=2.799 µm
Solution:
Non-conventional milling cutter with a fully innovative design based on the broaching technology
Unique axial and radial positioning of the inserts which allows each of them to remove constant chip thickness
A single insert provides the quality of the machined surface Maximum optimizing of the number of teeth.
BF SAF
   
Gear SAF

Flexible Gear cutting system. Reduce Tools Inventory and achieve great performance.
With GEAR-SAF Gashing System one tool is able to produce a wide range of different gears, both internal and external, with high productivity rates and outstanding quality.

System Description
Nearly 30 years of experience and success in Europe
Wedge system for inserts clamping (improved tool life, easy and improved inserts clamping)
Utilize one tool with inserts for roughing and finishing (only one pass instead of multiple passes)
Utilize one tool for different diameters and modules (by changing the inserts)
Utilize one tool for internal and external gears (by changing the inserts)
We use internal air to each insert
Machining of the entrance chamfer optional
Available all the Safety’s grades for different materials
Cutter bodies feature very long life. Body is 50-52 HRC
Experience from M5 to M45
Gear SAF
   

Back SAF
A flexible, quicker & safer tool !

Coolant actuated Back Spot Facing Tool
   
Gear Teeth Chamfering
65% of additional productivity Thanks to the global process management in the milling of a specific complex shape: the gear entry angles
Solution:
Our offer covers the design and 3D machining simulation up to complete delivery of the service including machine kinematics, thus allowing full control of all the quality parameters
It addresses both continuous generating machining technology and discontinuous machining
Features:
Part: gear box pinion
Material: steel to be cemented (0.15-0.3% of carbon)
Machined diameter: 102 mm
Discontinuous machining
Gains:
65% of additional productivity: number of machined parts per insert (with identical cutting conditions): 1000 parts (i.e. 47000 teeth) against 600 parts (i.e. 28200 teeth) with the previous solution
No burrs
Full control of quality criteria (geometry, roughness)
Gear Teeth Chamfering
   
Grade 5050 – Universal Milling Grade for Tough Applications

PRODUCTIVE. RELIABLE. VERSATILE

TAKING TOUGHNESS TO NEW HEIGHTS


Tough conditions? Multiple materials?
Want predictable performance?
We have your solution.

The 5050 grade excels at high feed rates and in the toughest conditions for maximum time and cost savings.

Thanks to its innovative substrate, insert failure is virtually eliminated and tool life is increased. 5050 provides unmatched performance, perfectly suited for unmanned operations where unpredictable stop is not an option. Safety’s new tough grade protects your milling operations through its proven reliability.

5050 is a versatile grade with excellent performances in various materials, allowing for inventory reduction and ease of insert selection.
Grade
5050
   
Grade VP2003 – Submicrograin Milling Grade

High Performance Grade specifically designed for the Mould Industry

Grade VP2 003 is a high performance grade specifically designed for the mould industry. It covers both semi-finishing and finishing applications for hardened steels and cast iron.

Combined with a highly heat-resistant AlTiN-based coating, its high-tech substrate can also cover the machining of composite materials for which it complements PCD grades.
 
VP2003