In recent years, indexable tools have become increasingly more popular and versatile, and are now the method of choice for many metalworking applications.
”Indexable endmills for example have fantastic versatility compared to solid carbides, not to mention never having to regrind the cutting edges, thereby eliminating the administrative and logistical costs involved,” observes Tungaloy’s shoulder milling assistant product manager, Yosuke Yamada.
“Some customers, however, believed solid carbide tools to be stronger and more productive as indexable insert tools often have lesser flutes or pockets. Another concern is the size of the screw for the small inserts which is difficult to handle and often had issues of breakages during machining.
“TungForce-Rec, Tungaloy’s latest end milling cutter eliminates these concerns,” he continues. “The insert positioning on the cutter body allows the insert to be wider than other competitor products and the installation provides enhanced support under the insert from an extra-large back section further increasing tool rigidity. The new layout offers the possibility to position a higher number of inserts on the tool compared to other endmills in the market.”
Insert stability is increased by the new insert with V-shaped bottom and improved clamping, which prevents insert from moving during machining. Flexibility, strength, and speed are all enhanced while production costs are reduced, the company claims.
TungForce-Rec’s cutting edge features a large positive rake angle to ensure smooth cutting and an obtuse angled insert flank adds additional strength to the cutting edge and reduces chipping. A wide cross-section allows the inserts to feature a large holding screw, preventing screw shearing or movement during production.
Tungaloy recently conducted a case study with one of its customers. The conclusion was that solid endmills with a higher number of flutes could not be used at high parameters as they increased vibration when machining a narrow workpiece such as a guide shaft.
The guide shaft was manufactured from S45C and C45 (25HRc) steels using a TungForce-Rec 12mm diameter cutter (EPAV06R012M12.0-03) and AVGT060304PBFR-MJ AH3135 insert. Cutting conditions were: Vc = 151mm/minute; f = 0.05mm/revolution; Vf = 601mm/minute; Ap = 3.2mm; and Ae = 2.5mm. A BT40 VMC was used for the trial and machining was carried out using coolant.
“The results were conclusive.” Mr Yamada reports. “TungForce-Rec improved productivity by 1.57 times compared with the current solid carbide endmill.
“The strong cutting edge and its design allow TungForce-Rec to machine a slim, rigid workpiece such as a guide shaft, with high productivity whereas solid carbide endmills with a higher number of flutes experienced excessive levels of vibration.