|
|
Ultra-Mill Successful Solutions |
| When it comes to face mills, it's easy to pinpoint
what you need. You want tools that: With Ultra-Mill, that's exactly what you get! |
![]() |
||||
| Our design provides a better milling
system. Our system features the easiest setting procedure you'll find on any
face mill, and a body that was designed specifically for PCD usage.
SP3's advantage begins with our one cartridge style that fits all of our cutter bodies. Our geometry changes on the cartridge, not on the body. We can achieve four to six re-tips on our cartridges before they have to be replaced. And, there's more! Our cartridges direct the cutting force into the axial center for rigidity. Our designs leave no open cavities for chips to collect inwhere they can destroy finished cutsand our aluminum bodies are warranted for two years against chip-wash destruction. The real test of Ultra-Mill products comes when they are put in real-work situations, where their superior design and performance can be fully demonstrated under practical conditions and real production deadlines. We welcome the opportunity to show why we're a leader in our field. The following case studies illustrate the superior qualities of Ultra-Mill products and the difference they can make. In each situation, we evaluated the operation to be performed, and the process and tools used. We proposed solutions, ran tests, and evaluated the results. In each case, switching to an Ultra-Mill cutter body provided significant process improvements and frequently production cost savings. |
|||||
| 1. Milling aircraft composite panels made of multi-layer substrates. | |
| 2. Surface finish and burr control on aluminum auto parts. | |
| 3. Surface finish problems milling aluminum castings. | |
| 4. Surface finish and tool life problems milling aluminum die castings. | |
| 5. Tool life, surface finish and specs, and cycle time problems milling water pump covers. | |
| 6. Tool life, surface finish and cycle time problems milling front covers. | |
| 7. Problems with surface finish and cycle times while milling aluminum cylinder heads. | |
| 8. Chatter and drag marks milling aluminum cylinder heads. | |
| 9. Problems with surface appearance, blend and flatness, and erratic tool life while milling transmission parts. | |
| 10. Poor tool life and surface finish while milling aluminum iron-sleeved cylinder blocks. | |
| 11. Poor tool life and drag marks milling aluminum cylinder blocks with iron sleeves. | |
| 12. Surface finish and tool life problems milling motorcycle clutch side covers. | |
| 13. Surface finish problems milling cast-auminum parts. | |
| 14. Erratic tool life and poor surface appearance while milling cylinder heads. | |
| 15. Poor surface finish, excessive tool lines and chatter while milling aluminum outboard motor housings. | |
| 16. Poor tool life and surface finish causing major finish-milling problem. | |
| 17. Unsatisfactory part appearance and tool life, milling intake manifolds. | |
| 18. Poor tool life, leading to low part count and high unit cost, milling aluminum castings. | |
| 19. Poor finish appearance and llimited tool life while milling Corian sinks and countertops. | |
| Solution #1 |
| THE CUSTOMER: An aerospace company was experiencing problems with poor tool-life, erratic tool life, and burrs on machined surfaces. The specific symptoms included chipped cutting edges, chips at the depth of the cut line, tool deformation, and excessive tool-body wear. |
| APPLICATION: Mill the outside shape of
the panels used for aircraft floors and walls from an aircraft composite with
eight different substrate materials: Aluminum skin .020 thick Pressure sensitive adhesive (gummy) Polyimide film element Epoxy film adhesive Epoxy / graphite Phenolic / fiberglass Phenolic / graphite Epoxy potted Nomex honeycomb core - .285 thick The customer was using a Kennametal KIPR100PC02 with 1" diameter and 2 flutes, and an EDR-100-031 insert cartridge. Tool life varied widely from 5 to 40 pieces. PROCESS AND TOOL EVALUATION: In the existing application, the tool used was wrapping a thin, stringy aluminum chip around the cutting edges and causing the tool to re-cut the chip several times before it was freed from the tool. Most of the chips were balled up around the periphery of the tool. THE SOLUTION: An Ultra-Mill end mill cutter (tool body: UE-1.00-3-SS-.750; cartridge: UEDR-10-03) was selected for this application. It was chosen for its chip-clearance properties and for the way the cartridge is mounted in the tool. RESULTS: Chip evacuation was no longer a problem and the chips did not wrap around the tool. Tool life was increased to a consistent 75 pieces and the part profile was well within the tolerances allowed. The performance of the Ultra-Mill tool was superior in this application because of its chip-evacuation qualities. Because the tool did not re-cut material in the process, the cutting edge stayed sharp for a longer time. The customer now uses our tools in production. |
| Back to top |
| Solution #2 |
| THE CUSTOMER: An automotive cooling system fittings manufacturer was dealing with problems related to the quality of the surface finish, burrs around the periphery of parts, and long cycle-times. Their specific symptoms included poor surface finishes, uneven tool mark patterns, and burrs at the exit sides of parts. |
| APPLICATION: Milling of aluminum
extrusion, a very soft, gummy aluminum. The customer was using an Ingersoll 5"
diameter face-mill with five stations, and a carbide insert. Tool life could
not be determined because the customer could not produce a good part.
