Milling cutters | Precision tools for machining centers & Co.
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Whether end mills, thread mills, high-performance milling cutters: The demands on the small Precision tools for machine tools, machining centers, NC and CNC machines are constantly increasing. The special geometry and sharpness of the Router enable precise material removal and complex shapes in the MetalworkingThis article presents innovations and explains possible applications in modern manufacturing.
Content
- Patented bayonet connection for interchangeable head milling cutters
- With material-friendly thread milling cutter for clean threads
- Milling cutters for tool and mold making
- End mill for roughing and finishing with high feed rates
- Cutting material series for milling iron cast materials
- Four-flute solid carbide end mill with high cutting performance
Patented bayonet connection for interchangeable head milling cutters
26.07.2024 | Mapal will be on the AMB 2024 an innovative, patented bayonet connection point for interchangeable head milling cutters. This new technology offers users user-friendly handling, a rigid connection and improved cooling.
The Principle is simple: The interchangeable head is inserted, rotated 90 degrees and locked, which is much easier than the conventional method with thread. Thanks to the large cylinder face, the bayonet system achieves high rigidity and optimal force distribution. A new holder design has cooling channel holes that provide a higher cooling volume for the Cooling lubricant enable.
The Coolant is directed directly to the cutting edges. This increases the service life of the tools and the machining quality of the workpieces. By omitting a cooling channel bore, the rigidity of the milling heads is improved. This results in better shape and position tolerances, smoother process control and longer service life.
Two first applications will be presented at the AMB: a five-edged milling head for constant velocity joints and a Form cutter for drive shafts.
With material-friendly thread milling cutters for clean threads
09.07.2024 | Thread quality is often the decisive factor for success or failure. Since threads are usually created at the end of the machining process, the highest precision and process reliability are required. Shank thread milling cutters such as the Monothread – SGF and the MonoThread – SFSE from the Performance Line by Ceratizite set standards here. The latest generation of these tools offers a performance increase of up to 20% compared to the previous models and extended service life.
Interpolation turning for combined turning/milling
In recent years, thread milling has emerged as an attractive Alternatives for tapping, forming and whirling threads. This is mainly due to the numerous advantages of thread milling cutters. Instead of a thread on the cutting edge, they have a corrected profile whose distance corresponds to the pitch. This achieves a precise thread position and different dimensions with the same pitch can be produced in numerous materials.
Thread milling enables safe processes
“Thread milling is suitable for all standardized thread profiles with all tolerances. It is used especially for asymmetrical, large and very expensive workpieces, as thread milling produces very short chips, which makes the process much safer,” explains Markus Mack, Product Manager at Cerazitit. In addition, the machines require less drive power than thread cutting. This also applies when used in materials that are relatively difficult to machine, such as high-strength or tempered steels.
The process also reduces the Tool costsbecause left- and right-hand threads with different thread tolerances as well as blind and through holes can be produced with just one tool. In contrast to thread cutting, milled threads can be produced with high precision over the entire length right to the bottom of the hole.
Clean threads even at high speed
A Comparison of thread profiles of thread taps and thread milling cutters from the Performance Line quickly shows clear differences: The surface structure of the milled threads is much smoother, especially on the flanks. While the thread tap tears out material particles and forms craters, the milled thread remains almost free of breakouts. "What really helps in such cases is the use of coolant. Monothread - SGF and Monothread - SFSE prevent material breakouts through an axial coolant supply, among other things," explains Markus Mack.
Drill | Precision tool for machine tools
Due to the low cutting pressure, thread milling is also suitable for thin-walled components. The monothread tools can also be used with high feed and high cutting speed. The monothread thread milling cutters are also sustainable. Some of them can even be reground several times.
Milling cutters for tool and mold making
29.11.2019 | Sleep Pramet has expanded its range of milling cutters for tool and mold making as well as for general machining with new components. These include the new double-sided WSP SNGX11 for milling with high feed rates and cutting depths of up to 1,7 mm.
The robust cutting edge guarantees a high degree of durability and process reliability - especially when milling pockets. With eight cutting edges, the square SNGX11-Indexable insert It is also a very economical solution. The inserts, which are available in two geometries, are very versatile. For example, for copy milling, circular milling, ramping, progressive plunging and face milling. The M geometry is intended for machining steel, but also hardened steel and cast iron. MM is also suitable for stainless steel, softer steel and superalloys with a softer cut.
The range of plates is complemented by the new SSN11 cutter with diameters from 32 to 125 mm and intermediate sizes for applications in tool and mold making. All cutters have special coolant channels to further improve process reliability. They also offer a high overhang to support milling at depths of up to 10xD.
The proven ADMX07 milling program also received an addition: a F-Geometry for finishing and semi-finishing. The extension is in line with the existing M, FA and HF geometries and is aimed at the light machining of stainless steel and low-carbon steels. The chip breaker is very suitable for vibration-sensitive machining and offers an extremely positive geometry with a narrow edge area. This reduces chatter and enables a uniform cutting process without burrs on the machined wall.
End mill for roughing and finishing with high feed rates
21.05.2017 | HAM has developed the solid carbide end mills 40-5390 and 40-5490 for roughing and finishing with high feed rates. They have a special geometry with uneven helix pitch. This means that in addition to aluminum, other materials such as copper and cast alloys as well as non-ferrous metals can be milled with great smoothness.
The tools offer a high metal removal rate and a maximum infeed in full cut up to 1,5 x D. The milling result is completely burr-free and after roughing, a fine, smooth surface is created. This reduces the amount of work required for additional rework. During milling, the surface remains completely free of shading.
Cutting material series for milling iron cast materials
10.02.2017 | Especially for milling cast iron materials, Mapal a new cutting material series has been developed that covers the entire range of cast iron materials GJL, GJV and GJS. Initial results show that the new cutting materials not only significantly increase tool life but also enable higher cutting speeds.
The cutting material series is based on newly developed Hard metal substratesThe structures of the hard metals were modelled in such a way that they each have an optimal ratio between toughness and wear resistance.
The cutting material series includes three PVD-coated hard metals and two CVD-coated grades. The PVD coating consists of an optimized TiAlCrN with the finest structuring of the layer structure, which creates an optimal ratio between toughness and hardness/wear resistance. The CVD coating is based on an MT-TiCN with an alpha-Al2O3 top layer. This layer combination offers good temperature resistance in addition to high wear resistance.
For both PVD coating and CVD coating, a special aftercare developed, which ensures an extremely smooth surface and thus guarantees optimal chip drainage. This reduces tribochemical wear to a minimum. With CVD coating, the post-treatment also specifically adjusts the residual stress state of the layer, thus stabilizing the cutting edge and increasing the toughness of the cutting material.
Four-flute solid carbide end mill with high cutting performance
21.12.2016 | As an introduction to the world of trochoidal and high-speed milling, HAM the solid carbide (VHM) milling cutter of type 40-1491. This produces a very good surface quality and enables high cutting performance.
The four-edged cutter with 45-degree corner bevel has a special geometry with equal pitch and unequal twist pitch. This enables low-vibration operation with little deflection. The tool scores points when machining different types of steel, stainless steel, gray cast iron and titanium. When milling peripheral and contours, it achieves, among other things, high profile accuracy.
Process-impairing Chip ball and nests do not occur when machining with this tool. This is ensured by newly developed chip spaces that enable smooth chip flow. The milling cutter is available in diameters from 3 to 20 mm.
Source: This article is based on information from the following companies: Ceratizit, Dormer-Pramet, HAM, Mapal.
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