Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.

If desired, the cutter body tool life can be further extended in engineered solutions with PCD inserts protected by rows of carbide inserts, a configuration that also serves to increase the depth of cut capability. While the basic tool with PCD inserts offers 2–4 mm (0.079–0.157 inch) depth of cut in full engagement, this can be boosted to in excess of 4 mm (0.157 inch) using the engineered solution with protective rows of carbide inserts.

Capable of both face and shoulder milling, the M5Q90 is also suitable for many applications in the general engineering and aerospace sectors.

Distance between the bottom of the cut and the uncut surface of the workpiece, measured in a direction at right angles to the machined surface of the workpiece.

M5Q90 cutter bodies are designed according to customer specifications, and therefore meet the requirements of high-productivity machining – the tool can operate in high-speed conditions in excess of 20,000 rpm. However, all cutter bodies offer the same design of tip seat, coolant channel, lead angle and rake angle. Inserts are always kept in stock.

Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

“The inserts, which are easy to handle and adjust, offer reduced cost per part along with high accuracy and repeatability,” adds Jacques Gasthuys, global automotive application engineer.

Cutting tool material consisting of natural or synthetic diamond crystals bonded together under high pressure at elevated temperatures. PCD is available as a tip brazed to a carbide insert carrier. Used for machining nonferrous alloys and nonmetallic materials at high cutting speeds.

Angle between the side-cutting edge and the projected side of the tool shank or holder, which leads the cutting tool into the workpiece.

Engagement of a tool’s cutting edge with a workpiece generates a cutting force. Such a cutting force combines tangential, feed and radial forces, which can be measured by a dynamometer. Of the three cutting force components, tangential force is the greatest. Tangential force generates torque and accounts for more than 95 percent of the machining power. See dynamometer.

The technique makes use of the Y-axis, and all three axes are used simultaneously when machining. The tool rotates around its own center, the insert is placed for machining in the Y-Z plane and the milling spindle axis interpolates during turning. This allows intricate shapes to be machined with a single tool.

Angle of inclination between the face of the cutting tool and the workpiece. If the face of the tool lies in a plane through the axis of the workpiece, the tool is said to have a neutral, or zero, rake. If the inclination of the tool face makes the cutting edge more acute than when the rake angle is zero, the rake is positive. If the inclination of the tool face makes the cutting edge less acute or more blunt than when the rake angle is zero, the rake is negative.

To summarize, Y-axis turning is a method for simultaneous three-axis turning with interpolation of the milling spindle axis. The new tools can also be used in “static mode” with a locked spindle for flexible two-axis turning with fast insert indexing. The method is suitable for all materials and requires a multitask machine with options to allow interpolation of the milling spindle axis during turning.

SANDVIK COROMANT has developed two new tools to support a new turning method – Y-axis turning. The new CoroTurn® Prime variant is recommended for turning shafts, flanges, and components with undercuts. The CoroPlex® YT twin-tool, featuring CoroTurn TR profiling inserts and CoroTurn 107 round inserts with rail interface, can be used for components with pockets and cavities.

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Aluminum cylinder heads and engine blocks will be among the principal components to benefit, typically in automotive foundries or Tier 1/Tier 2 suppliers. By way of example, the cubing operation on a cast cylinder head would involve machining the camshaft face, inlet/outlet face and combustion face. Typical cutting data using M5Q90 might include a speed of 2,500 m/min. (8,202 sfm) and feed per teeth of 0.20 mm (0.008 inch). Users also benefit from high-precision coolant channels that provide the option for either emulsion or MQL application.

To boost the first-stage roughing operation on newly cast aluminum parts for the automotive industry, cutting tool and tooling systems specialist Sandvik Coromant is introducing its M5Q90 tangential milling cutter. Designed to complete "cubing" (first machining of faces after casting) in a single operation without creating burrs, the new tool is fitted with PCD tangential inserts that provide a smooth and stable cutting action to lower power consumption and eliminate vibration. This concept ensures reliable performance, improved tool life, exceptional surface finish, high metal-removal rate and an increased number of parts per insert.

The ability to machine several features with a single tool reduces cycle time, and no tool changes are required, which minimizes the risk of “blend points,” or irregularities between adjacent machined surfaces. The main cutting forces are directed into the machine spindle, thus improving stability and reducing the risk of vibration. A constant entering angle drastically improves chip control and makes it easier to avoid chip jamming.

The M5Q90 completes the Sandvik Coromant offer for machining aluminum automotive parts, complementing the M5B90, M5C90, M5F90, CoroMill Century/590 and M5R90 tooling solutions.

“One could say that these advances, together with progressive capabilities in modern machines and CAM software, have paved the way for the new Y-axis turning method,” explained Staffan Lundström, product manager, Turning. “And with the tools and method now in place, we look forward to exploring the possibilities this method can present to our customers.”

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“To enhance efficiency, our new M5Q90 tangential milling cutter features fully engineered cutter bodies matched with dedicated PCD insert geometries that feature a positive cutting angle to reduce cutting force and load on the machined component,” explains Emmanuel David, global automotive product manager at Sandvik Coromant.

Loosely, any milling tool. Horizontal cutters take the form of plain milling cutters, plain spiral-tooth cutters, helical cutters, side-milling cutters, staggered-tooth side-milling cutters, facemilling cutters, angular cutters, double-angle cutters, convex and concave form-milling cutters, straddle-sprocket cutters, spur-gear cutters, corner-rounding cutters and slitting saws. Vertical cutters use shank-mounted cutting tools, including endmills, T-slot cutters, Woodruff keyseat cutters and dovetail cutters; these may also be used on horizontal mills. See milling.

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