Micro Solid Carbide Endmill

Key Features:

• Material: Made from premium solid carbide, known for its superior hardness and resistance to wear. Carbide tools outperform high-speed steel (HSS) in demanding conditions, allowing for faster cutting speeds and longer tool life.
• Micro-Diameter: Available in a variety of micro-diameters typically ranging from 0.2mm to 3mm, the Micro Solid Carbide Endmill is ideal for micro-machining applications where standard tools cannot achieve the necessary precision.
• Flute Count: Available in 2-flute, 3-flute, and 4-flute configurations, allowing you to select the best flute arrangement for your specific machining needs:
  • 2-flute design: Excellent for high material removal rates and chip clearance, making it ideal for softer materials.
  • 3-flute design: Provides a balance between cutting performance and tool stability, suitable for general-purpose milling operations.
  • 4-flute design: Increases rigidity and produces superior finishes, making it ideal for precision finishing operations in small workpieces.
• Cutting Edge Geometry: Precision-ground cutting edges with high rigidity for fine detail work. The geometry is optimized for high-speed cutting, smooth finishes, and minimal tool deflection, ensuring optimal performance in small-scale applications.
• Coating Options: Coatings such as TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), and AlTiN (Aluminum Titanium Nitride) are available, providing enhanced wear resistance, reduced friction, and better heat resistance in demanding applications.
• Versatility: The Micro Solid Carbide Endmill is capable of cutting a variety of materials, including aluminum, stainless steel, copper, plastics, composites, and hardened steels. This makes it a versatile tool for various industries, including medical, aerospace, automotive, and electronics.

Applications:

The Micro Solid Carbide Endmill is ideal for applications that require high precision and fine detail. Common uses include:

• Micro Milling and Micro Machining: Perfect for creating tiny features, such as micro-holes, small slots, pockets, and contours, in a variety of materials.
• Precision Machining: Ideal for parts requiring tight tolerances and intricate designs, especially in the medical, electronics, aerospace, and automotive industries.
• Medical Device Manufacturing: Used in the production of components for medical devices that require high precision and cleanliness, such as surgical instruments, implants, and micro parts.
• PCB and Semiconductor Milling: Perfect for milling small features in printed circuit boards (PCBs) and semiconductor materials, ensuring precision and quality in electronics manufacturing.
• Prototype Development and Mold Making: Suitable for creating prototypes and small parts with intricate shapes, including mold cavities, small gears, and other fine features.
• Engraving and Marking: The micro end mill can also be used for engraving small text or logos on a variety of materials, ensuring a clean, detailed result.

Advantages:

1. Unmatched Precision:

   • The Micro Solid Carbide Endmill is designed to handle extremely tight tolerances and produce highly detailed features, making it ideal for precision applications. The small diameter and precise cutting edges ensure fine finishes and reduced error rates in micro-machining operations.
   • Minimal tool deflection reduces vibration, enabling smoother cuts and more accurate results in small workpieces.

2. Enhanced Durability:

   • Solid carbide construction offers superior wear resistance, ensuring longer tool life even during high-speed machining operations. Carbide tools maintain their sharpness for longer periods, reducing the need for frequent tool changes and increasing productivity.
   • Coatings like TiAlN and AlTiN provide additional protection, improving the tool’s performance in high-temperature environments and prolonging tool life.

3. Superior Surface Finish:

   • The small, sharp cutting edges provide a smooth cutting action, which minimizes burrs and improves surface finish. This is especially important in applications where part quality is critical, such as in medical or electronics manufacturing.
   • The 4-flute design can produce exceptionally smooth finishes, especially when used for finishing passes on delicate features.

4. High-Speed Machining:

   • Designed for high-speed milling, the Micro Solid Carbide Endmill can achieve faster feed rates and higher cutting speeds without compromising on accuracy. This leads to shorter cycle times and improved productivity in small-scale and micro-machining operations.
   • Its ability to maintain high performance during high-speed cuts makes it suitable for both roughing and finishing operations, depending on the flute design chosen.

5. Versatility Across Materials:

   • The Micro Solid Carbide Endmill can be used with a variety of materials, from soft metals like aluminum and copper to harder materials like stainless steel, tool steels, and even hardened alloys.
   • Coatings like TiN, TiAlN, and AlTiN improve performance in specific materials and applications, allowing for better wear resistance, higher speeds, and better chip evacuation.

6. Compact and Cost-Effective:

   • Although the initial cost of carbide tools is typically higher than HSS, the long tool life and increased cutting efficiency of the Micro Solid Carbide Endmill make it a cost-effective solution for small-scale and high-precision machining jobs.
   • The tool’s longer lifespan reduces downtime for tool changes, which is particularly beneficial for industries where rapid prototyping and low-volume production are common.

Technical Specifications:

• Tool Type: Micro Solid Carbide Endmill
• Diameter Range: Typically available from 0.2mm to 3mm or more, depending on the specific application and tool design.
• Flute Count: Available in 2, 3, or 4 flutes, depending on the type of operation (roughing, finishing, etc.).
• Cutting Length: Varies from 3mm to 15mm, depending on the tool’s design and diameter.
• Coating Options: TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), AlTiN (Aluminum Titanium Nitride)
• Material: Solid Carbide
• Application Types: Micro milling, micro machining, engraving, PCB milling, medical device manufacturing, mold making, prototype development.

Recommended Cutting Parameters:

To achieve optimal performance and maximize tool life, consider these general cutting recommendations for the Micro Solid Carbide Endmill:

• 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
  • Plastics: 500-1500 SFM (depending on type)
• Feed Rate: Typically 0.001 – 0.005 inch/tooth, depending on material hardness and the cutting operation.
• Depth of Cut: For roughing, depths up to 0.5x tool diameter; for finishing, a shallower depth of cut is recommended (e.g., 0.2x tool diameter) to improve surface finish.
• Coolant: Use coolant or cutting fluid where possible to manage heat and improve chip removal, especially when working with metals like stainless steel or hardened steels.

Coating Options:

• TiN (Titanium Nitride): Ideal for general-purpose micro-machining, providing excellent wear resistance and smooth cutting.
• TiAlN (Titanium Aluminum Nitride): Offers superior heat resistance, making it ideal for high-speed cutting in tougher materials.
• AlTiN (Aluminum Titanium Nitride): Best for high-performance applications in heat-resistant alloys, providing longer tool life and better performance under extreme cutting conditions.

Toolholding Compatibility:

The Micro Solid Carbide Endmill can be used with various toolholders to ensure precision and stability during micro-machining:

• Collet Chucks: Ideal for precise clamping and minimizing runout in small-diameter tools.
• End Mill Holders: Offer high rigidity and are well-suited for both light and heavy-duty operations.
• Shrink Fit Toolholders: Provide excellent concentricity and rigidity, which is crucial for high-precision micro-machining.

Conclusion:

The Micro Solid Carbide Endmill is an essential tool for precision machining of small-scale features and intricate parts. Its solid carbide construction, combined with its fine cutting edges and versatile design, ensures high-speed, high-accuracy performance in a wide range of applications. Whether you are working with soft metals, hard alloys, plastics, or composite materials, this tool provides excellent surface finishes, long tool life, and reduced cycle times, making it the ideal choice for industries where fine detail and precision are paramount.