Press Release Summary:
Fix-Perfect aluminum milling cutter inserts have on-edge orientation and 34 deg positive rake angle. This geometry reduces insert edge buildup, improves tool life, and provides free cutting action that makes it possible to machine thin-walled parts. Inserts are available in uncoated, coated, and polycrystalline diamond versions.
Original Press Release:
New Aluminum Milling Cutters Double Metal Removal Rate At Same Horsepower
Latrobe, PA -- November 16, 2001) Kennametal has introduced a new line of Fix-Perfect aluminum milling cutters that can double metal removal rate without increasing horsepower consumption. The new inserts offer a unique on-edge insert orientation that makes it possible to double chipload relative to traditional cutters. Another unique feature is an industry-high 34O positive rake angle that can reduce horsepower consumption by 50% for a given feed rate. The new cutters are offered with uncoated, coated, and polycrystalline diamond inserts designed specially to take advantage of their unique capabilities. "We have demonstrated dramatic increases in productivity to nearly every customer who has tried these new cutters," said Tim Marshall, Product Manager for Kennametal. "The new cutters can typically remove metal twice as fast without drawing any more horsepower or lowering tool life."
One of the keys to the success of the new cutters is the unique on-edge or tangential design that puts a half inch of carbide behind the cutting edge of a one-half inch inscribed circle insert as opposed to only one-eighth or three-sixteenths of an inch with traditional inserts. The extra shock resistance provided by this geometry makes it possible to substantially increase feed rates without any impact on tool life, aid Glenn Sheffler, Standard Products Engineer for Kennametal. The 34O positive rake angle minimizes horsepower consumption. This means that the new cutters can improve productivity even on existing machines which are already running at their horsepower limit. The geometry also reduces insert edge buildup, improves tool life, and provides a free cutting action that makes it possible to easily machine thin-walled parts.
Fix-Perfect aluminum milling cutters are available in three styles that all use the same inserts. "Our new cutters make it possible to perform roughing and finishing in a single operation, reducing cycle time, and improving surface finish," Sheffler said. HSM cutters offer rigid steel bodies for high speed machining and are available in metric sizes from 50 to 100 mm effective cutting diameters. HPM cutters are available with aluminum and steel bodies in sizes from 1.5" to 12". On both HSM and HPM cutters, all pockets are adjustable, eliminating the need for wiper inserts by making it possible to dial in standard inserts to run as a wiper. Providing adjustment for all insert pockets also makes it possible to use diamond inserts. HSM cutters may be dialed in on the machine to achieve optimum balance. PM cutters are available in steel bodies in medium and fine pitch from 1.5" to 12' diameter. Most of these style cutters have a number of adjustable pocket seats designed for use with wiper inserts.
A key to the performance of these new cutters is the availability of high-performance KENNA PERFECT aluminum milling grades. KllOM is an uncoated tungsten carbide grade with a polished face that prevents built-up edge in machining aluminum. KC510M is a titanium aluminum nitride coated carbide that provides very good wear resistance, especially in machining low-silicon aluminum alloys. KD1410 and KD1415 are polycrystalline diamond (PCD) tipped inserts that provide the ultimate in high surface speeds, long tool life, and excellent surface finish. Kennametal offers a reconditioning service for PCD inserts that reduces insert costs by 30% while providing immediate replacements.
Using all the machine's available horsepower with high performance tooling will ensure the highest productivity possible. How this helps the customer is simple; by increasing tool life only, user gets more parts but at the same time / part reducing part cost by up to 2%. Increased cutting speeds and tool life not only reduces part cost appoximately 15% but allows for greater capacity on the shop floor. The customer has more capacity to take on additional jobs without investing in more machines.