The new HFC 19 indexable-insert milling system from Sheffield-based Ceratizit WNT Ltd (www.wnt.com) targets high-chip-volume applications that demand ‘elevated process security’.

According to the company, milling cycle times can be reduced by as much as 57%, thanks to a combination of the insert geometry, WNT’s Dragonskin coating and the design of the cutter body.

Furthermore, the inserts have a patented rectangular edge geometry and a large corner radius that provide rigidity and soft cutting, reducing stress on the machine spindle.

A further benefit is that the cutting forces are in the axial direction, which helps to minimise noise levels.

Greater depths of cut (up to 3.3mm) and feed per tooth can be achieved, says WNT.

By way of example, a recent trial involved the machining of Ti6Al4V titanium alloy components.

Here, a 63mm-diameter WNT HFC 19 cutter could be run at 0.71mm feed per tooth, compared with 0.25mm for a competitor cutter, achieving a cycle time of 52min instead of 120min.

Tool life was also increased significantly, with one set of cutting edges machining three components, compared to just one component using the competitor cutter.

HFC 19 cutters allow machine shops to plunge mill, face mill and circular/free-form mill, as well as undertake intermittent cutting — all with the same tool and inserts.

Customers have a choice of insert geometry, with F40 positive geometry being suitable for the finish- and rough-machining of heat-resistant materials such as titanium and super-alloys, while M50 is WNT’s universal geometry for the light to medium roughing of steel components.