The chatter or vibration in metal cutting poses an eternal challenge for manufacturers. The ISCAR products of the latest HIGH QLINE family of cutting tools offer an interesting solution: Indexable Milling Insert with an asymmetric shape. This insert opens up new opportunities for reduction of vibrations in metal cutting.
The design of the new one-sided insert HM90 ADCT ...-CF follows a different and unique approach compared to traditional Milling inserts in the Market. The insert has different Helix Angles on the two cutting edges and the two edges are colored gold and black. The concept is to mount gold and black edges alternately resulting in variable helix configuration for the cutter.
This feature ensures significant improvement of the cutters' performance in shoulder milling by reducing vibrations. Typically, the tool life of the insert increases by 15-20 percent and the power consumption is reduced by 10 percent or more.
This solution is ideally suited for:
1) Less rigid set-up.
2) Long overhang applications
3) Thin-walled workpieces
4) Problematic workholding.
It is important to note that the new asymmetric insert is suitable for already existing and popular Heli-Mil Family of Milling cutters.
Chatter has a complex nature. Simulating vibrations is difficult because it depends on many factors. In the design stage, simulation does not always help to find the geometry of a vibration-proof indexable milling cutter for broad-spectrum applications. Therefore, the ability of simple "cutter tuning" for a vibration-free mode only by changing the order of insert clamping looks very promising.
Related Glossary Terms
Condition of vibration involving the machine, workpiece and cutting tool. Once this condition arises, it is often self-sustaining until the problem is corrected. Chatter can be identified when lines or grooves appear at regular intervals in the workpiece. These lines or grooves are caused by the teeth of the cutter as they vibrate in and out of the workpiece and their spacing depends on the frequency of vibration.
- gang cutting ( milling)
gang cutting ( milling)
Machining with several cutters mounted on a single arbor, generally for simultaneous cutting.
Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.
- milling cutter
Loosely, any milling tool. Horizontal cutters take the form of plain milling cutters, plain spiral-tooth cutters, helical cutters, side-milling cutters, staggered-tooth side-milling cutters, facemilling cutters, angular cutters, double-angle cutters, convex and concave form-milling cutters, straddle-sprocket cutters, spur-gear cutters, corner-rounding cutters and slitting saws. Vertical cutters use shank-mounted cutting tools, including endmills, T-slot cutters, Woodruff keyseat cutters and dovetail cutters; these may also be used on horizontal mills. See milling.