OUR GOAL: To produce parts to the customer's surface-finish requirements (1.4 Ra) PROCESS AND TOOL EVALUATION: In the existing application, pneumatic power and air shock absorbers were used to control the feed rate and cutting pressure. The fixture was very good and the parts were held rigidly. The part being produced is a rectangular extrusion that is about 1.5" wide and about 4" long. Parts were being machined on two different machines and were fixtured differently on each machine. One held the part vertically and the other held the part horizontally. The same tool was used on each machine, but the finishes were totally different: the results were acceptable on one operation and very bad on the other. THE SOLUTION: After reviewing the operation and evaluating parts produced by each machine, we concluded that the parts which were held vertically had the best finish because more than one tooth was in the cut at the same time. This seemed to stabilize the feed rate. Conversely, the part that was held horizontally had only one tooth in the cut at any time. We recommended using a 5" diameter face-mill with 16 stations. This assured us that more than one tooth would be in the cut on each operation. We tested two UM-5.00-16-1a cutter bodies with UCDR-11-00 cartridges on each machine. RESULTS: The finishes on each machine were identical, and the cycle time was shortened by approximately 70 percent. The finish requirement is 1.4 Ra with no burrs. The finish results on our test were 0.0 Ra with no burrs. (We checked and calibrated the measuring machine to make sure that this reading was correct.) The customer is now using our tools. The customer understands that a stable cutting environment is the most important part of any application, and that there are many ways to achieve the needed stability, including using fewer pockets. |
| Back to top |
| Solution #3 |
| THE CUSTOMER: An Indiana aluminum foundry was having problems with surface finishes, specifically poor surface finish, waviness, and chatter marks. |
| APPLICATION: Milling intake manifolds
from aluminum castings. The customer was using a ClappDico 6" diameter Dov-loc
style with 20 stations and an SDR100093-E1 insert. Tool life was approximately
five weeks. PROCESS AND TOOL EVALUATION: The existing application was a challenging environment with high spindle RPMs and aggressive feed rates. The machine, a CNC Dial, was in good condition and the fixtures were rigid. There were four cutters running on the same station simultaneously. There were two 3" diameter, eight-station cutters and two 6" diameter, twenty- station cutters. Several problems were identified in this application. The process of running four cutters at once caused vibration because the natural frequency of the work piece was always in conflict with the natural frequencies of the differing cutters and spindles. The effect was magnified by the short cycle times required to meet production requirements. THE SOLUTION: The 6" cutters were replaced with Ultra-Mill Cutters (UM-6.00-20-1A) that have more than twice the cartridge density of the ClappDicos: (18) Cartridges - UCDR-22-03, (2) Wiper Cartridges - UT-97. We ran the cutters at the same speed and fed as required by cycle times. RESULTS: In the test runs the tool life was increased by 20 percent. The surface finish was improved by 53 percent on the left-hand side and by 74 percent on the right side. The test went very well and all the customers' requirements were met. The average finish before our test was 1.34 Ra. That improved to 0.63 Ra. on the left side and 1.19 Ra. and 0.31 Ra. on the right side. The test was very successful because of the cutter geometry and the use of wiper cartridges. We reduced the cutting pressure on the part, which reduced the chatter. The wiper cartridges cleaned up the rest. Tool life was increased because of the reduced chatter. |
| Back to top |
| Solution #4 |
| THE CUSTOMER: A Japanese-owned aluminum die caster was experiencing problems related to tool life, surface finishes, and cycle times. The specific symptoms included erratic tool life, appearance of chatter, and blend lines. |
| APPLICATION: Milling V6 oil pans from
cast aluminum. The customer was using an NTK 4" face-mill with eight stations
