Expanded Modular End Mill Series More than Doubles Options
Kennametal is building on its Duo-Lock modular end mill by offering more sizes, geometries and shank styles.
Kennametal is building on its Duo-Lock modular end mill by offering more sizes, geometries and shank styles. The system is a modular end mill with the performance of solid carbide. It uses a double-cone locating surface like that of the company’s KM or KM4X tooling design so that radial runout values do not exceed 5 µm (0.0002"). The machine maintains Z-axis coupling repeatability of 10 µm (0.0004") or better. The system provides tool-to-tool repeatability of 50 µm (0.002"), preventing the need for offset adjustment or off-line presetting when changing tools.
The system is rigid, with an intelligent coupling thread to absorb torque. These features enable 1×D full-width slotting cuts and side milling up to 50-percent radial engagement along its entire 1.5×D cutting length, even in titanium and similar high-strength alloys.
This expansion more than doubles the existing cutting tip product offering. The variable Harvi helix design reduces chatter, even in difficult-to-machine materials, while an asymmetrical flute angle enables higher feed rates. The eccentric flute relief increases edge stability, providing a commensurate increase in tool life. A tapered core provides rigidity, and its axial and radial rake angles reduce tool pressure. The same tool can perform roughing and finishing, or users can utilize dedicated roughers and finishers in the same interface.
Four- to six-flute versions are available, as are several PVD-coated micro grain carbide grades. These include KCSM15 for titanium and other high-temperature, aerospace-grade alloys; KCPM15 for steel, stainless steel and cast iron; and the multilayer KC643M for wet-cutting a range of materials. All grades can machine metals up to 52 HRC and are said to reduce depth of cut notching, edge wear and cratering in difficult materials.
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.
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.
Creating threaded holes in titanium alloys calls for proper techniques based on an understanding of both the properties of these materials and the peculiarities of the tapping process.