End Carbide

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carbide end mills | solid carbide end mills | carbide drills | solid carbide drills

For many machining applications, it is needless to worry whether or not your machine has enough power to perform what you are asking of it; how-ever, there are instances (usually roughing applications) that require the programmer/operator to figure how much power is required to operate a given cutter. The need to calculate power consumption can become even more important when using machines equipped with high-speed spindles that usually generate very little horsepower at lower rpms. For these machines, it is often necessary to apply smaller diameter cutters in order to run at optimum parameters for machine, cutting tool and material to be machined. The following information will discuss a few areas that need to be addressed as well as new cutting tool technology being applied in the moldmaking industry today for maximum efficiency in roughing applications.

Know Your Machine

To determine if a machine has the power to operate at a given set of parameters, personnel must familiarize themselves with the spindle power chart of the machine. The spindle power chart will reveal the horsepower and torque characteristics of the machine and is usually split into two separate ratings (30-minute and continuous ratings). This chart should be kept handy for reference.

Estimating Power Consumption

As mentioned earlier, determining the horsepower necessary to operate a given tool can be very important. Much has been written on how to estimate the amount of power needed to machine a given material. The following information will cover the basics.

The common method for determining horsepower consumption for a given tool is to multiply the metal removal rate (mrr) by the power factor. The metal removal rate (mrr) is obtained by multiplying width-of-cut, depth-of-cut and feedrate of the tool being used (mrr = woc * doc * F). The power factor (p factor) is a predetermined power constant and varies for different materials, it is determined by the amount of horsepower required to cut a given material at a rate of one cubic inch per minute (charts showing power constants for materials with various hardness levels can be found in publications such as the machinist handbook).

It is important to note that this method of figuring horsepower is merely an estimate and there are many other factors that con-tribute to horsepower calculations. The efficiency of the machine tool spindle, mat-erial hardness, cutter and insert geometries, cutting fluids, tool wear, and more can all have an effect on horsepower requirements.

It is clear that many factors need to be considered when making horsepower calculations and that the cutting tool is one of those factors. In some instances, when using high feed cutting tools for roughing applications, the machine spindle will be the deciding factor when determining cutting tool diameters and machining parameters to be used. For roughing operations on any machine, and in particular those machines with smaller spindle connections such as CAT/BT 40 and HSK40, it is important to make the required power calculations, knowing where to begin in order to achieve maximum productivity while avoiding undesirable spindle overloads and cutting conditions. A machining power calculator—which covers these new high feed cutting tools and greatly reduces the time and effort needed to estimate power consumption for milling, drilling and turning applications—has been developed. By choosing from drop down menus and filling in some remaining information about cutter, cutter geometry, speed, feed, etc., programmers/operators can quickly determine whether or not the machine has approximately enough horsepower for the application at hand.

Cutting Tool Technology for Roughing Applications

Now that you know how to get the most out of your machines for roughing applications, it is time to discuss getting the most out of your cutting tools. A new design of cutting tool has been developed specifically for maximizing metal removal in roughing operations, which allows the use of very high feedrates, producing metal removal rates that can significantly reduce the cycle time and cost involved with roughing operations.

The tools work very well on both 2-D and 3-D part geometries and come in a variety of styles and sizes. Another option for users is to go with modular style tooling that allows the flexibility of using different shanks with screw on heads, enabling the operator to set the projection length and attain maximum rigidity for each application.

For smaller applications, cutting tools with replaceable inserts designed for high feed applications have been developed. Available in 10, 12 and 16mm, these tools are capable of operating at very high feedrates (12 mm tool running at 300 i.p.m. in tool steel at .025 depth cut) and are effective for improving metal removal on machines equipped with high-speed spindles and lower horsepower. The replaceable insert also is a more economical solution when compared to that of solid carbide and is successful in milling hardened tool steel up to approximately 54 Rc.

