You should put some images in here with certifications like the Better Business Bureau or any awards General Cutting Tools has. August 12, 2010
Finish Face Mills by Ingersoll
Ingersoll announces its latest line of “Tangential Tooling” in the form of finish face mills now shipping to Chicago, Illinois, Indiana, Iowa, Michigan, Wisconsin, Minnesota and the rest of the US. These S-MAX Finish Face Mills are designed to do finish cuts only and many times can eliminate subsequent grinding operations. The surface should be pre-machined with another face mill before using the S-MAX Finishing Face Mill. This assures the Depth of Cut (DOC) is consistent and controlled. Surface finishes below 32 
microinches are easily obtained. Finishes into the single digits are obtainable also if extra care is taken. The feature that allows us to achieve this finish is the precision elliptical grind on the rake face of the insert. Inserts and cutters are manufactured to a very tight tolerance thickness to drastically reduce face run out. Inserts are available exclusively from Ingersoll. These finish mills are similar to our older line 7F2K tools, however they incorporate the new S-MAX technology to make the most of your machines.
ADVANTAGES:
This cutter is able to eliminate the need for grinding operations in many cases. Surface finishes of 32 microinches or less are very achievable. The insert has a parallelogram as compared to the former rectangular design. This allows closer cutting to a shoulder when this type of feature exists on the work piece. It is also more positive radially to make the cut more cleanly than before. The highest point of the insert is at the center of the insert. The drop from the highest point of the insert to the lower point on the face of the insert is .0003 inches on both the large and small insert. This acts like an extremely shallow lead angle and allows you to take up to .080 advances per tooth per revolution. The chip load you finally achieve is ultimately a function on what you are trying to achieve for surface finish and flatness. The OVERALL DIAMETER is .49″ larger on the YXM324 inserts and .70″ larger on the YXM434 inserts when compared to the effective finishing diameter. This difference is smaller than the older 7F2K series tools.
Surface finish is measured in many ways, either by comparison “scratch pad” specimen standards for rougher finishes, or by profilometers used to measure finely machined surfaces. Surface finishes can be described in terms of Ra, Rq and others, but these are simply different methods used to measure the deviation of the actual surface from the nominal surface. The deviation can be measured in terms of microinches or micrometers. It is important to know which one you are using. Microinches are one millionth of an inch (.000 001 inch) and micrometers are one millionth of a meter (.000 001 meter). Another term for micrometers is microns. One microinch = .0254 micrometer. Profilometers do not measure flatness, they simply look for surface irregularities as compared to the nominal surface. Flatness can be measured with a CMM or a dial indicator once a plane of reference is established.
CARBIDE INSERTS:
There are TWO different sizes of STOCK carbide inserts used in the Ingersoll S-MAX Finish Face Mills.
The larger insert is the YXM434 size which is 18mm (.708″) long, fitting into the SF6N series.
The smaller insert is the YXM324 size which is 10.50 mm (.400″) long, fitting into the SN6H series.
IN1505: Alloyed, Low and Med Carbon, and Tool Steels, Titanium, Hi-Temp Nickel Alloys, Stainless Steels, Aluminum
IN1540: Alloyed, Low and Med Carbon, and Tool Steels, Stainless Steels
IN1510: Gray Cast, Ductile and Nodular Irons, Aluminum
CUTTER BODIES & HARDWARE:
There are no pins in this design, or other hardware items to be concerned with, other than the insert screws. There are two different types of screws used in the face mills. The smaller YXM324 insert uses SM40-120-20 (DS-T20T) screws and a T15 Torx bit driver Tx-15 (DS-T15T). These screws should be tightened to 30-35 inch pounds. The larger YXM434 insert uses SM50-160-10 (SE03-70) screws and a T20 Torx bit driver Tx-20 (DS-0034). Screws should be tightened to 35-40 inch pounds.
