CERATIZIT redesigned its MonsterMill – ISO-S line of milling cutters to provide manufacturers efficient cutting, long tool life and excellent surface finishes when milling nickel- and titanium-based alloys. In addition to its proven 4- and 5-flute cutters, the MonsterMill – ISO-S line now includes a 6-flute cutter for superior surface finishes that reduce secondary operations.
Machining Inconel, Hastelloy, Waspaloy, and other nickel-based alloys demands more from tools than conventional metals. The high tensile strength and extreme hardness of superalloys rapidly accelerates tool wear and drives up machining costs. The MonsterMill – ISO-S series, however, excels in machining those difficult-to-machine materials with a perfectly balanced combination of solid carbide, advanced geometries and tough coatings that deliver consistent and reliable smooth cutting action.
“Machining nickel-based alloys comes with its own set of challenges,” says Eric Gerringer, Technical Director, CERATIZIT USA. “One of the challenges is the materials’ low thermal conductivity that keeps heat concentrated in the tool instead of dispersing it into the chips. We modified the geometry to keep the heat generated by the machining process as low as possible. Polished chip flutes and an optimized coating also minimize machining friction and ensure efficient chip flow.”
CERATIZIT designed its DPX22S Dragonskin coating on these cutters specifically for machining nickel-based alloys. The coating is applied in 4-6 micrometer layers to provide high thermal stability and outstanding wear resistance due to its special layer structure.
Variable helix and irregularly pitched cutting edges minimize vibrations, which significantly increases tool performance and prevents breakage. With less vibration, the tools ensure long working lives. Plus, the new geometries are engineered for regrinding to extend tool lives even further.
Perfect for the aerospace sector, the MonsterMill – ISO-S is available as a 4-flute cutter in two different lengths with a diameter range of 3-20mm. These tools come with HA and HB shank types and have a corner radius of RE 0.2-0.5mm. The 5-flute cutter is also available with HA and HB shank types with a diameter range of 6-16mm and various corner radii. The new 6-flute cutter is available with diameters of 6-16mm and shank type HA along with corner radii of 0.2- 2mm.