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Double Octomill Tools Designed for Milling Applications on Small Machines

Double Octomill Tools Designed for Milling Applications on Small Machines

Added to MTDCNC by MTDCNC on 20 August 2012

Seco Tools (UK), the leading manufacturer and supplier of carbide cutting tools and tooling systems solutions has introduced a new range of Double Octomill™ 05 tools designed for milling applications on small machines.

With sixteen edge inserts at cutting depths up to three millimetres (sufficient for many applications), the Double Octomill 05 range is a new tool size made specifically for smaller machines and provides manufacturers the best of both worlds - lower tool costs and exemplary performance and productivity.

Seco’s Double Octomill 09 face milling cutter is a success story in high-productivity general machining environments, but it was and is geared towards relatively large milling machines.

With the arrival of Double Octomill 05, which features smaller inserts and half the cutting depth compared to the larger Double Octomill 09 range, the scope of the entire Double Octomill range has been extended.

“It’s a question of economy,” says Seco’s Technical and Marketing Manager, Mike Fleming. “In many applications you don’t need more than two to three millimetres. With smaller cutters and inserts, tool costs can be reduced without any loss of productivity.”

Double Octomill 05 pockets have grooves for axial and radial location pins which are made from high speed steel and have a hardness of 62 HRC, matching a smaller groove on the inserts. In the centre of each pocket is a strong lock screw. This makes it easy to mount the inserts correctly and keep them fixed during operation. With a maximum radial and axial run-out of only 10 to 20 microns, the results are an excellent finish and improved tool life.

“Simplicity is the key,” says Mike Fleming. “When the insert is in the correct position you hear a distinct ‘click’, which makes it virtually impossible to get it wrong.”

The pockets have a negative angle of eight degrees to allow for double-sided inserts and stable operation, and the geometry of the inserts creates a positive rake angle that minimises the power demand, making Double Octomill 05 even more suitable for small milling machines.

Extending overall tool life is ensured by the cutter body’s hardness (40 HRC). It comes in three different pitch alternatives: normal, normal+ and close. A closer pitch will increase productivity in certain applications.

“Under stable machining conditions and with enough power in your milling machine, you should go for normal+ or close pitch,” says Mike Fleming. “Otherwise, normal is the preferred alternative.”

A closer look at Double Octomill 05 inserts reveal that they have four geometries: M10, ME10, M11 and ME11. The M signifies an insert with a primary chamfer, and ME denotes that the edge has only been honed; the former offers better edge protection.

“If you need a high surface finish you should use M11 or ME11 that have wider wiper flats,” says Mr Fleming. “When a rougher surface is acceptable, the first option can be the M10 or ME10 because they generate lower cutting forces. Also, a wide wiper creates more friction that may increase the risk of vibration.”

When a particularly fine surface finish is required, a regular insert on the cutter body can be replaced with a special wiper insert. This has a 3.2 mm wiper flat and should be used together with M10 inserts. Each wiper insert has four right-hand and four left-hand wipers, with the latter intended for left-hand cutters. The wiper insert, which is slightly larger size than other inserts, determines the surface quality attained.

“We’re talking about a much higher surface finish in terms of both Ra and Rz values, but the actual figures vary depending on the material being machined,” says Fleming.

The one wiper insert configuration means reduced tool expenditure and fewer operations for certain applications. And since an insert has a total of sixteen indexable edges — eight on each side — the cost per edge is also kept down.

Inserts for Double Octomill 05 are available in a number of grades for a wide range of materials, from cast iron to exotic materials.

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