The new face of face milling

AMJuly17features - Sandvik1
AMJuly17features - Sandvik1

Aerospace Manufacturing discovers how Sandvik Coromant is helping to lower cost per component with the introduction of its CoroMill 415 high feed face mill indexable insert cutter solution.

 

As one of the most common machine shop operations, face milling is a process that benefits enormously from new technological advances. Production engineers are under almost constant pressure to reduce component costs in order to stay ahead of the competition and win market share. In addition, the unwanted costs associated with scrap and a large tooling inventory are also coming under increased scrutiny as companies look to operate as economically as possible.

Hearing these concerns, Sandvik Coromant has set about creating a small diameter, high feed face milling concept that can help machine shops make genuine strides towards the optimisation of this important operation.

Cost per component forms the basis of success for any machining business; with the caveat that quality must not be compromised. For production engineers tasked with cost-reduction exercises, the major focus of attack is productivity, which in machining terms is related to metal removal rate (MRR) and machine utilisation. Of course, the more metal that is removed in a single pass, the more vibration and potential cutter deflection is introduced into the process. So, any face mill selection must be based on both its suitability for delivering elevated MRR and its capability with regard to process reliability and security. This in turn, will help reduce scrap rates, an important factor in an era when raw material is proving expensive.

When it comes to tooling inventory, many machine shops are guilty of tying up excessive amounts of investment in too many different types of cutting tools. Having one tool dedicated for one application or material type is not viewed favourably when it comes to the balance sheet. With this in mind, the benefits of a high feed cutter that is interchangeable with a range of other cutter types, will also prove highly beneficial.

Competitive gain

With its new CoroMill 415 high feed face mill, Sandvik Coromant has produced an indexable insert cutter that pushes the boundaries of this mature milling process, offering machine shops the opportunity to achieve genuine competitive gain.

Beginning with cost per component, CoroMill 415 is able to produce extremely high MRR and reduced cutting forces thanks to the high number of inserts in the cutter and high feed capacity. What’s more, it accommodates inserts featuring four cutting edges, which in combination with high MRR capability improves both cost-efficiency and productivity. This is supplemented by the extra close H pitch, which can be deployed thanks to the tool’s inherent stability, ensuring that more than one tooth is always engaged in cut. The result? Reduced cost per component.

To address the issue of process stability in relation to high MRR, CoroMill 415 features the iLock insert seat interface. All machining generates forces on the tool in use, and these are exacerbated in high MRR operations. Such forces can cause micro-movements of the insert in its seat, and even the smallest movement can have a negative effect on both tool performance and the final outcome.

Secure performance

The iLock is a secure locking interface between insert and toolholder, which prevents cutting forces from affecting insert position. Tools with iLock have rails or serrations on the tool-holder and corresponding slots on the insert for tight locking. This results in improved performance in terms of precision, tool life and chip control. With regard to the latter, CoroMill 415 also includes standard internal coolant channels with radial exit on all cutter bodies, thus further optimising chip evacuation.

To highlight the potential benefits on offer, a recent customer case study demonstrated impressive results when face milling a clamp component made from P20 steel (320 Hb). Using a 25mm diameter CoroMill 415 cutter, MRR could be increased by 26% from 76 to 96cm³/min (4.64 to 5.86in³/min), thus lowering cost per component, while tool life was increased by 25% from four to five completed parts as a result of increased process security. The cutting data included 0.7mm (0.028in) axial depth of cut, 19mm (0.748in) radial depth of cut, 171m/min (561ft/min) cutting speed, 0.55mm/rev (0.022in/rev) feed rate and 2,178rpm spindle speed.

These benefits are available to machine shops in sectors that include aerospace, die and mould, general engineering and oil and gas, for example. In fact, anywhere with a need for high feed rough face milling and/or pocketing in diameters from 13 to 32mm (0.512 to 1.26in). Pocketing is possible because the cutter also offers circular ramping (helical interpolation) capacity.

Enter the problem-solver

CoroMill 415 represents a genuine problem-solver in ISO M and ISO S applications where high feed conditions are used. While the management and engineering team will enjoy lower cost per component, operators will also benefit as the inserts are easy to handle thanks to the iLock insert seat.

For purchasers, a major advantage is the potential of CoroMill 415 to reduce tooling inventory. This is because the cutter is available with the Coromant EH (Exchangeable Head) coupling for enhanced tooling flexibility. With Coromant EH, manufacturers can access a wide assortment of solid carbide cutting heads, indexable milling cutters, boring heads, integrated machine adaptors and shanks to reduce their inventory of tools. In fact, CoroMill 415 can be combined with the Coromant EH coupling and Silent Tools damped adaptors for high reliability and a significant productivity gain where there is a need for long and slender tools.

www.sandvik.coromant.com

 

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