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MILLING TOOLS


Martin agreed. “A typical 3" [76.2-mm] high-feed mill running in steel can easily achieve MRRs that will nearly stall out a 30-hp [22.4-kW] machine. In addition to horsepower, traverse [feed] rate is often a constraint as well. Many older machines may max out at 200–300 ipm [5080–7620 mm/ min] and can constrain the ability of the tool to achieve maximum productivity. If we take the same 3" cutter and run it in steel, the recommended starting feedrate is at least 250 ipm [6350 mm/min].” The machine’s CNC must be able to process lines of code fast enough to be able to feed the tool to its capability, added Schultz. “Some 1980’s-vintage machines may not able to feed faster than 40 ipm [1016 mm/min], and high-feed milling feeds will be 10 times that, so you should evaluate your CNC to see if it is capable of running HFM. It is possible to apply new high-feed mills on older machines, but they work best with large cutters because feeds and speeds are not as accelerated.” Walther added that, without good look-ahead software, circular shapes will be misinterpolated into polygons.


“Machines with stronger and faster acceleration capabilities are also more benefi cial for smaller workpieces.”


Work Materials and Tool Selection


The type of HFM tools selected depends on the type of work materials being machined. “For heat-resistant alloys like Inconel and Hastelloy and other nickel-based alloys, I lean toward a positive insert, meaning one-sided, that has relief and is freer cutting,” said Schultz. “A double-negative, double-sided insert is a good option for carbon steels and easier-to-cut materials. According to Martin, positive axial rake tools will be better for superalloys, titanium, stainless steel, and negative geome- tries can be better for diffi cult steels, hardened steels, and cast iron. “A heavier edge preparation and a neutral or negative rake angle that works well in hardened steel can create diffi cult work-hardened areas in a stainless steel,” he said. According to Raun, both the type of work material and the frequency with which a shop changes out jobs and


MAXIMUM MATERIAL REMOVAL RATE FOR


MaxQ delivers unmatched material removal rates at high speeds for a diverse range of materials from steel, cast iron, stainless and exotic metals. No matter the challenge, Take It On!


MAXIMIZED PROFITABILITY LMT Onsrud LP


1081 S. Northpoint Blvd Waukegan, IL 60085 Phone 800 234 1560


Visit www.onsrud.com for more information


See us at CMTS Booth #3807 52 AdvancedManufacturing.org | August 2017


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