Today's indexable insert end mills can be used in a wide range of small diameter end mills to replace conventional high speed steels or solid carbides. Although high speed steel and solid carbide end mills are still the best choice for profiling cuts with long axial depths, indexable insert end mills are suitable for large batches involving medium axial depths of up to 16 mm. Diameter processing provides a more economical alternative.
Indexable insert end mills offer several cost-saving advantages. The most obvious is that they dramatically reduce the cost of tool replacement. Cobalt high speed steel and solid carbide are expensive. When they break, the entire tool must be replaced at the cost of the new tool. On the contrary, a broken blade can be replaced with a few dollars.
Indexable insert end mills also eliminate the need for regrind, which is a labor-intensive activity and it is costly. Regrind also causes a loss of tool diameter. In the case of slot milling, that means an additional finishing process to meet the cost increase caused by the critical size requirement.
Finally, indexable insert end mills offer a wide range of versatility to cut costs. In many cases, simply changing the insert material or groove shape in the same tool body can be used for different workpiece materials or machining - allowing you to easily and economically transfer from medium carbon steel to titanium alloys or from milling slots Switch to quick copying.
In general, indexable insert end mills are best suited for machining that involves a small axial depth of cut. But they are not limited to small diameter machining. For example, Seco offers larger indexable insert end mills with a diameter of 38mm and above. It also provides effective finishing profiling capability for depths of cut of more than 3 to 4 inches. These larger indexable end mills are even more economical than their smaller counterparts compared to small diameter HSS or solid carbide end mills. Large diameter high speed steel or solid carbide tools are both expensive and expensive to regrind.
High performance plus versatility
Many end mills used in automotive, aerospace, tooling, and other industries involve small diameter machining on low power machines with low spindle torque and stiffness. A major trend today is the de facto market for the rapid growth of machining centers of less than 15 horsepower capacity (including many 10 horsepower or less). The small diameter end mills used in these machines are limited to small to moderate axial depths of cut, but offer the advantages of high cutting speeds and feed rates.
Indexable insert end mills for small diameter applications can be purchased separately or as components of a universal end mill system. An example of the latter is Seco's famous Little Devil System (which offers a choice of 150 blade types and 70 toolholder designs that can be combined to create a wide variety of milling cutters ranging in diameter from 6mm to 20mm. ). Each steel or heavy metal arbor uses only a simple two or three effective cutting edges for indexable inserts, allowing the tool user to quickly change from a ball end mill to a point drill within seconds of the machine tool Or from slot cutter to chamfer milling. The patented blade clamping mechanism ensures good rigidity and securely clamps the blade.
These small diameter end mills provide excellent performance and productivity. For example, using high-speed steel arbors that are balanced, they can safely operate at extremely high cutting speeds of up to 3,600 meters per minute. At high feed rates, the metal removal rates obtained were five times higher than those obtained with the overall HSS tool.
The little devil milling cutter system is also very accurate. For example, precision ball noses achieve dimensional accuracy from +0.005mm to -0.03mm, easily matching the effect that can be achieved with any solid carbide or HSS tool.
Finally, these end mills with a combination of arbor blades offer outstanding versatility. They achieve the same efficiency in a 50 horsepower machining center or in a variety of low-power machine tools such as Bridgeport milling machines or light-duty machining centers. With a wide range of insert materials and geometries, tools created from the Little Devil System can be used for roughing to ultra-fine finishing of materials ranging from plastics and aluminum to hardened steels and superalloys. Possible machining includes milling planes, slot milling, chamfer milling, slashing, ramp milling, profiling, and spiral interpolation. Like the solid carbide end mills, the Little Devils end mills also machine genuine 90-degree square shoulders that meet ANSI or industrial precision standards, using blades with sharp rounded corners or pre-sharpened corner radii. With the change of the blade, the same knife can also complete the 90-degree center hole drilling, 120-degree drilling and plunge milling. In these functions, vertical plunge milling and large-angle bevel milling cannot be accomplished with conventional high-speed steel or solid carbide end mills.
