Alu-Jet-Cut Solid Carbide End Mills from Emuge Corp. are designed for large-volume machining of aluminum.
Developed in conjunction with major aircraft manufacturers, the company said the tools are effective for material removal in monolithic airframe structural components manufacturing where, on average, as much as 95 percent of the weight of a solid block of material is machined away.
The end mills also are suited for industries that are reliant on rapid material removal in aluminum, including mold and die, automotive and machine-tool manufacturing. The company said the tools have twice the rate of material removal of any previously known carbide end mill.
Alu-Jet-Cut end mills are capable of cutting speeds in excess of 3,000 surface ft per min. A tough, wear-resistant carbide substrate helps the tools resist vibrations that could lead to premature chipping of cutting edges at the high cutting speeds typical of their range of operation.
Additionally, a chip breaker provides control over chip shape and directional flow to increase chip evacuation capacity, enabling stable operations with full radial engagement, as in slot milling, at one-times-diameter depthof- cut to achieve material removal rates in excess of 650 cu. in. per min.
The tools are put through a specialized grind and polish process that provides a high quality surface within the flutes to reduce the tendency for aluminum build-up or cold welding along the cutting edges. That high quality surface combined with the shear velocity at which the tool operates reduces the period of heat transfer from chip to tool by as much as 60 percent compare with standard carbide end mills.
The end mills also feature progressive flute spacing to further minimize vibrations at high cutting speeds.
For increased process safety and reliability, the tools’ shanks are put through a special surface treatment that roughens them while maintaining an extra narrow h5 tolerance. That increases the coefficient of static friction within the holder/shank interface that is typically considered the weak spot in high volume machining.
The tools are offered in various corner radii and roughing and finishing designs. Roughing cutters are available with three flutes and finishing cutters with three and four flutes. All tools are made with throughcoolant capability that is also suitable for minimumquantity lubrication.