Discover End Carbide On eBay Below:

Lot of 10 Carbide 2 Fluted End Mill Excellon CNC Router Bit PCB Dremel Engraving
Lot of 10 Carbide 2 Fluted End Mill Excellon CNC Router Bit PCB Dremel Engraving
$36.50
Rushmore 3 16 4 Flute 40 C C Carbide Single End Mill w AlTiN Pack 2
Rushmore 3 16 4 Flute 40 C C Carbide Single End Mill w AlTiN Pack 2
$38.19
Rushmore 1 8 x 1 2Fl 6 Flute 45 C C nACo Carbide Single End Mill 010Rad
Rushmore 1 8 x 1 2Fl 6 Flute 45 C C nACo Carbide Single End Mill 010Rad
$40.16
3 Data Flute Solid Carbide End Mills 1 4 Diameter 1 Rougher and 2 Finishers
3 Data Flute Solid Carbide End Mills 1 4 Diameter 1 Rougher and 2 Finishers
$31.99
1 4 AlumaCut 3 Flute Extended Reach Carbide End Mill for Aluminum 5 Pack USA
1 4 AlumaCut 3 Flute Extended Reach Carbide End Mill for Aluminum 5 Pack USA
$56.00
1 KEO 035 x 052 BALL NOSE CARBIDE END MILL 3 Flute Long Reach NEW 86028 USA
1 KEO 035 x 052 BALL NOSE CARBIDE END MILL 3 Flute Long Reach NEW 86028 USA
$11.39
1 piece KEO 045 X 135 x 1 8 4 FLUTE END MILL SOLID CARBIDE SQUARE 84035 USA
1 piece KEO 045 X 135 x 1 8 4 FLUTE END MILL SOLID CARBIDE SQUARE 84035 USA
$9.60
diameter 16mm HRC45 2 flutes Carbide Ball Nose End Mill CNC milling cutter
diameter 16mm HRC45 2 flutes Carbide Ball Nose End Mill CNC milling cutter
$52.15
LOT  30  INTERSTATE SPEB432 CHAMFER FACE MILLING END MILL CNC CARBIDE INSERTS
LOT 30 INTERSTATE SPEB432 CHAMFER FACE MILLING END MILL CNC CARBIDE INSERTS
$69.75
1 16 062 2 FLUTE CARBIDE BALL END MILL Centercutting 10 pack 1 16 Haas CNC
1 16 062 2 FLUTE CARBIDE BALL END MILL Centercutting 10 pack 1 16 Haas CNC
$29.98
47942 2 Flute Stub Length Solid Carbide Double End Mill Tool Material Solid Car
47942 2 Flute Stub Length Solid Carbide Double End Mill Tool Material Solid Car
$51.10
30mm 6Flute Solid Carbide End Mill 143mm OAL 72mm Cut Length
30mm 6Flute Solid Carbide End Mill 143mm OAL 72mm Cut Length
$139.99
20 705 648 Solid Carbide 6 Flute CNC Precision Single End Countersinks Include
20 705 648 Solid Carbide 6 Flute CNC Precision Single End Countersinks Include
$121.10
N57545 4 Flute TiALN Coated Solid Carbide Stabilizer Ball Nose End Mill For Stai
N57545 4 Flute TiALN Coated Solid Carbide Stabilizer Ball Nose End Mill For Stai
$156.00
1 x 1 1 2 High Speed Steel Roughing Single End Mill Resharp
1 x 1 1 2 High Speed Steel Roughing Single End Mill Resharp
$19.99
QCT Solid Carbide 2 Flute End Mill 3 8 DIA
QCT Solid Carbide 2 Flute End Mill 3 8 DIA
$8.00
3 Alfy Curtil USA Solid Carbide 55mm 4 Flute End Mill 90 LOC 25 OAL
3 Alfy Curtil USA Solid Carbide 55mm 4 Flute End Mill 90 LOC 25 OAL
$31.99
2 Alfy Curtil USA Solid Carbide 6mm 4 Flute End Mill 80 LOC 25 OAL
2 Alfy Curtil USA Solid Carbide 6mm 4 Flute End Mill 80 LOC 25 OAL
