Milling Tool Removes More Metal with Lower Machining Forces
Kennametal is featuring its Harvi Ultra 8X milling cutter, which was developed to meet needs in the aerospace and machine tool building sectors, providing high metal removal rates and enabling higher cutting speeds with lower machining forces. The company claims this tool can predictably remove 20 cubic inches of Ti-6Al-4V per min. while attaining 60 min. of tool life per cutting edge.
A double-sided yet positive rake insert delivers the lowest cost per edge possible and is said to simultaneously reduce power consumption by up to 50 percent. Thanks to a special AlTiN+TiN PVD coating that provides robust resistance to thermal fatigue, Kennametal’s high-performance KCSM40 carbide grade enjoys much longer tool life. The cutter body is constructed of a higher-quality steel for improved stiffness and rigidity under high cutting forces. In addition, a BTF46 (bolt taper flange) connection provides high deflection resistance compared to traditional shell mill-type holders. The variable helix design of the Harvi Ultra 8X breaks up the harmonics that lead to chatter, further improving tool life, part quality and throughput.
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?
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.