When creating a CAM program for the high-feed machining of complex 3D profiles in typical mould-making applications, it is common to use a theoretical corner radius for programming the insert radius. However, this method leaves excessive stock on the workpiece after machining, adding processes.

To create the ideal platform for subsequent finishing processes, many job shops are using solid-carbide square-end mills with large radii during roughing. The latest R2 insert requires no programming for the theoretical corner radius, as its 2 mm corner radius leaves no uncut material on the machined surface. This concept ensures that the TungForce-Feed series makes a good replacement for costly solid-carbide end mills.

With an insert design that is 10% thicker than competitor products, the TungForce-Feed line is built to perform at higher machining parameters by withstanding fracture forces. Furthermore, the robust insert screws and seat design reduce screw neck shearing under high cutting forces. The insert design incorporates a positive inclination angle for smooth chip evacuation which further reduces cutting forces by controlling chip formation, especially when shoulder and slot machining.

Suitable for face and shoulder milling, as well as helical interpolation and ramping, the close insert pitch makes the TungForce-Feed line a good option for all milling applications. The series has been designed with a small entry angle for chatter stability that improves efficiency and tool life, even when machining in long-reach areas, says Tungaloy.

The R2 insert has an optimised geometry that gives it the potential to perform as a full profiling insert for semi-roughing and semi-finishing processes. Free-cutting geometry eliminates chatter and improves surface finish quality and, when combined with the built-in side wiper that helps reduce burr formation on walls and corners while improving wall accuracy, the TungForce-Feed line shows its potential for mould and die applications.

Tungaloy’s TungForce-Feed line is available in two insert designations that include the AH3225 and AH8015 grades. The AH3225 grade incorporates nano multi-layer coating technology with three major properties for optimal cutting-edge integrity. This design increases resistance to wear, fracture, oxidation, built-up edges and delamination.

The AH8015 designation has a hard coating layer and carbide substrate with a strong resistance to wear, heat and built-up edges that makes it suitable for machining hard or difficult materials.

The two grades are said to provide optimal machining performance on materials from carbon, alloy, pre-hardened and stainless steels, through to cast iron, titanium and heat-resistant alloys.