PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

PRODUCTIVITY INCREASING - OBJECTIVE

The main outcome of raised productivity is achieved by much higher cutting speeds
and feed rates.
While the speed increases, the cutting time decreases.

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

Rotary cutter (RC) : actively driven tools (ADT) or self-propelled tools (SPT)

Why rotary cutting tool is applied?

to overcome cutting temperature rise when cutting speed
is high how ?
as the cutting tool rotates and it is cooled during the noncutting time in one rotation of the tool, it is expected that
the temperature of the tool will decrease
it is also expected that the rotary cutting tool can be used
for high speed cutting of difficult-to-cut materials

FIXED TOOL
temperature

contact time

time

ROTARY TOOL
temperature

time

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

Why rotary inserts ?

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

The cutting inserts applied on rotary heads result with

30% improved cutting time with the incomparable better
results of tool wear.
Tool wear is dispersed over the entire length of the round
cutter, thus, efficiency of tool usage is better.

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

The insert material selection hot hardness

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

The insert material selection tool wear
Productivity

140
120
100
80
60
40
20
0
Productivity

Conventional
Carbid inserts
60

Rotary Carbid
inserts
90

Rotary Silicon
Nitride inserts
130

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

The insert type (fixed or rotary) selection tool wear
FIXED INSERT

ROTARY INSERT
ROTARY
INSERT
ROTARY
INSERT

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

The insert type selection chip forms (by turning)
ROTARY INSERT

FIXED INSERT

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

Work-piece material - WNr 1.2311 (40CrMnMo7)

tensile strength of 950-1100 MPa
hardness level of approximately 50 HRC

Si

Mn

Min

0,35

0,2

1,3

Max

0,45

0,4

1,6

P
0,035

S
0,035

Cr

Mo

1,8

0,15

2,1

0,25

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

The row material - thickness 300mm (medium and large sized)

PRODUCTIVITY INCREASING BY APPLICATION OF ROTARY MILLING CUTTER

The tools used for machining

CUTTING CONDITIONS
Insert diameter 6mm.
Cutting head diameter is 66mm
Rotation speed of cutting head 1100 rpm
velocity of cutting 275 m/min,
depth of cutting 3 mm.

consistent surface finishes of 2.0 - 3.2 micrometer Ra can

be obtained.
The Rotary Milling Cutter is most efficient at depths of cut
less than 4 mm
When using silicon nitride inserts, coolant is generally not
required

CONCLUSIONS

Milling cutters play an important role in performing milling

operations. The knowledge aimed in this direction assists in
determining the type of cutter(s) to be employed,
Application of rotary milling cutter results with raised productivity in comparison with conventional. While the cutting
speed increases, the cutting time decreases,
With application of the same insert type, cutting time is 30 %
better for rotary milling than for conventional milling method,
Tool wear results are several times better for rotary milling
cutter,
Tool wear is dispersed over the entire length of the round
cutter, thus, efficiency of tool usage is better.