High-Performance Chip Splitter Maximizes Metal Removal Rate

Hanita, a Widia brand, announced its release of the VariMill Chip Splitter for dynamic and trochoidal milling operations in steel, stainless steel and heat-resistant superalloys. The VariMill Chip Splitter is said to deliver higher metal removal rate (MRR) by separating long, undesirable, stringy chips from deep cavities and dynamic milling paths by cutting material into shorter, more manageable sections.

This high-performance end mill is designed with non-overlapping chip splitters along the flute cutting edges. The result is more efficient MRR, while maintaining the ability to make finishing passes. The unequally spaced design feature enables each sequential cutting edge to remove any remaining material left by the chip splitter of the previous flute. The tool’s design reportedly reduces breakage and makes it versatile enough for both roughing and finishing passes.

“The Hanita VariMill Chip Splitter helps machinists cut faster and longer by enhancing the ability to flush or blow away stringy chips from deep axial cuts, without forming clumps of intertwined swarf. This is very important to avoid re-cutting of chips, which could damage the cutting edges and shorten tool life. Additionally, the ability to rough and finish with the same tool provides great benefit in cycle time and inventory management, both in the tool crib and the machine’s carousel,” says Steve George, senior manager of Hanita Product Engineering.

VariMill Chip Splitter End Mills are available in five- and seven-flute configuration in ½"-1" standard dimensions in both WP15E and WS15PE grades. The end mill can cut up to 4.5xD, reportedly achieving the highest feed-rate per tooth values, significant reduction in radial forces and consequential improvements to MRR and overall tool life without compromising surface quality. According to the company, the five-flute chip splitter maximizes performance needs when machining steel materials and the seven-flute chip splitter excels in machining stainless steel, and heat-resistant superalloys such as 17-4 PH, inconel and titanium.