Wolverhampton-based Tungaloy UK Ltd (www.tungaloy.com/uk) has expanded its TungForce-Feed line of indexable small-diameter high-feed milling cutters to include R2 inserts, which feature a corner radius of 2mm.

Available in diameters of 8, 10, 12 and 16mm, the TungForce-Feed line ensures high levels of productivity; it is also ‘an economic profiling solution for the mould and die industry when compared to conventional solid end mills and indexable tools of similar size’.

Tungaloy says that when designing a CAM program for the high-feed machining of complex 3-D profiles in typical mould-making applications, it is common to use a theoretical corner radius for programming the insert radius — a method that leaves excessive stock on the workpiece after machining, adding subsequent processes.

“To create the ideal platform for subsequent finishing processes, many job shops use solid-carbide square-end mills with large radii when rough machining.

"However, the new R2 inserts require no programming for the theoretical corner radius, as their 2mm corner radius leaves no uncut material on the machined surface.

"This ensures that the TungForce-Feed series makes a good replacement for costly solid-carbide end mills, helping manufacturers to reduce their tool costs.”

With an insert that is 10% thicker than most similar products, the TungForce-Feed line can accommodate higher machining parameters; furthermore, the robust insert screws and seat design reduce ‘screw neck shearing’ under high cutting forces.

The inserts also incorporate a positive inclination angle that provides smooth chip evacuation, further reducing the cutting forces by controlling chip formation — especially when shoulder milling and slot machining.

The new cutters have been designed with a small entry angle for chatter stability; this significantly improves efficiency and tool life, even when machining in long reach areas.

The TungForce-Feed line is available in two grades — AH3225 and AH8015.

AH3225 incorporates nano multi-layer coating technology designed to increase resistance to wear, fracture, oxidation, built-up edge and delamination.

Meanwhile, AH8015 has a hard coating layer and carbide substrate and can be used for machining hard or difficult materials.