Near endless tool life with Gühring milling cutters
Producing flat surfaces with a good surface finish quality or demanding cavities with a high metal removal rate?
Milling operations are some of the most versatile machining operations in metal cutting. Depending on the application Gühring provides suitable milling tools. Our programme stretches from allrounder to specialists, from conventional to modern HPC/HSC strategies such as trochoidal milling or iMachining (SolidCAM).
Optimised roughing geometry for a higher metal removal rate: 60% longer end mill tool life
The new Ratio® high-performance roughing end mill have gone through several geometry adaptations in order to drastically increase the metal removal rate and to prolong the tool life by up to 60 percent compared to similar end mills on the market.
The new roughing geometry distinguishes itself thanks to a constant diameter flute run-out to protect the area under stress and a deeper, rounder flute geometry. Thanks to larger flutes small chips are produced for improved chip evacuation. In contrast to the conventional geometry the roughing geometry is asymmetrically designed. The more stable asymmetrical cutting knuckles produce a smooth rough-finish surface. This reduces the cutting pressure in comparison to smooth cutting milling cutters.
The smooth cutting operation makes the application possible on less powerful machines or with unstable clamping conditions. Gühring end mills can handle these issues easily. Thanks to the new tool material DK400N the end mills are now significantly tougher and have less of a tendency to crumbling of the cutting edges. By utilising the full cutting edge length a higher metal removal rate is achieved. Also the end mill life scores points with a plus of up to 60 % compared to similar tools on the market.
Performance plus at a glance with Gühring end mills
The improved performance capability of the end mill is due to its optimised roughing geometry and the new tool material DK400N. It results in shorter chips and longer end mill tool life. By utilising the entire cutting edge length a higher metal removal rate can be achieved. In addition, the milling cutter achieves up to 60% longer end mill tool life with high process reliability. Therefore, it is also suitable for less powerful machines and unstable clamping conditions.
Different options for a wide range of machining tasks
There are various options of end mills available. The RF 100 U Ratio end mill is suitable for universal application, RF 100 VA for the machining of stainless steels and RF 100 A end mill for the machining of aluminium.
With the new RF 100 Speed milling bits, the sharpest and fastest HPC milling cutter in Gühring’s Ratio programmer is available on the market. It distinguishes itself thanks to a steep helix of 48° and its unequal cutting edge distribution for a smooth and quiet cutting operation. The milling tools are available in various designs.
Its toughness, chemical resistance and low thermal expansion makes titanium indispensable for highly stressed components as applied, for example, in the aviation industry. At the same time, these characteristics create enormous machining difficulties. Gühring’s RF 100 Ti Aircraft milling tool was especially developed to meet these requirements.
Ratio end mill 100 Ti Aircraft milling bits possess a special face geometry enabling process reliable milling, slotting and roughing in special and titanium-alloys. An optimised chip chamber possesses a deeper flute in the frontal cutting edge area for improved chip evacuation. Furthermore, the transition angle of RF 100 Ti Aircraft milling bits provide the Ratio end mill more stability. The optimised corner radius ensures long tool life.
Even more performance with less milling tool wear: Guhring’s ZENIT
As a special tool RF 100 Ti Aircraft milling bits are also available with ZENIT-coating. Developed to improve the performance of the tool in titanium-alloys regarding tool life and cutting parameters, the ZENIT-coating also reduces the formation of built-up edges when machining aluminium and titanium. Where Ti-based coatings have the tendency to bind with the material to be machined, the zirconium nitride based coating ZENIT chemically reacts only slowly with titanium and titanium-alloys. A reduction in cutting edge stresses and friction forces results in longer tool life.
RF 100 Ti Aircraft in application
- Application: Wet machining in TiAl6V4Cutting parameters:
ap: 24 mm ae: up to 0.53 mm
vc: 155 m/min S: 4125 min-1
fz: up to 0.18 mm vf: up to 3100 mm/min
- Metal removal rate: Q = 36 cm³/min
Tool life in excess of 135min for roughing
Application example – material 16MnCr5
RF 100 Speed, #6761, Ø 16 mm, HPC clamping chuck + PINLock-protection
|vc 410 m/min||fz 0,450 mm||hm 0,123 mm|
|ae 1,2 mm||ap 45 mm||vf 14690 mm/min|
|Q = 793 cm³/min|
Application example – material Hardox 400®
RF 100 U, #3871, Ø 20 mm, Weldon chuck
|vc 200 m/min||fz 0,180 mm||hm 0,049 mm|
|ae 1,5 mm||ap 55 mm||vf 2290 mm/min|
|Q = 189 cm³/min|
RF 100 Diver, #6736, Ø 12 – Z4,
|vc 300 m/min||fz 0,120 mm|
|n 7960 U/min||vf 3820 mm/min|
|ae 1,5 mm||ap 24 mm|
|Q = 138 cm³/min|
5 radial feeds per
1200 mm path
Machining time = 1.34 min
HPC milling cutter, Ø 16 – Z4, Weldon chuck
|vc 140 m/min||fz 0,070 mm|
|n 2790 U/min||vf 780 mm/min|
|ae 7,5 mm||ap 12 mm|
|Q = 70 cm³/min|
2 axial feed per
1200 mm path
Machining time = 3.05 min
RF 100 SF, #3632, Ø 16 – Z6, Weldon chuck
|vc 160 m/min||fz 0,100 mm|
|n 3185 U/min||vf 1910 mm/min|
|ae 1,2 mm||ap 30 mm|
|Q = 69 cm³/min|
10 radial feeds per
900 mm path
Machining time = 4.43 min
Indexable insert milling cutter Ø 25 – Z3
|vc 200 m/min||fz 0,120 mm|
|n 2550 U/min||vf 920 mm/min|
|ae 12 mm||ap 2 mm|
|Q = 22 cm³/min|
5 axial feeds per
900 mm path
Machining time = 14.40 min
Carbide or HSS? The competences of tool materials are clearly defined – and carbide as the tool material for drilling tools has nowhere near been able to establish itself in all fields of application. Particularly with small and medium series production, with unstable machining conditions and always when toughness is required, users continue to rely on drilling tools in high-speed steel (HSS/HSCO). With an enormous product range and an extraordinary high manufacturing depth Gühring’s HSS/HSCO drills product range is unequaled worldwide.
- Morse taper shank drills up to Ø 98.42 mm are also part of Gühring’s standard product range and are absolutely essential for large engine production, particularly in shipbuilding.
- Standard extra length HSS drills with a flute length of 850 mm and a total length of 1000 mm with a diameter of 10 mm are for example applied in the mould, die and tool making industry.
- HSS drills with internal cooling and with straight shank or with Morse taper shank for the machining of steel beams for example.
- Furthermore, the standard HSS/HSCO drills range also includes twist drills to all current standards, centre drills, NC spotting drills, subland drills, and core drills.
- Besides the standard range this product diversity especially also applies to the special tool sector. Here, Guhring can manufacture HSS/HSCO drilling tools with a diameter up to 105 mm for example. The various designs of HSS/HSCO drills are virtually unlimited.