The HX blades have established themselves for reaming operations. Thanks to the hexagonal form they have six usable cutting edges and thus ensure very good cost-effectiveness during machining. MAPAL has now succeeded in making the HX blades available also for milling operations.
Whereas to date only brazed PcBN blades with one cutting edge could generally be used for face milling during the finishing of cast iron and hardened steel it is now possible to use the six cutting edges of the HX blade.
With 63 mm diameter, for example, the newly designed milling cutter has five PcBN milling inserts. The use of proven adjustment and clamping systems guarantees the optimum backlash-free mounting of the HX blades. Since six cutting edges can be used with each indexable blade and both adjustment and changing is very simple, the new milling cutter is extremely cost-effective. The costs per part are significantly reduced.
The new milling cutter with PcBN blades shows its strengths particularly in the automotive sector and in mould making where the extremely good surface finishes are demanded that the new milling cutter produces. Furthermore, the central coolant supply is directed straight at the inserts to ensure an optimum chip flow.
During face milling of a part of GJL25, for example, surfaces are produced with Rz = 3 µm and Ra = 0.4 µm at a cutting speed of up to 2000 m/min and a spindle speed of 10,110 rpm (d = 63 mm). The maximum cutting depth that can be achieved with the new milling cutter is 1 mm in cast materials.
In hardened steel with a hardness of HRC58 ± 2, the maximum cutting depth is 0.2 mm. During machining, surfaces are produced with Rz = 1.3 µm and Ra = 0.16 µm at a cutting speed of up to 250 m/min and a spindle speed of 1400 rpm (d = 63 mm).
Source: MAPAL Dr. Kress KG