IMTS 2012: Achieving Low Torque, High-Rate Metal Removal with Innovative Tool Design
MAG will be presenting its innovative Cyclo Cut Max-Flute end mills at its IMTS 2012 booth this in Chicago next month. These 16-flute designs are capable of high removal rates at low torque, running at 2037 rpm and 5.8 m/min (231 ipm) to achieve removal rates of up to 131 cm3/min (8 in3/min) with only 33.8 Nm (25 ft lb) of torque and 6.7 kW (9 hp).
When cutting titanium, 60 to 70% of the heat generated is normally transferred to the tool, dramatically reducing tool life. Max-Flute tools use shallow, radial widths of cut, which transfers less heat to the cutting tool and allows higher surface speeds for roughing titanium, Inconel and other high temperature alloys that have traditionally required high torque at low rpm to achieve desired removal rates.
Used in conjunction with TrueMill software, Max-Flute end mills maintain a constant angle of engagement, making the radial cuts more consistent throughout the cutter path, increasing material removal rates and decreasing cycle times, while extending tool life.
"The current approach to high-speed machining involves taking very light cuts," said Dan Cooper, Cyclo Cut Product Manager for MAG Global Services. "The Max-Flute/TrueMill enables the machine to make heavier cuts at high speeds, and by using the maximum flute density available, maximum feed rates are achievable."
Max-Flute tools are designed with a differential pitch on the tool flutes to break up harmonics and reduce chatter.
"Titanium is very prone to chatter, which affects part quality, and can cause unpredictable tool failure," added Cooper. "By using extremely high feed rates and light radial cuts, we can remove a lot of material with very little risk of scrapping parts."
