MonsterMill ISO — perfect for machining nickel-based alloys

The MonsterMill ISO-S is available as a four-edge cutter in two different lengths with a diameter range of 3–20mm

When machining materials like nickel-based or titanium alloys, the limits of efficient manufacturing can often be very limited. In order to tackle this problem and remain successful in the top tier of machining, Ceratizit has reimagined its MonsterMill – ISO-S range of milling cutters. The perfectly balanced combination of carbide, coating and geometry provides sturdy tools deliver a smooth cutting action every time. Alongside the proven four- and five-edge cutters, is the new six-edge MonsterMill – ISO-S.

The machining of Inconel, Hastelloy, Waspaloy and other nickel-based alloys is significantly more demanding than conventional materials and relentlessly drives up machining costs. The high tensile strength of the material, combined with its extreme hardness rapidly accelerates tool wear. Only tools designed specifically for this material, such as Ceratizit‘s MonsterMill – ISO-S, can minimise wear, maximise tool life and guarantee reliable processes.

Michael Wucher, Ceratizit’s global product manager (solid carbide milling), said: “Machining nickel-based alloys comes with its own set of particular challenges.” One of these is the material’s low thermal conductivity, which means the heat is concentrated in the tool instead of dispersing into the material. He continued: “To deal with this, we adapted the geometry of the new milling cutters to keep the heat generated in the machining process as low as possible. The polished chip flutes and optimised coating minimise friction and ensure an efficient chip flow.”

The irregular pitch of the cutting edges and a variable helix angle effectively minimise vibrations, which significantly increases the tool’s machining performance and helps to prevent tool breakage. This also significantly increases the workpiece’s surface quality and reduces the need for further rework in the process.

The tool’s microgeometry has also been precisely tailored to the specific material. A special, precision-engineered cutting edge preparation reduces the cutting forces and stabilises the cutting edges, which in turn significantly increases the tool life. Mr Wucher added: “And because regrinding was already taken into account when designing the new product, the overall construction provides clear benefits in the regrinding process.”

Outstanding wear resistance
The DPX22S Dragonskin coating, developed specifically for these milling cutters, was designed for use on nickel-based alloys. It is applied in 4–6µm thick layers and provides high thermal stability and outstanding wear resistance thanks to its special layer structure. The MonsterMill ISO-S is available as a four-edge cutter in two different lengths with a diameter range of 3–20mm. These tools are available with shank types HA and HB. All milling cutters have a corner radius of RE 0.2–5.0mm. The five-edge cutter is also available with shank types HA and HB with a diameter range of 3–16mm and with various corner radii.

The new six-edge cutter (pictured left) is available with diameters of 6–16mm and shank type HA. The tools have a corner radius of 0.2–2mm, meaning that the most common dimensions in the aerospace industry are covered and even custom sizes can be provided on request. Mr Wucher provides a glimpse of what is to come: “We are already planning some interesting practical additions to the range, which will further enhance the versatility of the ISO-S specialists.”

Ceratizit also has further solutions in its portfolio for machining heat-resistant materials such as titanium and various super alloys that are commonly used in the aerospace industry. One example is the MaxiMill – 211-DC indexable insert milling system, made using an additively manufacturing (AM) process, which provides targeted cooling for temperature control and enhanced tool life thanks to its ideal nozzle position.

Mr Wucher concluded: “When it comes to aluminium machining, we also have high-performance tools such as the brand-new AluLine high-volume milling cutter in our range. Whatever the material — we can provide the ideal machining solution.”