High-speed cutting is not a new thing. It has been in many industries such as mold manufacturing for decades. As a process, it used to be seen as a small tool for high-spindle speed machines. However, today, high-speed cutting has a wider range of applications.
High speed cutting (HSM)
Thanks to the research and development of machine tool builders, software developers, cutting tool manufacturers and research institutes, high-speed cutting (HSM) now has a wider application space. Most importantly, the actual process of high-speed cutting has not only stayed in theory, but has been applied to all aspects of the shop. The development of innovative milling tools makes high-speed cutting a more practical and profitable method in the mold manufacturing industry. Any cutting process rule, including high-speed cutting, is as effective as the machining capabilities of machine tools, software, and cutting tools. In many years of practical applications, the development of tools in high-speed cutting has moved toward higher performance. Milling is a key part of the high-speed cutting process, and its innovations have influenced the performance of milling cutters in many tooling applications. In high-speed cutting, speed is a keyword that represents the spindle speed, cutting speed or feed rate. High-speed cutting can be achieved by optimizing the milling process with high cutting speed or high feed rate.
In the past, high-speed cutting focused on high spindle speeds ranging from 8,000 to 100,000 rpm. Many applications are experimentally driven by the machine tool and the aerospace industry, and early high-speed cutting primarily used these aspects. However, in the workshop practice, the spindle speed during high-speed cutting is always kept in a very low range.
In the 1990s, the development of high-speed cutting focused on the overall concept, including the creation of machine tools with a spindle speed of 200,000 rpm. High spindle speeds and high feed rates are highly valued. Research institutes have shown that high speeds can have serious consequences and high risks when tool or machine tool parts do not match the application. The main factors to consider are: cutting force, surface texture, metal removal rate, tool life and safety. These studies demonstrate the importance of optimizing high-speed cutting factors for successful high-speed cutting.
New developments in aluminum die milling
When it comes to high-speed cutting and indexable tools, safe blade fixing is a top priority. Increasingly high milling machine spindle speeds and table feeds (especially when performing aluminum cutting) result in high centrifugal forces and the resulting large load on the blade mounting components. The finite element method for analyzing load distribution is particularly valuable when developing satisfactory solutions and finding working models for indexable tools for high-speed cutting faster, and it can be used to design optimal cooling. The liquid channel and outlet structure help the chip evacuation in an optimal way. This has resulted in a new generation of high speed cutting tools for aluminum alloy cutting.
The CoroMill790 indexable end mill is an example of a tool for machining aluminum alloys at high speeds. This type of end mill is mainly used in high-speed machining processes such as cavity cutting, edge cutting, slot milling, and profiling in mold manufacturing. The fixing of the blade is realized by a specially developed blade-tool body interface. The serrated contact surface design of the bottom surface of the insert groove and the back of the blade not only maximizes the safety in high-speed milling, but also ensures the machining accuracy. The blade is evenly stressed, making the processing smoother and safer, and prolonging the tool life. The above design greatly enhances the cutting quality and improves the processing capacity.
The CoroMill 790 end mill serrated contact surface design can also be widely used in face milling cutters used in aluminum machining, especially cast aluminum parts such as molds, engine blocks, gearbox housings, etc. From semi-finishing to super-finishing, the cutting speed is increased to 8000 m/min. The positive rake angle of the CoroMill 790 end mill can be made of cemented carbide, polycrystalline diamond (PCD) or cubic boron nitride (CBN). This design makes the milling cutter widely suitable for aluminum alloy cutting and even cast iron cutting. The high-tech CoroMill 790 end mill structure is not complicated, its blade axial adjustment is simple and convenient, and it also has the advantages of cutting force balance, wide application field and precise machining allowance.
Interchangeable solid carbide tool
Solid carbide cutting tools, especially small diameter tools, are widely used for die cutting of various materials. Between the indexable insert and the solid carbide tool, there is now an alternative third solution that can cover the characteristics of the first two to some extent, and it provides both cutting The indexable nature of the blade provides the benefit of using a medium to small diameter solid carbide end mill. Up to now, the prospects for this field have been evaluated, pointing out its potential advantages and disadvantages. However, a new tool concept can fully exploit this area.
