Record the inspection results and machining parameters for each batch. This documentation can help you trace the cause of a problem and encourage improvements to the cutting process.

Endmilling

HM42 series milling cutters, featuring high-speed steel with 8% cobalt known as M42 or just "cobalt", provides higher performance over standard high-speed steels, because the added cobalt increases hardness and resists abrasion. These qualities make cobalt end mills a desirable alternative to carbide end mills in applications with abrasive, heat-resistant materials that tend to chip carbide cutting tools.

High-Speed Performance Milling 1 (HSPM1)  HSPM1 series milling cutters feature unequal flute spacing (variable pitch) to reduce or eliminate unwanted harmonic vibrations, commonly known as chatter. The 4-flute end mills feature a 38° helix angle on the flute geometry and chamfers on the cutting edges to guard against chipping and premature wear of the edges in roughing applications. The end mills are center cutting, but the HSPM1 chamfer mills are not designed for cutting with the sharp center point of the tool.

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• Corners have a sharp, square profile • 90° cutting angle • Most common corner type • Used for slotting, profiling, and plunge milling • Creates flat bottoms with square corners

Cutting and machining titanium presents a unique challenge. It is vital to advancing industries that depend on its superior properties. Cutting titanium effectively is crucial to maximizing its benefits for critical applications, from aerospace to automotive and medical. We can achieve industry standards by mastering titanium technology and adopting best practices.

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The plasma cutting method is best suited for thicker titanium sheets. The metal is melted using a high-velocity jet of ionized gases. It’s faster and cheaper than waterjet or laser cutting but less precise. This may result in a heat-affected zone, which may need further processing.

Milling cutter

When you're machining pockets with an end mill it's not uncommon to get a stack of chips in the pocket that's hard to get out. Mark takes a look at several styles of end mills that cut your chips into smaller pieces, making them a lot easier to get out of the pocket before your end mill gets damaged re-cutting those same chips.

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When choosing the right titanium cutting tool, it is important to choose tools that can withstand its hardness and heat resistance. The tools made of carbide are used a lot because they retain their hardness even at high temperatures. High-positive rake tools and sharp edges help reduce heat generation.

Consider using techniques like sandblasting or electropolishing to improve the surface of titanium components. These methods improve appearance and corrosion resistance.

High-Temperature Performance Milling (HTPM) HTPM series milling cutters have unequal flute spacing (variable pitch) and multiple helix angles (35° and 37°) to reduce chatter and harmonics for improved stability and better finishing. This also optimizes chip formation and chip evacuation. These 4-flute end mills feature chamfers or different available corner radii to strengthen the edges in roughing applications.

Helical

These end mills all have a square corner profile and a 30-degree helix design. We carry common fractional diameters up to 1" with 4-flutes and 2:1 length-of-cut to diameter ratios. The 3/4" and 1" versions are also available with 6-flutes. Most diameters are also available with a longer 4:1 flute length and 4-flutes.

HEPM series milling cutters are designed for side-cutting and trochoidal toolpaths only. High-efficiency milling and high-speed milling toolpaths subject the end mill to a light radial depth of cut (Ae) and heavy axial depth of cut (Ap) at high feedrates, with reduced tool stepover for more radial passes. This dramatically increases the material removal rate, while decreasing cutting pressure, reducing and dispersing heat, reducing tool wear, and improving surface finish.

Titanium’s high strength and tensile toughness can lead to excessive tool wear and generate significant heat when cutting. The low thermal conductivity of titanium means that heat cannot be quickly dissipated and can cause damage to the material or cutting tool.

Tool material, coating, and geometry are all important factors to consider when selecting tools for titanium cutting. The tools must be able to withstand wear and keep their sharpness.

Recommended for non-ferrous materials. Fewer flutes allow for excellent chip clearance on larger chips, and deeper cut depths. Ideal for aluminum in heavy roughing and finishing applications.