OPERATING GUIDELINES:
For this group of cutters, the speed can be higher than you are accustom to for a given material. Generally, a higher speed will yield a shinier, more reflective finish. A slower speed will give a more brushed finish. Although you may be able to accomplish single digit micro-inch finishes with a fully loaded cutter, if an extremely good finish is required, one option you could try is to fly cut. This method uses only one insert in the cutter and thus reduces runout to zero. Also, if there are issues with steps between passes at the same Z depth, a fly cut will reduce the pressures to a minimum. This problem may be more noticeable when the material is softer, and is a function of a machine tool which may be deflecting more than it should. Lighter feed rates generally leave better finishes, but not loading up the cutter properly will create drag and rubbing as opposed to clean cutting. If there is a difference between the larger and smaller inserts, the larger one could a get better finish because it thins the chip over a longer distance, but may result in higher axial pressure.
Coolant may help you get a better finish by providing lubricity to the operation. It is not necessarily recommended in terms of tool life gains, however in trying to gain improved surface finishes, you may find a situation where it gains you just enough improvement to keep this cutter on the spindle.
The following guidelines are correct, but updated from those on page M493 in the Super Catalog. The original guidelines were printed incorrectly.
MAINTENANCE:
Maintenance is very similar to any indexable milling cutter. Cleanliness is essential to proper function and seating of the insert in the cutter pocket. Wiping, brushing, or compressed air blasts are all proven methods of cleaning the inserts and cutter pockets. Indexing a cutter in a well lit area also helps identify any foreign materials which might interfere with the fit between the insert and the cutter. Using a .001” feeler shim stock between the seating surfaces of the carbide and steel body, help to reassure the user of a properly seated insert.
Insert screws should be replaced periodically. The exact timing depends on what type of cutting is done and how well the screws are consistently torqued during insert indexing. If the countersink under the heads looks worn and smeared, and the screw seems to have less holding power than a new screw, it should be replaced.
LITERATURE:
SMAX Finishing Face mills are listed in the SuperCatalog on page M260 and M261.
The catalog pages in this announcement are updated with correct information and supercede the data in the SuperCatalog.
General Cutting Tools is an authorized Ingersoll Cutting Tools distributor.
For more information about these products or any others in the Ingersoll product line, call 847-677-8770.
June 23, 2010
Ingersoll Evolution of Technology
The EVOlution of TEChnology!
Ingersoll announces Evo-Tec, the next generation in their MAXline family! A dynamic combination of strength and stability lift chip control to a new level. Longer tool life results from a larger insert seating surface plus a stronger cutting edge.
The multi-purpose insert works well in all materials, its primary land, dramatically improving cutting edge strength. 4-edged inserts offe
r an economical advantage over the 2-edged competition and a DOC capability of up to .420″. Available corner radii are .031″, .062″, .093″, & .125″r. Cutter diameters range from 1.250″ thru 4.00″ and coolant/air through the tool is available. Medium and High Density versions are also available.
General Cutting Tools is an authorized distributor for Ingersoll Cutting tools in Chicago.
We carry a full line of tools to choose from. Contact us for more information or for a quote.
(847) 677-8770 or info@generalcuttingtools.com
June 21, 2010
Ingersoll High Feed Cutters
S-Max Strength – High-Feed Productivity!
In the SP6H/SP6N S-Max face mills, high-feed is made possible by an aggressive 80° lead angle for an extreme (5x) chip thinning factor.S-Max High-Feed also features ramping capability.
Inserts, which feature 4 cutting edges with a DOC of up to .072”, are available in Multi-Purpose geometry or a High-Shear geometry for Titanium/Hi Temp alloys. Diameters range from 2.00” thru 8.00”. Medium and High Density cutters are available. Coolant/Air-through is featured on some styles.
General Cutting Tools is your source for Ingersoll Cutting Tools products. We have been in business for over 30 years and have the experience to help you.
Contact us today.