and a PCD tipped carbide insert. Tool life was erratic. PROCESS AND TOOL EVALUATION: The NTK cutter is very difficult and time consuming to set properly; thus, it rarely is. The tool setters did not have sufficient time to set the cutter as required, so "close enough" was the rule. This greatly affected tool life and surface finish. Additionally, too much pressure on the part caused blend lines. Blending the straight corners in the program with radii solved some of the blend-line problems. A free cutting tool would help. THE SOLUTION: We recommended that the 4" Face Mill be replaced with an Ultra-Mill cutter (UM-4.00-12-1A) and a UCDR-11-03 cartridge. We set the spindle speed at 8000 RPM and the feed rate at .003 IPT, or 288 IPM. The speeds and feeds were adjusted to obtain maximum tool life. RESULTS: The surface finishes were improved, blend lines were not as noticeable, and flatness was improved. The customer was very happy with cycle times and is monitoring tool life and consistency. They are very pleased with the results so far. Tool life has been increased by 30 percent and tool-life consistency has been improved. |
| Back to top |
| Solution #5 |
| THE CUSTOMER: An Ohio contract machine shop was having problems with tool life, surface finishes, cycle times, and with Rm and Rd surface specs not being achieved. Specifically, they were experiencing erratic tool life and the appearance of chatter. |
| APPLICATION: Milling water-pump covers
for Ford Motor Co. The customer was using a Winco 5" diameter with six stations
and the insert was a PCD tipped cartridge. Tool life was erratic, varying from
three to five days with the production of 1,400 parts per day.
PROCESS AND TOOL EVALUATION: After reviewing the application, several problems were identified: (1) The chatter problem was not consistent to any fixture or placement in fixture. One fixture held four parts. There were two machines with the same fixtures on each. (2) The profile lines from the tool were very inconsistent. (3) The application used steel-post, spring-operated support posts in the middle area of each part. The face mill was cutting almost the full diameter at certain points. THE SOLUTION: We recommended using an Ultra-Mill cutter (UM-5.00-8-1A) and an UCDR-11-00 cartridge. We set the spindle speed at 6,230 RPM and the feed rate at .003 IPT, or 150 IPM. RESULTS: In the initial test runs, the results were not adequate. The chatter appearance was still there and the tool lines were still inconsistent. The Rm/Rd spec was very good at 62 percent (results between 40 percent and 80 percent are acceptable), but tool life was not consistent. In the second test runs, we used our UT-88 cartridge, which has a 45-degree lead rather than a radius, to reduce the down pressure on the part and to help maintain the Rm/Rd spec. We added rubber caps to the steel support posts to absorb the chatter of the part. The inconsistent thickness of the cast parts is the cause of varying chatter marks on the fixture stations. Pressure on the support posts varies from one part to another. The results of the second test were excellent. The parts had consistent tool lines and surface appearance. The Rm/Rd spec was at 68 percent and the chatter was eliminated from both machines. Tool life was increased by three to five days, and tool-life variability was improved dramatically. The customer was very pleased with our technical help and with our commitment to excellence. The use of the rubber caps and the free-cutting cartridges has eliminated the chatter, which has increased tool life and improved part appearance. Spindle speeds have been decreased and feeds have been increased to help tool life. |
| Back to top |
| Solution #6 |
| THE CUSTOMER: A Michigan die caster was experiencing problems with tool life, surface finishes, and cycle times. The customer was particularly concerned with poor tool life. |
| APPLICATION: Milling front covers. The
customer was using a Claymore face mill with four stations, and a carbide
insert. Tool life was approximately 2,000 parts. PROCESS AND TOOL EVALUATION: This application had many strengths. The machines were in good condition and the operators were concerned about producing quality work. Spindle speeds and feed rates could be increased to maximize cycle time and tool life. THE SOLUTION: We recommended using an Ultra-Mill cutter (UM-3.00-8-1A) with a UCDR-11-00 cartridge. We set the spindle speed at 5,600 RPM and the feed rate at .004 IPT, or 180 IPM. RESULTS: The test was a success. Part finishes improved by 50 percent and cycle times were reduced by 50 percent, as well as doubling their production rate. The customer was very pleased with the results and has switched to our cutter. They plan to explore other applications of our products. |
| Back to top |
| Solution #7 |
| THE CUSTOMER: Lingenfelter Performance Engineering was experiencing problems with surface finishes and cycle times. The specific symptoms included appearance of chatter and poor surface finish. |
| APPLICATION: Milling aluminum cylinder
heads. The customer was using a Rottler SFOE decking machine (14" diameter with
one station) and full top round PCD tipped inserts. Tool life was not an issue
