NTK Introduces Lightweight Hyper High Feed Face Mill Line

High material removal rates when machining aluminium alloys is a common task that NTK has now taken to a new level with the arrival of its new Hyper Feed Cutter (HFC) line of face milling tools.

As the name suggests, NTK has now introduced a face milling line that can carve through some of the most challenging materials at a cutting speed from 1m to 5m/min with a feed rate up to 0.2mm per tooth. Furthermore, the tool can perform at these speeds and feeds with an astonishing depth of cut up to 6.35mm. The NTK HFC Series is the Japanese manufacturer’s lightest milling series to date. This is credit to a lightweight aluminium tool body and innovative design that reduces stress upon the machine tool spindle and also the cutting forces generated by the HFC Series.

The new HFC is available with diameters of 50, 63, 80, 100 and 125mm with 7, 10, 12, 16 and 22 insert seats on the respective tool diameter bodies. The high density of insert pockets ensure the HFC can operate at feeds and speeds up to 50% higher than competitor products. The high density of inserts and the lightweight design optimise the performance of a face milling line that has an overall weight of just 0.23kg for the 50mm diameter tool and 1.1kg for the largest 125mm face mill.

These impressive weight characteristics permit the smallest 50mm face mill to run at machining speeds up to 20,000rpm whereas the largest 125mm tool can cut through the hardest of materials at a maximum spindle speed of 15,000rpm. To maintain a high level of insert security and high clamping forces, NTK has developed a wedge clamping system that robustly locks the inserts in position to eliminate vibration and enhance surface finishes and tool life when conducting high-feed machining.

The PD1insert grade that is available with the new HFC Series is a PCD grade that can be re-ground up to four times to reduce cost per insert and maximise the efficiency of the PD1 inserts. The PD1 is offered with three different geometries and corner radii for specific applications. Two PD1 geometries are wiper inserts with a 6 degree rake angle, a 7.5mm cutting edge length and a corner radius for improved burr control and surface finishes. The third insert has a 10 degree rake angle and double chamfer geometry to reduce cutting forces. For further information on how to drastically improve your high feed machining of challenging materials, contact NTK Cutting Tools.