High-performance cutters for micro-milling applications

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Jongen Werkzeugtechnik GmbH

Ramada Acos

With the aid of a finite element analysis (FEA), it has been possible to develop a new, highly stable tool geometry in the meantime. As a result, micro-milling cutters are now available that, on the one hand, show a significantly lower risk of breakage and, on the other hand, permit much more precise machining results with high process reliability, and thus also realise the required very short machining times. The tension distribution (image 1a) shows the most fracture-sensitive point on a conventional end mill at the transition from the long and slim cutting edge part to the shaft. In order to increase the static and dynamic stability, the "weak point" was shifted to the area where there is less stress (image 1b).

Cutting-edge micro-topography influences performance

The cutting-edge micro-topography naturally also has a decisive influence on the tool performance. The notchiness caused by grinding grooves can be smoothed through ion beam treatment. This leads to much better tool life.

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The cutting effects that occur in the micro-sector sometimes appear to virtually turn the physics of the macro-world upside down. In such cases, only the vast experience of the development and application experts can bring these new requirements back to the firm ground of secured knowledge, because the main requirements in the application of micro-tools remain unchanged compared with macro-machining: process reliability with high workpiece quality and low production costs.

Choosing the right pulse in laser micromachining

Two practical examples demonstrate the performance of micro-cutters in different ways. On the one hand, we are dealing with machining hardened metal of extrusion dies for tablet presses (image 2 above). On the other hand, we are dealing with the substitution of gravers through micro-cutters for the production of embossing dies (image 3 next page). Both examples are taken from the production process at Fette Compacting.

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