Kennametal's KOR 5 End Mill Enables Higher Feed Rates Roughing Aluminum
Kennametal’s KOR 5 solid carbide end mill is designed for high-speed aluminum roughing in aerospace applications. The five-flute tool is said to allow for increased feed rates of 66% compared to three-flute tools.
A tapered core, variable-pitch design and 35-degree helix reduce chatter and tool deflection, the company says. Through-tool coolant flushes chips away while reducing heat. The tool’s chip splitter pattern is designed to break up long chips to avoid recutting while also contributing to surface quality.
The KOR 5 enables machining with low radial engagement but high depth of cut, resulting in higher metal removal rates than traditional methods, according to Kennametal. Use with the company’s Safe-Lock shanks increases the tool’s predictability and prevents pull-out at higher feed rates.
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.