The innovative tool system THETAtec 25N Feed allows, like its positive (sister) systems, higher cutting rates and thus the highest performance and efficiency in an application.
For machining with high material removal rates, as required in rough machining of steel, cast, and stainless materials, high feed milling (HPC - High Performance Cutting) has established itself. Highest feed speeds maximize the time volume and thus reduce machine occupancy times. This is advantageous in terms of the increasingly cost-relevant energy efficiency of processes and creates additional manufacturing capacities. High feed milling thus brings productivity increases and simultaneously measurable cost reductions.
With the new THETAtec 25N Feed, Boehlerit has also added another tool system at a high-end level for this machining strategy. Unlike its positive representatives from Boehlerit, the THETAtec 25N Feed now for the first time uses a negative cutting insert concept with 8 practically usable cutting edges, without having to accept losses in performance, as many insights have been gained over the years in high feed applications. In the development of this new system, the well-implemented simulation software was specifically used to address the multitude of application cases as well as the materials to be machined and thus further optimize the cutting behavior. The uncompromising tuning of the negative indexable insert concept and cutting friendliness has been achieved, among other things, through a specifically defined arrangement of clearance area proportions and the tuning of macro geometries, says Patrick Schwaiger, Product Manager Milling. The result is extremely stable milling tools with optimally tuned indexable inserts, which, thanks to sophisticated cutting geometries and innovative cutting material grades, are characterized by excellent wear resistance, ideal chip flow, and precise roundness properties.
Tuned down to the detail
A key feature of the THETAtec 25N Feed is, despite the negative concept, the positive cutting geometry of the tools, which ensures a light cut. Due to the explicitly tuned milling geometry, this also applies when HFC milling in full grooves, adds Schwaiger. Specifically arranged radii over the cutting edge enable optimal absorption and distribution of axial cutting forces. Thus, in high feed milling, considerable tooth feeds (fz) of up to 1.4 mm are possible, with a plate size of 09. Also, thanks to tuned clearance area proportions, it is possible to ramp linearly and helically into the full without compromises.
This was extremely important to us at the beginning of the new development, to not lose any machining options, emphasizes Patrick Schwaiger further.
Great variety of cutting materials for a wide range of applications
The special capability of the THETAtec 25N Feed milling tool systems and their applicability in a wide range of applications is also made possible by a well-established variety of cutting materials in the market. A highlight here are the proven Boehlerit fine grain grades in combination with high-tech HIPIMS PVD coatings.
At the beginning of the reintroduction, Boehlerit relies on a total of 5 cutting material grades to optimally process materials from the material groups P, M, K, H, and S.
The new high feed system is available as a shell mill in diameters from 40 to 100 mm for plate size 09, as well as a shank mill with diameters from 25 to 32 mm and as a screw-in mill with diameters from 25 to 42 mm. As with DELTAtec 90P Feed, the THETAtec 25N Feed system also features axially and radially well-tuned tools with various tooth counts and the proven uneven division, to generate stability and minimize vibrations. The screw-in mills can also be used with VHM extensions up to overhangs of 300 mm.
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