Category: Milling

ENGIS: ElectroMill® Diamond Milling Tool

Engis® ElectroMill® Diamond Milling Tool – One Tool, Endless Possibilities

The flat machining of bi‐metal surfaces or milling applications involving an interrupted cut can present daunting challenges to PCD or carbide milling cutters.  The inserts may chip during the milling process, resulting in high machining costs and elevated levels of sub‐standard or rejected parts. The Engis ElectroMill is designed to produce high quality, flat milled surfaces, even if an interrupted cut is present or multiple materials need to be machined simultaneously. It effectively replaces expensive, complex cutters in high volume applications such as high strength alloys, stainless steel, ceramics, cast iron, fiberglass pipe, composites and aluminum.

Features and benefits include high stock removal rates, stress-free cutting action, extended tool life, industry standard adapter mountings and milling cutting dimensions.  Additionally, superabrasives deliver longer tool life than conventional milling technology.

Combined with high pressure coolant, the ElectroMill can machine several materials to an extremely accurate value of flatness with very low tooling costs.  On cast iron, this hybrid tool can achieve flatness of up to 20 µm and surface finishes as smooth as 8 Ra over a single continuous length of 25,000 inches.  In some cases, customers have been able to reduce scrap and reworks significantly; this contributes to increased productivity and an improved bottom line.

Engis: ElectroMill® Diamond Milling Tool – One Tool, Endless Possibilities

Engis ElectroMill Diamond Finishing Tools
The Engis ElectroMill is designed to produce high quality, flat milled surfaces including interrupted cuts or machining bi-metallic materials

Engis Corporation, an industry leader respected throughout the world for providing high-quality superabrasive finishing systems, showcased the ElectroMill Diamond Milling Tool at the recently held IMTEX 2025 Exhibition, as part of its Electrogrip® superabrasive solutions.

The flat machining of bi‐metal surfaces or milling applications involving an interrupted cut can present daunting challenges to PCD or carbide milling cutters.  The inserts may chip during the milling process, resulting in high machining costs and elevated levels of sub‐standard or rejected parts. The Engis ElectroMill is designed to produce high quality, flat milled surfaces, even if an interrupted cut is present or multiple materials need to be machined simultaneously. It effectively replaces expensive, complex cutters in high volume applications such as high strength alloys, stainless steel, ceramics, cast iron, fiberglass pipe, composites and aluminum.

Features and benefits include high stock removal rates, stress-free cutting action, extended tool life, industry standard adapter mountings and milling cutting dimensions.  Additionally, superabrasives deliver longer tool life than conventional milling technology.

Combined with high pressure coolant, the ElectroMill can machine several materials to an extremely accurate value of flatness with very low tooling costs.  On cast iron, this hybrid tool can achieve flatness of up to 20 µm and surface finishes as smooth as 8 Ra over a single continuous length of 25,000 inches.  In some cases, customers have been able to reduce scrap and reworks significantly; this contributes to increased productivity and an improved bottom line.

ElectroMill has been used successfully in the marine, small engine automotive, off-road, agriculture, aerospace and defense industries, as well as ferrous, non-ferrous and exotic materials.

Please contact us for more information on the new Engis Electromill Diamond Milling Tools.

HORN Mastering Processes: High Feed Milling

 

 

Tool Systems manufactured by Paul Horn GmbH offer users the ability to design machining processes for high productivity and cost efficiency. Especially in tool and mould making, high feed milling can be used economically and productively. High performance milling is not only defined by high infeeds, but in high feed milling also by small infeeds coupled with high traverse speed of the cutter.

 Machining applications have changed and challenges have become more complex and demanding. Shorter product life cycles and reduced development times dictate that several different components must be produced on one machine in shorter cycle times. For the tool manufacturer, this requires designing tool systems for the different applications. It means, for example, that a tool may not only be used for corner milling, but should also have the optional ability to plunge cut. Another aspect is modern machine dynamics. The acceleration and deceleration of the axes as well as their synchronisation have been significantly optimised. For relatively new technologies such as trochoidal and high feed milling, tool systems must be able to withstand the high dynamic loads.

Low Infeed – High Metal Removal Rate

A few years ago, Horn introduced a system for high feed milling – DAH cutters for face milling. Due to the load being in the axial direction, the tool and spindle mainly experience compressive force and the shear forces are relatively low. Due to their low tendency to vibrate, the tools are able to withstand the high loads typically generated by a feed per tooth of fz  = 1 mm at cutting depths ap up to 1.2 mm. The large radius on the main cutting edge of the three-edged inserts creates a soft cut, ensuring an even distribution of the cutting forces and long tool life. On the inside, a small cutting edge radius ensures trouble-free and fast plunging. A primary and secondary clearance angle leads to a stable wedge angle and very good cutting edge stability. Due to significantly higher feed rates compared with conventional milling, metal removal rate in high feed milling is significantly increased, despite the lower infeed depths.

 

 

HORN: DAH High Feed Milling System

 

High Chip Volume with High-Feed Milling

Paul Horn GmbH is pleased to present a new development for high-feed milling. The DAH82 and DAH84 systems from Horn represent a new generation of products for this milling process. The precision-sintered insert has eight usable cutting edges, resulting in a low cost per edge and a high level of cost-effectiveness. Despite the negative mounting position, the positive cutting geometry ensures a smooth and soft cut combined with good chip removal. Horn offers the inserts in the substrate SA4B, which is suitable for universal use in various materials. The large radius on the main cutting edge of the indexable insert results in a soft cut, ensures even distribution of the cutting forces and, in turn, extends the tool life. The maximum cutting depths supported are ap = 1.0 mm (0.039″) (DAH82) and ap = 1.5 mm (0.059″) (DAH84).

The DAH82 variant is available as an end mill and screw-in milling cutter in the following diameters: 20 mm (0.787″) (z = 2), 25 mm (0.984″) (z = 3), 32 mm (1.260″) (z = 4), 35 mm (1.378″) (z = 4) and 40 mm (1.575″) (z = 5). As an arbour milling cutter, it is available in diameters of 40 mm (1.575″) (z = 5), 42 mm (1.654″) (z = 5) and 50 mm (1.969″) (z = 6). For diameters in excess of 50 mm (1.969″), the larger DAH84 indexable insert is used. This can be supplied as an arbour milling cutter in the following standard diameters: 50 mm (1.969″) (z = 4), 52 mm (2.047″) (z = 4), 63 mm (2.480″) (z = 5), 66 mm (2.598″) (z = 5), 80 mm (3.150″) (z = 6), 85 mm (3.346″) (z = 6), 100 mm (3.937″) (z = 7) and 125 mm (4.921″) (z = 8). All tool bodies receive a special surface treatment, which results in high strength and hardness, thereby providing long-term protection against abrasive wear from chips.

Please contact us for more information on the Horn DAH High Feed Milling solutions.