Tungaloy’s New R2 Insert Eliminates Finishing Processes

Tungaloy is expanding its TungForce-Feed line of indexable small-diameter high feed milling cutters to include R2 inserts that feature a corner radii of 2mm. Available in diameters of 8, 10, 12 and 16mm, the TungForce-Feed line ensures high productivity levels and it is an economic profiling solution for the mould and die industry when compared to conventional solid end mills and indexable tools of similar size.

 

When designing a CAM program for high feed machining of complex 3D profiles in typical mould making applications, it is common to use a theoretical corner radius for programming the insert radius. This method leaves excessive stock on the workpiece after machining, adding processes. To create the ideal platform for subsequent finishing process, many job shops are using solid carbide square end mills with large radii in the roughing process. The new R2 inserts require no programming for the theoretical corner radius as its 2mm corner radius leaves no uncut material on the machined surface. This ensures that the TungForce-Feed series makes a good replacement for costly solid carbide end mills, helping customers reduce tool costs.

 

With an insert design that is 10% thicker than competitor products, the TungForce-Feed line is built to perform at higher machining parameters by withstanding fracture forces. Furthermore, the robust insert screws and seat design reduce screw neck shearing under high cutting forces. The insert design incorporates a positive inclination angle that promotes smooth chip evacuation that further reduces cutting forces by controlling chip formation, especially when shoulder and slot machining.

 

Perfect for face and shoulder milling as well as helical interpolation and ramping, the close insert pitch makes the TungForce-Feed line a formidable option for all your milling applications. The new series has been designed with a small entry angle for chatter stability that significantly improves efficiency and tool life even when machining in long reach areas.

 

The new R2 insert has an optimised geometry that gives it the potential to perform as a full profiling insert that is ideal for semi-roughing and semi-finishing processes. The free cutting geometry eliminates chatter and improves surface finish quality and when this combines with the built-in side wiper that helps reduce burr formation on walls and corners while improving wall accuracy, the TungForce-Feed line proves itself as the ultimate performer for the mould and die market.

 

The TungForce-Feed line is available in two insert designations that include the AH3225 and AH8015 grades. The AH3225 grade incorporates nano multi-layer coating technology with three major properties for optimal cutting edge integrity. This increases resistance to wear, fracture, oxidation, built-up edges and delamination. The AH8015 designation has a hard coating layer and carbide substrate with a strong resistance to wear, heat and built-up edges, this makes it ideal for machining hard or difficult materials. The two grades provide optimal machining performance on materials from carbon, alloy, pre-hardened and stainless steels through to cast iron, titanium and heat resistant alloys.