Round Inserts for Mold/Die Machines Boost Free-Forming Milling Reliability, Productivity

Tungaloy has introduced an enhanced FixRMill round insert “button cutter” line that boasts high performance while providing tool reliability when copy milling (free-form milling) the curved surfaces of stainless steel and difficult materials in five-axis machining. This line includes four inserts and eight cutter bodies. 

FixRMill uses round inserts for machining molds and dies, especially complex male-female main parts such as cavities and projections. The round inserts feature anti-rotation notches on the insert clearance side and matching locations on the pocket seats. These notches are said to not only prevent the insert from rotating under heavy load but also help the operator get a true, distinct index every time he/she goes for a new edge; this ensures the entire insert is utilized.

The round inserts are available in size 12 in two geometries: RQMT1204ENC8-MM enables up to eight indexes for 1.4 mm (0.055″) or smaller D.O.C. and up to four indexes when used at 6.0 mm (0.236″) D.O.C., featuring optimized per index cost. Alternatively, RQMT1204ENC6-MM can provide up to six indexes for 2.6 mm (0.102″) or smaller D.O.C. The two inserts are interchangeable for the same FixRMill cutter body.

The MM-style chipbreaker provides the cutting edge with sharpness and robustness, demonstrating exceptional reliability in varying cutting forces typically generated during copy milling operations, Tungaloy says. Two insert grades are available: AH3135 grade provides improved cutting performance over a range of material groups and AH8015 showcases high performance in difficult materials.