Square shoulder milling accounts for the largest proportion of milling operations in today's milling process. Similarly, continuous improvement in production efficiency, reliability, and quality levels also has great potential. In many end milling applications where face, edge, and groove cutting is required, square shoulder milling can often be seen. Almost every workshop needs more or less some form of process, and the number of applications is also increasing.
There are currently two major directions in improving the milling process: one is through higher metal removal rates, especially on smaller machines; the other is through a pass to generate better surface quality. And these capabilities can be combined with a unique new milling cutter concept.
Processing is changing
At present, there are many obvious trends in the workshop, some of which will have a great influence on the direction of the shoulder milling ability of the other party. In general, on the machine tool side, smaller machine tools or low-power spindles are increasing; spindle speeds are higher and higher cutting speeds are available; machine tools can apply higher feedrates; and magazine capacity highlights the The need for good tool versatility and performance, as well as the need for operator supervision on the side should also be limited.
In terms of operation, small depth of cut is preferred due to its favorable machine tool and low power consumption availability; the pursuit of more combinations of roughing/finishing machining; increasingly demanding tool accessibility; and simultaneous requirements Higher flexibility, more efficient tool setting, and burr/sticker errors are completely intolerable.
When developing a new tooling platform for square shoulder milling cutters, the progress and experience gained in expanding the established CoroMill series of milling tools played an important role. Along with the development of CNC machine tools, this long process has lasted for 20 years, and it has also led to the emergence of many tool concepts that greatly increase the shop's processing performance in different manufacturing sectors. For the development of today's new type of shoulder-shoulder milling concept, a brief review of these concepts will help us to fully view this development.
CNC milling goes through a long road
The CoroMill 290 shoulder milling cutter incorporates several advantages such as a pre-hardened cutter body and a cost-effective square cutter with four cutting edges, as well as the use of a central screw (to provide high strength in many demanding processes) By ensuring high precision and improved blade positioning, it is easy to obtain better results than previously required. This 90-cutter has become a very versatile tool for small to large diameters and can achieve a considerable depth of cut.
Pure face milling, including finishing to a mirror-like surface and roughing with very high metal removal rates, has been combined into a face milling cutter - CoroMill 245. With a lead angle of 45, the cutting force balance can be achieved for specific passes when high table feeds or tool overhangs are too long. In general, subsequent operations can be eliminated through the wiper band option on the blade. In most workpiece materials, this tool has become a sign of face milling.
Whether it is deep or shallow shoulder milling, there are unique needs in the tool, 90 tools is an essential choice. Similarly, CoroMill 790 represents a new direction, initially focusing on the cutting of non-ferrous materials, such as aluminum wings in the aerospace industry. This tool has a very high metal removal rate, can leave a high-quality square shoulder surface during high-speed cutting, and its tooling error is negligible. Because it was developed specifically for lighter cutting action, the low power requirement is clearly an advantageous feature. In addition, the extremely safe and high-precision blade positioning also makes this tool suitable for ramp milling, interpolation milling, large depth of cut, and plunge milling.
The end mill is the most versatile milling tool because it performs most of the processes. The CoroMill 390 indexable insert gave new meaning to the tool type when it was launched. Here, 90 knives can perform all the tasks that CNC machine tools are required to perform, namely modern light-cutting endmilling in all its forms, including high-efficiency deep-to-shallow square shoulder milling with good surface quality. When the larger blade models are subsequently rolled out, not only are the restrictions even less, they have even eliminated most of the restrictions.
The blade number determines the cutting parameter capability, cutting time, tool life, reliability, and versatility. The recently introduced new generation of coated carbide grades can provide considerably higher levels of performance. This not only makes the shop more competitive, but also meets tighter deadlines and achieves higher quality consistency. The new grades of CVD and PVD coated inserts allow higher cutting parameters to enable reliable and more predictable high-speed cutting over a wide range of applications. Especially for the new type of face milling, the development of this grade also makes it possible to use lighter and more precise cutting with a sharper positive rake angle and without reducing the blade strength.
Combination ability is essential
When developing the new face shoulder milling cutter concept, it is crucial to combine the ability to produce a high quality end surface with the square shoulder surface. Some milling cutters can cut high-level end faces or square shoulders, but no cutter can both achieve both high precision and high surface quality.