Although indexable insert technology offers many benefits, modern solid carbide cutting with long radial cutting edges and axial feed capability is important, especially when the tool diameter is small. Advantages include high precision, high surface quality, knife performance and light cutting. The use of indexable insert tools requires a quick and easy replacement of the cutting portion of the tool, optimizing the performance of this part of the tool and increasing the use advantage.
The indexable insert end mill has a diameter as small as 12 mm. Below this diameter, the mounting and clamping of the insert becomes impractical. On the other hand, the diameter of the solid carbide end mill can be as small as 1 mm or less. The diameter of 10-25 mm is the range of both types of end mills and can be used in many machining processes. The interchangeable end mill combines the indexable insert with the solid carbide. The indexable insert can be used for high-efficiency roughing to semi-finishing, and solid carbide for semi-finishing to superfinishing. Processing. As a third option, the head-removable end mill has the potential to be optimized in the cross-application area of ​​the two.
A key part of the CoroMill 316 interchangeable head tool is the interface between the cutting head and the body. One of the most important parts of the interface is a specially developed, patented self-centering thread for pulling up and holding the top into the shank (for tensioning the tip and body) without any gaps. The axial support surface is as large as the radial support surface, and the inner end of the cutting head is supported inside the shank along the tapered surface, thus providing the highest bending strength. The cutting head of the cutting tool can be easily fixed and tightened with a slight turning of the wrench. The unique interface between the cutting head and the shank provides high rigidity for the full groove roughing process and high precision for precision finishing operations. The CoroMill 316 tool has an axial tool length repeatability and a radial runout limited to 0.02 mm.
The CoroMill 316 tool has a balanced design so it can use a relatively high spindle speed. The combination of high speed and multi-tooth cutting heads provides very high feed rates and high cutting speeds. The interchangeable head concept also allows the tool geometry to be easily adapted to the workpiece material without the need for excessive tool stability. The tool stability of conventional solid carbide tools is affected by the core diameter.
Blade grade for higher speeds
When discussing blade grades for indexable milling cutters, high speed cutting requires the use of higher performance insert grades, especially when production efficiency is a priority over cutting versatility. When the metal removal rate and processing cycle need to be prioritized in mold milling and the cutting conditions are good, the performance of the general grade may not be good enough. When high cutting speeds, prolonged contact, and harder materials are used, crater wear, hot cracks, and plastic deformation may occur, which may reduce tool life and predictability.
In order to achieve higher processing safety when improving cutting parameters, the requirements for wear resistance are clearly higher than the requirements for toughness. Therefore, in order to make the blade harder, consider using ISO P20 insert grades in steel mold applications. This is to avoid premature breakage of the cutting edge and to achieve higher cutting parameters. In order to further improve the cutting performance, it is generally considered that no coolant is used in the milling of steel molds.
Since high cutting rates are commonly used today, even if the amount of coolant is large, it is difficult to have a significant influence on the cutting edge, so dry milling should be used. Most of the coolant is evaporated during wet cutting, and the remaining coolant can only intermittently cool the blade as it enters and exits. At this point, the change in heat is amplified, which can have a worse impact on the blade than the actual high temperature. Modern coating grades are designed for high-speed milling of steel, providing high safety without the need for coolant at high cutting speeds and high feed conditions, but most grades are good under both dry and wet processing conditions. Work.
High speed and high feed mean more heat. However, the use of steel milling grades such as GC4220 will not be a negative factor. It is an ISO P20, CVD coated grade designed to achieve maximum performance with high cutting parameters. Some processes require higher productivity than versatile requirements, and therefore require higher wear resistance. Perhaps this is one of the ways to deal with harder steel. Therefore, the heat-related wear mechanism becomes a more prioritized problem and requires a grade that can withstand such cutting edge breakage. The GC4220 is the first choice for cutting time with higher cutting speeds. It has a wide range of applications and is even the optimizer for many steel mold materials and is a good choice for cast iron milling with high heat problems.
