Diamond- and CBN-electroplated grinding solutions from Engis UK Ltd, Henley-on-Thames (www.engis.com), are designed to replace complex tungsten-carbide or PCD milling cutters in the production of high-quality flat milled surfaces for high-precision high-volume applications — even those with an interrupted cut or where multiple materials must be machined simultaneously.

Termed ElectroMill and designed for use on a wide variety of machining centres (VMCs, HMCs and five-axis machines — in fact, any system with high-pressure coolant and spindle speeds greater than 10,000rev/min), these tools are said to improve surface finish and flatness, while significantly extending tool life and reducing the cost per part.

ElectroMill solutions are offered either as an integral unit providing high levels of rigidity and internal balance, or as a multi-part (shell) design that offers more flexible options and “adaptability for legacy tool-holding situations”.

A number of standard taper options are also available.

Engis says that the major benefits of ElectroMill include: reduced numbers of operations, set-ups and inspections; high stock removal rates; and low heat build-up for a stress-free cool cutting action.

“ElectroMill extends tool life compared to conventional milling cutters because the diamond starts sharp and stays sharp with constant controlled micro-fracturing — and no dressing cycles are required. In addition, ElectroMill can be used with water-soluble or synthetic coolants.”

ElectroMill can be used in various industry sectors, including marine, automotive, aerospace and defence — and across a wide variety of components in ferrous, non-ferrous and exotic materials.