60% longer service life compared to tools with standard cooling: Machining titanium and super alloys is a breeze with the MaxiMill – 211-DCThe MaxiMill 211 DC is a 3-D printed shoulder milling cutter manufactured by Ceratizit and available in the UK from Sheffield-based
Ceratizit UK and Ireland Ltd. This new tool is designed for the machining of high-grade titanium components and super alloys — when machining heat-resistant materials, such as these, two factors play an especially crucial role in controlling temperature and maximising service life downtime — top quality tools and a targeted coolant supply.
The additively manufactured MaxiMill – 211-DC indexable insert milling system showcases how proper nozzle positioning can be a game-changer. As any manufacturer involved in the machining of titanium parts and super alloys will attest, there is no getting around using improvised strategies aimed at cutting costs and time. Despite high-speed machining, these incredibly tough materials simply make it challenging to ensure process reliability.
Robert Frei, product manager at Ceratizit in Germany, said: “If these processes are to be carried out in an even remotely financially viable manner, engineers often have to deviate from the proven ‘roadmap’ and be open to trying out new strategies — that is why we have developed our 3-D printed indexable insert milling system MaxiMill – 211-DC.”
Ceratizit recognised early on that AM solutions had the potential go beyond the limits of traditional manufacturing processes and deliver viable alternatives. Optimised coolant is essential for achieving top-quality results, especially when machining titanium and other heat-resistant materials. and it is here where the patented shoulder mill from Ceratizit comes into its own, as it features precision coolant placement on the milling indexable insert flanks — essential for machining titanium for example.
Mr Frei added: “When designing the MaxiMill — 211-DC, our objective was to funnel the maximum amount of coolant directly on the flank, which sounds straight-forward enough. However, pulling it off required a very complex construction process, which was only made possible with AM. Thus, we were able to create the perfect combination of geometric and functional properties, including the ideal nozzle position and an insert geometry precisely tailored for cooling.
“In doing so, we are able to guarantee full coverage wetting of the coolant on the indexable insert cutting surface. Despite the complexity of the numerous coolant holes present inside the tool body, the MaxiMill — 211-DC is compatible with standard adapters with through-coolant supply, without requiring any standard coolant on the chip breaker. Moreover, it provides the same performance and advantages as using direct cooling for turning tools.”
Furthermore, the MaxiMill – 211-DC boasts a 60% longer service life compared to rival tools with standard cooling. Mr Frei concluded: “This additional surplus of service life makes for fluid machining of titanium and super alloys, while delivering the benefits of secure manufacturing processes and minimising tool use.”