Lightweight face milling cutters for high-speed machining of aluminium
Horn is expanding its DTM lightweight milling system to include two new versions. The new DTM.CX09 arbour milling cutters are designed to act as roughing tools. In machining applications that involve high cutting depths and place fewer demands on surface quality, they represent a cost-effective alternative to the new finishing versions of this tool type. The DTM.CX09.AL.F face milling cutter for finishing adds an adjustable body to the existing product range. The axial run-out can be adjusted to the exact µm using a presetter. The insert adjustment system is designed to be user-friendly.
The aluminium body of the tool holders has a low mass, resulting in reduced energy consumption during acceleration and deceleration. Its weight is also less than that of a steel milling cutter, ensuring faster spindle speed changes and consequently highly dynamic machining. In addition, the cutter body features a protective hard coating to prevent wear caused by chip impact. The inserts are available from stock in several diamond materials and a variety of geometries. This makes it possible to obtain a cost-effective alternative to soldered face milling systems. The chip breaker geometries reduce the chip volume and increase process reliability.
Looking at the cutter bodies in more depth, they are available as arbour milling cutters with diameters between 40 mm and 125 mm. The number of teeth ranges from four to eight effective cutting edges. All body versions feature an internal coolant supply. The system is used for high-speed milling up to a maximum cutting speed of vc = 5,000 m/min. The lightweight aluminium body of the tool system protects the spindle at high speeds. The diamond inserts are available as PCD and CVD-D. PCD grade PD75 is a useful all-rounder for aluminium machining applications. Horn recommends substrate PD70 for alloys with a high silicon content. The substrate HD08 (CVD-D) is used for highly abrasive materials. CVD-D consists of 99.9 percent diamond and offers maximum wear resistance. All material versions are available in a range of different geometries to suit the application for which they are being used.