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The cutting performance of square shoulder milling can be improved from two main aspects, namely achieving a higher metal removal rate and a single pass machining to produce an excellent surface quality. With the continuous development of milling technology, Sandvik Coromant can now combine these necessary processing capabilities by introducing a unique new milling tool concept, CoroMill 490.
Machining is changing During the development of the concept of square shoulder milling tool, Sandvik Coromant has considered a number of machining trends in the current shop floor to ensure the efficiency of this new concept tool. For example, in the development phase of any tool, the increasing popularity of low-power machine spindles and the increased spindle speed and higher feed rates are critical.
From a cutting point of view, a small depth of cut is preferred because the lighter the cutting action of the process, the less damage to the machine tool and the lower power availability; in the shop, roughing and finishing cutting Putting it together is also the goal of the moment. In addition, in modern production environments, it is important to note that glitch/joint errors cannot be tolerated.
Another important factor influencing the development of the new tooling platform for the square shoulder milling concept is the progress made by Sandvik Coromant during the expansion of the CoroMill series of milling tools. The following overview helps us to take a holistic view of the company's recent developments in milling innovation.
CNC milling has been a long-distance long-distance CoroMill 290 square shoulder milling cutter that combines several advantages, such as a pre-hardened body and a cost-effective blade with four cutting edges, as well as the use of center screws (in many demanding processes) Used to provide high strength) and improved blade positioning for high precision.
Pure face milling, including finishing to mirror-like surfaces and very high metal removal rates for roughing, has been combined into a face milling cutter: CoroMill 245.
Whether it is deep or shallow shoulder milling, there are very different needs - 90 degree tools are an essential choice. For non-ferrous metals, CoroMill 790 has become a mature tool with a very high metal removal rate, which leaves a high-quality square shoulder surface for high-speed cutting, and the tooling error is negligible.
End mills can be used in most processes, and the CoroMill 390 indexable insert gives new meaning to the tool type when it is launched. Here, the 90 degree tool is able to perform all the tasks required for the CNC machine, ie the modern light cutting end milling process in all forms.
The ability to combine is critical When developing the concept of a new square shoulder milling cutter, it is critical to combine the high quality plane with the square shoulder surface. Some milling tools are capable of cutting high-level end faces or square shoulders, but no tool can combine both high precision and high surface quality. In addition, in order to achieve higher production efficiency, it is necessary to combine excellent end face and square shoulder finishing milling with a roughing process with high metal removal rate, and sometimes it can be processed in one pass.
For many users, the tool cost is the same as the tool inventory and is placed in a prominent position. The square insert provides four cutting edges and also provides the optimum cutting edge for each insert.
New challenges for milling tools In order to achieve the ambitious goal of combining roughing and finishing tools (whether or not a square blade is used), it is necessary to provide a new cutting edge that can simultaneously produce end faces and square shoulders.
In any multi-tooth milling tool, parallel forging of the cutting edge is a decisive factor in the generation of the end faces. Parallel forging must be longer than the feed per revolution of the tool to ensure a good surface quality. One of the problems with parallel forging is that the cutting edge is too long to increase the cutting force and is therefore prone to vibration. How to have the most suitable parallel forging without inherent disadvantages is the main challenge.
Based on a sufficiently large axial rake angle and a sharp cutting edge in the insert, the solution was further developed with this lightweight cutting tool design. The shearing of the basic tool geometry also indicates that the blade will enter the material at a negative lead angle, which ensures smoothness and increased strength. The unique new parallel insert forging and tooling features successfully developed is a key factor in ensuring CoroMill 490's processing capabilities. This tool achieves the best metal removal rate per unit of power consumption.
Wiper technology Wiper technology is at the heart of this solution. Developed by Sandvik Coromant for turning, and further developed for CoroMill 490 parallel forging and insert cutting edges for square shoulder cutting. When cutting, tools with multiple inserts can easily cause some tooling errors through the transitions produced by each blade forging. There is also the problem of tool skew. All tools have a certain program skew when cutting, and the use of conventional parallel forging often has a negative impact on the surface quality due to the sharp transition edges.
The CoroMill 490 blade parallel forged multi-curved Wiper design compensates for tolerances and angular misalignments during cutting. This not only minimizes the tendency for any tooling errors, but also eliminates the need for subsequent finishing.
Optimized with insert grades Sharp cutting edges with positive rake geometry are key features for light cutting, especially for large parallel forgings, which results in high productivity, high surface quality and true 90 degree through the use of square inserts. Square shoulder. In order to achieve this characteristic at high feed rates and high cutting speeds, the blades must have high strength and durability.
For CoroMill 490, the new PVD coated grade GC1030 is the answer, especially for small diameter applications, unstable conditions, large tool overhangs, and demanding tool cuts and cuts.
The CoroMill 490 is available in a wide range of insert grades including CVD coatings and PVD coated grades. Blades made with CVD grades are not as sharp as those made with PVD grades, but are still used in CoroMill 490, which provides higher cutting speeds and longer tool life. For example, GC4230 (CVD) is a general-purpose insert grade with wear resistance that optimizes cutting speed for end mill applications, while GC4240 (PVD) is a tough steel grade with cutting edge toughness for this grade. It is its decisive parameter.
Optimized with insert geometry The square shoulder milling process typically uses a very modest feed rate. Recent studies have shown that the vast majority of feed rates per tooth are below 0.12 mm. These feed values ​​are acceptable for the finishing process, but they are somewhat inadequate for cost-effective general and roughing processes.
The CoroMill 490 is a power efficient tool with high metal removal rates (up to 0.22mm per tooth feed) and high precision milling (feedrates down to 0.05mm per tooth). To optimize its wide range of applications, three different insert geometries are now available: L, M and H.
The H-slot shape is suitable for a large range of feed per tooth, while the L-slot blade transforms the CoroMill 490 into a powerful finishing tool. The per-tooth feed range of the M-blade geometry covers the central general range.
Depth no longer needed Now, small depth of cut is preferred in the shop floor, as is the case with small machine tools. Power limiting is also one of the factors, especially for ISO taper 30 and 40 machining centers and for deploying most turning and milling machines and turning centers.
This helps to clarify the direction of the new generation of square face milling cutters. Test results show that the maximum depth of cut for CoroMill 490 is 5.5mm and the recommended value is 4mm. It offers the possibility of a new concept tool with a square insert, which also lays the foundation for high blade stability and good tool economy through precise and safe blade positioning.
Choosing the right shoulder milling cutter Tool selection depends on the existing cutting process, but when they match the high performance of the CoroMill 490, it must be preferred for optimum performance, results and predictability. With the first tool CoroMill 490 based on the new square shoulder milling platform, milling has taken a big step forward.
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Sandvik Coromant's milling path
Looking at the world, the most common milling process currently on the shop floor is square shoulder milling, which means that this special prismatic metal cutting strategy has great potential for improvement in production efficiency, usability and product quality. In many end milling applications where end faces, perimeters and grooves are required, square shoulder milling is often seen.