Long Solid Carbide Endmill

Key Features:

• Material: Manufactured from premium solid carbide, providing superior hardness (up to 70 HRC), wear resistance, and thermal stability. Carbide end mills outperform high-speed steel (HSS) in demanding environments, especially when high cutting speeds and extended tool life are needed.
• Long Reach Design: The extended length of the tool makes it perfect for machining deep cavities, pockets, and internal features without needing multiple tool changes. This design improves overall workflow and reduces machining downtime.
• Flute Count: Available in 2, 3, or 4-flute configurations, allowing you to select the best option based on the material being cut:
  • 2-flute: Offers high chip clearance and is ideal for rapid material removal.
  • 3-flute: Provides a balance between speed and finish quality for general-purpose milling.
  • 4-flute: Best for achieving fine finishes and improving rigidity, particularly in finishing applications.
• Cutting Edge Geometry: Precision-engineered cutting edges are designed for smooth, stable cutting with reduced deflection, ensuring consistent performance in deep cuts and complex milling operations.
• Coating Options: Coatings like TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), and AlTiN (Aluminum Titanium Nitride) are available, providing enhanced wear resistance, reduced friction, and increased heat resistance, extending tool life and improving performance in high-temperature environments.
• Versatile Application: Suitable for a wide range of materials including aluminum, stainless steel, carbon steel, tool steels, composites, and plastics. Ideal for deep slotting, pocketing, profile milling, and drilling operations.

Applications:

• Deep Cavity and Pocket Milling: The long reach design is ideal for machining deep pockets, channels, and cavities in parts with complex geometries or hard-to-reach areas.
• Slotting and Grooving: Perfect for cutting deep or narrow slots and grooves, especially in high-precision applications where tool deflection must be minimized.
• Profile and Contour Milling: Used for creating complex shapes, contours, and profiles in parts with intricate designs.
• Precision Finishing: Offers excellent surface finishes with minimal burrs, making it ideal for precision finishing operations.
• Drilling and Holemaking: In some cases, can be used for drilling or holemaking in deep or confined areas, providing the necessary reach without the need for additional tools.
• Edge Milling and Chamfering: Great for creating clean, precise edges, chamfers, or deburring operations in parts.

Advantages:

1. Increased Reach with Stability:

   • Designed to handle deep cavity milling and other hard-to-reach applications, the long solid carbide end mill provides excellent reach without sacrificing cutting stability.
   • Tool deflection is minimized, ensuring precision and improving the quality of the finished part, even when working with long-overhang tools.

2. Superior Durability and Tool Life:

   • Solid carbide provides excellent wear resistance and allows for high-speed cutting in challenging materials. With proper cutting conditions, these tools offer an extended lifespan, reducing the need for frequent tool changes.
   • Coatings such as TiAlN and AlTiN increase heat resistance, allowing the tool to maintain sharpness in high-heat applications.

3. Optimal Cutting Performance:

   • Precision cutting edges provide smooth, stable cuts, ensuring high-quality finishes and reduced cutting forces, which are essential for long, deep cuts.
   • The geometry and flute design help manage chip removal efficiently, preventing clogging and overheating, which could damage the tool or workpiece.

4. Enhanced Surface Finish:

   • The 4-flute design improves rigidity, providing better control during finishing operations and helping to achieve a smoother surface finish.
   • Reduced vibration and chatter lead to a more precise and refined surface, even when machining deep cavities or complex profiles.

5. Versatility Across Materials:

   • The long carbide end mill is highly effective across a wide range of materials:
     • Aluminum: Great for high-speed machining with high material removal rates.
     • Stainless Steel & Tool Steels: Performs exceptionally well under challenging conditions with tough materials, providing extended tool life when combined with coatings like TiAlN or AlTiN.
     • Composites & Plastics: Ideal for machining non-metallic materials with excellent finish quality.

6. Increased Productivity:

   • The ability to perform deep and complex cuts without changing tools improves overall productivity and reduces downtime.
   • High cutting speeds and reduced cycle times are achievable, particularly in high-speed machining environments.

Technical Specifications:

• Tool Type: Solid Carbide Long End Mill
• Flute Count: 2, 3, or 4-flute configurations (based on the application)
• Diameter Range: Available in a range of diameters from 3mm to 20mm or more, depending on the specific application.
• Cutting Length: Varies depending on tool design, typically ranging from 30mm to 150mm or more.
• 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, precision finishing, chamfering, holemaking.

Recommended Cutting Parameters:

To ensure optimal performance and maximize the lifespan of the long solid carbide end mill, consider the following 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: 0.003 – 0.008 inch/tooth, depending on the 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, depths of 0.5x tool diameter (3mm) are recommended for best surface finish.
• Coolant: Use coolant or cutting fluid, especially when machining hard materials or operating at high cutting speeds, to reduce heat and improve chip evacuation.

Coating Options:

• TiN (Titanium Nitride): Provides a durable, smooth surface that enhances wear resistance and reduces friction for general-purpose machining.
• TiAlN (Titanium Aluminum Nitride): Ideal for high-speed cutting, providing superior heat resistance and wear protection, especially when machining hard materials like stainless steel and tool steels.
• AlTiN (Aluminum Titanium Nitride): Offers the highest resistance to heat and wear, making it suitable for high-performance, high-speed machining in tough materials.

Toolholding Compatibility:

The Long Solid Carbide End Mill can be paired with a variety of toolholders to ensure optimal clamping and precision during machining:

• ER Collet Holders: Ideal for small to medium-sized end mills, offering precise clamping for stability.
• End Mill Holders: Offer rigidity and stability, especially for larger tools or heavier-duty operations.
• Tool Extensions: For additional reach, tool extensions can be used without sacrificing tool performance.

Conclusion:

The Long Solid Carbide End Mill is an essential tool for machining deep cavities, pockets, and intricate parts that require precision and extended reach. Its solid carbide construction ensures durability and precision, even in demanding applications. Whether you're cutting hard metals, composites, or plastics, this end mill provides superior performance, reduced downtime, and exceptional tool life, making it a valuable asset in any machining environment.