Faster holemaking – cutting tools MetalTech Report

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End mills for 3D machining
Emuge Corp.’s new High Productivity Cutting (HPC) End Mills build on the success of the Multi-Jet Cut end mills, which permit rapid material removal of a wide range of materials.

Emuge has added new designs that extend the range of application to include the ability to perform complex 3D machining, as well as roughing and pre-finishing operations. The end mill program includes several tools.

The original Multi-Jet-Cut features an optimized geometry and high performance carbide for accurate, large volume machining in a variety of materials including steel up to 44 Rc, cast iron, brass and bronze.

Multi-Jet-Cut IKZ end mills utilize internal coolant/lubricant capability to provide the most efficient chip evacuation in a wider range of materials. These end mills are available in the original flat end design as well as a torus or radius corner design. The coolant-through-the-spindle feature expands the range of application to include titanium and nickel based alloys.   

HPC-Jet-Cut end mills, available with positive, negative and neutral rake angle geometry, provide exceptional tool life with smooth and efficient cutting in roughing and finishing operations in a variety of materials including steels up to 56Rc.   

Multi-Jet-Cut Ball-Nose designs are ideally suited for high volume 3D machining applications such as those used in mould and die manufacturing, as well the power generation and aerospace industries.

All-in-one carbide end mill
Iscar’s new “all in one” solid carbide end mill, combines three of the company’s most innovative endmills, says Iscar: FeedMill, Chip Splitter and ChatterFree.  

The new EFP solid carbide end mills provide the highest advantage in cavity milling, which is especially useful in the die and mold industry. 

The Feedmill bottom utilizes a large radius cutting edge configuration that allows for greatly increased feed rates of up to 0.5 mm/tooth, at 0.3 to 1.0 mm depth of cut. This provides a significant reduction in cycle time, which increases productivity. The unique cutting edge geometry axially directs the resultant cutting forces towards the spindle. This results in high stability and enables machining at high feeds, even with long overhang. This feature should be used for the penetration stage of pocket machining.  

After penetration into the cavity, the chip splitting flutes should be used to widen the initial cavity. The serrated cutting edge features flat peaks that leave a better surface finish, in comparison to other rougher endmills. The chip splitting flutes also feature better force distribution combined with the ChatterFree variable pitch, which is the solution for maximum stock removal rates.  

The new end mills are effective even on low power machines (ISO40/BT40).  

They are available with 4 and 5 flutes, comprised of IC903, an ultra-fine grain substrate protected by the advanced AL-TEC coating technology. The combination of these parameters offers outstanding wear resistance and toughness. 

They are useful for machining materials such as hardened steel up to 65 HRc, P20, H13, cast iron, stainless steel, titanium and high temperature alloys. 

ISCAR’s new end mills will reduce cycle time and increase your productivity.

Drill, plunge mill in one tool
Komet has launched a new range of milling cutters, the Quatron hi.feed. Ideally suited for roughing operations, where large volumes of chips must be removed, the Quatron hi.feed relies on Komet’s four-effective Quatron indexable inserts to get the job done quickly. 

The four cutting edges of the Quatron inserts not only maximize the tool life and lower the production cost per cutter, they also make the Quatron hi.feed a universal tool, capable of performing the most difficult milling operations. Machinists can mill deep grooves and large cavities by performing plunge milling, milling, circular interpolation, or inclined plunging operations. The inserts also have a radial cutting action, which translates to a considerably higher degree of flexibility in plunge and pocket milling when compared with two- or three-edged inserts.

Ideal when producing larger drilled holes using small or low performance machines, the Quatron hi.feed is also capable of high feed rates up to 2 mm per cutting edge.

Sandvik Coromant
Economical milling
Sandvik Coromant recently launched three new styles of inserts for the CoroMill 316 exchangeable head milling system. 

The three new designs of end mill, each with two cutting edges, are perfect problem solvers with maximum strength and security and extend the depth of cut for the CoroMill 316 range to 0.8 x Dc.