Wide range of requirements for a wide range of options
In addition to their versatility and high performance, today's indexable insert end mills have a wide variety of forms to meet a wide range of application requirements and processing preferences. For example, the recent addition of the Seco Young Devils system is a blade design with a triple-edged, large helix corner with internal cooling holes. There is a wide range of tool bars available, ranging from short cylindrical patterns for high-speed machining to very long patterns for increased depth. The advanced blade design allows these indexable insert end mills to operate at full speed (5 times the HSS cutting speed) of solid carbide. At the same time, the three-edged tool retains economy, maintaining the cost advantages and extensive versatility of the replaceable blade. On the contrary, the same design applied to solid carbide end mills will make their use cost prohibitively high.
The other important advantage of the three-edge indexable insert end mill is the reliability of a shorter, more stable arbour design. For solid carbide end mills, the tool length depends on the accessibility requirements, and long overhangs can create problems with tool stability and vibration.
In contrast, with the Little Devils milling system, the length of the tool depends on the existing tool type, depending on the machining to be performed. The longest tool bar meets any accessibility requirements while providing the stability required for good machining performance. Good machining performance includes increased tooling and speed for higher productivity and smaller tool vibration for better surface finish and longer tool life.
In order to complement the Little Devil small diameter system, Seco offers a series of larger-diameter conventional light-loaded indexable insert endmills for small and medium-sized machine tools, called small cyclone cutters. These cutters are from 12mm to 50mm in diameter. The standard endmill version offers four types of toolholder options, including cylindrical, side-mounted, Morse-type, and extra-long. In addition, cutterhead patterns for shoulder milling and flat milling are also available. Like the Little Devil Milling Cutter, the Small Whirlwind Cutter features excellent free-cutting grooves for high metal removal rates, as well as cooling through-hole capability and versatility for a wide range of applications. Although the cutting length of the indexable insert used is only 9mm, the knife can bear a depth of 5mm in the full-width milling process and 6mm in the profiling process. Other processes include ramp milling, plunge milling, and circle and spiral interpolation on solids.
In order to increase the economics of the 90-degree milling, profile milling and square shoulder milling at cutting depths up to 8 mm, Seco offers its 'mini square shoulder' series end mills. These cutters use a small square blade with a 9mm blade length, providing significant initial cost advantages and four cutting edges, resulting in a lower average cost per blade. Three tool body styles have a wide range of application versatility, including Arbor-type end mills with diameters from 25mm to 32mm, cutterhead mills with diameters from 38mm to 100mm, and adjustable cassette mills with diameters from 80mm to 250mm Cutter. Both cutter head mills and adjustable chuck mills have a normal pitch and a dense pitch pattern.
Seco also offers a family of indexable indexing milling cutters called CombiMaster that can meet virtually any mold or aerospace machining (including high-speed finishing) needs. This modular series consists of steel arbors of various lengths and various forms of cutting heads with indexable inserts with threaded connections. Existing tool heads include a button-type milling cutter using a 12-mm diameter circular blade for face milling, bevel milling and plunge milling at high metal removal rates and a tool for high-speed semi-finishing and finishing of contours The standard 90 degree ball head style also has a spiral blade design for large depth of cut or thin wall milling. In addition, a unique 120 degree ball head design for true three-dimensional cutting and high-speed semi-finishing of straight wall parts.
A wide variety of indexable insert endmills offers an effective choice of toolholder form and length that cannot be found with any solid carbide end mills. For example, the Little Devils and Split Milling cutters offer a wide range of toolholder lengths. They also include arbors made of a heavy metal material to eliminate vibration in long overhang applications. In addition, all Seco indexable insert end mills offer a patented, integrated insert with indexable inserts. This integrated blade increases safety by protecting the blade body in the event of blade failure.
For application flexible materials/grooves
The wide range of existing blade materials and geometries further expands the capabilities of small diameter indexable insert end mills. This can be seen first with existing cutting materials. For example, the Little Mavur ball end mill uses a fine-grain carbide insert with a very sharp cutting edge and an advanced PVD (Physical Vapor Deposition) coating to effectively process hardened Rockwell steel at 55 degrees. In fact, the small-diameter end mills equipped with these inserts have been successful in the finishing of the die industry, injection molds, and glass bottle molds. With a small depth of cut at high feed rates, the PVD-coated cemented carbide generates an ultra-light surface that virtually eliminates the need for fitter dressing.
