When it comes to chips and milling, size does matter

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Jongen Werkzeugtechnik GmbH

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Iscar Ltd

Cut up the chips to cut down the power

A high metal removal rate creates substantial cutting forces and therefore demands considerable machine power. In such a situation, a tool works under difficult conditions and experiences significant heat load. The chip-splitting ability of the extended flute cutters contributes greatly to the reduction of the acting cutting forces and the required power. This, in turn, diminishes the thermal loading of the cutter. Such relief is said to be important for machining hard-to-cut aerospace materials like titanium alloys, where minimising heat generation during cutting is an important source of better performance and longer tool life. In addition, reducing cutting forces makes it possible to use the cutter in machine tools with low-power drives.

Boosting productivity through better vibration resistance

In rough milling with the use of extended flute cutters, a high cutter overhang is quite common. Vibrations and bending of the cutter are well-known problems faced by technologists and operators. To solve these problems, the cutting data should be reduced. However, this may affect productivity. Improved vibration dampening of the cutters using inserts with a chip splitting cutting edge significantly improves the dynamic behaviour of the cutters and allows users to overcome these problems.

Company inserts target rough milling

Iscar said its Helitang T490 milling family with tangentially clamped inserts ensures the type of productivity gains associated with the aforementioned chip-splitting advantages. Combined with the progressive cutting geometry and Sumo Tec post-coating insert treatment, the family provides high-efficiency tools for productive rough milling of deep shoulders, cavities and edges, it explained. The inserts are available in sizes of 08, 13 and 16 mm and are intended for a wide diameter range of the cutters.

Inserts with the chip-splitting edge were introduced in the Helido H490 milling cutter family with radially clamped inserts, in 12 and 17 mm versions. Furthermore, the company said the chip-splitting approach was also successfully adapted in the HM APCR 2206 inserts for Helialu milling cutters, which are used for machining aluminium alloys. The combination of the chip-splitting cutting edge with a modern design and the newest technology in the company’s milling inserts is said to have substantially increased productivity of rough milling operations.

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