Cutting Tools Avoiding swarf clearance: End mills for challenging materials

Editor: Alexander Stark

To address the issue of swarf clearance that might occur when machining soft, tough and high-alloyed materials, Guhring has introduced the new RF100 Sharp Series of high-performance end mills.

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The new Sharp RF100 in use on a turning centre.
The new Sharp RF100 in use on a turning centre.
(Source: Guhring)

Chip jamming and swarf sticking to the cutting tool can create a major impact upon productivity and machining performance — to eliminate this problem, Guhring has developed the new RF100 Sharp Series of solid carbide end mills. Being the company’s sharpest solid carbide milling tool to date, the end mill delivers high-quality machining results with good swarf evacuation on the most challenging of materials, the company states. Not only does the new RF100 Sharp demonstrate extremely smooth cutting action and chip removal, but it is also a flexible end mill that is suitable for slotting, ramping, roughing, helical milling, finishing and trochoidal cutting. The smooth cutting action combined with the potential to be used in a wide variety of applications makes the new RF100 Sharp, ideal for milling challenging material types.

With a rake angle of 12°, the end mills can be applied to materials with high ductility and tensile strength from 300 to 900 N/mm2. This makes the 4-flute end mills suitable for machining steel, stainless steel, aluminium, aluminium alloys and other challenging materials. The performance of the new RF100 Sharp is derived from a tough carbide grade that combines with an AlCrN coating to prevent tool breakages under the most demanding of conditions whilst the coating technology increases the wear protection, regardless of the cutting speed. Complementing this composition is a geometry that has an optimised facet that dampens vibration, smooths the cutting action and increases tool life. This tool life improvement is further enhanced with a corner protection chamfer that increases stability and edge strength during the most difficult of machining applications.

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The RF 100 Sharp is available in three versions, an extra-long design long (DIN+) that is an extension on the long (DIN) version, but has an even longer cutting edge and there is also a standard length end mill. The RF100 Sharp with the standard and long (DIN) are available in diameters from 1 to 3 mm in 0.5 mm increments with the range including all common sizes up to 20 mm diameter. Depending upon the chosen diameter, the RF100 Sharp is supplied with an overall length from 50 to 104 mm with a flute length from 3 to 41 mm.

The longest tools in the range have a long neck to facilitate reaching into difficult to machine areas. With the longer series tools, the overall length ranges from 50 to 126mm with a combined flute and neck length that ranges from 5.5 mm on the 1 mm diameter tool through to 75 mm on the 20 mm diameter variant. This increases the reach and flexibility of the series significantly, enabling end users to reach into cavities and difficult to access surfaces.

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