(847) 677-8770 or info@generalcuttingtools.com
April 28, 2010
Ingersoll Cutting Tools Ball Nose Chip Thinning
We at Cutting Tools Chicago aka General Cutting Tools along with Ingersoll Cutting Tools are going beyond the basics of finish milling to help you Increase feed rates by understanding and applying ball nose chip thinning factors.
Axial Chip Thickness
In this example, the SFM is 500 at a 2.000" diameter. The effective cutting diameter is .968", at which point, the SFM is 242. The RPM must be increased to 1973 in order to achieve 500 SFM at the .968" effective cutting diameter.
Effective Diameter: When applying ball nose end mills, quite often the full diameter of the cutter is not engaged in the work. Since ball nose end mills cut to center, the speed in SFM is reduced to 0 as the centerline of the cutter is reached (see Fig.1).
To determine the Axial Chip Thinning Factor (ACTF), first determine the effective cutting diameter.
As the DOC varies, so does the effective cutting diameter. Since SFM calculations are based on the diameter of the cutter engaged in the cut, they must be made at the effective cutting diameter, not the nominal diameter of the tool.
The effective cutting diameter can be found in Chart A on pages M466-M467 by using the nominal tool diameter at the top and the DOC on the side. The SFM is calculated using the resulting effective cutting diameter at DOC.
In order to achieve the best productivity possible, be sure to consider the effective cutting diameter when setting RPM for a profiling ball nose application.
Chip Thickness
Due to the spherical form presented to the workpiece, axial chip thinning can affect chip thickness the same way as a lead angle on a face mill. This can have an adverse effect on the performance of a ball nose end mill. The ACTF must be applied when calculating the desired chip thickness and resulting feed rate.
The ACTF is determined by the radius of the ball nose at a given DOC. Figure 2 illustrates the concept of axial chip thinning. Notice as the axial DOC increases, so does the axial chip thickness.
Whenever the axial DOC is equal to or greater than the radius of the ball nose, the ACTF is equal to 1.
Next, determine the RCTF by the chart on pages M466-M467 or the formula. As Figure 3 shows, the RCTF is determined by the radius of the cutter at a given radial DOC. When determining the RCTF, use the effective diameter of the ball nose rather than the cutter diameter. Radial DOC is the same as the radial “step over.” The formula used to calculate axial chip thinning is the same as that used for radial chip thinning.
Ultimately, the purpose of determining the chip thinning factor is to optimize the feed rate. To calculate the proper feed rate, first multiply the ACTF by the RCTF.
This result is the Feed Correction Factor (FCF):
FCF = RCTF x ACTF
Divide the desired chip thickness by the FCF. This result is the desired APT to maintain proper chip thickness:
APT = CT/FCF
Finally, to arrive at the feed rate in Inches Per Minute (IPM), multiply the APT by the number of effective flutes and the RPM:
IPM = RPM x (No. of Flutes)
Overall performance would also improve since the cutter would be taking a true “bite” at the new feed rate. At the lower feed rate, the carbide may rub rather than cut.
Example
Figure 1 shows a 2.000″ diameter ball nose end mill running at .125″ DOC and a .125″ radial DOC (step over). the effective diameter at this DOC is .968″. If the desired SFM is 500, the RPM would normally be set at 955 RPM for a 2.000″ diameter cutter. However, since the effective diameter is .968″, the RPM should be set at 1973 to achieve 500 SFM. This is an increase of more than 100 percent.
The DOC also affects the feed rate due to axial chip thinning. At .125″ DOC, a 2.000″ diameter has a chip thinning factor of .48. If the desired chip thickness is .010″, the feed rate will need to be increased more than 100 percent. Without chip thinning, the feed rate would be set at 19.7 IPM (1973 x .010″). However, at this DOC, the ACT would be only .0048″ (.010 x .48). To achieve the proper chip thickness (APT or ACT), divide the desired chip thickness by the chip thinning factor.
