Radius End Mills for High Feed Roughing

1.Multi-blade type high-feed corner radius end mills:

The mold industry generally adopts the cutting method of small depth of cut and large feed to achieve efficient machining, but the market demand requires further improvement of machining efficiency. In response to this need, Hitachi Tools has developed multi-edge tools and coatings that can withstand high cutting speeds even under high feed conditions.

The design concept of the multi-edge high-feed round over end mill.Is to reduce the size of the cutting edge according to the previous design method of the number of edges within the limited outer diameter of the tool, but it will not reduce the edge strength. Set the main cutting edge radius of the insert for the high feed corner round end mill to R8. Compared to a round insert with the same radius of R8, it has the same edge strength, but minimizes the insert area to achieve multi-edge. In the past, inserts with an outer diameter of φ32 had two cutting edges, but the multi-edge type high-feed fillet end mills have as many as five cutting edges, which is 2.5 times higher than previous products.

2.Features of large feed tools:

In the past, indexable tools used for roughing were generally equipped with round inserts. On the surface, it seemed that a large depth of cut could be obtained, and a large amount of material could be cut at one time. The contact length of the insert increases, so the cutting resistance increases, and it is difficult to achieve high-feed cutting. In addition, the round insert is subjected to radial force in the machining occasion with long tool overhang, which is easy to cause the tool to bend and vibrate. The cutting edge of the multi-blade high-feed corner round end millis designed at the bottom of the rotary axis of the tool, so the cutting resistance mainly acts on the axial direction.Chatter vibration occurs, enabling stable machining. At the same time, through the miniaturization of the insert, the length of the cutting edge is significantly shorter than that of the previous high-feed tool, which reduces the cutting resistance and effectively controls the cutting force through multi-edge.

3.Advantages of small depth of cut and large feed processing:

Small depth of cut and large feed machining are the application conditions for large feed tools, and their advantages are large material removal rate and high machining efficiency. Compared with high-efficiency machining with a large depth of cut, when the depth of cut is reduced, high-efficiency rapid-feed machining can be performed within the maximum feed limit of the machine table.

When the round insert is used to increase the machining efficiency by increasing the depth of cut, there will be obvious cutting residues on the workpiece after machining, which will increase the machining load of the subsequent finishing tool. Although rough machining is very efficient, it will reduce the machining efficiency of subsequent operations. Compared with this, when a small depth of cut and large feed are used, the residual part of rough machining is reduced, and the shape is closer to the final finishing shape, which can reduce the load of the finishing tool in the subsequent process, and make the rough machining and finishing easier. Efficiency is improved at the same time, and high-efficiency machining is achieved stably and reliably.