The industry is most concerned about production efficiency, so it is necessary to combine the ability to perform fine milling of the face and square shoulders with the quality obtained in the rough machining process to perform high metal removal. In some applications it is also required to combine roughing and finishing passes. The single-cutting capabilities combine high metal removal rates with good square-shoulder surface quality, with no trade-offs in performance, and conversely only constant improvements, which are the capabilities sought in many modern applications.
Although the cost of cutting tools accounts for only a small part of the total production cost of all parts, many users have put the cost of the tool and inventory issues together in a prominent position. The square blade provides four cutting edges and also provides the best cutting edge for each blade. But a square blade means 90 rounds, and it seems limited in its scope of application for the combination of capabilities required by the new efficient square shoulder.
New challenges
When developing a new high-performance milling tool with a true 90 declination angle, the requirements of the opposing blade also represented one of the challenges. High precision and elimination of any related tooling errors, as well as high metal removal capabilities are absolutely essential. In addition, the angular accuracy must also be several times higher than the current tool concept. By relying on existing CoroMill solutions and developing new concept directions at the same time, a model for a new type of shoulder milling machine platform was established. Recent developments in methods and metrics involving the manufacture of new milling tools have provided support for this.
In order to achieve the ambitious goal of combining roughing and finishing tools, and also for the use of square inserts, it is necessary to provide a completely new cutting edge that can produce both end faces and shoulders. At this point, it is necessary to establish favorable cutting action and high finishing ability.
In any multi-tooth milling tool, the wiper edge of the cutting edge plays a crucial role because it is the decisive factor in creating the end face. The wiper band must be longer than the feed per revolution of the tool to ensure good surface quality. One of the problems with the use of wiper belts is that the cutting edge is too long to increase the cutting force. As a result, there is a tendency for vibration to occur and leads to higher power consumption, as well as higher requirements for cutting stability. For CoroMill 490, one of the challenges is how to have the most suitable wiper band without any inherent disadvantages.
It is based on having a large enough axial rake for the insert in the tool and a sharp positive rake on the insert. The 490 solution was fundamentally developed through such a lightweight cutting tool design. The shearing of the basic cutter geometry also indicates that the insert will fall into the material, which means smoother and increased strength. Tool accuracy also contributes to this solution and guarantees advantageous cutting action, especially for finishing. The successful development of unique new blade trim ribbons and tooling characteristics is not only a key factor in ensuring the capabilities of the CoroMill 490, but it is also a key factor in finding the best metal removal rate per unit of power consumed by the tool.
Wiper technology
Wiper technology is a core part of the milling solution. Since the Wiper technology was developed by Sandvik Coromant for turning, it was further developed for the CoroMill 490 wiper band and blade cutting edge for square shoulder cutting. During cutting, tools with multiple blades can easily pass through the transitions produced by each blade land, creating some misalignment errors.
In addition, there is also a problem of tool skew. All tools exhibit a certain degree of program skew during cutting, and the use of conventional wiper belts often negatively affects the resulting surface due to the sharp edge transitions.
The multi-arc wiper design of the 490 blade wiper band compensates for tolerances and angular deviations for cutting. This not only minimizes the tendency for any knife-to-tool error, but also improves the accuracy of the face and shoulder surfaces. Essentially the same effect can now be achieved between different passes on square shoulders or surfaces created by different blades on the end face, which often requires additional finishing.
Use brand for optimization
A sharp cutting edge with a positive rake angle is the key to lightweight cutting characteristics and is especially important when there are a large number of wiper edges so that high productivity, high surface quality and true 90 squareness can be achieved by using square blades. shoulder. In addition, in order to achieve this characteristic at high feed rates and high cutting speeds, the blades must have high strength and durability. This can be achieved by developing a new generation of blade brands.
For CoroMill 490, the new PVD coating grade GC1030 provides the main tool material for a suitable insert geometry and has subsequently become the first choice for these materials. This grade is particularly suitable for small diameter applications, unstable conditions, large tool depths, demanding tool in and out, and small tool knives, all of which are commonly encountered in the shoulder milling process.
