CUTTING TOOLS
ing center line of at least one builder today. The C10 features a robust design with a 100-mm flange that requires high pull force to actuate the clamping in the machine,” he said. “The higher the pull force, the greater the rigidity and
stiffness that the tool assembly has. This rigidity is extremely beneficial for aerospace applications that require long reach both on structural parts or for reaching down into tubular barrel-type components like engine casings.”
Optimizing Machining Parameters Is Always Critical “When I think about difficult-to-machine materials, titanium comes to mind, so does Inconel, and so do stainless steels, which are also very difficult to machine. The ductility of the ma- terials is much harder, the yield strength and tensile strength are closer in a way to each other, making it difficult to shear and break the chip,” said Scott Etling, director, global product management, indexable milling, Kennametal Inc. (Latrobe, PA). Optimizing machining parameters is critical in machining titanium where heat and forces are the enemies of carbide.
“You have to have the right PVD coating, a tough substrate, the right geometry, right edge prep, and high shear geom- etries, not big T lands on the edge of the insert. The heat doesn’t go into the chip like it does in steel. The heat has to go somewhere, so for most titanium applications you have to use an enormous amount of coolant,” said Etling. Kennametal’s customers are now able to benefit from the advanced titanium cutting technology of Stellram, which has been fully integrated into the Kennametal family. “Stellram’s 7792VX high-feed milling cutter and X-grade carbide are spe- cifically designed for machining nickel, cobalt, and titanium- based alloys. The insert angle in the cutter body is optimized so that the cutting forces are pushing into the spindle so there isn’t a lot of deflection when you’re machining these tough materials and the cutting edge is very sharp with an optimized geometry,” said Etling. “In addition, the rigidity of tool and spindle connection so important for vibration-free and deflection-free machining of these metals is provided by our second-generation KM4X spindle connection. The KM4X has a four-ball clamping mechanism and is capable of improving metal removal rate by increasing depth of cut and feed rate. We are working closely with machine tool builders to offer KM4X to the market,” said Etling.
HAIMER Power Series:
Rock solid and highest precision – The best on this planet.
Long Extension in Milling Creates Challenges Regardless of Material “Long extension, or overhang, while
Tooling Technology Shrinking Technology Haimer USA, LLC | 134 E. Hill Street | Villa Park, IL 60181 Phone: +1-630-833-1500 | E-Mail:
haimer@haimer-usa.com |
www.haimer-usa.com Balancing Technology Measuring Instruments
milling creates many challenges, espe- cially when combined with difficult to cut materials such as titanium or high temperature alloys. In virtually every industry, there are machining environ- ments which require extensions that ex- ceed normal reliable diameter to length ratios. In this arena, deflection com- promises productivity and adversely affects tool life. Many of today’s lighter duty machines with smaller spindle adaptation suffer even more,” said Terry Carrington, national product manager- milling, Iscar Metals Inc. (Arlington, TX). “To address this, lighter radial engagement combined with longer axial length of cut allows higher metal
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AdvancedManufacturing.org | January 2015
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