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Text Box: Forging die test cut with Millstar TO insert

Objective

The demo was conducted to demonstrate the high-speed, high volume and high hardness machining capabilities of Millstar insert type cutting tools.

 
 
 

 

 


 

 

 

 

 

Machining Summary

44 HRC Forging die cavity was machined using a 3D NC program to demonstrate the high-speed, high volume and high hardness machining capabilities of Millstar insert type cutting tools.

 

The size of the die is 160 X 290 X 60. The previous machining method was to rough machine using a round insert type twin insert tool (toroid type) and a solid carbide tool to reach bottom of the die with total machining time of 7 hours using 2 tools. 

 

HSMCIL conducted the same operation with one tool of Diameter 12 TO with corner radius of 3 mm. Total machining time for the roughing operation was 2 hours.
 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Tool Adapter

Collet Chuck (MST)

Tool Holder

CYF 12 - 150 - 12 (MILLSTAR)

Holder material

Steel

Neck diameter

D2=12 mm

Neck length

L1=42 mm

Insert, back draft

TO-12-N (R 3.0) MILLSTAR

Tool coating

Exalon™ (AlTiN)

Toolpath Strategy

Z level machining

Cutting Depth

0.6 mm / pass

Stock remaining

0.1 mm

Step Over

5 mm

Feed

3200 mm/min

Spindle speed

3200 RPM

Machining time

120 minutes

                                                                                               

 

 

 

 


Roughing       Dia 12TO R 3.5    2500min       1000mmmin    0.5 mm/pass              360 mins 

 (1st Step)

 

Roughing       Dia 10 Solid          3800min      760mmmin      0.5 mm/pass              60 mins  

 (2nd  Step)             carbide

 

Total Machining Time

420 Mins / Cavity