Aplicação de fresagem helicoidal

Um foco principal nas operações de fresagem é a redução do tempo de usinagem. Com geometrias de ferramentas específicas para usinagem de bolsos fechados e redondos, muitas vezes é possível eliminar o processo de pré-perfuração. Na fresagem helicoidal, os caminhos de ferramentas são programados com entradas helicoidais adequadas para dimensões de bolso.
On a rendered example component, an operation is highlighted.
Visão geral das ferramentas para as seguintes etapas de usinagem:
  1. Usinagem de desbaste de componentes
  2. Material residual desbaste
  3. Semi-acabamento
  4. Acabamento

Usinagem de desbaste de componentes

Roughing operations are responsible for most of the chip removal capacity. Special milling strategies such as high-feed machining or trochoidal milling can reduce machining time and thus increase profitability. In addition to tools with indexable inserts and solid carbide milling cutters, high-performance milling cutters with special roughing geometry are used.
  • OptiMill®-3D-CR

    Solid carbide corner radius milling cutter
    • Finishing of 3D moulds with a high-precision corner radius
    • High precision corner radius with high level of radius accuracy
    • Wide selection for hard and soft machining of steel
    • Different numbers of teeth available
    • Available in cylindrical and conical forms

  • OptiMill®-3D-HF

    Solid carbide high-feed milling cutter
    • Perfect for high-feed machining with a high material removal rate and high process reliability
    • Innovative face geometry
    • Extremely quiet running
    • Different numbers of teeth available

  • OptiMill® roughing cutter

    Solid carbide roughing cutter
    • OptiMill®-Uni-HPC-Plus for universal steel machining
    • OptiMill®-Hardened for roughing of parts with a hardness from 45 HRC
    • Excellent tool life 
    • Wear-resistant coating
    • Different corner radii available

  • OptiMill®-Uni-Wave

    Solid carbide roughing cutter
    • Five-edged cord roughing cutter for roughing at high feed rates
    • Highly cost-effective thanks to higher feed rates
    • Optimum chip removal thanks to short, tightly rolled chips
    • Few vibrations, therefore very quiet running

  • OptiMill®-Uni-HPC-Pocket

    Solid carbide universal milling cutter
    • Economical production of pockets and bores
    • Three-edged milling cutter with integrated drill tip
    • Inclined plunging up to 45°
    • Full helix milling and grooving
    • High material removal rate up to 2xD

  • NeoMill®-HiFeed90

    90° corner/high-feed milling cutter
    • Universal tool system to ensure maximum productivity
    • Tool body with indexable inserts for high-feed and shoulder milling
    • Maximum rate of removal due to very high feed rates and large cutting depths
    • Double-edged and four-edged indexable inserts available
    • Large selection of corner radii available

  • NeoMill®-ISO-360

    Round-insert milling cutters
    • Roughing and pre-finishing of 3D contours
    • Optimum contours due to the indexable inserts being installed in a neutral position
    • Soft cutting behaviour for low vibration machining
    • Offered as shell type, shank and screw-in milling cutters in the diameter range 10-160 mm


Residual material roughing

After roughing, in a second machining step, users machine the residual material, especially in corners and cavities, removing material as constantly as possible. Usually tools with corner radius or high-feed milling cutters are used. In some cases a ball cutter can be used to remove the residual material in corners.
  • OptiMill®-3D-HF

    Solid carbide high-feed milling cutter
    • Perfect for high-feed machining with a high material removal rate and high process reliability
    • Innovative face geometry
    • Extremely quiet running
    • Different numbers of teeth available


Pre-finishing

If there are high demands on dimensional accuracy and surface finish, semi-finishing is recommended before finishing. With pre-finishing, machining approaches the final mould profile. The aim is to obtain a residual material that is as constant as possible in order to enable fast finishing with high demands on the surface quality. The stock removal after roughing is approx. 0.5-1 mm for hardened materials and 0.03-0.5 mm for soft materials. After pre-finishing, the constant stock removal is 0.05-0.1 mm for hardened materials or 0.1-0.3 mm for soft materials.
  • OptiMill®-3D-CR

    Solid carbide corner radius milling cutter
    • Finishing of 3D moulds with a high-precision corner radius
    • High precision corner radius with high level of radius accuracy
    • Wide selection for hard and soft machining of steel
    • Different numbers of teeth available
    • Available in cylindrical and conical forms

  • OptiMill®-3D-CS

    Solid carbide shoulder radius milling cutter
    • Milling with a large operating radius
    • Finishing of complex free-form surfaces and complicated workpiece geometries
    • Short machining time due to large line interlacing
    • High surface quality

  • OptiMill®-Uni-HPC-Pocket

    Solid carbide universal milling cutter
    • Economical production of pockets and bores
    • Three-edged milling cutter with integrated drill tip
    • Inclined plunging up to 45°
    • Full helix milling and grooving
    • High material removal rate up to 2xD

  • NeoMill®-ISO-360

    Round-insert milling cutters
    • Roughing and pre-finishing of 3D contours
    • Optimum contours due to the indexable inserts being installed in a neutral position
    • Soft cutting behaviour for low vibration machining
    • Offered as shell type, shank and screw-in milling cutters in the diameter range 10-160 mm

  • NeoMill®-3D-Torus

    Toric end milling cutter
    • For the highest requirements regarding precision and process reliability
    • Special tool body for toric plates with additional stabilisation of the cutting edge
    • Precise rotational tolerances
    • Different corner radii available


Finitura

La lavorazione di finitura rimuove le dimensioni residue per ottenere la forma finale. Le dimensioni dei materiali temprati dopo la prefinitura sono pari a 0,05-0,1 mm, mentre quelle dei materiali morbidi a 0,1-0,3 mm. Le frese a profilo sferico e/o a profilo torico sono gli utensili da scegliere in funzione dei profili finali del pezzo da lavorare.
  • OptiMill®-3D-BN

    ソリッドカーバイド・球面シートカッター
    • 3D輪郭の高精度加工
    • 半径精度の高い高精度ミリングカッター
    • 鋼鉄の硬質・軟質加工用の豊富な品揃え
    • z=2およびz=4のバリエーション、作用高さがある場合とない場合
    • 円筒形および円錐形

  • OptiMill®-3D-CR

    Fresas com raio de canto de metal duro integral
    • Acabamento de formas 3D com raio de canto de alta precisão
    • Raio de canto de alta precisão com elevada exatidão de raio
    • Grande seleção para usinagem em aço duro e maleável
    • Vários números de dentes disponíveis
    • Formas cilíndricas e cónicas

  • OptiMill®-3D-CS

    Fresas barril de metal duro integral
    • Fresagem com grande raio de atuação
    • Acabamento de superfícies complexas de forma livre e geometrias complicadas de peças
    • Curto tempo de usinagem devido a maiores linhas entrelaçadas
    • Qualidade de superfície elevada

  • NeoMill®-3D-Torus

    Fresas de toro
    • Para os mais altos requisitos em termos de precisão e fiabilidade do processo
    • Corpo base especial para placas de toro com estabilização adicional da aresta de corte
    • Tolerâncias de rotação precisas
    • Vários raios de canto disponívei