Accurate and efficient plunge milling with CrazyMill Cool P&S square / corner radius
Product summarize
The newly designed, through-shaft cooled square/corner radius 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 square / corner radius is available in the following standard milling sizes: diameters from 1 to 8 mm (.039” to .315”, fractional inches available) and in two versions: for Type A the maximum milling depth is 2.5 x d, for Type C 5 x d.
A - Milling process - Keyways with Type A
Mikron Tool recommends a machining process in 3 steps to guarantee the tolerance of the slot:
- Plunge milling or plunging with a linear ramp
- Slot milling
- 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.
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.
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.
Slot milling
Attention: After the slot milling, a finishing operation has to be planned. For the corresponding choice of tools (diameter), see “Selection of tools for keyway slotting”. Information regarding feed fz,s see cutting data for slot milling.
Side milling
When milling pockets (keyways), it is necessary to execute a finishing operation in order to reach the required tolerance and highest squareness.
B - Milling process - Through slots with Type A and C
When milling through slots, highest cutting parameters are admissible.
C - Milling process - Plunge milling with Type A and C
With CrazyMill Cool P&S, plunge milling (drilling) can be executed in two variants:
- Direct plunging
- Plunging with 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 for Type A is 2.5 x d1 (ap,max = 1 x d1) and for Type C 5 x d1 (ap,max = 1 x d1). Information regarding feed fz,p see cutting data for plunge milling.
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.
D - Milling process - Linear ramp with Type A and C
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 plunge – slot milling.
E - Milling process - Side milling with Type A and C
Semi-Finishing
Recommended cutting parameters:
vc and fz = as specified in the cutting data
ap = max. 1 x d - 2 x d
ae = Type A 0.2 x d; Type C 0.1 x d
Finishing
Recommended cutting parameters:
vc and fz = as specified in the cutting data
ap = 2.5 x d with Type A and 5 x d with Type C
ae = Type A 0.05 – 0.1 x d; Type C 0.02 - 0.05 x d, depending on required surface quality
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 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.