It isn’t easy to drill titanium. To control heat, it’s essential to use carbide-tipped drilling tools and drill at a moderate to slow speed. Retract the drill bit regularly to remove chips, and use generous amounts of cutting fluid to cool and lubricate the area.

I have over ten years of professional experience in sheet metal fabrication, specializing in laser cutting, bending, welding, and surface treatment techniques. As the Technical Director at Shengen, I am committed to solving complex manufacturing challenges and driving innovation and quality in each project.

High-Speed Aluminum Milling 1 (HSAM1)  HSAM1 series milling cutters are 3-flute, center-cutting, high-performance end mills for aluminum. They have unequal flute spacing (variable pitch) to break up harmonics and reduce chatter and vibration. The wiper facet design improves floor finishes. These end mills provide extraordinary metal removal rates (MRR), by combining roughing and finishing operations for any aluminum plunging, slotting, and profiling application. The proprietary flute geometry is designed for rigidity and improved chip evacuation, generating wall-to-floor perpendicularity, even in thin-wall applications.

Recommended for ferrous materials. High flute count yields a thicker core for greater tool strength and less deflection, while increasing material removal rates. Ideal for high-efficiency/high-speed milling in steel, stainless, cast iron, and high-temp alloys

Titanium Aluminum Nitride (TiAlN) coating increases the resistance of wear, ductility, and heat transfer through the chips, making these cutters a good all-around choice for roughing and finishing steel, stainless steels, cast iron, and high temperature alloys.

Cutting

High-Speed Aluminum Milling 3 (HSAM3)  HSAM3 series milling cutters are solid carbide 2-flute end mills designed specifically for high-speed machining of aluminum and other non-ferrous materials. The mirror-like surfaces of the flutes produce excellent surface finishes and greatly enhance chip removal.

High-Speed Performance Milling 2 (HSPM2) HSPM2 series milling cutters feature unequal flute spacing (variable pitch) to reduce or eliminate unwanted harmonic vibrations, commonly known as chatter. The 5-flute end mills feature a 38° helix angle on the flute geometry and sharp corners on the cutting edges. These cutters are well suited for semi-finishing and finishing applications. The end mills are center cutting.

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HM2 series milling cutters, available in 2 or 3-flutes, are center-cutting, high performance end mills for aluminum applications. Made of M2 high-speed steel, with molybdenum and tungsten as its main elements, this composite provides outstanding wear resistance and hardness. These end mills feature a 42° helix angle, providing highly efficient chip evacuation.

Aluminum Titanium Nitride (AlTiN) coating has a higher aluminum content than TiAlN, making it harder, with better lubricity. The drawback is that edges can chip in very hard materials.

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Recommended for ferrous materials. Higher flute count increases the tool strength, but reduces the cut depths. Ideal for finishing or high-efficiency milling in steel, stainless, cast iron, and harder materials.

For the past 10 years, I’ve been immersed in various forms of sheet metal fabrication, sharing cool insights here from my experiences across diverse workshops.

Diamond-Like Carbon (DLC) coating provides superior edge strength and increased tool life; excels in hard aluminum, and at high speeds.

When cutting titanium, it is important to use personal protective equipment, such as safety glasses, gloves, and hearing protectors. Maintaining proper cooling and lubrication is also essential to prevent fires caused by titanium’s flammable chip.

Sharpen and check your cutting tools regularly to ensure optimal performance. Consider professional resharpening for tools such as drills and endmills to restore precision. A scheduled maintenance program will extend the life of your tools and improve cutting accuracy.

High-Temperature Milling (HTM) HTM Series milling cutters are designed for high-performance milling of titanium and stainless steels. They also work well in alloy steels and cast iron. The high-performance, dual-core geometry is designed for superior chip evacuation, while still providing strength and rigidity, for excellent performance slotting and heavy profiling. These cutters feature unequal pitch for chatter-free cutting.