The new range includes a ballnose for profile milling, aluminium machining, and finishing, equipped with a strong cutting edge for profile roughing. It also includes a corner radius for slot milling, shoulder milling, plunge milling, face milling, ramping and pocketing—excellent for chip evacuation problems when slot milling, and a chamfer for chamfer milling of different angles and optimized for spot drilling capability. 

The system of exchangeable end mills are connected to the tool shank by a unique threaded coupling which combines high strength with guaranteed accuracy, claims the company.

Small machine milling
Seco has introduced the Double Octomill 05, bringing the product family’s strong cost and performance benefits to smaller machines. This face milling cutter is available in diameters from 25 mm to 125 mm and provides optimal performance in applications requiring a maximum of 3 mm depth of cut. 

The insert pockets incorporate a strong centre lock screw and grooves for axial and radial location pins, simplifying the mounting of inserts and ensuring maximum stability during operation. The pockets also feature an 8° negative angle to allow the use of double sided inserts, while the inserts themselves use a positive rake angle to minimize power consumption.

Seco offers four insert geometries that can be applied across a range of materials. For applications requiring high surface finishes, a wiper insert with a 3.2 mm wiper flat can be incorporated to provide roughing and finishing in a single operation. 

All Double Octomill cutters make use of inserts that provide sixteen numbered cutting edges to minimize cost per edge and per part.

Rough milling
Sumitomo Electric Carbide Inc.’s new Wax Wave Mill Series reduces the costs and time typically associated with rough milling to finishing of non-ferrous materials. 

The series also boasts a safety-oriented design that prevents tool failure by inhibiting the insert dislodgement that can result from centrifugal force. The diamond-like carbon coating (DLC) applied to the inserts promotes adhesion resistance. With these enhancements, the new cutters offers exceptional ramping and helical milling of aluminum alloys.

Slot milling
For productive and accurate machining of grooves and slots, Tungaloy America has now launched the TecSlot side milling range of cutters. The new cutter with a tangential insert with tough cutting edge has been developed for medium to heavy machining of steel, cast iron and stainless steel.

Cutter design incorporates a close insert pitch and optimized chipbreaker for exceptional productivity levels with unparalleled chip evacuation. A geometry gives each insert two right and two left hand cutting edges to reduce tooling costs for the end user. 

The new TecSlot is available with the option of a 16, 19 or 25 mm edge width with diameters that include 100, 125, 160, 200 and 250 mm. The 16 mm edge width cutter offers 10, 12, 14, 16 and 18 inserts for the respective diameters while the 25 mm option provides 8, 10, 12, 14 and 16 inserts for the respective diameters up to 250 mm. 

Well suited to slot and shoulder milling, the TecSlot inserts offer a wiper edge for improved surface finish, a large inclination to reduce cutting forces, an end pocket for chip evacuation and a wide insert design that supports chip removal. The inserts offer a selection of corner radii that include 0.8, 1.6, 2.4 and 3.2 mm that are all available in Tungaloy’s AH725, AH140 and AH120 grades.

Cartridge type cutter
Walter USA LLC has introduced the Walter Valenite F4050 cartridge type cutter, an innovative new approach to the challenges of high speed milling of non-ferrous materials. Features include the use of high tensile steel cartridges with brazed PCD carbide tips. An adjusting key guarantees a micron-precise runout of the cartridges. Toolsetting is done through clamping screws tightened according to defined torques, enabling high limiting speeds.

F4050 is available in diameters ranging from 80 to 200 mm. A carbide chip deflector supports the significant level of chip production in both roughing and finishing operations. The tool is equally productive at maximum cutting speeds in the range from 5000 to 7000 m/min.

Cartridges with a 90° clearance angle and cutting depths of up to 4 mm, or cartridges with a 75° clearance angle and cutting depths of up to 1.1 mm are currently available.

High feed milling
Widia has two new insert families: the M270 Series and M370 series.

The M270 inserts are based on Widia-Hanita X-Feed geometry. Three grades are available: TN2505 for good wear-resistance in materials up to 60 HRc hardness; TN6540 for added toughness; and TN6525, a mix of toughness and wear-resistance for dry machining applications in steel. 

The M370 series is designed for high feedrate productivity; its double-sided concept and six cutting edges provide security and optimal metal removal with an efficient cost per edge. 

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