Faster feed and higher speed in the depth of the cut
Today, in many mold shops, the trend in CNC milling is to use higher feed rates and smaller depths of cut after roughing. This is good for the machine tool, which improves the machining results. Power limitations are also an increasing factor to consider, especially on machining centers with tapers of ISO 40 and 30. The higher speeds and feeds of today's machine tools also mean the ability to use small diameter milling cutters more efficiently and to cut shoulders and end faces by repeated passes. These factors help to set the direction for the development of a new generation of shoulder milling cutters. Therefore, in the new CoroMill milling cutter series, the maximum depth of the CoroMill490 milling cutter should be at a lower value: 5.5 mm, with a recommended value of 4 mm. This also provides an opportunity for new square shoulder milling cutters with square inserts, as well as the basis for high blade stability and good tool economy through precise and safe blade positioning.
The CoroMill 490 insert has optimized the blade support points and placed them as far apart as possible along the edge of the seat, thus minimizing the effects of cutting forces that easily move the blades on the seat. A small depth of cut tends to amplify the lever effect with a blade screw compared to a long cutting edge radial knife. However, the structure of the CoroMill 490 compensates for this, which guarantees high stability. High stability is a prerequisite for large feed per tooth, consistent high precision and surface quality, and long tool life.
In some applications, the ability to machine large diameters is critical to the design requirements of the part, requiring a wide range of milling cutters, custom or dedicated blade radii. The CoroMill 490 insert has a nose radius of between 0.4 and 1.6 mm and is suitable for finishing to roughing applications in shoulder milling.
For the ability of the CoroMill 490 in high-speed machining, the successful development of the unique, new parallel forging used in the insert is one of the key innovations. This type of tool has been proven to achieve the best removal rate per unit of power.
in conclusion
With the continuous development of various cutting tools, milling has taken a new level in the performance of high-speed cutting, using new indexable insert end mills to improve the cutting capacity of high-speed and high-feed aluminum molds. The new indexable tool is based in part on a new blade-knife interface that secures the blade at high spindle speeds. The interface innovation between the new tool body and the interchangeable tool cutting head is optimized in two ways, taking the cutting performance of the solid carbide tool to a new level. The development of the new coated carbide insert grade directly affects the durability of the insert at high cutting speeds. New developments in square shoulder milling with indexable inserts have opened up new horizons for milling in mold making.
High speed cutting (HSM)
Thanks to the research and development of machine tool builders, software developers, cutting tool manufacturers and research institutes, high-speed cutting (HSM) now has a wider application space. Most importantly, the actual process of high-speed cutting has not only stayed in theory, but has been applied to all aspects of the shop. The development of innovative milling tools makes high-speed cutting a more practical and profitable method in the mold manufacturing industry. Any cutting process rule, including high-speed cutting, is as effective as the machining capabilities of machine tools, software, and cutting tools. In many years of practical applications, the development of tools in high-speed cutting has moved toward higher performance. Milling is a key part of the high-speed cutting process, and its innovations have influenced the performance of milling cutters in many tooling applications. In high-speed cutting, speed is a keyword that represents the spindle speed, cutting speed or feed rate. High-speed cutting can be achieved by optimizing the milling process with high cutting speed or high feed rate.
In the past, high-speed cutting focused on high spindle speeds ranging from 8,000 to 100,000 rpm. Many applications are experimentally driven by the machine tool and the aerospace industry, and early high-speed cutting primarily used these aspects. However, in the workshop practice, the spindle speed during high-speed cutting is always kept in a very low range.
In the 1990s, the development of high-speed cutting focused on the overall concept, including the creation of machine tools with a spindle speed of 200,000 rpm. High spindle speeds and high feed rates are highly valued. Research institutes have shown that high speeds can have serious consequences and high risks when tool or machine tool parts do not match the application. The main factors to consider are: cutting force, surface texture, metal removal rate, tool life and safety. These studies demonstrate the importance of optimizing high-speed cutting factors for successful high-speed cutting.
New developments in aluminum die milling
When it comes to high-speed cutting and indexable tools, safe blade fixing is a top priority. Increasingly high milling machine spindle speeds and table feeds (especially when performing aluminum cutting) result in high centrifugal forces and the resulting large load on the blade mounting components. The finite element method for analyzing load distribution is particularly valuable when developing satisfactory solutions and finding working models for indexable tools for high-speed cutting faster, and it can be used to design optimal cooling. The liquid channel and outlet structure help the chip evacuation in an optimal way. This has resulted in a new generation of high speed cutting tools for aluminum alloy cutting.
