01.01.2020
The new FaceMill-Diamond: Process-reliable face milling with a long tool life
Research and development is responsible for an increased productivity through achieving the highest feedrates and chip removal rate
MAPAL customers rely on the FaceMill-Diamond PCD face milling cutter for face milling work at high volumes, on unstable parts and in the HPC, high performance cutting, sector. With its solid steel tool body and the permanently brazed PCD cutting edges, it achieves top feed rates and material removal rates that are second to none. Following comprehensive further development, MAPAL has increased the productivity of the PCD face milling system once again.
“Particularly in the area of high performance cutting, the number one customer requirement is the achievable material removal rate alongside the best possible component surface,” reports Andreas Wittenauer, Head of Application Technology in the PCD Tool division. He goes into more specific detail by adding: “For this reason, the FaceMill-Diamond features an exceptionally high number of permanently brazed cutting edges for its diameter. The cutting edges are designed for a cutting depth of up to 10 mm. Furthermore, the robust tool body absorbs the vibrations generated during machining and prevents damage to the component surface.” Additionally, the FaceMill-Diamond can be inserted directly into the machine when newly equipped – without time-consuming adjustment work requiring operator expertise.
Based on this, MAPAL further developed the PCD face milling cutter in two ways in 2019, increasing its potential for further productivity.
Based on this, MAPAL further developed the PCD face milling cutter in two ways in 2019, increasing its potential for further productivity.
A longer tool life and improved chip removal thanks to coolant outlets directly at the cutting edges
“High cutting values and the resulting chip volume may, under certain circumstances, lead to washout of the tool body. To counteract this effect and maintain an economical product life cycle, we have optimised the cooling concept and positioned the coolant outlets directly at the cutting edges,” explains Andreas Wittenauer. “This ensures improved chip removal and protects the tool body, especially for applications with minimum quantity lubrication or air cooling.”
A direct compare with the new generation of the FaceMill-Diamond and the previous model provides the specific improvements. A customer machines a part made of AlSi1 with cooling lubricant on a machining centre. The application parameters of the 63 mm diameter milling cutter have deliberately been left the same for the comparison: a cutting speed of almost 3,000 m/min and a spindle speed of 15,000 rpm. Due to the high-gloss surface requirement, the feed per tooth is 0.04 mm and the cutting depth is 0.8-1.2 mm. “The customer was delighted with the new tool right away,” says Andreas Wittenauer. “The surface it achieves is noticeably higher in quality and it removes the chips more effectively. We are pleased that we were able to increase the tool life by 15 percent with the new FaceMill-Diamond, and that the customer is now successively converting their entire inventory.”
A direct compare with the new generation of the FaceMill-Diamond and the previous model provides the specific improvements. A customer machines a part made of AlSi1 with cooling lubricant on a machining centre. The application parameters of the 63 mm diameter milling cutter have deliberately been left the same for the comparison: a cutting speed of almost 3,000 m/min and a spindle speed of 15,000 rpm. Due to the high-gloss surface requirement, the feed per tooth is 0.04 mm and the cutting depth is 0.8-1.2 mm. “The customer was delighted with the new tool right away,” says Andreas Wittenauer. “The surface it achieves is noticeably higher in quality and it removes the chips more effectively. We are pleased that we were able to increase the tool life by 15 percent with the new FaceMill-Diamond, and that the customer is now successively converting their entire inventory.”
Modular variant provides greater flexibility
Customers with a diverse range of machinery want a certain degree of flexibility as far as tool use is concerned. In order to meet this demand, the FaceMill-Diamond is now also available in a modular version with a milling head. Andreas Wittenauer provides us with more details: “The modular version of the FaceMill-Diamond can be used flexibly – particularly for small series production and machinery that uses different interfaces, or even for large series where production is initiated on one machine and then continued on another.”
In the context of a customer project, the modular version offered improvements for both the surface and the cycle time compared to the competing tool used previously. With a spindle speed of 12,000 rpm and a feed per tooth of 0.1 mm, the machining tool variant of the FaceMill-Diamond mills about three seconds faster than the previously used tool. As such, the quadruple mounting on the machine results in a saving of twelve seconds in the cycle time.
In the context of a customer project, the modular version offered improvements for both the surface and the cycle time compared to the competing tool used previously. With a spindle speed of 12,000 rpm and a feed per tooth of 0.1 mm, the machining tool variant of the FaceMill-Diamond mills about three seconds faster than the previously used tool. As such, the quadruple mounting on the machine results in a saving of twelve seconds in the cycle time.
Optimierte Radträgerbearbeitung: Standzeit exponentiell von 3.000 auf 40.000 gesteigert
Der FaceMill-Diamond kommt neben den ausgeführten Standardvarianten auch als individuelle Sonderlösung zum Einsatz, wie die Bearbeitung eines Radträgers aus der Aluminiumlegierung AlSi12(T4) auf einem Bearbeitungszentrum zeigt. Die Verantwortlichen beanstandeten die Planfräsanwendung im ursprünglichen Prozess. Mit dem ursprünglich eingesetzten Wettbewerbswerkzeug haben die aus Taktzeitgründen geforderten hohen Schnittwerte in Kombination mit dem Aufmaß zu einer prozesskritischen Gratbildung geführt. Konkret wurde der Span am Bauteilaustritt um 90° umgebogen, nicht geschnitten, und ist als sogenannte Gratfahne an der Bauteilkante verblieben. Im ersten Gespräch mit MAPAL haben sich mehrere Herausforderungen abgezeichnet. Andreas Wittenauer: „Das wärmebehandelte Bauteil neigt stark zum Schwingen und die harten Späne waschen den Grundkörper aus. Darüber hinaus sind mehrere Fräsoperationen an verschiedenen Positionen am Bauteil durchzuführen – das Aufmaß beträgt axial bis zu 7 mm und radial bis zu 3 mm.“
Die Spezialisten des Kompetenzzentrums PKD-Werkzeuge entschieden sich für eine kombinierte Sonderschneidengeometrie, um alle genannten Anforderungen zu erfüllen. Bei unveränderten Schnittwerten von 15.400 mm/min Vorschubgeschwindigkeit und einer Drehzahl von 7.000 min-1 ist die Standzeit des neuen Werkzeugs exponentiell höher: Statt bisher 3.000 Bauteile fräst der FaceMill-Diamond prozesssicher 40.000 Radträger. Heute hat der Kunde 16 FaceMill-Diamond im Umlauf, um seine Jahresproduktionsmenge von 600.000 Bauteilen zu bearbeiten.
Die Spezialisten des Kompetenzzentrums PKD-Werkzeuge entschieden sich für eine kombinierte Sonderschneidengeometrie, um alle genannten Anforderungen zu erfüllen. Bei unveränderten Schnittwerten von 15.400 mm/min Vorschubgeschwindigkeit und einer Drehzahl von 7.000 min-1 ist die Standzeit des neuen Werkzeugs exponentiell höher: Statt bisher 3.000 Bauteile fräst der FaceMill-Diamond prozesssicher 40.000 Radträger. Heute hat der Kunde 16 FaceMill-Diamond im Umlauf, um seine Jahresproduktionsmenge von 600.000 Bauteilen zu bearbeiten.
Neuer FaceMill-Diamond verfügbar
Mit dem FaceMill-Diamond steht ein Hochleistungsprodukt zum Planfräsen zur Verfügung, das durch die Weiterentwicklung noch wirtschaftlicher und flexibler einsetzbar ist. Die weiterentwickelten Varianten können mit kurzen Lieferzeiten bestellt werden.