We encounter many problems when cutting titanium. Why? It is tough, resistant, and requires precision. However, cutting titanium can be simple and effective with the right approach. This post will guide you through all the steps to handle titanium confidently.

Aluminum Chromium Nitride (Hybrid AlCrN) reduces wear and increases heat resistance. These end mills are ideal for high-speed machining and high-efficiency milling of steels, stainless steels, cast iron, and high-temp alloys for increased material removal rates and fine surface finishes.

For turning toolholders, as for indexable inserts, there is a similar ISO designation system. The system is designed so that each important feature and ...

Water jet, plasma, and laser cutting are some of the most advanced titanium cutting techniques. These techniques have a smaller heat-affected area, faster cutting speeds, and the ability to create complex designs and cuts. These technologies minimize the mechanical stress placed on the material while maintaining its inherent properties.

In a composite machined at 90" to the fibre direction, the fibres are subjected to bending and are sheared off. In contrast to laminates with 0" fibres, each ...

Use precision measuring tools, such as micrometers, calipers, and CMMs (Coordinate Measuring machines), to ensure that the dimensions are within tolerances specified by the design.

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Waterjet cutting is the best way to cut titanium without damaging its structure. It uses high-pressured water and an abrasive to cut through titanium without creating heat, preserving the material’s properties and avoiding heat-induced deformations.

Laser cutting is a precision way to cut titanium, particularly for intricate designs. It is essential to control the laser settings carefully to prevent overheating. The pulsed mode reduces thermal stress and ensures clean cuts.

Milling machine

• Corners have slight a radius • Helps distribute cutting forces evenly • Prevents damage to the end mill • Extends corner • Creates flat bottoms with slightly radiused corners

Titanium is known for its incredible strength-to-weightstrength-to-weight ratio, biocompatibility, and corrosion resistance. These attributes present significant challenges in machining. Its hardness can cause cutting tools to wear out quickly, and the metal’s low thermal conductivity may cause heat to build up, altering its properties.

Jul 28, 2024 — Feeds and speeds are important because they're the key to Longer Tool Life, Faster Machining Speeds (through higher Material Removal Rates), and Better Surface ...

The titanium material retains heat, so the proper cooling fluids are essential. High-pressure systems can penetrate the cutting zone effectively. These systems flush out chips, reduce the temperature at the cutting edges, and lubricate surfaces to reduce friction and wear.

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Harvey Tool

Cutting titanium using methods that preserve the metal’s integrity while maintaining precision is best. Waterjet techniques, laser cutting, and CNC machining are all highly effective. Waterjet cutting, for example, uses a cold-cutting process to avoid heat-induced distortions.

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Constructed of premium-grade micrograin carbide, these 6-flute end mills feature a 45° helix angle for higher productivity and longer tool life, and unequal flute indexing to reduce harmonic vibrations (chatter) and improve surface finishes. These tools utilize a unique chip splitter that reduces chip length by up to two-thirds. Combined with chip thinning, high-efficiency milling, and high-speed machining toolpaths, these tools provide superior chip evacuation to carry heat away from the tool and workpiece.

Use cutting tools with chip-breaker designs to create smaller, more manageable pieces. Ensure that the coolant flow is adequate to remove the chips. Clean and inspect the work area regularly to ensure a clear path for cutting and reduce tool interference.

Recommended for ferrous materials. The low flute count allows for excellent chip clearance for general purpose roughing and slotting. Ideal for steel, stainless, and cast iron.

Standard tools are sometimes used to cut titanium. However, due to titanium’s toughness and thermal properties, they may not perform well or suffer from excessive wear. Specialized carbide tools are recommended for better performance and durability.

Cutting Tools

Deburring is the removal of sharp edges and burrs, which can hurt both safety and functionality. Vibratory finishing, abrasive sandblasting, and manual deburring using hand tools can be effective, depending on the precision of the project.

