Solution: Employ a new tool concept that is capable of efficiently removing large volumes of metal.
Rough face milling operations can be divided into different categories, and often a general 45-degree entering-angle cutter or even a round-insert cutter is fine for the job. But for one category of milling, typically involving large, often uneven surfaces of metal, a really rugged cutter is needed when a combination of efficient and secure machining is a priority.
The new CoroMill 360 face mill is based on the classic 60-degree entering angle for heavy-duty milling. As such it provides scope for large depths of cut, high feed capability, reasonable surface finish and balanced cutting forces. Inserts are seated in cassettes that are clamped onto serrated seats in the cutter, allowing quick and easy indexing in the machine. Cutter setting is unnecessary, and the replaceable cassettes save the cutter body from wear or damage.
The capacity for large axial depths of cut is vital to productivity because a large, sometimes uneven mass of metal can be removed in just one pass. The chip-thinning effect of the 60-degree angle affords the capability of high feed rates and thus shorter machining times. The advantage of using a relatively large entering angle also allows the use of generously wide parallel lands on inserts with minimal compromise on cutting-depth capacity. These lands are the means to generate good surface finish without including a wiper insert in the cutter. The advantageous distribution radially and axially of cutting forces is another feature of the 60-degree entering angle, giving stability and thus security in this category of heavy-duty machining.
Both cutter body and inserts of CoroMill 360 have been developed for high metal-removal capability and low power consumption as well as flexibility and good handling characteristics. It works with two kinds of inserts, offering cutting-depths of up to 0.512 and 0.709 inch, respectively.
Learn more about Milling Solutions from Sandvik Coromant.
Originally published in Metalworking World 2.2009, a business magazine published by Sandvik Coromant.