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Accurate and efficient plunge milling with CrazyMill Cool P&S

Product summarize

The newly designed, through-shaft cooled plunge-mill / drill-mill for roughing and finishing sets new standards for milling of slots, pockets and faces in smallest spaces in regards to speeds, performance, tool life and surface quality. It combines HSC (high-speed-cutting) and HPC (High Performance Cutting) and becomes therefore a HSPC-Milling cutter (HighSpeedPerformanceCutting).

The used tungsten carbide, geometry, coating and especially through-shank coolant supply, which ensures perfect cooling of the cutting edges and removes the chips cleanly from the work area, support high cutting speeds, good depth (up to 1 x d) and fast feeds.

The CrazyMill Cool P&S is available in the following standard milling sizes: diameters from 1 to 6 mm (.039” to .236”) while the maximum milling depth is 2.5 x d.

Milling process - Milling of keyways

Mikron Tool recommends a machining process in 3 steps to guarantee the tolerance of the slot:

  1. Plunge milling or plunging with a linear ramp
  2. Slot milling
  3. Side milling (finish milling)

Mikron Tool generally recommends the time- and space saving plunge milling (vertical). Alternatively plunging in a linear ramp can also be done.

MikronTool-Products-Process-CrazyMill-Cool-P&S-milling_key-slot

Plunge milling or linear ramp

When plunge milling, an increase of the drilling diameter of approx. 0.05 mm compared to the milling bit diameter is necessary. The maximum plunge depth is 2.5 x d1 (ap,max = 1 x d1). Information regarding feed fz,p see cutting data for plunge milling.

MikronTool-Products-Process-CrazyMill-Cool-P&S-milling_plunging

With a linear ramp the maximum plunge angles α depend on the material and cannot be exceeded (see table below). Information regarding feed fz,s see cutting data for keyway milling.

MikronTool-Products-Process-CrazyMill-Cool-P&S-linear-ramp-milling
MikronTool-Products-CrazyMill-Cool-P&S-Additional-Tech-Specs-Ramping_Angle-EN

Slot milling

Attention: After the slot milling, a finishing operation has to be planned. For the corresponding choice of tools (diameter), see tables “Selection of tools for keyway slotting”. Information regarding feed fz,s see cutting data for slot milling.

MikronTool-Products-Process-CrazyMill-Cool-P&S-milling_slotting

Side milling

When milling pockets (keyways), it is necessary to execute a finishing operation in order to reach the required tolerance and highest squareness.

 

MikronTool-Products-Process-CrazyMill-Cool-P&S-milling_finishing

Milling process - Milling of through slots

When milling through slots, highest cutting parameters are admissible. See tables with cutting parameters for through slots.

 

MikronTool-Products-Process-CrazyMill-Cool-P&S-milling_open-slotting

Milling process - Plunge milling

With CrazyMill Cool P&S, plunge milling (drilling) can be executed in two variants:

  1. Direct plunging
  2. Plunging with helical interpolation
MikronTool-Products-Process-CrazyMill-Cool-P&S-milling_plunging
MikronTool-Products-Process-CrazyMill-Cool-P&S-milling_Helical-interpolation

Direct plunging

When plunge milling, an increase of the drilling diameter of approx. 0.05 mm compared to the milling bit diameter is necessary. The maximum plunge depth is 2.5 x d1 (ap,max = 1 x d1). Information regarding feed fz,p see cutting data for plunge milling.

MikronTool-Products-Process-CrazyMill-Cool-P&S-milling_plunging

Plunging with helical interpolation

The maximum plunge angles α depend on the material and cannot be exceeded (see table below). Information regarding feed fz,s see cutting data for keyway milling.

Attention: the minimum diameter of the bore is dbore = 1.3 x dtool.

MikronTool-Products-Process-CrazyMill-Cool-P&S-milling_Helical-interpolation

 

MikronTool-Products-CrazyMill-Cool-P&S-Additional-Tech-Specs-Ramping_Angle-EN

Milling process - Side milling

Semi-Finishing

Recommended cutting parameters:

vc and fz = as specified in the cutting data table
ap = max. 1 x d
ae = 0.2 x d

MikronTool-Products-Process-CrazyMill-Cool-P&S-up-cut-milling

Finishing

Recommended cutting parameters:

vc and fz = as specified in the cutting data table
ap = 2.5 x d
ae = 0.05 – 0.1 x d depending on required surface quality

MikronTool-Products-Process-CrazyMill-Cool-P&S-up-cut-milling

 

Tested and approved

Mikron Tool has determined the ideal cutting parameters (ratio of tool life to process reliability) for the use of CrazyMill Cool. These are listed in the cutting data charts for the milling tool's diameter, milling tool type and type of machining (copy, side milling) as well as the material to be machined. Unique cutting data tested at Mikron Tool such as cutting speed vc, feed per tooth fz and cutting depth ap or cutting width ae ensure quick and safe machining.

The cutting data chart overview for material group, type of material, degree of hardness or tensile strength, material number, DIN and AISI/ASTM/UNS ensure a quick determination of the cutting data to be used.

Packaging

An impact-resistant and user-friendly drill packaging is absolutely necessary for CrazyMill Cool. Mikron Tool offers all tools of the CrazyMill Cool family in a high quality, single package.

Notes or further questions

Please find more information about tool holders, cooling or lubrication under “Additional Info”.

Mikron Tool has an international team of cutting technology experts who are pleased to answer your questions (how to use a drill, tools, machines, tool holders, cooling, machining process…).

Use this link to contact us directly.

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