Casting Light on First-Stage Aluminum Machining

In order to boost the first-stage roughing operation on newly-cast aluminum parts for the automotive industry, the M5Q90 tangential milling cutter from Sandvik Coromant US (Fair Lawn, NJ) is designed to complete ‘cubing’ (first machining of faces after casting) in a single operation without creating burrs. This tool is fitted with PCD tangential inserts that provide a smooth and stable cutting action to lower power consumption and eliminate vibration. This concept ensures reliable performance, improved tool life, exceptional surface finish, high metal removal rate and an increased number of parts per insert. “To enhance efficiency, this tangential milling cutter features fully-engineered cutter bodies matched with dedicated PCD insert geometries that use a positive cutting angle to reduce cutting force and load on the machined component,” explained Emmanuel David, the global automotive product manager at Sandvik Coromant. “The inserts are easy to handle and adjust, and offer reduced cost per part along with high accuracy and repeatability,” added Jacques Gasthuys, a global automotive application engineer.

Aluminum cylinder heads and engine blocks are among the principal components to benefit, typically in automotive foundries or Tier 1/Tier 2 suppliers. By way of example, the cubing operation on a cast cylinder head involves machining the camshaft face, inlet/outlet face and combustion face. Typical cutting data using M5Q90 might include a speed of 2,500 m/min (8,202 fpm) and feed per teeth of 0.20 mm (0.008 in). Users also benefit from high precision coolant channels that provide the option for either emulsion or MQL application. Capable of both face and shoulder milling, the M5Q90 is also suitable for many applications in the general engineering and aerospace sectors. It complements the patent-pending M5F90 face-milling cutter designed for machining thin-walled aluminum automotive parts without burring, scratching or chipping. The two-in-one M5F90 cutter features an innovative design concept that allows roughing and finishing in a single operation, delivering shorter and more efficient machining strategies.

The M5F90 cutter body diameter (25 mm to 80 mm/ 0.98 in to 3.15 in) carries brazed PCD inserts that, thanks to the application of new production processes, need no adjustment and enable high feed rates without vibration. As a result, the potential time and cost savings available to users are considerable. No scratches, burrs or breakages are produced on the machined part due to a combination of cutting angles, insert shape, edge preparation and cutting parameters. Notably, roughing and finishing operations are facilitated by a single tool, saving on inventory costs. In terms of roughing, the tool works as a conventional cutter with all rough-cutting edges positioned on the same diameter and height. The M5F90 is able to machine up to a 4 mm (0.157 in) depth of cut. With regards to finishing, this portion of the tool consists of radial and axial stepped cutting edges. Such a configuration ensures burr-free milling and outstanding surface finish on thin-walled aluminum parts while enabling a close pitch in order to avoid cutting vibration.

“The inherent flexibility of being able to rough and finish mill makes it possible to machine different positions on the same part with just one cutter,” noted David. “Moreover, the reliable and secure performance of the M5F90 delivers superior tool life in comparison to a milling cutter featuring a conventional body. The tool is also environmentally friendly due to its low coolant consumption,” stated Philippe Andre, a global automotive application engineer. Although dedicated to thin-wall milling operations on aluminum parts such as gearbox casings and housings, the M5F90 is also able to machine large engagement material for applications across the automotive segment.

Sandvik Coromant US, 1702 Nevins Road, Fair Lawn, NJ 07410-0428, 201-794-5000, Fax: 1-201-794-5157, www.sandvik.coromant.com.