due to the "job shop" nature of the workload. PROCESS AND TOOL EVALUATION: A review of the application showed that speeds and feeds could be increased and the number of stations in the cutter could be increased to improve cycle times. The machine was in new condition and the fixture was very good. The head is manually loaded and removed. THE SOLUTION: SP3 designed an Ultra-Mill style cutter to fit the Rottler machine with six cutting stations. The UCDR-33-40 cartridge was selected for its radii size and the length of the wiper flat. Spindle speed was increased to the machine maximum of 2,000 RPM and the feed rate was set at the maximum. The cast heads were machined with UCBR-22-40. The machine cut with all six cartridges, which enabled us to increase the feed rate by five times, and the spindle speed was run at 2,000 RPM. The surface finishes improved 40 percent. Tool life is undetermined at this time. The spindle speed was reduced 50 percent and the feed rate was reduced by 25 percent for the cast-head test. |
| Back to top |
| Solution #8 |
| THE CUSTOMER: Lingenfelter Performance Engineering was having problems with surface finishes and cycle times. The specific symptoms included the appearance of chatter, and drag marks across the aluminum. |
| APPLICATION: Milling aluminum cylinder
blocks with cast sleeves from bimetal. The customer was using a Rottler face
mill and a full top round carbide insert. Tool life was not an issue due to the
"job shop" nature of the workload. THE SOLUTION: An Ultra-Mill style cutter was selected to fit the F-65 machining center, and the UT-3443-6A cartridge (our bimetal cartridge). During the test runs, we set the spindle speeds and feeds to obtain correct surface finish. RESULTS: The surface finishes were better than required and the cycle times were reduced. |
| Back to top |
| Solution #9 |
| THE CUSTOMER: A Wisconsin die caster was experiencing problems with surface finishes, blend, and flatness. They were having problems with erratic tool life, surface appearance, and bows in parts being produced. |
| APPLICATION: Milling a part for a
transmission. The customer was using a machine with a 4" diameter with 5
stations, and using a carbide insert. Tool life was approximately 500 parts.
PROCESS AND TOOL EVALUATION: The application was observed and finished parts were inspected. The evaluation showed that tool pressure should be reduced and cycle times should be increased. THE SOLUTION: Both the Ultra-Mill cutter (UM-5.00-16-1A) and UCDR-40-00 cartridges were selected. These cartridges were selected because they feature big radii and no wiper, which result in reduced tool pressure. Because the Ra surface requirement was not a concern, no wiper was needed. RESULTS: The blend lines are now smooth and consistent. The Ra surface finish is improved and the cycle time was reduced by six seconds, which was an added bonus for the customer. They not only got a part that is acceptable to their customer, but they profited from the reduction of cycle time. Approximately 20,000 parts per week are run. The six seconds saved in each operation results in a savings of 33 production hours per week. |
| Back to top |
| Solution #10 |
| THE CUSTOMER: A major automotive company was experiencing problems at its Western Ohio plant with tool life and surface finishes. The symptoms included poor tool life and drag marks across the aluminum. |
| APPLICATION: Milling 8-cylinder aluminum
block with iron sleeves. The customer was using a Clapp & Haney 12.4"
diameter face mill with 20 stations and PCD tipped cartridges SDR100093E1. Tool
life was erratic, varying from 200 to 2,000 blocks per run. PROCESS AND TOOL EVALUATION: This application is special because of the iron sleeves that are cast into the aluminum block. The top surfaces of the sleeves are qualified with a boring operation. The total amount of aluminum stock milled from block is .090. The machine made two passes across the head deck. The first pass removed .070 of the aluminum stock at maximum speeds, and the finish cut of .020 was done at a reduced speed. They were running at 942 surface feet with a feed of .0045 IPT. THE SOLUTION: We recommended that the number of stations in the Ultra-Mill cutter be increased to 44, which would accommodate 40 finishing cartridges and 4 wipers. The change reduced the surface speed without affecting cycle time and reducing the feed to .0032 IPT. Slower surface speeds produced less heat, which improved tool life. The tight manufacturing tolerance of the Ultra-Mill cutter improved the surface finish and the consistency of tool life. RESULTS: The surface finishes improved by about 40 percent with minimal cast iron particle draglines across the aluminum. Tool life was improved to 6,000 blocks consistently. Ford Motor Company now uses the Ultra-Mill cutter. |
