Long Solid Carbide End Mill

Key Features:

• Material: Manufactured from premium solid carbide, which is known for its exceptional hardness, wear resistance, and strength. Carbide material provides excellent performance even in high-speed and high-heat conditions, making it suitable for tough materials such as stainless steel, tool steels, and high-alloy materials.
• Long Reach: The extended length design allows for machining deep pockets, cavities, and intricate features without the need for multiple tools. This added reach is ideal for parts with complex geometries, long-overhang applications, or deep-hole drilling.
• Flute Count: Available in 2, 3, or 4-flute configurations, the flute count can be selected based on the specific application:
  • 2-flute design: Ideal for rapid material removal and high feed rates in softer materials.
  • 3-flute design: Balances cutting speed and stability, suitable for general-purpose machining.
  • 4-flute design: Provides superior finish quality and improved rigidity, making it ideal for finishing and precision work.
• Coating Options: Coating options like TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), and AlTiN (Aluminum Titanium Nitride) are available, which provide additional wear resistance, reduced friction, and enhanced heat tolerance.
• Cutting Edge Geometry: Precision-engineered cutting edges are designed for smooth, stable cutting and reduced vibration, ensuring accurate cuts even at longer tool lengths. This geometry helps improve tool life and surface finish, reducing the chances of tool deflection.

Applications:

The Long Solid Carbide End Mill is designed for a variety of challenging milling applications, including:

• Deep Cavity Milling: Perfect for creating deep cavities or pockets where extended reach is needed.
• Slotting and Grooving: Ideal for cutting long, narrow slots or grooves, especially in deep or hard-to-reach areas.
• Profile and Contour Milling: Suitable for profiling, contouring, and creating complex shapes or forms in parts with intricate geometries.
• Precision Finishing: Excellent for finishing operations that require tight tolerances and smooth, burr-free surfaces.
• Drilling and Holemaking: In some cases, can be used for shallow drilling or holemaking, particularly in hard-to-reach locations.
• Toolpath Extensions: Suitable for extending tool paths when the part geometry is deeper or the workpiece setup requires more reach.

Advantages:

1. Enhanced Tool Reach:

   • The long design allows for deep cavity milling without the need for multiple tools, reducing setup time and increasing efficiency.
   • Perfect for high-reach applications, such as cutting deep pockets, long slots, or intricate features where other tools may not fit.

2. Superior Durability and Wear Resistance:

   • Solid carbide construction offers exceptional hardness, enabling it to withstand the heat and wear typically encountered in high-speed and high-precision machining.
   • Carbide's durability allows it to maintain sharp cutting edges for longer periods, reducing downtime for tool changes and improving overall productivity.

3. Improved Cutting Stability:

   • Designed to reduce tool deflection during milling operations, the long carbide end mill ensures a more stable cutting action, which leads to better precision and surface finishes, even when machining deep or challenging features.
   • The geometry of the end mill helps maintain cutting efficiency with reduced chatter, vibration, and wobble, which are common issues with extended tools.

4. Versatility in Material Machining:

   • The long carbide end mill can be used to machine a variety of materials, including aluminum, stainless steel, tool steels, composites, and plastics.
   • Coatings like TiAlN and AlTiN can significantly improve tool performance in hard-to-machine materials, such as high-temperature alloys and hardened steels.

5. High Precision and Quality Finish:

   • The tool is capable of achieving high-quality surface finishes and tight tolerances, making it ideal for both roughing and finishing operations.
   • The 4-flute design offers better rigidity and a smoother finish, reducing the need for additional finishing processes.

6. Improved Efficiency:

   • Longer tool reach eliminates the need for multiple tool changes during deep cuts, enhancing process efficiency and reducing machining time.
   • Reduces the need for additional tool extensions or adapters, which can introduce flex and reduce cutting accuracy.

Technical Specifications:

• Tool Type: Solid Carbide Long End Mill
• Flute Count: 2, 3, or 4 flutes (customizable based on the application)
• Diameter Range: Available in a variety of diameters, typically from 3mm to 20mm or more.
• Cutting Length: Varies depending on the specific tool (typically ranges from 30mm to 150mm).
• Coating Options: TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), AlTiN (Aluminum Titanium Nitride)
• Material: High-performance solid carbide
• Application Types: Deep cavity milling, slotting, profile milling, precision finishing, pocketing, holemaking.

Recommended Cutting Parameters:

To ensure optimal performance and longevity of the Long Solid Carbide End Mill, it’s important to follow proper cutting parameters:

• 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: 0.003 – 0.010 inch/tooth, depending on material 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, shallower depths of 0.5x tool diameter are preferred to achieve smooth finishes.
• Coolant: Using coolant or cutting fluid is recommended, especially when machining harder materials or operating at high cutting speeds to manage heat and improve tool life.

Coating Options:

• TiN (Titanium Nitride): Offers basic wear resistance and increased tool hardness for general-purpose milling, especially on softer materials like aluminum and brass.
• TiAlN (Titanium Aluminum Nitride): Ideal for high-temperature machining of stainless steel, tool steels, and other tough materials. Offers excellent wear and heat resistance.
• AlTiN (Aluminum Titanium Nitride): Provides superior heat resistance and is particularly effective for high-speed machining of hard alloys, high-temperature materials, and dry cutting conditions.

Toolholding Compatibility:

The Long Solid Carbide End Mill is compatible with various toolholders, including:

• ER Collet Holders: Provide precision and excellent clamping for small-to-medium size end mills.
• End Mill Holders: Excellent for heavy-duty operations, offering higher rigidity and stability during milling.
• Tool Extensions: If additional reach is required, the tool can be paired with extensions or adapters that minimize tool flex.

Conclusion:

The Long Solid Carbide End Mill is an essential tool for machining deep or complex features in a variety of materials. Its extended reach, combined with superior carbide performance and cutting precision, makes it ideal for a wide range of demanding milling applications, including deep cavity milling, slotting, and precision finishing. With the ability to achieve high material removal rates and smooth surface finishes, this end mill offers exceptional productivity and tool life, ensuring maximum efficiency for high-precision, high-performance machining tasks.