It will enable users to significantly reduce the time spent on finishing processes carried out on 5-axis machines, while achieving improved surface qualities at the same time, says WNT (part of the Ceratizit Group).
The 3D Finish tool range is a development of the ball-nose end milling cutter and has been designed with a large radius (up to 1,500 mm) in the cutting area. This feature allows the cutters to achieve considerably increased step-overs when compared to conventional ball-nose cutters with the same tool diameter. The result is processing times in pre-finish and finish machining reduced by up to 90%, without the workpiece, tool and machine being subjected to a higher load. Much greater widths of cut (ap) are also possible so, in addition to reduced cycle times, surface quality is maintained, but is the user chooses to reduce the step-over then surface quality can be improved significantly. A typical 20 mm diameter ball-nosed cutter would achieve a surface quality of Ra1.6 µ with a step-over of 0.5 mm, but with the 3D Finish and a radius of 1,500 mm, the step-over could be increased to 6.93 mm with the same surface quality result.
The 3D Finish tools are available in a barrel, oval, taper or lens shape and are ideal for the 5-axis finishing of free-form surfaces, such as in tool and die production or, in the aviation and aeronautical industries. The cutters are available in a wide variety of size and style to ensure the ideal cutter geometry for any component shape. Also, in terms of application they are universal in that the 3D Finish milling cutters are suitable for machining steel, stainless steels, cast iron, non-ferrous metals, heat-resistant steels and hardened steel.
In assessing the cost-effectiveness of the WNT 3D Finish tools, the machining experts at the Ceratizit Group carried out extensive trials. These highlighted the major time savings that can be achieved when compared to a conventional 10 mm diameter ball-nose cutter. In the trial, a 100 by 200 mm component was milled at a feed of Vc 200 m/min. Owing to the higher step-over of 1.5 mm for the 3D Finish (compared to 0.1 mm for the ball-nose cutter), the total milling travel was reduced from 200 m to just 13 m, with a corresponding reduction in cycle time from 79 minutes to 7 minutes and a resulting reduction in machining cost of 88%. To fully exploit the advantages of the 3D Finish tools fully, a modern 5-axis machining centre and compatible CADCAM software are required, such as Open Mind’s hyperMILL MAXX, which supports the tool geometry, other software suppliers also offer CADCAM solutions.
See Machinery article here.
