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Kennametal Increasing chip flow in heavy roughing

| Editor: Rosemarie Stahl

Compacted graphite iron is a material that often exceeds its metal counterparts in its mechanical attributes. To manage to machine this difficult material requires special robust cutting tools. Kennametal's Mill 16 is one of them.

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Kennametal’s Mill 16 has a wedge-style clamping system, numbered pockets and inserts, and an open pocket design to increase chip flow in heavy roughing.
Kennametal’s Mill 16 has a wedge-style clamping system, numbered pockets and inserts, and an open pocket design to increase chip flow in heavy roughing.
(Source: Kennametal)

Iron is the most abundant element on earth by mass. For over twenty-five centuries it’s been used to plow fields, build bridges, cook food, and wage war. Without iron, the Industrial Revolution would have gone nowhere, we would have no trains, automobiles, or machine tools today, and mankind would still be an agrarian society. It is quite simply the most important metal in history.

There’s a newcomer to this metal family, though, one that’s making manufacturers take notice. As automakers strive for increasingly fuel efficient and environmentally friendly vehicles, they’re turning away from traditional iron favorites such as gray and ductile iron (GCI and DCI) to compacted graphite iron, or CGI. Also known as vermiculate graphite iron, CGI’s mechanical attributes meet or exceed its counterparts, sometimes drastically so.

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Unfortunately, CGI is also more difficult to machine, requiring cutting tools both tough and wear-resistant. And because of the continuing call for cost-effective machining solutions across all manufacturing industries, these tools must also offer a low cost per part and predictable tool life. For face milling applications, Kennametal's tool is Mill 16.

“Compared to cast iron, CGI has lower weight and greater strength, and is ideal for components that are exposed to both thermal and mechanical stresses like engine blocks and heads for cars and trucks, exhaust manifolds, and brake parts,” says Senior Global Product Manager for Indexable Milling, Marcelo Campos. “As with other cast irons, however, it is quite abrasive, and somewhat gummy to machine. We developed Mill 16 as a best in class face mill not only for CGI, but for all types of cast iron, which remains a popular choice for gear boxes, housings, pump bodies, and other components used in the automotive, agricultural, and heavy equipment sectors.”

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