Stable cast iron milling from Mitsubishi Carbide

The VOX series of cutters are available in fine or coarse pitch types from 63-250 mm diameter and feature a side-on or vertical insert that allows the cutting forces to be absorbed through the whole length of the insert instead of through the far thinner face-to-face dimension. This absorption of cutting forces has several knock-on benefits for increased efficiency and versatility. It enables the maximum depth of cut to be greatly increased, compared to conventional cutters. Fairly large depths of cut can also be achieved with standard methods, but this usually results in instability, caused by vibration and lack of rigidity that compromises both component quality and tool life of the inserts. In one example, when machining a cast iron (GG40) press mould base, the usual 5 mm depth of cut was doubled to 10 mm, with cutting speed set at 230 m/min and table feed of 2,050 mm/min. In addition to the efficiency savings due to the increased stability, the new SONX type inserts also boast eight cutting edges, compared to the usual four typically found on vertical type inserts. The increased number of usable edges provides benefits in economy, but in synergy with the convex geometry of the actual cutting edge and the shaped face relief, it also offers valuable reductions in cycle times through an efficient cutting action. The clamping of the insert itself is achieved with a single screw and provides easy usability. The extremely smooth surface provided by the black, super smooth coating technology, in conjunction with the newly developed CVD coated carbide grade MC5020, helps prevent problems with welding that are common when machining cast iron.