| Back to top |
| Solution #11 |
| THE CUSTOMER: A major automotive manufacturer was having problems with tool life and surface finishes at its Ohio facility. Specifically, there were concerns about poor tool life, and about drag marks across the aluminum. |
| APPLICATION: Milling 6-cylinder
vee-aluminum block with iron sleeves. The customer was using a Clapp &
Haney 12.4" diameter face mill with 20 stations, PCD tipped cartridge
SDR100093E1 inserts. Tool life was erratic, and varied from 200 to 2,000 blocks
per run. PROCESS AND TOOL EVALUATION: This application is special because of the iron sleeves that are cast into the aluminum block. The total amount of aluminum stock milled from the block is .040" and cast iron DOC is .010". The machine made one pass across head deck. They were running at 942 surface feet with a feed of .0045 IPT. THE SOLUTION: We recommended that the number of stations in the Ultra-Mill cutter be increased to 36 to accommodate 32 finishing cartridges and 4 wipers. RESULTS: The test is in progress. We anticipate that the results will be the similar to those at the Western Ohio plant. |
| Back to top |
| Solution #12 |
| THE CUSTOMER: A Pennsylvania die caster was having problems with poor tool life and poor surface finish. |
| APPLICATION: Milling a motorcycle clutch side cover. The
customer was using Clapp & Haney, Winco, and Valenite bodies, PCD tipped
cartridges, and carbide inserts. Tool life was erratic. PROCESS AND TOOL EVALUATION: This application was difficult due to the condition of the machines. The fixtures were adequate and they are manual-load machines. The finish on the parts was inconsistent and poor. THE SOLUTION: We changed the speeds and feeds to 4,200 SFM and .003 IPT feed rate, and used an Ultra-Mill UM-6.00-20-1A cutter body, loaded with UCDR-11-01 cartridges. This reduced the current surface speed and decreased the cycle time, which was still well within production requirements. Part finish and burr control were major concerns. RESULTS: The surface finishes were improved by 60 percent and the cycle time was reduced by eight seconds. There were no burrs on the parts, and mark lines were very consistent. No chatter was apparent. |
| Back to top |
| Solution #13 |
| THE CUSTOMER: An Indiana production machine company was having problems with poor surface finishes. |
| APPLICATION: Milling cast-aluminum
parts. The customer was using a Valenite 4" face mill with six inserts, and
carbide inserts. Tool life was approximately 400 parts. PROCESS AND TOOL EVALUATION: A review of the equipment and the processes revealed that the problems were caused by the tool and the cutting path. THE SOLUTION: We used the 2" Ultra-Mill straight shank with six stations and UCDR-11-00 cartridges. The cutter path was changed to the contour of the part and the speeds and feeds were increased to maintain chip load. RESULTS: A better surface finish was achieved, cycle times were reduced considerably (50 seconds per cycle), and tool life was increased to 35,000 parts. Down time was reduced because there were no insert changes or readjustments for wear. Productivity was increased because cycle times and down time were reduced. A savings of about $0.076 per cycle was achieved. That represents a savings of $13,921.68 since October 1. Better than expected results led to the customer purchasing an Ultra-Mill for each machine. |
| Back to top |
| Solution #14 |
| THE CUSTOMER: A Japanese auto company was experiencing problems at its Alabama facility with surface appearance and erratic tool life. |
| APPLICATION: Milling cylinder heads. The
customer was using a ClappDico cutter body and SDR100093E1 inserts. Tool life
was erratic, varying from 200 to 2,000 units. PROCESS AND TOOL EVALUATION: A review of this application revealed that the head surface was finished in one pass. The machine and fixture used were in good condition and were adequate for this process. THE SOLUTION: We recommended changing the cutter to an Ultra-Mill with UCDR-22-00 cartridges. We changed the speed and feed rate to reduce cycle time and increase tool life. RESULTS: Surface appearances improved dramatically and tool life was improved. Simple and reliable setting procedures added to the results achieved by this change. |
| Back to top |
| Solution #15 |
| THE CUSTOMER: A Wisconsin marine manufacturer was having problems with poor surface finish, excessive tool lines, and chatter. |
| APPLICATION: Milling cast aluminum outboard
motor housings. The customer was using a Valenite 6" face mill with eight
inserts, and PCD tipped inserts. Tool life was two days of production.