The CoroMill790 indexable end mill is an example of a tool for machining aluminum alloys at high speeds. This type of end mill is mainly used in high-speed machining processes such as cavity cutting, edge cutting, slot milling, and profiling in mold manufacturing. The fixing of the blade is realized by a specially developed blade-tool body interface. The serrated contact surface design of the bottom surface of the insert groove and the back of the blade not only maximizes the safety in high-speed milling, but also ensures the machining accuracy. The blade is evenly stressed, making the processing smoother and safer, and prolonging the tool life. The above design greatly enhances the cutting quality and improves the processing capacity.
The CoroMill 790 end mill serrated contact surface design can also be widely used in face milling cutters used in aluminum machining, especially cast aluminum parts such as molds, engine blocks, gearbox housings, etc. From semi-finishing to super-finishing, the cutting speed is increased to 8000 m/min. The positive rake angle of the CoroMill 790 end mill can be made of cemented carbide, polycrystalline diamond (PCD) or cubic boron nitride (CBN). This design makes the milling cutter widely suitable for aluminum alloy cutting and even cast iron cutting. The high-tech CoroMill 790 end mill structure is not complicated, its blade axial adjustment is simple and convenient, and it also has the advantages of cutting force balance, wide application field and precise machining allowance.
Interchangeable solid carbide tool
Solid carbide cutting tools, especially small diameter tools, are widely used for die cutting of various materials. Between the indexable insert and the solid carbide tool, there is now an alternative third solution that can cover the characteristics of the first two to some extent, and it provides both cutting The indexable nature of the blade provides the benefit of using a medium to small diameter solid carbide end mill. Up to now, the prospects for this field have been evaluated, pointing out its potential advantages and disadvantages. However, a new tool concept can fully exploit this area.
Although indexable insert technology offers many benefits, modern solid carbide cutting with long radial cutting edges and axial feed capability is important, especially when the tool diameter is small. Advantages include high precision, high surface quality, knife performance and light cutting. The use of indexable insert tools requires a quick and easy replacement of the cutting portion of the tool, optimizing the performance of this part of the tool and increasing the use advantage.
The indexable insert end mill has a diameter as small as 12 mm. Below this diameter, the mounting and clamping of the insert becomes impractical. On the other hand, the diameter of the solid carbide end mill can be as small as 1 mm or less. The diameter of 10-25 mm is the range of both types of end mills and can be used in many machining processes. The interchangeable end mill combines the indexable insert with the solid carbide. The indexable insert can be used for high-efficiency roughing to semi-finishing, and solid carbide for semi-finishing to superfinishing. Processing. As a third option, the head-removable end mill has the potential to be optimized in the cross-application area of ​​the two.
A key part of the CoroMill 316 interchangeable head tool is the interface between the cutting head and the body. One of the most important parts of the interface is a specially developed, patented self-centering thread for pulling up and holding the top into the shank (for tensioning the tip and body) without any gaps. The axial support surface is as large as the radial support surface, and the inner end of the cutting head is supported inside the shank along the tapered surface, thus providing the highest bending strength. The cutting head of the cutting tool can be easily fixed and tightened with a slight turning of the wrench. The unique interface between the cutting head and the shank provides high rigidity for the full groove roughing process and high precision for precision finishing operations. The CoroMill 316 tool has an axial tool length repeatability and a radial runout limited to 0.02 mm.
The CoroMill 316 tool has a balanced design so it can use a relatively high spindle speed. The combination of high speed and multi-tooth cutting heads provides very high feed rates and high cutting speeds. The interchangeable head concept also allows the tool geometry to be easily adapted to the workpiece material without the need for excessive tool stability. The tool stability of conventional solid carbide tools is affected by the core diameter.
