Modern Machine Shop

MAR 2017

Modern Machine Shop is focused on all aspects of metalworking technology - Providing the new product technologies; process solutions; supplier listings; business management; networking; and event information that companies need to be competitive.

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Page 84 of 156

82 MMS March 2017 FEATURE Marshall says. Yet given that the number of useful edges increases by 100 percent, this is still seem- ingly an obvious bargain. In addition, the insert's small and complex geometry, in combination with the large screw through this form to hold it securely, produces a particular set of strengths. While the insert can cut effectively at any depth across its length, from light finishing cuts of 0.010 inch to full-insert-length cuts of 0.433 inch, it's actually at its best near one of these extremes, either heavy cutting or light. There is also an unexpected benefit that comes from the complex design. The insert combines a high positive angle of the cutting edge with a high negative angle that provides clearance so the adjacent useful edge does not interfere with the cut. Mr. Marshall says this geometric combination has proven effective for increasing metal-removal rate in some applications—that is, increasing it over what a two-edge tool could deliver. Trial cutting has shown that the union of these two The modular Duo-Lock system saves on the cost of carbide by combining a steel shank with a replace- able carbide tip. Replaceable-tip milling tools are typically used for light cutting. An engineered thread designs allows this system to be used for heavy cuts. angles produces an insert able to withstand higher cutting forces than a simpler tool providing just the positive edge. CASTING AS AN ENABLER Marcelo Campos, also senior global product manager for indexable milling, points out that advances in casting are part of what is providing many shops with the opportunity to investigate larger-edge-count tools. An insert with a particu- larly large number of edges needs a relatively light depth of cut (or else the insert itself would have to be very large to get the other edges out of the way). Increasingly, workpieces made through casting are allowing and even requiring the lighter

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