New anti-vibration additions to milling tools are adding versatile options to a variety of milling applications. By Ikuo Takikawa, applications engineer (end mill development division), OSG Corporation.
In the past, end mills were developed based on specific application needs. As machining requirements evolved over time, the need for versatile milling solutions has become increasingly vital.
As a result, end mills such as OSG’s AEVMS anti-vibration carbide end mill have been developed for milling efficiency and finish quality suitable for a variety of milling applications.
Enhancing processing efficiency was one of the key objectives of the end mill’s development project, which could lead to various cost savings due to machining time reduction. An additional focus was to ensure high quality surface finish.
The concept of the AE-VMS focussed on the problem of burrs generated during metal processing. As many conventional end mills have this problem, the development team sought for a new method to eliminate burrs.
This resulted in the development of a sharp positive rake angle geometry that reduced cutting force to minimise tool wear and potential damage to the workpiece.
Cutting vibration was minimised with the unequal spacing of teeth and variable-lead geometry. Furthermore, the flute form helped facilitate chip evacuation to enable stable and consistent performance.
The end mill saw stable performance at an overhang length of L/D=4, and the high tool rigidity suppressed the occurrence of burrs.
The addition of a multi-layer coating called Duarise saw improved lubricity, friction-resistance and high oxidation temperature qualities, minimising thermal cracks and allowing machining in various applications, such as water-soluble oil.
The end mill was able to suppress cutting heat generation, resulting in stable surface roughness.
Various Milling Operations
Cutting trails demonstrated surface finish with no vibration and minimal burrs, including stainless steel.
With the next generation of end mill designs, accommodations can be made for a wide range of milling operations. These include slotting, side milling, helical milling, contour milling and ramping in stainless steel, cast iron, carbon steel, alloy steel and hardened steel (up to 40 HRC).
APMEN Metal Cutting