Blade grade for higher speeds
When discussing blade grades for indexable milling cutters, high speed cutting requires the use of higher performance insert grades, especially when production efficiency is a priority over cutting versatility. When the metal removal rate and processing cycle need to be prioritized in mold milling and the cutting conditions are good, the performance of the general grade may not be good enough. When high cutting speeds, prolonged contact, and harder materials are used, crater wear, hot cracks, and plastic deformation may occur, which may reduce tool life and predictability.
In order to achieve higher processing safety when improving cutting parameters, the requirements for wear resistance are clearly higher than the requirements for toughness. Therefore, in order to make the blade harder, consider using ISO P20 insert grades in steel mold applications. This is to avoid premature breakage of the cutting edge and to achieve higher cutting parameters. In order to further improve the cutting performance, it is generally considered that no coolant is used in the milling of steel molds.
Since high cutting rates are commonly used today, even if the amount of coolant is large, it is difficult to have a significant influence on the cutting edge, so dry milling should be used. Most of the coolant is evaporated during wet cutting, and the remaining coolant can only intermittently cool the blade as it enters and exits. At this point, the change in heat is amplified, which can have a worse impact on the blade than the actual high temperature. Modern coating grades are designed for high-speed milling of steel, providing high safety without the need for coolant at high cutting speeds and high feed conditions, but most grades are good under both dry and wet processing conditions. Work.
High speed and high feed mean more heat. However, the use of steel milling grades such as GC4220 will not be a negative factor. It is an ISO P20, CVD coated grade designed to achieve maximum performance with high cutting parameters. Some processes require higher productivity than versatile requirements, and therefore require higher wear resistance. Perhaps this is one of the ways to deal with harder steel. Therefore, the heat-related wear mechanism becomes a more prioritized problem and requires a grade that can withstand such cutting edge breakage. The GC4220 is the first choice for cutting time with higher cutting speeds. It has a wide range of applications and is even the optimizer for many steel mold materials and is a good choice for cast iron milling with high heat problems.
Faster feed and higher speed in the depth of the cut
Today, in many mold shops, the trend in CNC milling is to use higher feed rates and smaller depths of cut after roughing. This is good for the machine tool, which improves the machining results. Power limitations are also an increasing factor to consider, especially on machining centers with tapers of ISO 40 and 30. The higher speeds and feeds of today's machine tools also mean the ability to use small diameter milling cutters more efficiently and to cut shoulders and end faces by repeated passes. These factors help to set the direction for the development of a new generation of shoulder milling cutters. Therefore, in the new CoroMill milling cutter series, the maximum depth of the CoroMill490 milling cutter should be at a lower value: 5.5 mm, with a recommended value of 4 mm. This also provides an opportunity for new square shoulder milling cutters with square inserts, as well as the basis for high blade stability and good tool economy through precise and safe blade positioning.
The CoroMill 490 insert has optimized the blade support points and placed them as far apart as possible along the edge of the seat, thus minimizing the effects of cutting forces that easily move the blades on the seat. A small depth of cut tends to amplify the lever effect with a blade screw compared to a long cutting edge radial knife. However, the structure of the CoroMill 490 compensates for this, which guarantees high stability. High stability is a prerequisite for large feed per tooth, consistent high precision and surface quality, and long tool life.
In some applications, the ability to machine large diameters is critical to the design requirements of the part, requiring a wide range of milling cutters, custom or dedicated blade radii. The CoroMill 490 insert has a nose radius of between 0.4 and 1.6 mm and is suitable for finishing to roughing applications in shoulder milling.
For the ability of the CoroMill 490 in high-speed machining, the successful development of the unique, new parallel forging used in the insert is one of the key innovations. This type of tool has been proven to achieve the best removal rate per unit of power.
in conclusion
With the continuous development of various cutting tools, milling has taken a new level in the performance of high-speed cutting, using new indexable insert end mills to improve the cutting capacity of high-speed and high-feed aluminum molds. The new indexable tool is based in part on a new blade-knife interface that secures the blade at high spindle speeds. The interface innovation between the new tool body and the interchangeable tool cutting head is optimized in two ways, taking the cutting performance of the solid carbide tool to a new level. The development of the new coated carbide insert grade directly affects the durability of the insert at high cutting speeds. New developments in square shoulder milling with indexable inserts have opened up new horizons for milling in mold making.
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