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Casting Light On First-Stage Aluminium Machining

Casting Light On First-Stage Aluminium Machining

In order to boost the first stage roughing operation on newly cast aluminium parts for the automotive industry, Sandvik Coromant is introducing its  M5Q90 angential milling cutter. Designed to complete “cubing” (first machining of faces after casting) in a single operation without creating burrs, the new tool is fitted with PCD tangential inserts that provide a smooth and stable cutting action to lower power consumption and eliminate vibration. This concept ensures reliable performance, improved tool life, exceptional surface finish, high metal removal rate and an increased number of parts per insert.

“To enhance efficiency, our new M5Q90 tangential milling cutter features fully engineered cutter bodies matched with dedicated PCD insert geometries that feature a positive cutting angle to reduce cutting force and load on the machined component,” explained Emmanuel David, Global Automotive Product Manager at Sandvik Coromant. “The inserts, which are easy to handle and adjust, offer reduced cost per part along with high accuracy and repeatability.”, added Jacques Gasthuys, Global Automotive Application Engineer.

M5Q90 cutter bodies are designed according to customer specifications and hence meet the requirements of high-productivity machining – the tool can operate in high-speed conditions in excess of 20,000 rpm. However, all cutter bodies offer the same design of tip seat, coolant channel, lead angle and rake angle. Inserts are always kept in stock.

If desired, the cutter body tool life can be further extended in engineered solutions with PCD inserts protected by rows of carbide inserts, a configuration that also serves to increase the depth of cut capability. While the basic tool with PCD inserts offers 2-4 mm (0.079-0.157 inch) depth of cut in full engagement, this can be boosted to in excess of 4 mm (0.157 inch) using the engineered solution with protective rows of carbide inserts.

Aluminium cylinder heads and engine blocks will be among the principal components to benefit, typically at automotive foundries or Tier 1/Tier 2 suppliers. By way of example, the cubing operation on a cast cylinder head would involve machining the camshaft face, inlet/outlet face and combustion face. Typical cutting data using M5Q90 might include a speed of 2500 m/min (8202 ft/min) and feed per teeth of 0.20 mm (0.008 inch). Users also benefit from high-precision coolant channels that provide the option for either emulsion or MQL application.

The M5Q90 completes the Sandvik Coromant offer for machining aluminium automotive parts, complementing the M5B90, M5C90, M5F90, CoroMill® Century/590 and M5R90 tooling solutions.

Capable of both face and shoulder milling, the M5Q90 is also suitable for many applications in the general engineering and aerospace sectors.

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