Among other tool materials, PCBN (Polycrystalline Cubic Boron Nitride) inserts are now being successfully used in the ultra-high speed machining of die steels and hard cast irons.
In the aviation industry, PCD (Polycrystalline Diamond) inserts are playing an important role in aluminum milling. A proprietary application is the thin-walled aluminum extrusion frame that is riveted together for use inside the aircraft. Seco's own Little Devils milling cutters with PCD inserts are widely used to machine many of these parts' required shapes. These parts are usually obtained by the bar feed through the processing center to get 1.6mm thick 25 ~ 50mm wide finished product.
With many types of insert geometries (including flat tops, straight rake rakes, sharp cutting edges, honing cutting edges and negative chamfer-reinforced cutting edges), indexable insert endmills further provide application flexibility. The importance of these flexibility is obvious, for example, in the finishing of D-12 die steel profiles with a hardness of 55 degrees Rockwell. The use of a milling material coated with F30MPVD with a very good Tungsten-toughness, and a small devil-adjustable B90P90-degree ball with a groove shape (feed per tooth of 0.05mm) in the M05 can achieve remarkable results in this process. In practical applications, this tool has a 0.5mm step depth in the axial direction and a 0.25mm step (radial depth of cut) and a feed rate of 6600mm per minute. The tool has a surface finish of 0.4μm at a tool life of 90 minutes.
Regardless of the type of indexable insert end mill used, whether it is a small-diameter form like the Segovia or a slightly larger-diameter form like a small cyclone, the existing suitable insert material and groove shape make It is suitable for hand applications. Regardless of how they use it, the bottom line is that small-diameter indexable insert endmills have important advantages in terms of versatility, performance, machine tool availability, economy, and reliability compared to high-speed steel and solid carbide end mills.
Real world solutions
Many of the advantages of indexable insert endmills are economical solutions in a wide range of applications and industries. Here is an example of a Seco endmill product.
Reliable stainless steel processing
A manufacturer of stainless steel diaphragm valves used in the medical biotechnology industry is suffering from the processing of a 38mm diameter cavity on the 316L austenitic stainless steel forgings. Parts are designed for direct connection of tubes of the same diameter.
The end milling required to process the valve body cavity was performed on a 15-hp machining center with a tool changer. Similar to those used for mold processing, a three-axis simulation program was used. There are many challenges in machining conditions, including tool overhang, interrupted cutting, load fluctuations during cutting due to inconsistency in the forging process, and the toughness and stickiness of stainless steel.
The earliest tool used for this machining was a conventional single-tooth indexable insert end mill with a spindle speed of 3,800 revolutions per minute and feed of 0.08 mm per tooth in the presence of coolant. The total processing time for each part averages about 11 minutes, and the blade's life expectancy is 8 parts. However, the main problem is that due to the overhang of the long tool body, breakage may occur before the blade fails.
Looking for a processing solution, the manufacturer turned to the Seco small-diameter end mill system that has been used in other parts. The replacement is composed of a 20mm diameter heavy metal anti-vibration arbor and a 12mm diameter new F30MPVD coated milling cutter. Both provide important advantages. Heavy metal arbors provide excellent vibration resistance and rigidity. F30M carbide is specially designed for machining stainless steel, heat-treated steels and superalloys.
Although the heavy metal shank is actually smaller than the one used previously, it can be a solid resistance to the severe stresses that occur when processing valve body forgings. The use of new tools also allows for an overall increase in processing parameters. Spindle speed increased to 6900 rpm, nearly 2 times that of old tools. In addition, when the depth of cut is increased to 0.7mm, the feed rate has increased from 450mm per minute to a staggering 3300mm per minute, which is more than 7 times higher! Also, with these aggressive feed rates, the tool life increased by 50%, increasing from an average of 8 to 12 complete parts.
Indexable insert end mills offer several cost-saving advantages. The most obvious is that they dramatically reduce the cost of tool replacement. Cobalt high speed steel and solid carbide are expensive. When they break, the entire tool must be replaced at the cost of the new tool. On the contrary, a broken blade can be replaced with a few dollars.