Depending on the specific nature of the cutting, some processes will inevitably need to be optimized. Due to the different characteristics of the grades, it may happen that the CVD coating grade is more suitable than the PVD grade. Although not as sharp as the PVD grade, the CVD grade blade is still used by the CoroMill 490 to provide higher cutting speeds and longer tool life. This is especially true in the tool diameter and blade size, and heat-related wear threatens the cutting edge. The GC4230 is a cutting speed optimizer for end mill applications. It is also a very durable universal insert grade, while the GC4240 is a very strong steel milling grade. For this grade, cutting edge toughness is the decisive parameter.
Use troughs for optimization
The shoulder milling process usually uses a very modest feed rate, which prevents the production efficiency from increasing when the feed value directly affects the metal removal rate. Recent studies have shown that the vast majority of applied feed per tooth is less than 0.12 mm. These feed values ​​are acceptable for finishing operations. However, it should also be noted that for the current cost-effective ordinary processes and roughing processes, it is somewhat inadequate.
The CoroMill 490 has been developed as a low-power tool that can provide high metal removal rates (feed rate per tooth up to 0.22mm). At the same time, the tool can also perform high-precision finishing milling with fine chip thickness (feed rate per tooth as low as 0.05 mm). To optimize its wide range of applications, we offer three different insert geometries (L, M, and H).
The H-groove fits into a series of large feed per tooth values. This sturdy cutting edge is sufficient for heavy-duty cutting including thick chips, which makes the CoroMill 490 a light-cutting roughing tool. The L-groove blade transforms the CoroMill 490 into a powerful finishing tool that provides a higher level of square-face milling quality, which is unique to indexable insert tools. The CoroMill 490 with an M-shaped insert geometry has universal capabilities, so it should occupy a prominent position in its tool room on any CNC machine that must mill all kinds of faces, shoulders, edges, and even grooves. The feed range per tooth covers the common range in the middle. Thanks to a combination of possibilities, both in terms of different insert geometries and grades, and variations in the feed per tooth of the milling tool, the CoroMill 490 offers a very wide range of applications and is the best alternative to improve processing performance and results. select.
Depth no longer needed
Smaller depths of cut are usually required when machining parts in the shop, which of course is necessary for many smaller machines. In contrast, the development trend is higher feed rates and cutting speeds. Power limitation is also a factor, especially for ISO taper 40 and 30 machining centers, and especially for most multitasking machine tools and turning centers. The higher speeds and feeds of today's machine tools also mean that smaller diameter (25 to 80 mm) tools can be used more efficiently and that shoulders and faces can be cut by repetitive passes.
This background helps set the direction for the development of a new generation of shoulder milling cutters. The results show that the maximum depth of cut for the CoroMill 490 is 5.5 mm and the recommended value is 4 mm. This also provides an opportunity for the new tool concept to be equipped with square blades, which is the basis for obtaining high blade stability and good tool economy through precise and safe blade positioning. CoroMill 490 has optimized the blade support point and placed it as far away from the edge of the tool holder as possible to minimize the impact of cutting forces that can easily move the blade on the tool holder.
Choose the right shoulder mill
The main limitation of using square-blade cutters is that axial cutting cannot be performed, especially for cavity machining. In order to perform these operations, sufficient tool end play is required around the axial direction (ie, around the tool cutting edge).
The CoroMill 490 is no exception. Axial feed is not available except for circular interpolation, boring and some contour milling.
In this respect, the widely accepted CoroMill 390 complements the CoroMill 490 tool very well and is therefore capable of performing many other end milling operations such as ramping, circular interpolation, plunge milling and deep contour milling. The CoroMill 390 has two cutting edges per blade that can be machined for greater depth of cut and has a large insert radius option. With years of development, it has now formed a wide range of products that can be used in a large number of different processes in various materials and industrial sectors. The CoroMill 390 provides capabilities that the CoroMill 490 does not provide, and the same 490 tool can provide a considerable number of features that the 390 tool does not have.
The choice of a shoulder mill or end mill is basically a function of its operating characteristics, but when these properties are implemented one by one for the parameters of the CoroMill 490, they are optimized for performance, machining results, and predictability. It must be the first choice. With the first tool based on the new square shoulder milling platform and a new generation of insert grades, milling has taken a big step forward, thus improving the cutting competitiveness in the field of CNC milling, where each year is rapidly growing. Provides new potential.
