Extended-Flute Cutters Extend Milling Efficiency

From: BY: ANDREI PETRILIN
Time: 2017-06-05
Summary: Indexable extended-flute (sometimes referred to as long-edge, porcupine, and even porky) cutters are universally regarded as the ideal tools for high-performance rough milling, when a machining allowance per pass is significant.

新技术通过切碎芯片改善芯片去除

可转位延长槽(有时称为长边,豪猪,甚至猪肉)切割机在每次通过加工余量显着时被普遍视为高性能粗铣的理想工具。

为了研磨深度的肩膀,空腔和口袋或边缘(边缘),可转位铣刀有助于确保合适的结果。使用长笛刀在通用工程,铁路,航空航天,模具和模具等制造行业的许多重型作业中都是常见的。

不断增长的不断提高生产力的需求促使这些豪猪进一步发展,以创造所需的效率。


分裂芯片

Extended-flute cutters are placed under significant load when they remove a large material layer, and their work in such heavy-cutting conditions is characterized by high cutting forces, considerable power consumption, and substantial heat generation.

Intensive material removal requires the use of a cutter with a chip gullet of considerable volume to ensure effective chip evacuation. This decreases the number of the cutter’s flutes (effective teeth), reducing its productivity. In addition, high cutting forces acting cyclically induce serious vibrations. When using indexable inserts that have a chip splitting action, it is possible to avoid these difficulties.

Inserts featuring chip splitters have a geometry that enables the division of a wide chip into small segments.

As a result, cutting forces and power consumption are reduced, vibration is stabilized, and thermal problems are eased.

Inserts with serrated, wavy cutting edges provide efficient machining with a chip splitting (even chip crushing) action. For optimal chip crushing, it is recommended that users mount the inserts in alternative edge configurations on adjacent flutes of the tool.  However, even if the inserts are mounted randomly, the tool will continue to mill effectively.

Tangential clamping creates two important advantages within the tool design. First, it enables effective use of the insert’s cross section to enable it to resist heavy loads. Second, this approach ensures strength and rigidity in the tool body.

Radial Clamping

Other extended-flute cutters, such as Iscar’s MillShred P290 (shown here), adheres to the more common concept of clamping inserts radially. Under equal conditions, radial clamping may demonstrate less strength-related properties when compared to tangential clamping; however, radial clamping makes it possible to increase the chip gullets volume and, in doing so, significantly improves chip evacuation.

Not Only a Square Shoulder

The majority of extended-flute milling tools have 90-degree cutting edge angles and are designed to machine straight edges and square shoulders or slots. Although various manufacturing processes require productive roughing for inclined or 3-D surfaces, in these cases the extended flute can be a suitable means of improving efficiency.

Tapered tools with cutting edge angles from 22.5 to 75 degrees also are now available for heavy-duty machining applications.

Certain extended-flute ball nose end mills are now designed specifically for efficient profile and shoulder milling, mainly within the die and mould industry. These end mills carry straight-edge inserts that enable machining beyond the spherical (ball nose) cutting edge, which is generated by teardrop inserts. The design of the latter successfully adopted the chip splitting approach.

Milling High-temperature Alloys

The milling of titanium and high-temperature alloys places very specific requirements on extended-flute cutters.

在这些情况下,绝对必要的是直接通过切割机主体提供足够冷却液供给的内部通道。使用高压冷却液(HPC)或低温冷却液进行铣削具有自己独特的要求,在设计刀具时应予以考虑。这些要求导致各种定制工具的可用性。

然而,即使是标准系列的延长槽刀也适用于铣削与航空航天工业相关的难切割材料。

应该注意的是,延长槽刀的类型和设计配置不同,具有很强的性能潜力。如果它们以正确的方式应用,智能化的方式,它们可以扩展可转位铣削效率的前沿。

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