Kingswinford-based Kennametal UK Ltd has introduced the new KCFM 45 face milling cutter for cast iron applications. With fixed and adjustable pocket seats, the new milling tool provides the option for semi-finishing as well as fine-finishing applications.

With carbide, ceramic and PcBN inserts, the new cutter is a flexible, cost-effective and user-friendly solution that the company says is ideal for use on any type of CNC machining centre.

Carbide inserts are ideal for machining at lower rev/min, or in thin-walled workpieces and less stable conditions, while ceramic inserts (KY3500 grade) provide elevated surface speeds resulting in higher productivity — both offer excellent performance. For fine finishing operations, PcBN inserts will deliver the best possible surface finish, tool life, and throughput.

Michael Hacker, Kennametal product manager, said: “With the KCFM 45 face milling cutter, users can mix and match different insert options to suit the application requirements and machining conditions.

“For example, PcBN finishing inserts might be used in the adjustable pockets and ceramic or carbide inserts in all other pockets for wet machining or lower volume applications. Regardless of the configuration, the KCFM 45 exceeds the highest surface requirements.”

Wave killer
The inserts are positioned at a positive axial angle, but with a slightly negative radial angle for better tool life. That creates significantly lower machining forces than competing cast iron face mills, helping to eliminate chatter and further improving surface finishes.

Mr Hacker added: “The KCFM 45 with its adjustable pocket seats can generate surface finishes of 0.8µm Ra or better, and waviness lower than 10µm Wt.”

The KCFM 45 is suitable for gray cast iron, CGI applications, semi-finishing and fine-finishing operations.