Using an initial cutting speed of 53 m/min, WS40PM can achieve productivity gains of 25-35% with consistent tool life improvements, even when milling very tough materials like Ti-5553 and Super Duplex steels.
One aircraft manufacturer gained a 90% reduction in machining time per part with a tool life improvement of 50% during Ti-6Al-4V face-milling operations. At a UK workshop, insert flank wear was decreased by more than 90% when machining Inconel 625. This delivered a 70% reduction in tooling costs. In China, a turbocharger manufacturer increased tool life by 80% while machining an austenitic stainless steel component using WS40PM. As well as increased tool life, the customer improved surface quality, reduced cutting forces and enhanced chip flow.
In all instances, speeds and feeds were kept the same or, in some cases, increased to take advantage of WS40PM’s exceptional toughness, wear resistance and ability to battle thermal cracking. WS40PM was primarily designed to meet the needs of the aerospace, defence and medical industries, where titanium is used for everything from landing gear and seat tracks to lifesaving implants and surgical instruments.
But it is suitable for use with the other materials noted above, all of these causing tool failure, due to built-up edges and notching at the depth-of-cut line. Other common factors for failure are cratering, chipping and extreme heat generation, which in the case of wet-cutting operations leads to cracking. WS40PM significantly reduces the potential for all of these common machining problems.
To exploit WS40PM, a robust tool body platform, such as the WIDIA VSM490 shoulder-mill, is recommended. In addition, customers must also consider the rigidity and machining platform of the machine tool, toolholder and spindle interface when aiming for the utmost in productive titanium machining.
