Aluminum Machining

New Tangential Cutter for Aluminum Castings

| Editor: Alexander Stark

Sandvik Coromant promises burr-free initial machining (cubing) of cast aluminum surfaces in a single operation with the newly developed M5Q90 tangential milling cutter.

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The new M5Q90 completes the Sandvik Coromant range for machining aluminum components in the automotive industry. It complements the tool solutions M5B90, M5C90, M5F90, Coromill Century/590, and M5R90. According to the company, this new addition is predestined for face and shoulder milling.
The new M5Q90 completes the Sandvik Coromant range for machining aluminum components in the automotive industry. It complements the tool solutions M5B90, M5C90, M5F90, Coromill Century/590, and M5R90. According to the company, this new addition is predestined for face and shoulder milling.
( Source: Sandvik Coromant )

According to the manufacturer, the newcomer is equipped with tangential PCD cutting inserts that enable uniform and stable machining, while at the same time reducing power consumption and eliminating vibrations. Thus, the tool concept ensures reliable performance, improved tool life, exceptional surface finish, high cutting performance, and offers the ability to produce a larger number of workpieces per plate.

Sophisticated Milling Body Mixed with Special Cutting Insert Geometries

"To increase efficiency, the M5Q90 features special milling bodies in combination with special PCD cutting insert geometries that have a positive rake angle. This reduces the cutting force and thus the strain on the machined part," explains Emmanuel David, Global Automotive Product Manager at Sandvik Coromant. "The easy-to-handle and easily adjustable plates reduce the cost per part while providing high precision and repeatability," adds Jacques Gasthuys, Global Automotive Application Engineer.

M5Q90 milling bodies are designed according to customer specifications and thus meet the requirements for high productivity machining - the tool can be operated under high-speed conditions at over 20,000 min-1. However, according to Sandvik, all milling bodies have the same design in terms of plate seat, coolant channel, guide angle, and rake angle. The plates should also always be in stock.

Flexible Milling Cutter for the Cubing Process on Cylinder Heads

On request, it is also possible to extend the service life of the milling body in customer-specific solutions by using PCD inserts protected by rows of carbide inserts. This also allows the cutting depth to be optimized, they say. While the regular tool with PCD inserts can be used in full engagement in a cutting depth ranging from 2 to 4 mm, the version equipped with protection by carbide inserts offers a cutting depth exceeding 4 mm.

The tool experts predict that the machining of cylinder heads and engine blocks made of aluminum will benefit most from the new tool. Typically, these products are machined in automotive foundries or by Tier 1/ Tier 2 suppliers.

The conventional cubing process on a cast cylinder head would involve machining of the camshaft surface, the intake/exhaust surface and the combustion surface. Typical cutting data for the M5Q90 are a speed of 2,500 m/min and a tooth feed of 0.20 mm, says Sandvik. Users also benefit from high-precision coolant channels, which can be used either for emulsion or minimum quantity lubrication (MQL).

Extension of the Existing Aluminum Machining Program

According to the manufacturer, the M5Q90 completes Sandvik Coromant's range of products for machining aluminum components in the automotive industry and complements the tool solutions M5B90, M5C90, M5F90, Corromill Century/590, and M5R90 The new tangential milling cutter can be used for face and shoulder milling as well as for many other applications in general mechanical engineering and in the aerospace industry.

This article was first published by MM MaschinenMarkt.

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Fraunhofer IWU; Pixabay; Fraunhofer IFAM; Sandvik Coromant; Grenzebach; ; Siemens; Hochschule Landshut; Stratasys; Hornet; Altair Engineering GmbH; CSI; ANDREAS STIHL AG & Co. KG; gemeinfrei; Dr. Ing. h.c. F. Porsche AG