Optimised milling cycles — in particular for five-axis applications — can be undertaken using the MSX multi-function high-shear milling-cutter range from Sumitomo Electric Hardmetal Ltd, Princes Risborough (www.sumitomo-hardmetal.co.uk). Referred to by the tooling company’s development team as ‘Metal Slash Mills’, these cutters combine vibration-free cutting with high durability — especially when used at high feed rates.

Sumitomo says that five-axis machining is all about productivity and high utilisation, especially when profiling, ramping, helical milling and boring, “so accuracy and surface finish are improved by reducing vibration, plus there is the added bonus of longer tool life and higher levels of machine reliability”.

The MSX cutter range uses an alloy-steel body with a hardened surface; and to ensure that a stable and secure cutting condition is maintained, a double clamping arrangement to retain the insert has been developed. Furthermore, by creating a wide gullet in the body of the holder, chip evacuation is maximised to prevent swarf clogging and heat build-up.

Working in conjunction with the MSX tool-holders are Sumitomo’s new WDMT tri-lobed inserts, which are designed to significantly reduce cutting forces and help to prevent temperature build-up and wear when profiling, plunge cutting, ramping, face milling, slotting and helical boring on steel, stainless steel and cast iron. There are also two chip-breaker styles for general machining; for particularly demanding applications, there is an extra-strength edge design.

WDMT inserts are available in three recently introduced Super ZX grades — ACP200, ACP300 and ACK300. Each grade has an ultra-thin multi-layer CVD coating that allows the inserts to achieve more than double the tool life of more-conventional grades. ACP200 is recommended for general steels, and ACP 300 for die steel and stainless steels.

ACK300, which features a tough fine-grain substrate, is for machining ductile iron and cast iron. The MSX range is available as shank-style end mills with diameters from 16 to 63mm, face mills with diameters between 50 and 100mm and four to six teeth, and exchangeable-head end mills with diameters from 16 to 40mm.