End Mills For Large-Volume Machining

Developed in conjunction with major aircraft builders, Emuge’s Alu-Jet-Cut solid carbide end mills are designed for rapid, large-volume aluminum machining in mold and die, aerospace, automotive and machine tool manufacturing applications. The company says the tools are particularly useful for machining monolithic airframe structural components, which often require removal of as much as 95 percent of the weight of a solid block of material.

The end mills are capable of cutting speeds in excess of 3,000 sfm. A tough, wear-resistant carbide substrate helps resist vibrations that could otherwise lead to premature chipping of cutting edges at high cutting speeds, the company says. Additionally, a chip conveyor (chip breaker) provides control over chip shape and directional flow to increase chip evacuation capacity. This enables stable operations with full radial engagement (slot milling) at 1 × D depth of cut to achieve material removal rates in excess of 650 cubic inches per minute.

According to the company, the tools undergo a specialized grind/polish process that provides a high-quality surface within the flutes to reduce the tendency for aluminum build-up or “cold welding” along the cutting edges. This surface, combined with the cutter’s shear velocity, reduces heat transfer from chip to tool, the company says.

The end mills also feature progressive flute spacing to reduce vibration at high cutting speeds. For increased process safety and reliability, the tools undergo a special surface treatment that roughens the shanks, yet allows them to maintain a narrow h5 tolerance.

The tools are offered in various corner radii, roughing and finishing designs. Roughing cutters are available with three flutes and finishing cutters with three or four flutes. All tools feature coolant-through capability and are well-suited for machining with minimum-quantity lubrication (MQL), the company says.