There are currently two major directions in improving the milling process: one is through higher metal removal rates, especially on smaller machines; the other is through a pass to generate better surface quality. And these capabilities can be combined with a unique new milling cutter concept.
Processing is changing
At present, there are many obvious trends in the workshop, some of which will have a great influence on the direction of the shoulder milling ability of the other party. In general, on the machine tool side, smaller machine tools or low-power spindles are increasing; spindle speeds are higher and higher cutting speeds are available; machine tools can apply higher feedrates; and magazine capacity highlights the The need for good tool versatility and performance, as well as the need for operator supervision on the side should also be limited.
In terms of operation, small depth of cut is preferred due to its favorable machine tool and low power consumption availability; the pursuit of more combinations of roughing/finishing machining; increasingly demanding tool accessibility; and simultaneous requirements Higher flexibility, more efficient tool setting, and burr/sticker errors are completely intolerable.
When developing a new tooling platform for square shoulder milling cutters, the progress and experience gained in expanding the established CoroMill series of milling tools played an important role. Along with the development of CNC machine tools, this long process has lasted for 20 years, and it has also led to the emergence of many tool concepts that greatly increase the shop's processing performance in different manufacturing sectors. For the development of today's new type of shoulder-shoulder milling concept, a brief review of these concepts will help us to fully view this development.
CNC milling goes through a long road
The CoroMill 290 shoulder milling cutter incorporates several advantages such as a pre-hardened cutter body and a cost-effective square cutter with four cutting edges, as well as the use of a central screw (to provide high strength in many demanding processes) By ensuring high precision and improved blade positioning, it is easy to obtain better results than previously required. This 90-cutter has become a very versatile tool for small to large diameters and can achieve a considerable depth of cut.
Pure face milling, including finishing to a mirror-like surface and roughing with very high metal removal rates, has been combined into a face milling cutter - CoroMill 245. With a lead angle of 45, the cutting force balance can be achieved for specific passes when high table feeds or tool overhangs are too long. In general, subsequent operations can be eliminated through the wiper band option on the blade. In most workpiece materials, this tool has become a sign of face milling.
Whether it is deep or shallow shoulder milling, there are unique needs in the tool, 90 tools is an essential choice. Similarly, CoroMill 790 represents a new direction, initially focusing on the cutting of non-ferrous materials, such as aluminum wings in the aerospace industry. This tool has a very high metal removal rate, can leave a high-quality square shoulder surface during high-speed cutting, and its tooling error is negligible. Because it was developed specifically for lighter cutting action, the low power requirement is clearly an advantageous feature. In addition, the extremely safe and high-precision blade positioning also makes this tool suitable for ramp milling, interpolation milling, large depth of cut, and plunge milling.
The end mill is the most versatile milling tool because it performs most of the processes. The CoroMill 390 indexable insert gave new meaning to the tool type when it was launched. Here, 90 knives can perform all the tasks that CNC machine tools are required to perform, namely modern light-cutting endmilling in all its forms, including high-efficiency deep-to-shallow square shoulder milling with good surface quality. When the larger blade models are subsequently rolled out, not only are the restrictions even less, they have even eliminated most of the restrictions.
The blade number determines the cutting parameter capability, cutting time, tool life, reliability, and versatility. The recently introduced new generation of coated carbide grades can provide considerably higher levels of performance. This not only makes the shop more competitive, but also meets tighter deadlines and achieves higher quality consistency. The new grades of CVD and PVD coated inserts allow higher cutting parameters to enable reliable and more predictable high-speed cutting over a wide range of applications. Especially for the new type of face milling, the development of this grade also makes it possible to use lighter and more precise cutting with a sharper positive rake angle and without reducing the blade strength.
Combination ability is essential
When developing the new face shoulder milling cutter concept, it is crucial to combine the ability to produce a high quality end surface with the square shoulder surface. Some milling cutters can cut high-level end faces or square shoulders, but no cutter can both achieve both high precision and high surface quality.