The highly engineered 3-flute design provides more balanced cutting performance, without excessive heat buildup. In fact, while other end mills can gum up at high surface speeds, HSAM2 end mills keep cool by dissipating heat and providing outstanding chip evacuation. Combined with its ultra-micrograin carbide design, the results are:

Grades for Milling …………………………………… A3. Grade Comparison Chart. (CVD / PVD ... Cross Section of Cutting. Edge Coating TEM Structure. 10nm. AURORA Coat (DLC ...

In the following sections, I will discuss each method in greater detail and provide tips and instructions for improving your cutting technique. Look for valuable insights that will improve your metalworking abilities!

High-Speed Aluminum Milling 2 (HSAM2)  HSAM2 series milling cutters have a uniquely different flute design and superior corner protection from HSAM1 series cutters. The 3-flute “to the center” design, where all three flutes come to the center, is the ideal symmetrical shape. It works great at high spindle speeds, and is highly effective in vertical ramping up to 20 degrees, and step-over plunging applications. The engineered flute design provides effective chip evacuation at high feedrates, with lower cutting forces than competitive products.

Titanium has a low thermal conductivity so that it can cause high temperatures on the cutting edge. To manage this, cooling techniques, such as high-pressure cooling systems that target the cutting area, must be used. Optimizing cutting parameters such as speed and feed rate can also help reduce heat buildup.

Kennametal

Nondestructive methods, such as dye-penetrant inspections, X-rays, or ultrasonic tests, detect surface and internal defects.

Recommended for non-ferrous materials. Two-flute end mills have long been the industry standard when cutting aluminum and other non-ferrous alloys, where chip clearance is important to efficient material removal. The massive valleys between the two flutes accommodate the larger chips produced by high feed-per-tooth feedrates on softer materials.

These angle cutters use 2-sided hexagonal inserts with 12 true cutting edges. Double negative geometry provides strength needed for high metal removal rates.

Fix the titanium with robust fixturing to prevent it from moving during cutting. Ideal are clamping systems with uniform pressure distribution over the entire workpiece. This stability improves not only safety but also precision and quality.

Titanium requires slower speeds but higher feeds. This balance prevents the tool from lingering too long on the workpiece, which could cause overheating or hardening. It is often necessary to experiment and adjust based on the cutting conditions to find the optimal settings for each task.

Our titanium cutting services are designed to meet the demands of high precision and performance. Here are some of the key advantages you can expect:

These high-quality cobalt cutting tools are very cost-effective, especially in larger diameters, and can provide very stable production rates at low RPM.

• Corners have 45° chamfer • Helps distribute cutting forces evenly • Prevents damage to the end mill • Extends corner life • Creates flat bottoms with slightly chamfered corners

The correct cutting technique maintains integrity and performance. Incorrect techniques can result in suboptimal finishes, increased material waste, and damage to titanium. Using appropriate technology improves the quality of the titanium product.

Titanium is difficult to mill due to its low thermal conduction and tendency to become hardened when heated. To remove chips more effectively, use cutters with a high flute count and carbide inserts. A shallow cut and a high feed rate can reduce heat and help prevent tool wear.

You must be cautious when turning titanium to prevent tool wear and maintain the integrity of your workpieces. Use a rigid setup and positive rake sharp tools to minimize heat buildup. Moderate cutting speeds and constant feed rates are best. Coolant extends the tool’s life and reduces thermal stresses.

Titanium Aluminum Nitride (TiAlN) coating increases the resistance to wear, ductility, and heat transfer through the chips, making these cutters a good all-around choice for roughing and finishing steel, stainless steels, cast iron, and high-temperature alloys.

Aluminum Chromium Nitride (Hybrid AlCrN) coating reduces wear and increases heat resistance. These end mills are excellent for roughing and finishing, and fully capable of taking heavy cuts in steel, stainless steel, titanium/Inconel up to 40 HRc, as well as cast iron.