The design delivers powerful, quiet milling across a range of materials, including steel, stainless steels and cast iron, with the PCR cutter tackling roughing, finishing and vertical plunging.
WNT's MonsterMill PCR UNI’s four cutting edges give it a significant advantage over conventional plunge milling cutters having only three, as it can achieve feed rates that are up to a third higher. For ramping/plunging, slotting and profiling operations, feed/tooth rates of up to 0.137 mm/rev are also possible.
Despite achieving high cutting speeds, the cutters offer high process security, thanks to the special core geometry that has been designed to break chips and prevent spiral chips forming during plunging and drilling. With reliable swarf removal via its flutes, the elimination of chip jams and a more secure machining process are achieved.
Says WNT product manager Daniel Rommel: "We've compared the MonsterMill PCR UNI with two competitors. One of the plunge milling cutters did not break the chip at all and long continuous chips were formed. With the other milling cutter, drilling was only possible to a limited extent and a large built-up edge formed. With the MonsterMill PCR UNI, we witnessed excellent chip breakage and process-secure chip removal at higher feed rates."
With an irregular flute pitch and helix angle, vibration and oscillation are eradicated, delivering a quiet machining operation. This is true even when high ramping angles of up to 45° are being used, without reducing feed rates.
A stable process and maximum precision during angled ramping up to 90° is achieved by means of the patented 142° centring tip in the centre of the end cutting edge. This also means that rapid centring is possible, without having to perform helical milling in advance.
Rommel explains: “If users need to make a hole on a sloping surface, they previously had to mill down in a helix to 1xD, so that the drill is then guided laterally. Thanks to the centring pin of the PCR UNI, this process has become a thing of the past.”
There are also advantages when helical milling, due to Monstermill PCR UNI’s high ramping angle – up to 25° for helical drilling. "With the conventional method, it took 25 minutes to drill 100 holes (10 mm diameter), but with the MonsterMill we managed it in only 8 minutes and therefore trebled the level of performance."
“Having witnessed demonstrations of the new TracerM in action, early users of the advanced FARO system have calculated their return on investments by considering the advantages gained by eliminating costly non-conformances, streamlining their production processes and the elimination of previously used costly templates and hard tooling.”