If speed is your goal - check out these new tools that cut really fast. Advanced Manufacturing put together a list of advancements in cutting speed. "Another key trend in modern end mill design is the multiplicity of cutting edges, even nine or more flutes. Boss calls it the 'shiny new thing' that users are drawn to because it offers the possibility of machining faster." However, remember that the speed increase doesn't happen immediately. Training and user adjustment time must be taken into consideration. Click the link for more detailed information!
Geometric Improvements The idea of spacing an end mill’s flutes unevenly (unequal indexing) and/or changing the helix from flute to flute to reduce chatter is old news. It has also long been possible to vary the helix and the rake within a flute (i.e. from front to back). What’s new, according to Oliver Rapp, R&D manager for round tools at Ceratizit(Balzheim, Germany and Warren, MI), is the degree to which cutting tool manufacturers are combining these features in a single tool and the degree to which the market is willing to pay for this technology. At the same time, newer milling techniques like trochoidal milling and high dynamic cutting (HDC) are driving the demand for longer flute lengths. Rapp explained that varying the helix from 20° to 40° (for example) over the length of the flute can help with chip evacuation when the axial depth of cut (DOC) is two or more times the diameter of the tool (2 × D or more). “But it’s tricky. It’s not always a help and can be a problem. If the helix angle is too low, the tool gets noisy and you don’t have enough contact area with the workpiece,” he said. Ceratizit offers this technology in tools that cut at up to 5 x D, greatly reducing machining time. But Rapp added that doing so also requires the assistance of CAM software. “You can’t program these cuts manually,” he said. Read More