Aluminium Carbide End Mill Cutter

Key Features:

• Premium Solid Carbide Material: Made from solid carbide, the cutter offers exceptional rigidity, strength, and heat resistance. This enables the tool to handle high-speed machining without compromising cutting efficiency or tool life.
• Optimized Geometry for Aluminium Milling: The cutter is designed with special flute geometry that enhances chip evacuation and minimizes cutting forces. This design helps in reducing heat buildup, making it ideal for high-speed machining of aluminum and non-ferrous metals.
• High-Precision Cutting: The sharp cutting edges and precise flute design ensure smooth cutting action, enabling tight tolerances and clean finishes. This makes it perfect for both roughing and finishing applications, delivering high-quality surface finishes.
• 2-Flute, 3-Flute, and 4-Flute Options: The cutter is available in a variety of flute configurations:
  • 2-flute: Ideal for roughing and high-feed applications where chip removal is crucial.
  • 3-flute: Balanced for general-purpose milling, offering a good combination of chip removal and surface finish.
  • 4-flute: Best suited for finishing applications, providing a smoother surface and higher rigidity for precise cuts.
• Advanced Coatings Available (Optional): The cutter can be supplied with high-performance coatings such as TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), and AlTiN (Aluminum Titanium Nitride) to enhance wear resistance, reduce friction, and improve tool life under high-speed and high-temperature conditions.

Applications:

The Aluminium Carbide End Mill Cutter is engineered for a wide range of applications in both roughing and finishing operations:

• Slotting and Grooving: Perfect for creating narrow slots or grooves in aluminum and other non-ferrous metals. The cutter’s efficient chip removal helps maintain cutting stability even in deep cuts.
• Pocket Milling and Contouring: Suitable for pocketing, profiling, and contouring aluminum and similar materials. The cutter ensures efficient material removal while maintaining high precision.
• High-Speed Machining: The cutter is optimized for high-speed milling of aluminum, offering faster feed rates and reduced cycle times without sacrificing part quality.
• Finishing Operations: Ideal for finishing cuts where a smooth surface finish and tight tolerances are required. Its sharp cutting edges provide superior surface quality with minimal burr formation.
• Aluminum Alloys and Non-Ferrous Materials: Specifically designed for machining a variety of aluminum alloys (such as 6061, 7075, and A356), brass, copper, and plastics.
• Prototype and Production Runs: Whether in small prototype runs or large-scale production, the cutter ensures consistent, high-quality results.

Advantages:

1. Superior Cutting Performance:

   • The solid carbide construction of the end mill ensures rigidity, precision, and the ability to handle high-speed machining of aluminum and other soft metals. This allows for faster feed rates and more efficient material removal, reducing cycle times.
   • The flute design is optimized for chip clearance, which minimizes the risk of clogging and allows for smoother cuts and faster processing speeds.

2. Extended Tool Life:

   • Solid carbide is renowned for its wear resistance, meaning the cutter maintains its sharpness and cutting ability over a longer period compared to other materials like high-speed steel (HSS).
   • The option for TiAlN and AlTiN coatings enhances heat resistance and abrasion resistance, further extending the tool's lifespan even under demanding cutting conditions.

3. Precision and Surface Finish:

   • The sharp cutting edges and well-designed geometry provide high-precision cuts, delivering smooth finishes with tight tolerances. The tool’s efficiency reduces the need for post-processing, such as deburring or polishing, saving time and improving the overall part quality.
   • The cutter’s ability to handle both roughing and finishing operations means that it can deliver high-quality results in a wide variety of machining tasks.

4. Versatility:

   • The Aluminium Carbide End Mill Cutter is suitable for a broad range of materials beyond aluminum, including brass, copper, and plastics, making it a versatile tool for shops that work with different non-ferrous materials.
   • The multiple flute configurations (2, 3, and 4-flute) allow for flexible use depending on the type of application, whether it’s rough stock removal, general-purpose milling, or precise finishing.

5. Cost-Effective Productivity:

   • With its high cutting performance and long tool life, the Aluminium Carbide End Mill Cutter reduces the need for frequent tool replacements, improving cost-effectiveness in both prototype and mass production environments.
   • High-speed capabilities and superior chip removal allow for faster production cycles, increasing overall shop productivity and reducing downtime.

Technical Specifications:

• Tool Type: Solid Carbide End Mill Cutter
• Material: Premium solid carbide for superior rigidity and wear resistance
• Flute Count: Available in 2-flute, 3-flute, and 4-flute configurations
• Coating Options: TiN, TiAlN, AlTiN (Optional coatings available for increased wear and heat resistance)
• Diameter Range: Available in sizes ranging from 1mm to 20mm (Custom sizes can be made to order)
• Cutting Length: Standard and custom cutting lengths available
• Applications: Aluminum alloys, brass, copper, plastics, and other non-ferrous materials
• Made In India: Manufactured with advanced technology and competitive pricing for global markets

Recommended Cutting Parameters:

For optimal performance, use the following cutting parameters as a guideline:

• Cutting Speed (SFM):
  • Aluminum: 600-1200 SFM (depending on alloy and coating)
  • Brass/Copper: 500-1000 SFM
  • Plastics: 1000-3000 SFM
• Feed Rate: 0.005 – 0.02 inch/tooth, depending on tool diameter, material, and cutting depth
• Depth of Cut: For roughing, depths of up to 1x tool diameter; for finishing, depths of 0.1x to 0.2x tool diameter for smoother cuts
• Coolant: It is highly recommended to use cutting fluids or coolants for better chip removal, tool cooling, and extended tool life, particularly during high-speed operations.

Toolholding Compatibility:

• ER Collet Holders: Provide excellent concentricity, reducing tool vibration for precision milling.
• End Mill Holders: Offer excellent rigidity for heavy-duty machining tasks.
• Shrink Fit Toolholders: Ensure minimal runout and high accuracy for high-speed machining with less vibration.

Conclusion:

The Aluminium Carbide End Mill Cutter is a high-performance tool designed to meet the challenges of modern milling applications. Its solid carbide construction, optimized flute geometry, and available coating options make it an ideal choice for high-speed machining of aluminum and other non-ferrous metals. Whether for roughing or finishing operations, this end mill cutter delivers excellent cutting efficiency, precision, and tool longevity, making it a valuable asset to any workshop or production environment.