Brazed Ceramic End Mills Rough Nickel-Based HRSAs
Sandvik Coromant is releasing two series of ceramic end mills for optimal performance in nickel-based alloys: The CoroMill 316 and the CoroMill Plura. These brazed ceramic end mills are said to offer a more productive means of roughing ISO S materials compared to carbide milling cutters.
These end mills share the CC6060 grade designed for nickel alloy machining. The negative geometry provides a tough cutting edge. The six-flute geometry enables highly productive side milling operations, while the four-flute geometry eases face milling, according to the company. The choice between the two depends on machine conditions and the application. Those seeking solutions for difficult-to-reach applications or the extra flexibility of the exchangeable-head system can opt for the CoroMill 316, while those requiring better stability are advised to select the CoroMill Plura.
According to Sandvik Coromant, ceramic tools retain their hardness at the high temperatures associated with milling heat-resistant superalloys (HRSAs). As a result, 20 to 30 times the speed can be achieved in comparison to solid-carbide tools, delivering considerable potential for increased productivity. A stable setup is advised without the use of coolant, as coolant would simply burn at such high temperatures.
Beyond shoulder milling and face milling, the new end mills can also be used for pocket milling, helical interpolation, ramping and slot milling.
Cutting holes by interpolating a face milling cutter may be a better process choice for many rough and even finish boring operations. Software improvements and better cutter designs allow expanding use of the versatile face mill for hole making.
Running rotary milling cutters at the proper speeds and feeds is critical to obtaining long tool life and superior results, and a good place to start is with the manufacturer's recommendations. These formulas and tips provide useful guidelines.
Fast CNC processing and high-pressure coolant contribute to removing metal at dramatic rates. But what should a shop know about cutting tools in high speed machining?