Highly Productive Machining of Nickel Alloys

Ceramic tools retain their hardness at the high temperatures associated with milling heat-resistant super alloys (HRSAs). As a result, 20X to 30X the speed can be achieved in comparison to solid-carbide tools, delivering considerable potential for increased productivity. A stable set-up is advised without the use of coolant, as coolant would simply burn at this high temperature. With aerospace components manufactured from nickel-based alloys becoming increasingly prevalent, the demand for optimized cutting tools is growing. With this in mind, Sandvik Coromant US (Fair Lawn, NJ) developed two innovative series of ceramic end mills for optimized performance in nickel-based alloys that are ideal for the shoulder and face milling of nickel alloy aeroengine parts: The latest brazed ceramic CoroMill® 316 and ceramic CoroMill Plura end mills offer a more productive method for roughing in ISO S materials compared to standard carbide milling cutters.

“The ceramic substrate of these end mills allows for a different cutting process from traditional solid-carbide tools,” explained Tiziana Pro, the global product manager for solid end mills at Sandvik Coromant. “Our unique CC6060 grade is purposefully-designed for the superior machining of nickel alloys and is supported by negative geometry that provides a tough cutting edge.” The choice between these two end mills depends on machine conditions and the application. The six-flute geometry delivers highly productive side milling operations, while the four-flute geometry boosts face milling in both of these end mill versions. Those seeking systems for difficult-to-reach applications, or the extra flexibility of the exchangeable-head system, should opt for CoroMill 316, while those requiring superior stability are advised to select CoroMill Plura. Beyond shoulder milling and face milling, these end mills can also be used for pocket milling, helical interpolation, ramping and slot milling.

Both the CoroMill Plura and CoroMill 316 are part of the Optimized solutions series offered within the solid round tools range that also includes a ceramic ball-nose version of CoroMill 316 for blisk machining. This profile-milling system is suitable for semi-finishing operations.

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