Tru Cut End Mill

Key Features:

• Material: Made from high-quality solid carbide, the Tru Cut End Mill delivers exceptional wear resistance, hardness, and strength. Carbide’s superior properties allow for high cutting speeds, extended tool life, and consistent performance in demanding machining conditions.
• Flute Design: Designed with 2, 3, or 4-flute configurations to accommodate a variety of cutting needs:
  • 2-flute design: Provides faster material removal and excellent chip clearance, ideal for softer materials and higher feed rates.
  • 3-flute design: Offers a balance between chip removal, tool stability, and surface finish quality, making it suitable for general-purpose milling.
  • 4-flute design: Increases rigidity and provides superior surface finishes, perfect for finishing passes and working with harder materials.
• Coating Options: Available with advanced coatings such as TiN (Titanium Nitride), TiAlN (Titanium Aluminum Nitride), and AlTiN (Aluminum Titanium Nitride), which enhance tool life, reduce friction, and improve heat resistance. Coated tools reduce tool wear and provide better cutting efficiency, particularly in high-speed and high-heat applications.
• Precision Ground: The cutting edges are precisely ground to tight tolerances, ensuring consistent performance and minimal runout. This precision allows for better accuracy in milling operations, especially for tight-tolerance parts and fine finishes.
• Versatility: The Tru Cut End Mill is suitable for a wide range of materials, including mild steel, stainless steel, aluminum, titanium alloys, plastics, composites, and hardened steels, making it a versatile choice for various machining tasks.
• Available in Multiple Sizes: The Tru Cut End Mill is available in a range of diameters, from 1mm to 20mm or more, with different cutting lengths to suit various machining operations.

Applications:

The Tru Cut End Mill is ideal for a variety of machining tasks across multiple industries, including:

• General-Purpose Milling: Excellent for milling slots, pockets, and profiles, especially in medium to high-volume production runs.
• Precision Finishing: Ideal for finishing operations requiring fine surface finishes and tight tolerances, especially when used with a 4-flute design for added rigidity.
• High-Feed Milling: The 2-flute configuration is particularly suited for high-feed rate applications and roughing operations, where rapid material removal is necessary.
• Hardened Steel Milling: With coatings like TiAlN or AlTiN, the Tru Cut End Mill excels at machining tough materials like hardened steel (up to 50-55 HRC), providing high wear resistance and maintaining cutting performance under heat.
• Aluminum Milling: The Tru Cut End Mill performs excellently in high-speed machining of aluminum and non-ferrous materials, offering high material removal rates and clean cuts.
• Mold and Die Making: Ideal for mold making and other tooling applications requiring precision and durability, especially in tough steels and hardened alloys.
• Plastic and Composite Machining: Provides clean cuts and minimal burrs, making it suitable for plastic and composite machining applications in industries like automotive and electronics.

Advantages:

1. High Performance and Efficiency:

   • The Tru Cut End Mill is optimized for both roughing and finishing operations, providing versatility across a variety of machining tasks. It allows for faster feed rates and higher cutting speeds, which increases productivity and reduces cycle times.
   • The 2-flute design maximizes material removal rates, while the 4-flute design ensures superior finishes and stability during precision cutting.

2. Increased Tool Life:

   • The solid carbide construction provides outstanding durability and wear resistance, especially when cutting hard materials. Carbide’s ability to withstand higher temperatures and pressures extends the tool’s service life, reducing the need for frequent tool changes and minimizing downtime.
   • Coatings like TiAlN enhance tool longevity by providing superior heat resistance, which is essential for high-speed cutting and heavy-duty applications.

3. Superior Surface Finish:

   • The precision-ground edges and smooth cutting geometry result in excellent surface finishes, even on challenging materials. This makes the Tru Cut End Mill ideal for finishing passes where a high-quality surface is required.
   • The 4-flute configuration is particularly effective for reducing vibration, improving surface finishes, and minimizing chatter during fine machining operations.

4. Enhanced Chip Evacuation:

   • The flute geometry is designed for optimal chip clearance, helping to prevent chip clogging and reducing the chances of tool wear due to heat buildup.
   • The 2-flute design offers faster chip removal and is ideal for roughing operations, while the 3-flute and 4-flute designs strike the balance between chip clearance and tool stability for smoother cuts.

5. Versatile Application Range:

   • The Tru Cut End Mill can be used in a variety of materials, including metals like stainless steel, aluminum, and tool steels, as well as plastics and composites. This makes it an ideal tool for manufacturers in industries ranging from automotive to aerospace to mold making.

6. Reduced Vibration and Chatter:

   • The rigidity of the solid carbide material and the precision of the flute design minimize deflection and reduce vibrations during high-speed or deep cutting operations, ensuring more accurate and stable milling performance.

Technical Specifications:

• Tool Type: Solid Carbide End Mill
• Flute Count: 2, 3, or 4 flutes, depending on application
• Diameter Range: Typically available from 1mm to 20mm, with different cutting lengths (ranging from 3mm to 100mm or more)
• Cutting Length: Available in various cutting lengths to suit different applications (short and long cutting lengths)
• Coating Options: TiN, TiAlN, AlTiN, and other high-performance coatings
• Material: Premium Solid Carbide
• Application Types: General-purpose milling, finishing, roughing, high-feed milling, precision machining, mold making, plastic machining, aluminum machining, and hardened steel machining

Recommended Cutting Parameters:

To optimize tool life and performance, it’s recommended to use the following general cutting parameters:

• Cutting Speed (SFM):
  • Aluminum: 600-1200 SFM
  • Mild Steel (A36): 100-200 SFM
  • Stainless Steel (304): 80-150 SFM
  • Hardened Steel (45 HRC): 50-100 SFM
  • Plastics: 1000-3000 SFM (depending on type)
• Feed Rate: Generally, 0.005 – 0.02 inch/tooth, depending on material hardness and the tool’s flute count.
• Depth of Cut: For roughing operations, depths up to 1x tool diameter can be used; for finishing, a shallower depth of cut (0.1x to 0.2x tool diameter) is recommended for better surface finish.
• Coolant: Use coolant or cutting fluid to manage heat, improve chip removal, and extend tool life, particularly when cutting hard materials or running at high speeds.

Coating Options:

• TiN (Titanium Nitride): Offers good wear resistance and is suitable for general-purpose cutting and mild steel machining.
• TiAlN (Titanium Aluminum Nitride): Ideal for high-speed machining of tough materials such as stainless steels, tool steels, and high-temperature alloys.
• AlTiN (Aluminum Titanium Nitride): Best for machining hardened steels and high-temperature alloys, providing excellent heat resistance and wear protection.

Toolholding Compatibility:

The Tru Cut End Mill is compatible with a variety of toolholders:

• ER Collet Holders: Ensure precise clamping and minimal runout for high-accuracy applications.
• End Mill Holders: Offer rigidity and stability for heavier-duty cutting operations.
• Shrink Fit Holders: Provide excellent concentricity and rigidity, ideal for high-performance applications.

Conclusion:

The Tru Cut End Mill offers an exceptional balance of performance, durability, and versatility, making it ideal for a wide range of milling operations. Whether you are performing high-speed roughing, precision finishing, or cutting tough materials, the Tru Cut End Mill provides high-quality results with improved tool life and reduced cycle times. Its solid carbide construction, advanced coatings, and precise geometry ensure reliable performance, making it an essential tool for any machining task requiring superior cutting performance and precision.