Milling Tool Steel at a Record 1000cc/min
Recently, a pair of German companies—Machine builder CHIRON and cutting tool manufacturer Gühring—have collaborated, developing a new roughing cutter which blasts through 1000 cc (61 cu. in.) of 16MnCr5 steel in 60 seconds, removing eight kilograms (17.6 lbs.) of steel per minute.
The Guhring tool, the RF 100 Speed P, is a roughing cutter specially adapted for machining steel, high-strength steel and cast iron. According to the company, it has a 48° spiral angle with unequal blade pitch. This reduces the machine load and increases the volume performance. The recessed flute in the front cutting area creates an optimized chip space, improving performance when ramping and helical immersion. Chip breaker and extreme cutting edge length on the cutter ensure a smooth cut and smooth running.
Milling Strategy: HPC Roughing
Guhring's specialists applied a high performance cutting (HPC) strategy. Control of the cutter path with low radial feed allows a comparatively gentle seaming of the workpiece. HPC roughing is particularly suitable for machining large cutting depths, with the roughing cutter machining the workpiece at its entire depth with the entire length of the cutting edge. This way, cutting forces are reduced and evenly distributed over the entire length of the cutting edge. This enables high processing speeds and long service life. The service life of this cutter during testing was 60-250 minutes.
High performance cutting is the first choice for applications with enormous chip removal rates. The components to be machined are usually made of high-strength steels, which place increased demands on the machining. Under HPC conditions, the entire length of the cutting edge is used with a small cutting width (5-15 percent). Thus, enormously high feeds can be achieved. The feed per tooth was 0.5 millimeters. This means four teeth, two millimeters feed per revolution.
High material removal rate in tool steel is valued in many industries including the classic tool and mold making industry, where mainly high-strength steels are found, but above all aviation, where lightweight components made of solid material with a chip removal rate of up to 96 percent are produced.
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