INGERSOLL Werkzeuge GmbH has launched a new series of finishing mills with front-mounted tangential cutting edges. Unlike the already proven systems with adjustable side cutting edges, this tool uses a fixed insert seat and a newly developed 4-edged MicroMill geometry.
Easy handling
Unlike adjustable systems, this solution does not require special know-how, as the tool series is designed for general finishing operations without increased requirements. Based on experiences with adjustable systems, the optimal side cutting edge position of the indexable insert has been transferred diameter-related to the fixed insert seat.
Example: Material: EN-GJL-250 / 0.6025 and42CrMo4 / 1.722
Economics
The newly developed tangential indexable insert YDA-22L101 used here has 4 cutting edges and thus enables a highly economical finishing operation with very good surface results in conjunction with the 4.5mm long side cutting edge and optimal feed/speed ratio.
Areas of application
Due to the geometry of the insert, general finishing operations in the face milling area, as well as finishing up to shoulders, are possible, not least because of the corner radius of R0.5mm. The tool can also be used for finishing operations in face milling. The shortened side cutting edge and radially positive position of the indexable insert also prevent the axial pressure known in wide finishing systems, which the cutting edge projects onto the surface, often causing so-called chatter marks on thin-walled or unstable components that negatively affect the produced surface. The intended cutting materials IN2040, IN2540, and IN2010 cover a wide range of materials to be processed in the steel and cast area. There is also the possibility to expand the application range by incorporating PCD or CBN layers into the indexable insert.
The tool series is standardly available in the diameter range of 40-125mm.
Example: Face milling Material: 1.4462
Performance
When processing short and long chip materials, the new finishing mill achieves excellent results. The minimized axial pressure due to the insert geometry allows for clean transitions between the milling paths, leaving no vibration marks on the produced surface.
The integrated coolant holes with exit in the chip space prevent chip adhesion or pulling of chips onto the finished surface when coolant or air supply is used, especially during steel processing.
The 4.5mm long side cutting edge allows for very high feed rates with minimized contact time and excellent surface results.
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