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New Face Milling Cutter Design

"A newly developed face milling cutter from Seco Tools optimizes the large-taper, high-horsepower spindles as well as the speed and feed capabilities of advanced machines," said a company spokesperson.

The Double Quattromill 22 features several advancements to its body and inserts, including the use of eight double-sided insert cutting edges, free-cutting geometries and an optimized cutter body for long life and effective chip management.

With this new face mill, shops can lower cutting forces, extend tool life and still achieve large depths of cut at aggressive feeds and speeds. The Double Quattromill 22 was designed for versatile performance in a wide range of materials, including cast irons, steels, stainless steels, titanium and high-temperature alloys, while maintaining the free cutting benefits that its insert geometries provide.

"Conventional heat-treated, oxidized tool bodies made from standard materials wear out prematurely in high-performance use and typically rely on environmentally unfriendly nickel coatings," said the spokesperson. Conversely, the Double Quattromill 22 uses a high-strength corrosion-resistant tool steel cutter body manufactured to hold runout to within 20 microns. The tool body's optimal flute spacing promotes enhanced chip evacuation via a friction-reducing flute surface pattern exclusive to Seco.

Because face mill wedge-style insert mounting systems lack the insert security necessary under the high-stress forces of aggressive material removal rates, Seco Tools designed the Double Quattromill 22 with a center locking screw that mounts inserts to the tool body for greater stability. The cutter's ability to run at lower cutting forces and machine power consumption rates also assists in producing workpiece stability, which becomes especially important at deep depths of cut and high speeds and feeds. All Double Quattromill 22 cutter bodies feature through coolant from diameters of 3.0" to 6.0" (80 mm to 160 mm).

Shops that want the ability to adjust individual inserts for reduction or even elimination of axial runout, and to replace individual worn or damaged pockets instead of an entire cutter body, can opt for the cassette-style version of the Double Quattromill 22 in diameters from 8" to 12.5" (200 mm to 315 mm).

Fixed-pocket inserts mount in the cutter body, delivering increased rigidity as a result. Standard-pitch cutters with differential pitch promote good chip evacuation with sticky materials or when spindle power or rigidity run low. Close-pitch cutters optimize performance in higher-power machines that can sustain higher feedrates, or with short-chipping materials and cast irons. Where individual insert adjustment and replacement is less important than cutter stability, standard and close-pitch fixed-pocket inserts are available for the Double Quattromill 22 in metric and inch versions.

To reduce cutting forces even at full recommended depths of cut, insert lead angles include both 45° and 68° in ME12, M12 and M18 insert geometries. All three insert geometries feature 0.079" (2.0 mm) corner radii and 0.059" (1.5 mm) wiper flats. Maximum cutting length measures 0.354" (9 mm) on the 45° lead angles and 0.433" (11 mm) on the 68° alternatives. Average chip thicknesses vary depending on insert lead angle, but always run high enough to avoid vibration, poor surface finish and decreased tool life.

Individual insert geometries match up well with specific workflows and workpiece materials. The ME12 insert geometry suits sticky materials such as titanium and stainless steels. Its sharp edges create less cutting force than the other two insert options, making it a suitable choice with lower-horsepower equipment.

The M12 insert geometry works wells with sticky materials, some tool steels and super alloys. Its sharp edges and specific T-land dimensions create less cutting force than the M18 geometry for a good option at lower horsepower levels.

The M18 insert geometry is designed for use with steels, tool steels and cast irons. Of the three insert options, the M18 provides the best edge protection when machining abrasive materials.

Shops can reach depths of cut up to 9 mm (0.354") with the 45° lead angle version of the Double Quattromill 22, which lowers cutting forces, reduces power consumption, raises feedrates and produces enhanced chip thinning. This lead angle's greater bi-axial effect has a positive impact on cutting forces, directing virtually equal forces axially and radially. In situations with long overhangs, unstable or weak fixturing, bi-axial performance makes this lead angle a suitable choice.

The 68° cutter version achieves depths up to 11 mm (0.433"), producing a higher depth of cut within the same inscribed circle diameter on the insert. Cutting forces remain distributed both axially and radially but with greater force directed radially, providing better clearance than the 45° lead angle and making this version ideal in situations that require milling close to a sidewall or part fixture. The 68° cutter version also achieves better chip thinning than a 90° insert.

Highly positive insert geometries hold the key to the Double Quattromill 22's combination of double-sided inserts and free-cutting geometries. In addition to lead angle (KAPR), the angles with the greatest effect on face milling behavior and performance include axial rake (GAMP) and radial rake (GAMF). The many possible combinations of these angles produce varied face milling features and behaviors. The Double Quattromill 22 combines a negative axial rake (GAMP) with a negative radial rake (GAMF) to produce strong cutting-edge geometry and high productivity in situations with heavy feedrates, interrupted cuts and other difficult machining operations. Negative GAMP and GAMF also tend to push the workpiece toward the machine table or fixture, which can be helpful in some cases and unhelpful in others.

Authored by a Seco Tools Engineer

For more information contact:

Seco Tools LLC

2805 Bellingham Drive

Troy, MI 48083


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