Indexable insert end mills also eliminate the need for regrind, which is a labor-intensive activity and it is costly. Regrind also causes a loss of tool diameter. In the case of slot milling, that means an additional finishing process to meet the cost increase caused by the critical size requirement.
Finally, indexable insert end mills offer a wide range of versatility to cut costs. In many cases, simply changing the insert material or groove shape in the same tool body can be used for different workpiece materials or machining - allowing you to easily and economically transfer from medium carbon steel to titanium alloys or from milling slots Switch to quick copying.
In general, indexable insert end mills are best suited for machining that involves a small axial depth of cut. But they are not limited to small diameter machining. For example, Seco offers larger indexable insert end mills with a diameter of 38mm and above. It also provides effective finishing profiling capability for depths of cut of more than 3 to 4 inches. These larger indexable end mills are even more economical than their smaller counterparts compared to small diameter HSS or solid carbide end mills. Large diameter high speed steel or solid carbide tools are both expensive and expensive to regrind.
High performance plus versatility
Many end mills used in automotive, aerospace, tooling, and other industries involve small diameter machining on low power machines with low spindle torque and stiffness. A major trend today is the de facto market for the rapid growth of machining centers of less than 15 horsepower capacity (including many 10 horsepower or less). The small diameter end mills used in these machines are limited to small to moderate axial depths of cut, but offer the advantages of high cutting speeds and feed rates.
Indexable insert end mills for small diameter applications can be purchased separately or as components of a universal end mill system. An example of the latter is Seco's famous Little Devil System (which offers a choice of 150 blade types and 70 toolholder designs that can be combined to create a wide variety of milling cutters ranging in diameter from 6mm to 20mm. ). Each steel or heavy metal arbor uses only a simple two or three effective cutting edges for indexable inserts, allowing the tool user to quickly change from a ball end mill to a point drill within seconds of the machine tool Or from slot cutter to chamfer milling. The patented blade clamping mechanism ensures good rigidity and securely clamps the blade.
These small diameter end mills provide excellent performance and productivity. For example, using high-speed steel arbors that are balanced, they can safely operate at extremely high cutting speeds of up to 3,600 meters per minute. At high feed rates, the metal removal rates obtained were five times higher than those obtained with the overall HSS tool.
The little devil milling cutter system is also very accurate. For example, precision ball noses achieve dimensional accuracy from +0.005mm to -0.03mm, easily matching the effect that can be achieved with any solid carbide or HSS tool.
Finally, these end mills with a combination of arbor blades offer outstanding versatility. They achieve the same efficiency in a 50 horsepower machining center or in a variety of low-power machine tools such as Bridgeport milling machines or light-duty machining centers. With a wide range of insert materials and geometries, tools created from the Little Devil System can be used for roughing to ultra-fine finishing of materials ranging from plastics and aluminum to hardened steels and superalloys. Possible machining includes milling planes, slot milling, chamfer milling, slashing, ramp milling, profiling, and spiral interpolation. Like the solid carbide end mills, the Little Devils end mills also machine genuine 90-degree square shoulders that meet ANSI or industrial precision standards, using blades with sharp rounded corners or pre-sharpened corner radii. With the change of the blade, the same knife can also complete the 90-degree center hole drilling, 120-degree drilling and plunge milling. In these functions, vertical plunge milling and large-angle bevel milling cannot be accomplished with conventional high-speed steel or solid carbide end mills.
Wide range of requirements for a wide range of options
In addition to their versatility and high performance, today's indexable insert end mills have a wide variety of forms to meet a wide range of application requirements and processing preferences. For example, the recent addition of the Seco Young Devils system is a blade design with a triple-edged, large helix corner with internal cooling holes. There is a wide range of tool bars available, ranging from short cylindrical patterns for high-speed machining to very long patterns for increased depth. The advanced blade design allows these indexable insert end mills to operate at full speed (5 times the HSS cutting speed) of solid carbide. At the same time, the three-edged tool retains economy, maintaining the cost advantages and extensive versatility of the replaceable blade. On the contrary, the same design applied to solid carbide end mills will make their use cost prohibitively high.
