Face milling Six-edge cutters boost efficiency in non-ferrous metal machining

Related Vendors

Tungaloy U.K. Ltd.

Jongen Werkzeugtechnik GmbH

AMPCO METAL Deutschland GbmH

Japanese cutting tool expert Tungaloy has expanded its Tungmeister series with a new face milling head geometry for non-ferrous metal machining. What this means for surface finish and productivity.

In the machining of non-ferrous metal components, flat surface machining is often performed using the end cutting edges of general-purpose solid end mills. However, because the end cutting edges are designed with dish angles, it is difficult to obtain a sufficiently high-quality surface finish. Therefore, improving the quality of the machined surface has become a key challenge.

Furthermore, small-diameter tools typically have a limited number of flutes. As a result, in high-volume production applications such as D-cut and H-cut machining on Swiss-type automatic lathes, there is a strong demand for achieving both high surface quality and high machining efficiency.

In addition, in the machining of components such as motor cases, different tools are required for frame milling of the mating surface and seat-face machining inside the case, necessitating the use of both large-diameter face mills and small-diameter tools. The resulting increase in tool changes has also become a challenge, as it leads to longer cycle times.

Tungmeister is a head-changeable end mill series designed to deliver high-precision and high-efficiency machining. The lineup includes more than 45 head geometries and a wide variety of shank materials, covering tool diameters from 5 mm to 32 mm. With over 25,000 possible head and shank combinations, the series supports a broad range of machining applications. The system enables quick and easy tool changes with excellent repeatability, reducing setup time while maintaining stable cutting performance.

One of the distinctive features of the Tungmeister series is its face-milling head for flat surface machining. Previously available for applications involving steel and stainless steel, the lineup is now being expanded with a new head specifically designed for machining non-ferrous metals.

Optimised cutting edge geometry for non-ferrous metal machining

The cutting edge geometry is specifically designed for face milling and features a wiper edge on the peripheral cutting edge to deliver an excellent surface finish. A large positive rake angle and sharp cutting edges optimised for non-ferrous materials reduce cutting resistance and ensure stable machining. Large chip pockets also help prevent chip clogging, contributing to consistent surface quality.

High-efficiency machining with a small-diameter, multi-edge design

The general-purpose lineup covers diameters from ø10 mm, while the new series for non-ferrous metal machining is available from ø12 mm. Despite their small diameters, the cutters feature six cutting edges, enabling high-feed, high-efficiency machining to maximise productivity. They are particularly suited to high-volume production of small components, including D-cut and H-cut machining on Swiss-type automatic lathes. Compared with conventional four-flute solid end mills, the cutters can deliver both improved surface quality and higher machining efficiency. Their combination of high-efficiency machining and stable cutting performance supports increased productivity in mass production environments.

Multiple operations with a single tool for tool consolidation

The small-diameter design allows the tool to perform multiple operations, including frame milling of mating surfaces such as motor housings and seat machining inside the housing. Its compact size provides access to areas that are difficult to reach with larger-diameter face milling cutters, expanding machining capabilities. By performing multiple machining operations with a single tool, the solution reduces tool changes and setup time while improving overall productivity.

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