.010″/.48 = .021″ APT
The feed rate would be:
1973 RPM x .021 = 41.4 IPM
In the same manner, the radial DOC (step over) has the same effect on feed rate. The radial DOC on a ball nose end mill is the same as the radial WOC on an end mill or face mill. In this example, the radial DOC of .125″ has an RCTF of .67.
To achieve the desired chip thickness of .010″, multiply the ACTF by the RCTF resulting in the FCF.
.48 ACTF x .67 RCTF = .32 FCF
The APT is:
.010″/.32 = .021″ APT
Productivity in this example is three times greater by using the correct chip thinning factors. On a single flute, one effective tool using this example, the feed rate should be set at:
1973 RPM x .031″ APT = 61.3 IPM
At this feed rate, productivity is increased over 200 percent by using the proper chip thinning factors.
Ingersoll Cutting Tool Company provides speed and feed selectors which are designed to help obtain optimum speed, feed, and ACT multipliers. Ask your Ingersoll sales engineer for a complimentary selector.
Effective Diameter and Axial Chip Thinning Factor
Axial DOC will affect the effective cutting diameter and, consequently, the ACTF. Note that as the axial DOC increases, the effective diameter and ACTF also increase. A lower DOC results in a smaller effective diameter and, therefore, a lower ACTF; i.e., the spindle RPM and feed rate need to be increased to maintain a proper surface speed and chip load.
Cusp Height
Step over, or radial DOC, affects the cusp height. Cusp height is the theoretical surface finish produced by successive tool paths made by a radius tool. Larger step over or a smaller cutter diameter produces a larger cusp height; i.e. a rougher finish.
For the best surface finish, use the largest diameter tool possible at the lowest practical radial DOC.
General Cutting Tools is an authorized distributor for Ingersoll Cutting Tools.
We serve Illinois, Indiana, Michigan, Minnesota, Wisconsin, Iowa and ship to the entire US. Contact us to find out how General Cutting Tools can give you big cost savings.
(847) 677-8770 info@generalcuttingtools.com
April 27, 2010
Ingersoll Cutting Tools Radial Chip Thinning
We at Cutting Tools Chicago aka General Cutting Tools along with Ingersoll Cutting Tools are going beyond the basics of finish milling to help you Increase feed rates by understanding and applying radial chip thinning factors.
Radial Chip Thickness
Limitations on a cutting tool’s performance are generally established in terms of maximum chip load. Since commonly used speed and feed calculators show only Advance Per Tooth (APT), chip load and APT tend to be used interchangeably. This is an area of misunderstanding which can be significant. Chip load actually refers to chip thickness, not APT.
APT is defined as the increment of feed that takes place in the time necessary for the cutter to rotate the distance between cutting edges.
The chip thickness is the “bite” taken by each cutting edge as it performs its work. For a typical end mill in a radial Depth Of Cut (DOC) exceeding two-thirds the diameter of the cutter, the chip thickness increases until it equals the APT at the centerline of the cutter. The chip thickness then decreases to nothing as the cutting edge exits the cut (Figure 1).
Thus, APT is a constant for a given operation and the chip thickness is variable, changing cyclically.
Peripheral cutting
When end mill cuts are shallow in relation to the cutter diameter, the Actual Chip Thickness (ACT) is less than the APT. This chip thinning effect allows much higher feed rates (Figure 2).
For example, assume the following parameters:
2.000″ diameter end mill
Two-effective
500 Surface Feet per Minute (SFM)
.12″ radial Width Of Cut (WOC)
.005″ chip thickness
955 effective RPM
Even though the APT in this case is .0105″, the ACT (or chip load) is only .005″.
A two-effective, 2.000″ diameter end mill had an APT of .0105″ and a chip thickness of only .005″. The Radial Chip Thinning Factor (RCTF) is the ratio of chip thickness to APT or, in this example, .48.
Whenever the radial DOC is equal to or greater than the effective cutter radius, the RCTF is equal to 1.
