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New FMAX - High feed milling cutters

By Niraj M Wanikar, Chief Editor, CNCTimes.com, 2017-01-02 11:02:00

Renowned for its productive milling tools, Mitsubishi Materials has now extended its range with the introduction of the new FMAX series of high feed cutters for finish machining.

To achieve such impressive speed and feed rates, the FMAX consists of a lightweight and robust tool body design that combines alloy steel and aluminium to maximise rigidity and performance whilst simultaneously reducing stress on the machine tool spindle. This lightweight design combines with the anti-fly dovetail clamping mechanism of the insert pockets to enhance rigidity and resistance to forces during high speed machining. The indexable inserts also incorporate an angled face to increase the clamping forces on the insert.

In addition, the insert pockets have a chip breaker wall [body-protector] on the rake face that helps to form chip shapes and dispose the swarf away from the cutting area. To guarantee that swarf is disposed of efficiently, FMAX has the facility for through coolant with the jets directed at the cutting edge of each insert. The through coolant design is compatible with all standard through-coolant milling arbors.

From a precision perspective, each insert seat of the cutter body incorporates a fine pitch insert adjustment screw as well as a secondary ultra-fine adjustment nut. The fine and ultra fine pitch threads provide a precise run-out adjustment of better than 5 microns. This impressive and easy to use adjustment system guarantees surface finishes and unparalleled precision.

The new face mill is available with a coarse or fine insert pitch design and a selection of diameters that includes 50, 63, 80, 100 and 125mm. The coarse pitch cutter has 8, 10, 12 or 16 insert pockets respectively whilst the fine pitched cutter is offered with 10, 12, 14, 18 or 24 inserts. Capable of machining up to a maximum 2mm depth of cut, the new FMAX can run up to vc 3000 [m/min] to provide extreme feeds and material removal rates.

Machining at such high speeds is the result of not just the robust and lightweight body, but also the new MD2030 PCD insert grade. This new diamond sintered grade contains ultra micro-particle diamond that improves fracture resistance during interrupted cutting whilst offering an extremely stable cutting edge. This stable cutting edge prevents burrs and ensures an excellent surface finish result. To reduce costs for the end-user, the MD2030 PCD inserts can also be re-ground to extend tool life.

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