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Iscar has added to the built-in asymmetry of its EC-H Chatterfree solid carbide end mills to increase speed and process security in slotting and shoulder milling of ferrous metals. The end mills feature both variable-pitch flutes and varying helixes for vibration damping. Two flutes have a 35-degree helix angle, and the other two ascend at 37 degrees.
According to the company, the more asymmetry designed into a solid carbide tool, the greater its resistance to harmonic vibration and chatter. The variable helix is said to add an extra damping influence against harmonic vibrations, a principal cause of tool fracture in hard, but brittle, solid carbide end mills. It also minimizes chatter marks in the workpiece.
In addition, the EC-H Chatterfree end mills feature a free-cutting-edge geometry designed to improve chip evacuation and reduce cutting forces, making them well-suited for low-power machines with ISO 40 or BT40 adaptations, the company says. They can be safely used on slots as large as 2.5 × D in alloy and stainless steel.
The end mills are available in diameters ranging from 6 to 25 mm, with either Weldon (relieved) or cylindrical (straight) shanks. All have corner radii and are mode of IC900, a versatile PVD-coated grade. Three length and shank-type combinations are available: standard lengths with cylindrical shanks, standard lengths with relieved shanks, and extra-long 4 × D mills with cylindrical shanks.
Can Additive Manufacturing Increase Milling Feed Rates?
With PCD tooling, yes it can. The diamond cutting edges demand a large number flutes to realize their full effectiveness. Traditional methods for making cutter bodies limit the number of flutes, but 3D printing is delivering tools with higher flute density and other enhancements as well.