To find the Radial Chip Thinning Factor for a slabbing cut:
- Find the Depth of Cut on the horizontal scale.
- Locate the nominal diameter of the cutter on the vertical axis.
- Cross-reference the two figures.
- Locate the diagonal line closest to the intersection of the vertical and horizontal axes. The value of this diagonal is the Radial Chip Thinning Factor for your specific application.
The RCTF can also be found with the help of the graph in Figure 3.
A thorough understanding of the relationship between APT and chip thickness enables the tool engineer to establish optimum feed rates for a cutting tool. After determining the RCTF, the maximum permissible chip load is divided by the RCTF to arrive at the optimum APT.
Again, referring to the example, the chip load of .005″ is divided by the RCTF of .48 to arrive at the optimum APT of .0105″. This APT should be used in calculating the feed rate, in this case, 20.1 IPM.
In addition to increasing productivity, applying the RCTF can improve a cutter’s performance. At the higher feed rate, the insert will be taking a true bite. At lower feed rates without applying the RCTF, the insert may rub instead of cut and produce chatter, building heat and compromising tool life.
General Cutting Tools is an authorized distributor for Ingersoll Cutting Tools.
We serve Illinois, Indiana, Michigan, Minnesota, Wisconsin, Iowa and ship to the entire US. Contact us to find out how General Cutting Tools can give you big cost savings.
(847) 677-8770 info@generalcuttingtools.com
April 16, 2010
Ingersoll Cutting Tools Rigidity Analysis – #4
We at Cutting Tools Chicago aka General Cutting Tools along with Ingersoll Cutting Tools are going beyond the basics of finish milling to help you maximize the rigidity of your setup. Maximizing rididity will improve your end mill performance.
HSK Adaption
The HSK tool holder is designed to provide simultaneous fit on both the spindle face and the spindle taper.
At high speeds, centrifugal force causes the spindle to grow slightly. The face contact prevents the tool from moving up the bore. The hollow shank design is also susceptible to centrifugal force but is designed to grow with the spindle bore at very high speeds. I.D. clamping actually tightens its grip as spindle speed increases.
Supporting the cutting tool and holder in both the axial and radial planes creates a significantly more rigid connection between the tool and spindle.
Moreover, HSK end mill holders are available in a variety of clamping styles including shrink fit for solid carbide shanks; hydraulic for steel shanks, collet, and Weldon styles. Choose the most rigid and accurate assembly possible.
Other HSK advantages include lighter weight, lower deflection under load, extremely accurate repeatability, increased torque transfer capabilities, and significantly improved dynamic runout over 50-taper adaptations at high speeds.
General Cutting Tools is an authorized distributor for Ingersoll Cutting Tools.
We serve Illinois, Indiana, Michigan, Minnesota, Wisconsin, Iowa and ship to the entire US. Contact us to find out how General Cutting Tools can give you big cost savings.
(847) 677-8770 info@generalcuttingtools.com
April 15, 2010
Ingersoll Cutting Tools Rigidity Analysis – #3
We at Cutting Tools Chicago aka General Cutting Tools along with Ingersoll Cutting Tools are going beyond the basics of finish milling to help you maximize the rigidity of your setup. Maximizing rigidity will improve your end mill performance.
Tool Adaption
Rotary Tool Holder: Most end mills are run in rotary tool holders which connect the tool to the spindle. Ironically, due to the added length and extra joint, this is the least rigid of all end mill adaptations. To maximize rigidity with this adaption, an end mill with the largest diameter shank and the shortest adapter possible should be used.
Integral Shank: An improvement over the straight shank adaption is an integral shank. This eliminates the joints required with rotary tool holders and greatly improves length-to-diameter ratios. Many standard Ingersoll end mills are available with No. 50 taper adapters. Other tapers are available upon request.
No. 50 tapers have a standard .125″ gap between the flange and spindle face. To eliminate the gap, many Ingersoll machines have a simultaneous fit adapter designed to be used in conjunction with a precision spindle face. Because the adapter flange has bearing on the spindle face, the joint is more rigid.
