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Advantages of PPC 5-Axis and High Feed Milling
In this overview, we will share some of the advantages of PPC 5-axis milling and show you how to get high feed milling
PPC 5-Axis Milling
Advantages of the PPC process:
- Shorter machining times due to the large stepover.
- Lower set-up costs.
- General purpose tool bodies and specific indexable inserts.
- Higher surface qualities at shorter cycle times.
- Outstanding process reliability.
- Extreme wear resistance.
- Increased productivity.
Application of tools:
N - Aluminium
For machining 3.2581, 3.0615 and 3.3535
P - Steel
For machining Toolox 44, 1.7225, Toolox 33 and 1.0503
H - Hard
For machining HRC 67, HRC 65, HRC 60, HRC 55 and HRC 50
M - Stainless Steel
For machining 1.4462, 1.4539, 1.4571 and 1.4301
High Feed Milling
QUICK AND EASY RESULTS
Your goals in state-of-the-art machining:
- Maximum metal removal rate Q (cm3/min).
- Reliable production.
- Saving energy and protecting the machine.
- Economic efficiency.
The solution – high feed milling. High feed milling is a very easy to program milling strategy, which is very well suited to working on large areas.
We offer the GARANT Power Q family:
- Stable indexable insert bedding ensures process reliability.
- Low risk of damage to the carrier, even at high metal removal rates.
- Short and optimally rolled chips.
- Optimised chip evacuation.
At high feeds for higher metal removal rates
Enhancing one’s competitive edge is a prerequisite for any company in any industry to succeed. In machining production, there is a particular ongoing need for innovative tool systems that have an optimised service life, produce quality outputs, and are characterised by absolute process reliability. Increasing productivity levels is the primary aim, based not least on using all resources more economically. Over the years, there has been an increasing focus on using machines with increased dynamics, in order to meet these central requirements. Machine-based milling strategies are becoming ever more effective – above all high feed milling.
High feed milling – the operating principle.
In particular when it comes to tool and mould making, workpiece contours are milled layer by layer with relatively small cutting depths. High feed milling with high path feeds has a large number of advantages here. State-ofthe-art machining centres with improved dynamic values reliably implement the tool‘s potential path feeds – not only in linear movement but also when more complex geometries are being machined or in the event of acceleration or deceleration movements during the machining process. The productivity benefits that can be achieved thanks to use of high feed milling always depend on the machine tools, range of parts and the overall production strategy
THE RIGHT STRATEGY WHEN IT COMES TO ROUGHING.
DO YOU WONDER WHAT THE BEST MILLING STRATEGY IS? HIGH FEED MILLING – MORE EFFECTIVE THAN CONVENTIONAL SHOULDER MILLING.
High feed milling means reduced lateral forces and even more advantages
Compared with a conventional 90° shoulder milling operation, the feed rate per tooth in high feed milling can be increased 4-fold when working with the same cutting thickness. This machining process is extremely reliable, effective and versatile. The many advantages of this milling strategy are based on the principle of relatively thin, wide chips that are produced by the flat approach angle of the indexable inserts.
If one compares the effective chip thickness of a 90° shoulder milling cutter with a high feed indexable face mill, the economic advantage is quickly visible: Whereas the maximum chip thickness in 90° shoulder milling corresponds to the feed rate per tooth, the maximum cutting thickness for a 15° high feed indexable face mill is only 25% of the feed per tooth. In many cases, this means the metal removal rate can be increased two-fold or threefold in comparison with conventional 90° shoulder milling (see the calculation example to the right).
High feed milling – vibration-minimised running due to controlled force transfer.
The slightly inclined positioning of the indexable insert in the tool body minimises the radial cutting forces whilst at the same time strengthening the (desired) axial effect. During high feed milling, the cutting forces that occur are predominantly axial towards the spindle, which largely minimises vibration and enables significantly more stable conditions during the machining process, especially with long overhanging tools (see graphics for force transfer to the left).
A further advantage of high feed indexable milling cutters is thanks to the peeling cutter entry, which minimises the load on the cutting edges and thus contributes to significantly improved tool life. With conventional 90° shoulder milling on the other hand, the cutting edge enters the workpiece abruptly at the selected infeed length, which can lead to premature damage to the indexable insert and thus shortens the working life due to faster wear.
View our Garant application range of tooling
The GARANT high feed indexable milling cutters are optimally prepared for their application. The contemporary carrier design assists top performance – especially for special operations such as ramping. For example, component collision of the carrier tool is prevented due to the indexable insert positioning in the base and the chip grooves are correspondingly generously designed for improved evacuation of the chips and to prevent chips jamming. In order to be able to use the auxiliary cutting edges of the indexable inserts more efficiently during ramping and to keep the engagement lengths relatively short, the tools are recessed on the front. Precise supply of the coolant extends the service life of the cutting edges and effectively flushes out the chips. A hard nickel coating protects the tool surface against corrosion and damage.
