Circle Segment End Mills Increase Material Removal
With so much happening in a busy show year between NPE2018 and Amerimold 2018, MoldMaking Technology is revisiting some of the technology that was on display. In case you missed it: At IMTS 2018, Emuge Corp has circle segment cutters, a class of end mills designed to enable more material removal with fewer passes in five-axis machining.
Emuge Corp has introduced circle segment cutters, a class of end mills designed to enable more material removal with fewer passes in five-axis machining. They are said to reduce cycle times by over 80 percent and to produce smoother surface finishes. The end mills are ideal for machining turbine blades, impellers and blisks, as well as in moldmaking applications. They feature unique forms with large radii in the cutting area of the mills, enabling a larger axial depth of cut during pre-finishing and finishing operations.
The solid carbide end mills are offered in four geometries: barrel-shaped, oval form, taper form and lens-shaped. Oval and taper form mills are ideal for curved shapes such as blades or straight-walled pockets, freely engaging more of the cutting edge. Barrel mills provide effective flank milling to the sides of spiral grooves and similar applications, while lens-shaped mills are designed for narrow channels or in lands on molds. CAM software, such as the more recent versions of HyperMill or Mastercam, is required to support and compute the geometries of the end mills for maximum performance.
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.
The right choices in tooling and technique can optimize the thread turning process.
One of the most common methods of tapping in use today on CNC machines is 'rigid tapping' or 'synchronous feed tapping.' A rigid tapping cycle synchronizes the machine spindle rotation and feed to match a specific thread pitch. Since the feed into the hole is synchronized, in theory a solid holder without any tension-compression can be used.