$23.99
1 KEO 037 X 056 x 1 8 2 FLUTE CARBIDE MINIATURE END MILL 83632 NEWUSA
1 KEO 037 X 056 x 1 8 2 FLUTE CARBIDE MINIATURE END MILL 83632 NEWUSA
$9.99
FT9952 15 1 1 4 Radius End Carbide Tipped Counter Bore w Interchangeable Pilot
FT9952 15 1 1 4 Radius End Carbide Tipped Counter Bore w Interchangeable Pilot
$49.99
251432 1 Radius End Carbide Tipped Counter Bore w Interchangeable Pilot 3 Flute
251432 1 Radius End Carbide Tipped Counter Bore w Interchangeable Pilot 3 Flute
$34.99
FT9952 05 1 1 8 Radius End Carbide Tipped counter bore w Interchangeable Pilot
FT9952 05 1 1 8 Radius End Carbide Tipped counter bore w Interchangeable Pilot
$39.99
5PCS Diameter 6mm 8mm 10mm 12mm 14mm HRC45 Carbide Ball Nose End Mills set steel
5PCS Diameter 6mm 8mm 10mm 12mm 14mm HRC45 Carbide Ball Nose End Mills set steel
$99.99
1 Dia Carbide End Mill TiAIN 1loc x 3 ExtendedOAL 5 5FLMed Rougher
1 Dia Carbide End Mill TiAIN 1loc x 3 ExtendedOAL 5 5FLMed Rougher
$129.99
1 8 x 3 16 LOC 2FL Carbide D E End Mill 3 16 Shank
1 8 x 3 16 LOC 2FL Carbide D E End Mill 3 16 Shank
$14.99
1 8 x 1 8 x 1 2LOC Carbide End Mill TiAlN HANITA
1 8 x 1 8 x 1 2LOC Carbide End Mill TiAlN HANITA
$13.99
1 8 x 1 8 x 3 8LOC 2Flute DE Solid Carbide End Mill HERTEL
1 8 x 1 8 x 3 8LOC 2Flute DE Solid Carbide End Mill HERTEL
$12.67
1 8 Carbide B N End Mill NOS
1 8 Carbide B N End Mill NOS
$9.99
300mm x 45mm LOC Carbide End Mill 2FL 1 8 Shank
300mm x 45mm LOC Carbide End Mill 2FL 1 8 Shank
$11.99
3 16 x 3 16 x 5 8LOC Carbide End Mill TiAlN HANITA
3 16 x 3 16 x 5 8LOC Carbide End Mill TiAlN HANITA
$15.99
Seco MM10 10012 B90A30 M03 F40M Carbide End Milling Tip Insert NEW PACK OF 2
Seco MM10 10012 B90A30 M03 F40M Carbide End Milling Tip Insert NEW PACK OF 2
$52.00
3 64 x 1 4 Extended Carbide End Mill B N LOC 1 8 TiAIN
3 64 x 1 4 Extended Carbide End Mill B N LOC 1 8 TiAIN
$11.99
3mm Carbide End Mill 4FL Ball Nose SEM Qty 2
3mm Carbide End Mill 4FL Ball Nose SEM Qty 2
$19.99
5 16 x 1 Extended Shank End Mill Carbide TiAIN LOC 3 8 OAL 2 1 2 Med Rou
5 16 x 1 Extended Shank End Mill Carbide TiAIN LOC 3 8 OAL 2 1 2 Med Rou
$34.99
9 32 Carbide End Mill 3 4LOC 5 16 Shank TIN
9 32 Carbide End Mill 3 4LOC 5 16 Shank TIN
$24.99
AB Tools  CR2 078 Carbide Step End Mill
AB Tools CR2 078 Carbide Step End Mill
$99.99
Accupro 3FL SC ZRN 1 2 x 1 2 x 3 4 x 3 End Mill NOS
Accupro 3FL SC ZRN 1 2 x 1 2 x 3 4 x 3 End Mill NOS
$79.99
Hertel 7 8 x 1 1 2 x 7 8 x 4 2 Fl Solid Carbide Square End Mill 88247986
Hertel 7 8 x 1 1 2 x 7 8 x 4 2 Fl Solid Carbide Square End Mill 88247986
$72.00
2 Flute Solid Carbide Ball End Mill03mm LOC 50mm LongMG
2 Flute Solid Carbide Ball End Mill03mm LOC 50mm LongMG
$40.00

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