2019 Technology Review: Cutting Tools

End Mills Achieve Greater Depth of Cut in Aluminum

RobbJack’s FMHV two- and three-flute end mills are designed for high-horsepower, high-velocity aluminum aerospace machining. The company says its Mirror edge geometry progressively reduces vibration at greater Z-depths of cut. Anti-pullout shank technology prevents tools from pulling out of the holder.  Well-suited for high-speed machining of deep pockets and thin walls, the tools are available with through-coolant holes and a DLC coating that extends tool life in roughing applications. Overall length and reach length are designed to maximize gripping force in tight-tolerance toolholders. The company reports that a 1" diameter, three-flute FMHV with through-coolant holes and DLC coating can achieve a peak metal-removal rate of 713 ipm³ (72 lbs of 7075 aluminum per min.).

Circle Segment End Mills Increase Material Removal

Emuge Corp has introduced circle segment cutters, a class of end mills designed to enable more material removal with fewer passes in five-axis machining. They are said to reduce cycle times by over 80 percent and to produce smoother surface finishes. The end mills are ideal for machining turbine blades, impellers and blisks, as well as in moldmaking applications. They feature unique forms with large radii in the cutting area of the mills, enabling a larger axial depth of cut during pre-finishing and finishing operations. The solid carbide end mills are offered in four geometries: barrel-shaped, oval form, taper form and lens-shaped. Oval and taper form mills are ideal for curved shapes such as blades or straight-walled pockets, freely engaging more of the cutting edge. Barrel mills provide effective flank milling to the sides of spiral grooves and similar applications, while lens-shaped mills are designed for narrow channels or in lands on molds. CAM software, such as the more recent versions of HyperMill or Mastercam, is required to support and compute the geometries of the end mills for maximum performance.

New Indexable Insert Drill Provides Trouble-Free-Drilling in Virtually All Conditions

Walter has introduced the D3120, an indexable insert drill it says is built to provide trouble-free drilling in virtually all conditions. The D3120 features square positive indexable inserts with four cutting edges, enabling it to reduce cost per cutting edge. Available in five diameter sizes ranging from 0.63-1.654-in (16-42 mm) and with 2, 3, 4 x Dc, the new drill delivers maximum process reliability with simple and efficient chip removal, two coolant channels and polished flutes. Superior protection against friction is provided by the D3120 hardened and polished surfaces. This combination of surface hardness and improved coolant flow results in reduced wear on the drill surface.

The new drill is easy to use since it has one indexable insert shape for both outer and inner seat, and a measuring collar for easy diameter identification. The drill is suitable for ISO material groups P (steels), M (stainless steels), K (cast irons), N (nonferrous) and S (super alloys). Torx Plus screws give it secure indexable insert clamping and high stability in all working conditions. The D3120 features long tool life because of Walter Tiger·tec Silvergrade, which features increased wear resistance due to its unique aluminum oxide layer with optimized microstructure, as well as low wear due to the extremely smooth rake face it creates.

Insert Drill’s Redesign Improves Chip Control

Seco Tools LLC will spotlight its redesigned Perfomax indexable insert drill. Designed for more aggressive drilling parameters as well as improved chip control and evacuation, the drill’s flutes have updated helix angles and smoother chip flute exits. An engineered wave pattern reduces contact between chips and flute surfaces. The fronts of the Perfomax’s flutes have been hardened with a laser to prolong tool life. A hardness of HRC 60 enables the drill to withstand chip erosion for longer periods of time.

Perfomax drill bodies are available in diameters ranging from 0.594" to 2.375" (15 to 59 mm); in length-to-diameter ratios of 2×D, 3×D, 4×D and 5×D; and in most spindle interfaces.

Diamond-Tipped Tools Cut Sintered Carbide

Horn USA’s CVD-D-tipped tools are designed for drilling, turning and milling carbide in the sintered state, ranging to a hardness of 2,200 Vickers.Depending on the application, the geometrically defined cutting edges range from extremely sharp and rounded to positive and negative chamfers. With application-specific cutting edge optimization, CVD-D diamond can be useful for roughing work or fine finishing.

According to the company, the tools enable accurate profile machining in the micron range. In terms of roughness, polishability and corrosion behavior, the surface structure is reportedly comparable to grinding and eroding processes. 

Milling Tools Resist Chatter, Pullout

New geometries for Haimer’s Power Mill line of solid carbide end mills and and Duo-Lock line of modular milling heads include designs for aluminum and mold steels. Unequal flute and helix designs provide chatter-free machining. The company’s tools are made from K20-K40-grade fine-grain carbide. The latest tools include two- and three-flute end mills for aluminum, which are available in solid carbide or as a modular interface (Duo-Lock),  four- to 10-flute end mills for working in steel, and various specialized cutting tools. Special tools include a multifunction chamfer spotting tool, four- and five-flute roughing mills for steel, a quadrant end mill, and ball nose end mills for steel and aluminum. All are available as solid carbide end mills or Duo-Lock interfaces.The company also offers the Basic Mill line of solid carbide end mills and Duo-Lock milling heads for roughing, finishing and drilling. All tools are available with the optional Safe-Lock anti-pullout system.