The industry is most concerned about production efficiency, so it is necessary to combine the ability to perform fine milling of the face and square shoulders with the quality obtained in the rough machining process to perform high metal removal. In some applications it is also required to combine roughing and finishing passes. The single-cutting capabilities combine high metal removal rates with good square-shoulder surface quality, with no trade-offs in performance, and conversely only constant improvements, which are the capabilities sought in many modern applications.
Although the cost of cutting tools accounts for only a small part of the total production cost of all parts, many users have put the cost of the tool and inventory issues together in a prominent position. The square blade provides four cutting edges and also provides the best cutting edge for each blade. But a square blade means 90 rounds, and it seems limited in its scope of application for the combination of capabilities required by the new efficient square shoulder.
New challenges
When developing a new high-performance milling tool with a true 90 declination angle, the requirements of the opposing blade also represented one of the challenges. High precision and elimination of any related tooling errors, as well as high metal removal capabilities are absolutely essential. In addition, the angular accuracy must also be several times higher than the current tool concept. By relying on existing CoroMill solutions and developing new concept directions at the same time, a model for a new type of shoulder milling machine platform was established. Recent developments in methods and metrics involving the manufacture of new milling tools have provided support for this.
In order to achieve the ambitious goal of combining roughing and finishing tools, and also for the use of square inserts, it is necessary to provide a completely new cutting edge that can produce both end faces and shoulders. At this point, it is necessary to establish favorable cutting action and high finishing ability.
In any multi-tooth milling tool, the wiper edge of the cutting edge plays a crucial role because it is the decisive factor in creating the end face. The wiper band must be longer than the feed per revolution of the tool to ensure good surface quality. One of the problems with the use of wiper belts is that the cutting edge is too long to increase the cutting force. As a result, there is a tendency for vibration to occur and leads to higher power consumption, as well as higher requirements for cutting stability. For CoroMill 490, one of the challenges is how to have the most suitable wiper band without any inherent disadvantages.
It is based on having a large enough axial rake for the insert in the tool and a sharp positive rake on the insert. The 490 solution was fundamentally developed through such a lightweight cutting tool design. The shearing of the basic cutter geometry also indicates that the insert will fall into the material, which means smoother and increased strength. Tool accuracy also contributes to this solution and guarantees advantageous cutting action, especially for finishing. The successful development of unique new blade trim ribbons and tooling characteristics is not only a key factor in ensuring the capabilities of the CoroMill 490, but it is also a key factor in finding the best metal removal rate per unit of power consumed by the tool.
Wiper technology
Wiper technology is a core part of the milling solution. Since the Wiper technology was developed by Sandvik Coromant for turning, it was further developed for the CoroMill 490 wiper band and blade cutting edge for square shoulder cutting. During cutting, tools with multiple blades can easily pass through the transitions produced by each blade land, creating some misalignment errors.
In addition, there is also a problem of tool skew. All tools exhibit a certain degree of program skew during cutting, and the use of conventional wiper belts often negatively affects the resulting surface due to the sharp edge transitions.
The multi-arc wiper design of the 490 blade wiper band compensates for tolerances and angular deviations for cutting. This not only minimizes the tendency for any knife-to-tool error, but also improves the accuracy of the face and shoulder surfaces. Essentially the same effect can now be achieved between different passes on square shoulders or surfaces created by different blades on the end face, which often requires additional finishing.
Use brand for optimization
A sharp cutting edge with a positive rake angle is the key to lightweight cutting characteristics and is especially important when there are a large number of wiper edges so that high productivity, high surface quality and true 90 squareness can be achieved by using square blades. shoulder. In addition, in order to achieve this characteristic at high feed rates and high cutting speeds, the blades must have high strength and durability. This can be achieved by developing a new generation of blade brands.
For CoroMill 490, the new PVD coating grade GC1030 provides the main tool material for a suitable insert geometry and has subsequently become the first choice for these materials. This grade is particularly suitable for small diameter applications, unstable conditions, large tool depths, demanding tool in and out, and small tool knives, all of which are commonly encountered in the shoulder milling process.