Flat Back Drive: Another way to eliminate the .125″ gap is to use a flat back drive system. It consists of a centering plug with a pilot diameter on the spindle. The end mill is bolted directly to the spindle face. This adaption is often used for large, heavy-duty end mill operations requiring maximum rigidity.
General Cutting Tools is an authorized distributor for Ingersoll Cutting Tools.
We serve Illinois, Indiana, Michigan, Minnesota, Wisconsin, Iowa and ship to the entire US. Contact us to find out how General Cutting Tools can give you big cost savings.
(847) 677-8770 info@generalcuttingtools.com
April 14, 2010
Ingersoll Cutting Tools Rigidity Analysis – #2
We at Cutting Tools Chicago aka General Cutting Tools along with Ingersoll Cutting Tools are going beyond the basics of finish milling to help you maximize the rigidity of your setup. Maximizing rididity will improve your end mill performance.
Deflection
Deflection is produced by the cutting force on the tool. The tool’s length-to-diameter ratio determines the degree of effect cutting force has on the tool.
Deflection is directly proportional to L3 (length to the third power) and inversely proportional to D4 (diameter to the fourth power). In other words, deflection is radically reduced as diameter is increased and/or length is reduced.
Ingersoll has designed computer software to perform the many calculations required to determine the amount of deflection on the tool. Using Ingersoll’s “Rigidity Analysis” software, deflection for the following example can easily be determined:
Cutter: 2.000″ diameter, 4.00″ flute length,
No. 50 V-Flange adaption
Material: Low carbon steel
Speed: 400 SFM
Radial DOC: 1.00″
Axial DOC: 2.00″
Feed 12 IPM (.008 IPT)
The calculated theoretical deflection is .007″.
Deflection of .001″ or less is recommended for end milling operations. This example exceeds the desired maximum deflection of .001″. A cutter running under these conditions is likely to chatter, produce a poor surface finish, and exhibit reduced tool life.
The same example was recalculated after reducing the flute length from 4.00″ to 3.00″. Without making any other changes, the rigidity of the end mill improved dramatically. The theoretical deflection was reduced to .0009″.
By reducing the overall length-to-diameter ratio by 25 percent, deflection was reduced to less than half of the original example.
Many operational variables require additional rigidity. Among these are brittle cutting edge materials and any factor causing an increase in cutting forces such as negative cutting angles or tougher work piece materials.
General Cutting Tools is an authorized distributor for Ingersoll Cutting Tools.
We serve Illinois, Indiana, Michigan, Minnesota, Wisconsin, Iowa and ship to the entire US. Contact us to find out how General Cutting Tools can give you big cost savings.
(847) 677-8770 info@generalcuttingtools.com
April 13, 2010
April 12, 2010
Ingersoll Cutting Tools Better Surface Finishes – #4
We at Cutting Tools Chicago aka General Cutting Tools along with Ingersoll Cutting Tools are going beyond the basics of finish milling to help you attain better surface finishes.
Other Recommendations
Climb milling is generally best for finish milling because the cutter takes the thick part of the chip when it enters the cut. In conventional milling, the chip thickness starts at zero, causing rubbing or burnishing before the chip can reach its full thickness. 
Pressure and heat build up at the finished surface. The thin section will then weld to the cutting edge and be carried around to scratch the surface.
Avoid cutting with the full diameter of the tool. This also results in zero chip thickness at the point of cutting edge entry just as in conventional milling. Two-thirds of the tool diameter is best when finish milling. It is also important to cut in the same direction when consecutive passes are required.
Finish milling depths are usually light (.003″-.010″). Greater Advance Per Tooth (APT) can be used, sometimes as high as .125″. Finish milling cutters should be less dense than rough or semi-finish cutters, although high-density cutters may be required for some high production cast iron applications.