The other important advantage of the three-edge indexable insert end mill is the reliability of a shorter, more stable arbour design. For solid carbide end mills, the tool length depends on the accessibility requirements, and long overhangs can create problems with tool stability and vibration.
In contrast, with the Little Devils milling system, the length of the tool depends on the existing tool type, depending on the machining to be performed. The longest tool bar meets any accessibility requirements while providing the stability required for good machining performance. Good machining performance includes increased tooling and speed for higher productivity and smaller tool vibration for better surface finish and longer tool life.
In order to complement the Little Devil small diameter system, Seco offers a series of larger-diameter conventional light-loaded indexable insert endmills for small and medium-sized machine tools, called small cyclone cutters. These cutters are from 12mm to 50mm in diameter. The standard endmill version offers four types of toolholder options, including cylindrical, side-mounted, Morse-type, and extra-long. In addition, cutterhead patterns for shoulder milling and flat milling are also available. Like the Little Devil Milling Cutter, the Small Whirlwind Cutter features excellent free-cutting grooves for high metal removal rates, as well as cooling through-hole capability and versatility for a wide range of applications. Although the cutting length of the indexable insert used is only 9mm, the knife can bear a depth of 5mm in the full-width milling process and 6mm in the profiling process. Other processes include ramp milling, plunge milling, and circle and spiral interpolation on solids.
In order to increase the economics of the 90-degree milling, profile milling and square shoulder milling at cutting depths up to 8 mm, Seco offers its 'mini square shoulder' series end mills. These cutters use a small square blade with a 9mm blade length, providing significant initial cost advantages and four cutting edges, resulting in a lower average cost per blade. Three tool body styles have a wide range of application versatility, including Arbor-type end mills with diameters from 25mm to 32mm, cutterhead mills with diameters from 38mm to 100mm, and adjustable cassette mills with diameters from 80mm to 250mm Cutter. Both cutter head mills and adjustable chuck mills have a normal pitch and a dense pitch pattern.
Seco also offers a family of indexable indexing milling cutters called CombiMaster that can meet virtually any mold or aerospace machining (including high-speed finishing) needs. This modular series consists of steel arbors of various lengths and various forms of cutting heads with indexable inserts with threaded connections. Existing tool heads include a button-type milling cutter using a 12-mm diameter circular blade for face milling, bevel milling and plunge milling at high metal removal rates and a tool for high-speed semi-finishing and finishing of contours The standard 90 degree ball head style also has a spiral blade design for large depth of cut or thin wall milling. In addition, a unique 120 degree ball head design for true three-dimensional cutting and high-speed semi-finishing of straight wall parts.
A wide variety of indexable insert endmills offers an effective choice of toolholder form and length that cannot be found with any solid carbide end mills. For example, the Little Devils and Split Milling cutters offer a wide range of toolholder lengths. They also include arbors made of a heavy metal material to eliminate vibration in long overhang applications. In addition, all Seco indexable insert end mills offer a patented, integrated insert with indexable inserts. This integrated blade increases safety by protecting the blade body in the event of blade failure.
For application flexible materials/grooves
The wide range of existing blade materials and geometries further expands the capabilities of small diameter indexable insert end mills. This can be seen first with existing cutting materials. For example, the Little Mavur ball end mill uses a fine-grain carbide insert with a very sharp cutting edge and an advanced PVD (Physical Vapor Deposition) coating to effectively process hardened Rockwell steel at 55 degrees. In fact, the small-diameter end mills equipped with these inserts have been successful in the finishing of the die industry, injection molds, and glass bottle molds. With a small depth of cut at high feed rates, the PVD-coated cemented carbide generates an ultra-light surface that virtually eliminates the need for fitter dressing.
Among other tool materials, PCBN (Polycrystalline Cubic Boron Nitride) inserts are now being successfully used in the ultra-high speed machining of die steels and hard cast irons.
In the aviation industry, PCD (Polycrystalline Diamond) inserts are playing an important role in aluminum milling. A proprietary application is the thin-walled aluminum extrusion frame that is riveted together for use inside the aircraft. Seco's own Little Devils milling cutters with PCD inserts are widely used to machine many of these parts' required shapes. These parts are usually obtained by the bar feed through the processing center to get 1.6mm thick 25 ~ 50mm wide finished product.