Depending on the specific nature of the cutting, some processes will inevitably need to be optimized. Due to the different characteristics of the grades, it may happen that the CVD coating grade is more suitable than the PVD grade. Although not as sharp as the PVD grade, the CVD grade blade is still used by the CoroMill 490 to provide higher cutting speeds and longer tool life. This is especially true in the tool diameter and blade size, and heat-related wear threatens the cutting edge. The GC4230 is a cutting speed optimizer for end mill applications. It is also a very durable universal insert grade, while the GC4240 is a very strong steel milling grade. For this grade, cutting edge toughness is the decisive parameter.
Use troughs for optimization
The shoulder milling process usually uses a very modest feed rate, which prevents the production efficiency from increasing when the feed value directly affects the metal removal rate. Recent studies have shown that the vast majority of applied feed per tooth is less than 0.12 mm. These feed values ​​are acceptable for finishing operations. However, it should also be noted that for the current cost-effective ordinary processes and roughing processes, it is somewhat inadequate.
The CoroMill 490 has been developed as a low-power tool that can provide high metal removal rates (feed rate per tooth up to 0.22mm). At the same time, the tool can also perform high-precision finishing milling with fine chip thickness (feed rate per tooth as low as 0.05 mm). To optimize its wide range of applications, we offer three different insert geometries (L, M, and H).
The H-groove fits into a series of large feed per tooth values. This sturdy cutting edge is sufficient for heavy-duty cutting including thick chips, which makes the CoroMill 490 a light-cutting roughing tool. The L-groove blade transforms the CoroMill 490 into a powerful finishing tool that provides a higher level of square-face milling quality, which is unique to indexable insert tools. The CoroMill 490 with an M-shaped insert geometry has universal capabilities, so it should occupy a prominent position in its tool room on any CNC machine that must mill all kinds of faces, shoulders, edges, and even grooves. The feed range per tooth covers the common range in the middle. Thanks to a combination of possibilities, both in terms of different insert geometries and grades, and variations in the feed per tooth of the milling tool, the CoroMill 490 offers a very wide range of applications and is the best alternative to improve processing performance and results. select.
Depth no longer needed
Smaller depths of cut are usually required when machining parts in the shop, which of course is necessary for many smaller machines. In contrast, the development trend is higher feed rates and cutting speeds. Power limitation is also a factor, especially for ISO taper 40 and 30 machining centers, and especially for most multitasking machine tools and turning centers. The higher speeds and feeds of today's machine tools also mean that smaller diameter (25 to 80 mm) tools can be used more efficiently and that shoulders and faces can be cut by repetitive passes.
This background helps set the direction for the development of a new generation of shoulder milling cutters. The results show that the maximum depth of cut for the CoroMill 490 is 5.5 mm and the recommended value is 4 mm. This also provides an opportunity for the new tool concept to be equipped with square blades, which is the basis for obtaining high blade stability and good tool economy through precise and safe blade positioning. CoroMill 490 has optimized the blade support point and placed it as far away from the edge of the tool holder as possible to minimize the impact of cutting forces that can easily move the blade on the tool holder.
Choose the right shoulder mill
The main limitation of using square-blade cutters is that axial cutting cannot be performed, especially for cavity machining. In order to perform these operations, sufficient tool end play is required around the axial direction (ie, around the tool cutting edge).
The CoroMill 490 is no exception. Axial feed is not available except for circular interpolation, boring and some contour milling.
In this respect, the widely accepted CoroMill 390 complements the CoroMill 490 tool very well and is therefore capable of performing many other end milling operations such as ramping, circular interpolation, plunge milling and deep contour milling. The CoroMill 390 has two cutting edges per blade that can be machined for greater depth of cut and has a large insert radius option. With years of development, it has now formed a wide range of products that can be used in a large number of different processes in various materials and industrial sectors. The CoroMill 390 provides capabilities that the CoroMill 490 does not provide, and the same 490 tool can provide a considerable number of features that the 390 tool does not have.
The choice of a shoulder mill or end mill is basically a function of its operating characteristics, but when these properties are implemented one by one for the parameters of the CoroMill 490, they are optimized for performance, machining results, and predictability. It must be the first choice. With the first tool based on the new square shoulder milling platform and a new generation of insert grades, milling has taken a big step forward, thus improving the cutting competitiveness in the field of CNC milling, where each year is rapidly growing. Provides new potential.
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