Low-Torque Ti Roughing, with High Removal Rates

March 3, 2011
MAG end mills for machining internal structures in titanium, Inconel and stainless steel components
The 16-flute Max-Flute high-performance end mills are capable of removing up to 8 in.3/min with only 25 ft lb of torque.

The CYCLO CUT Max-Flute high-performance end mills from MAG present new options in titanium roughing with a 16-flute design that’s capable of high removal rates at low torque. The high-density end mills run at 2,037 rpm and 231 IPM to achieve removal rates of up to 8 in.3/min with only 25 ft lb of torque and 9 hp.

A MAG explains, in normal titanium cutting, 60-70 percent of the heat generated is transferred to the tool —which cuts the service life of the tool significantly. Max-Flute tools use shallow, radial widths of cut, which transfers less heat to the cutting tool and allows higher surface speeds for roughing titanium, Inconel and other high temperature alloys that have traditionally required high torque at low rpm to achieve desired removal rates.

When used together with TrueMill® software, MAG reports that the Max-Flute end mills will maintain a constant angle of engagement, thus making the radial cuts more consistent throughout the cutter path, increasing material removal rates and decreasing cycle times, while extending tool life.

"The current approach to high-speed machining involves taking very light cuts," stated Dan Cooper, CYCLO CUT product manager for MAG Regional Services. "The Max-Flute/TrueMill approach enables the machine to make heavier cuts at high speeds, and by using the maximum flute density available, maximum feed rates are achievable."

Max-Flute tools are designed with a differential pitch on the tool flutes to break up harmonics and reduce chatter. "Titanium is very prone to chatter, which affects part quality, and can cause unpredictable tool failure," Cooper added. "By using extremely high feed rates and light radial cuts, we can remove a lot of material with very little risk of scrapping parts."

Latest from Cutting Tools