Carbide Long Endmill

Key Features:

• Material: Constructed from premium solid carbide, known for its exceptional hardness, strength, and wear resistance. Carbide tools can withstand high cutting speeds, high temperatures, and demanding machining conditions, ensuring reliable performance over extended periods of use.
• Long Reach Design: Specifically engineered for deep cavity milling, pocketing, and applications requiring extended reach, the long design ensures access to areas that standard tools cannot reach, such as deep pockets or internal features within parts.
• Flute Count: Available in 2, 3, or 4-flute configurations, enabling you to select the optimal tool for your application:
  • 2-flute design: Ideal for rapid material removal and increased chip clearance, best suited for softer materials like aluminum.
  • 3-flute design: Provides a balance between material removal rates and tool stability, offering a versatile choice for general-purpose milling.
  • 4-flute design: Offers increased rigidity and better surface finishes, particularly in finishing operations or when machining harder materials.
• Coating Options: Coating options such as TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), and AlTiN (Aluminum Titanium Nitride) are available to improve tool life, reduce friction, and enhance heat resistance. These coatings also help extend the tool's performance in tough and high-temperature applications.
• Cutting Edge Geometry: Precision-engineered cutting edges ensure smooth, stable cutting with reduced deflection, allowing for improved surface finishes, higher cutting speeds, and better overall tool life in deep cuts or challenging operations.
• Versatile Application: The Carbide Long Endmill is suitable for machining a wide range of materials, including stainless steel, aluminum, tool steels, titanium alloys, plastics, and composites.

Applications:

The Carbide Long Endmill is ideal for machining deep or intricate features in various applications, including:

• Deep Cavity Milling: Perfect for creating deep pockets, cavities, or internal features in workpieces that are difficult to reach with standard tools.
• Slotting and Grooving: Well-suited for deep slotting or cutting narrow grooves, especially in hard-to-reach areas or when additional reach is required.
• Profile and Contour Milling: Excellent for machining complex profiles, contours, and shapes in parts with deep or intricate features.
• Precision Finishing: Ideal for finishing applications requiring high surface quality and tight tolerances, especially when combined with a 4-flute design for rigidity and smooth finishes.
• Pocketing: Used for creating deep pockets in workpieces, often in materials that require high removal rates and good chip management.
• Drilling and Holemaking: Can be used for drilling deep holes or holemaking in hard-to-reach locations, especially in deep or narrow workpieces.
• Edge Milling and Chamfering: Useful for finishing edges, creating precise chamfers, or performing light deburring in tight spaces.

Advantages:

1. Extended Reach with Stability:

   • The long design allows for greater reach without compromising tool rigidity, enabling the machining of deep cavities or features that would otherwise require multiple tools.
   • Minimized tool deflection during deep cuts improves precision and surface finish quality, even in high-speed operations.

2. Exceptional Durability and Wear Resistance:

   • Solid carbide construction provides superior hardness, wear resistance, and long-term durability. This is especially important when machining tough materials like stainless steel, titanium, and high-alloy steels.
   • The tool’s ability to withstand high temperatures and pressures extends its operational lifespan, reducing the frequency of tool changes and improving overall productivity.

3. Improved Cutting Efficiency:

   • Designed for high-speed milling, the Carbide Long Endmill can handle high feed rates while maintaining stable cutting performance. This increases productivity and reduces cycle times, particularly in deep milling applications.
   • The optimized flute design allows for efficient chip removal, preventing clogging and heat buildup, even during heavy material removal.

4. Superior Surface Finish Quality:

   • The 4-flute design provides increased rigidity, resulting in smoother cutting, reduced vibration, and better surface finishes. This is ideal for precision operations where high surface quality is required.
   • Ideal for finishing operations, the tool minimizes the risk of burrs and tool marks, delivering a clean, smooth surface finish.

5. Versatility Across Materials:

   • Suitable for a broad range of materials, the Carbide Long Endmill is effective in machining metals such as stainless steel, aluminum, tool steels, and titanium as well as non-metals like plastics and composites.
   • Coatings like TiAlN and AlTiN further enhance the tool’s performance in high-temperature and tough materials, improving cutting efficiency and tool life.

6. Cost-Effective Over Time:

   • Although carbide tools generally come with a higher upfront cost, their longer tool life and ability to maintain cutting performance over extended periods of use make them a more cost-effective option in high-volume or precision machining.

Technical Specifications:

• Tool Type: Solid Carbide Long End Mill
• Flute Count: 2, 3, or 4 flutes (depending on the application)
• Diameter Range: Available in a range of diameters, typically from 3mm to 20mm or more.
• Cutting Length: Available in various lengths, typically ranging from 30mm to 150mm, depending on the specific application.
• Coating Options: TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), AlTiN (Aluminum Titanium Nitride)
• Material: Premium solid carbide
• Application Types: Deep cavity milling, pocketing, slotting, profile milling, finishing, edge milling, holemaking.

Recommended Cutting Parameters:

To optimize tool life and ensure the best cutting performance, use the following general cutting guidelines:

• Cutting Speed (SFM):
  • Aluminum: 300-600 SFM
  • Mild Steel (A36): 100-200 SFM
  • Stainless Steel (304): 80-150 SFM
  • Hardened Steel (45 HRC): 50-100 SFM
• Feed Rate: Typically 0.003 – 0.008 inch/tooth, depending on material hardness and cutting conditions.
• Depth of Cut: For roughing, depths up to 1x tool diameter (e.g., 6mm for a 6mm diameter tool) can be used; for finishing, depths of 0.5x tool diameter are recommended for optimal surface finish.
• Coolant: Use coolant or cutting fluid to control heat, improve chip removal, and increase tool life, particularly when machining harder materials or running at high speeds.

Coating Options:

• TiN (Titanium Nitride): Ideal for general-purpose machining, providing excellent wear resistance and smooth cutting performance.
• TiAlN (Titanium Aluminum Nitride): Offers superior heat resistance, making it ideal for high-speed and high-temperature applications in tough materials.
• AlTiN (Aluminum Titanium Nitride): Best for machining hard alloys and high-temperature materials, providing enhanced wear resistance and longer tool life.

Toolholding Compatibility:

The Carbide Long Endmill is compatible with a variety of toolholders to ensure secure and stable cutting:

• ER Collet Holders: Suitable for light to medium-duty milling operations.
• End Mill Holders: Offer high rigidity for heavy-duty cutting, especially in long-overhang applications.
• Tool Extensions: For applications requiring additional reach, tool extensions can be used to maintain performance without sacrificing rigidity.

Conclusion:

The Carbide Long Endmill is a versatile, high-performance tool designed for deep cavity milling, precision cutting, and challenging material removal. Its solid carbide construction ensures excellent wear resistance, while the extended reach makes it ideal for machining deep pockets, slots, and features in parts with complex geometries. Whether you're working with soft metals, hard alloys, or composites, the Carbide Long Endmill provides exceptional performance, increased productivity, and longer tool life, making it a valuable tool for any machining operation.