PROCESS AND TOOL EVALUATION: An evaluation revealed that chatter was causing all of the problems. The fixture and machine were in good condition. The speeds and feed rates were the main problem. THE SOLUTION: We changed the cutter to an Ultra-Mill with UCDR-33-00 cartridges. We also changed the speed and feed rate to reduce cycle time and increase tool life. RESULTS: Surface appearances improved dramatically and tool life was improved. |
| Back to top |
| Solution #16 |
| THE CUSTOMER: A Washington aircraft company was experiencing a major problem at its facility because they could not finish-mill the entire table surface of the machine without changing inserts. The specific symptoms included poor tool life and poor surface finish. |
| APPLICATION: Work was on a 120 ft. x 30
ft. aluminum milling table. The customer was using a Kennametal 12" diameter
with three pockets, carbide inserts, and special cartridges. Tool life was
limitedoperators had to change inserts three times to finish a complete
tabletop. PROCESS AND TOOL EVALUATION: The evaluation showed that this was a simple operation in which a large area was machined to the same height. THE SOLUTION: We recommended that the cutter be changed to a special Ultra-Mill cutter and cartridges. The rake angle and the nose radii are special, and the number of teeth was increased to six stations. RESULTS: The test run was successful: the complete tabletop was machined with one set of cartridges. The cycle time was reduced by about 65 percent. The customer was very happy with the results and purchased the Ultra-Mill cutter. |
| Back to top |
| Solution #17 |
| THE CUSTOMER: A Michigan die caster wanted to address problems related to surface finishes and tool life. Specifically, they were concerned about part appearance and erratic tool-life. |
| APPLICATION: Milling intake manifolds.
The customer was using a ClappDico machine with SCR100093E1 inserts. Tool life
was erratic, but they had no specific information about usage.
PROCESS AND TOOL EVALUATION: This application was being run on a new dial machine. The fixture and machine were in new condition. The process involved three cutters that all ran at the same time on the same head. This presented a chatter condition and all of the tools involved were scrutinized. THE SOLUTION: We recommended that the nose radii on the cutter be changed to a 45-degree lead. This reduced tool pressure, which reduced chatter. The other tools involved were suited for there job and no changes were made to them. RESULTS: Chatter was reduced significantly and the tool life increased by about 20 percent. The appearance of the finished parts is much more acceptable. The customer changed the cutter to the Ultra-Mill and is very pleased with the service and the products. |
| Back to top |
| Solution #18 |
| THE CUSTOMER: A Pennsylvania die caster had a problem with poor tool life. Specifically, they wanted to address the problems of low part count, high cost per unit. |
| APPLICATION: Milling aluminum castings.
The customer was using a Valenite with a 4" diameter and three stations. They
were using PCD cartridges. Tool life was limited to approximately 2,100 pieces.
PROCESS AND TOOL EVALUATION: The evaluation showed that this was a simple face-mill application. THE SOLUTION: We recommended changing the cutter to an Ultra-Mill 3" diameter with six stations. RESULTS: The finish on parts was improved and the tool life was doubled to 4,400 pieces. The customer was very pleased with the outcome and purchased the Ultra-Mill cutter. |
| Back to top |
| Solution #19 |
| THE CUSTOMER: PPE Precision Process wanted to address problems related to tool life and surface finish. Specifically, they were concerned with poor appearance of finished parts and limited tool life. |
| APPLICATION: Milling Corian sinks and
countertops. The customer was using a carbide end mill. Tool life was limited
to production of one to four sinks. PROCESS AND TOOL EVALUATION: The evaluation showed that this application was special due to the material involved. Corian is a ceramic-like type of substance that is very abrasive to cutting tools. The cutting path and depth of cut presented no problems. THE SOLUTION: We changed the cutting tool to a Ultra-Mill cutter and used PCD to machine the parts. We selected a speed of 6000 RPM and a feed of .0034 IPT. RESULTS: Cycle time was reduced by 70 percent and the appearance of the parts was much better. Tool life was increased to 25 to 50 parts, depending upon the profile of the part. The build-up of the Corian material on the wiper side of the cartridge caused premature failure, but a cleaning step at the end of the day has taken care of this problem. Tool life was long and predictable. |
| Back to top |
| See why Ultra-Mill is defining the future in milling and machining of abrasive aluminum parts and components. Let us demonstrate these mills to youin your plant and on your machines. What they can do for youand your bottom lineis amazing! |
![]() |
For sales and technical assistancecall 888-547-4156 |