With many types of insert geometries (including flat tops, straight rake rakes, sharp cutting edges, honing cutting edges and negative chamfer-reinforced cutting edges), indexable insert endmills further provide application flexibility. The importance of these flexibility is obvious, for example, in the finishing of D-12 die steel profiles with a hardness of 55 degrees Rockwell. The use of a milling material coated with F30MPVD with a very good Tungsten-toughness, and a small devil-adjustable B90P90-degree ball with a groove shape (feed per tooth of 0.05mm) in the M05 can achieve remarkable results in this process. In practical applications, this tool has a 0.5mm step depth in the axial direction and a 0.25mm step (radial depth of cut) and a feed rate of 6600mm per minute. The tool has a surface finish of 0.4μm at a tool life of 90 minutes.
Regardless of the type of indexable insert end mill used, whether it is a small-diameter form like the Segovia or a slightly larger-diameter form like a small cyclone, the existing suitable insert material and groove shape make It is suitable for hand applications. Regardless of how they use it, the bottom line is that small-diameter indexable insert endmills have important advantages in terms of versatility, performance, machine tool availability, economy, and reliability compared to high-speed steel and solid carbide end mills.
Real world solutions
Many of the advantages of indexable insert endmills are economical solutions in a wide range of applications and industries. Here is an example of a Seco endmill product.
Reliable stainless steel processing
A manufacturer of stainless steel diaphragm valves used in the medical biotechnology industry is suffering from the processing of a 38mm diameter cavity on the 316L austenitic stainless steel forgings. Parts are designed for direct connection of tubes of the same diameter.
The end milling required to process the valve body cavity was performed on a 15-hp machining center with a tool changer. Similar to those used for mold processing, a three-axis simulation program was used. There are many challenges in machining conditions, including tool overhang, interrupted cutting, load fluctuations during cutting due to inconsistency in the forging process, and the toughness and stickiness of stainless steel.
The earliest tool used for this machining was a conventional single-tooth indexable insert end mill with a spindle speed of 3,800 revolutions per minute and feed of 0.08 mm per tooth in the presence of coolant. The total processing time for each part averages about 11 minutes, and the blade's life expectancy is 8 parts. However, the main problem is that due to the overhang of the long tool body, breakage may occur before the blade fails.
Looking for a processing solution, the manufacturer turned to the Seco small-diameter end mill system that has been used in other parts. The replacement is composed of a 20mm diameter heavy metal anti-vibration arbor and a 12mm diameter new F30MPVD coated milling cutter. Both provide important advantages. Heavy metal arbors provide excellent vibration resistance and rigidity. F30M carbide is specially designed for machining stainless steel, heat-treated steels and superalloys.
Although the heavy metal shank is actually smaller than the one used previously, it can be a solid resistance to the severe stresses that occur when processing valve body forgings. The use of new tools also allows for an overall increase in processing parameters. Spindle speed increased to 6900 rpm, nearly 2 times that of old tools. In addition, when the depth of cut is increased to 0.7mm, the feed rate has increased from 450mm per minute to a staggering 3300mm per minute, which is more than 7 times higher! Also, with these aggressive feed rates, the tool life increased by 50%, increasing from an average of 8 to 12 complete parts.
CPF-X wall-mounted Chlorine Dioxide Generator is a new type of small Chlorine Dioxide Generating System which is suitable for the secondary water supply and the situations that need small capacity of chlorine dioxide. It has functions of flow rate/ residual chlorine dioxide on-line control, linkage running with water pump, giving low liquid level alarm of raw materials, remote start / stop control and uploading the working states and alarm signals; and giving acoustic and optical failure alarm etc.
*Related Products:portable chlorine dioxide.
Small Chlorine Dioxide Generator
Chlorine Dioxide System, Chemical Chlorine Dioxide Generator, Clo2 Disinfection System
Nanjing Ligong Shuifu Environmental Protection Technology Co.,Ltd. , https://www.watermanclo2.com