Stay cool when machining superalloys

When machining heat-resistant materials, such as titanium and other super alloys, two factors play an especially crucial role in controlling temperature and minimising downtime: high-quality tools and a targeted coolant supply. The new additively manufactured MaxiMill-211-DC indexable insert milling system from Ceratizit showcases how proper nozzle positioning can prove a true differentiator.

“If the machining of titanium and superalloys is to take place in a financially viable manner, professionals often have to deviate from the proven ‘roadmap’ and be open to trying new strategies,” says Robert Frei, product manager at Ceratizit. “It’s for such stubborn instances that we developed our 3D-printed indexable insert milling system, the MaxiMill-211-DC.”

Optimised coolant is essential for achieving top-quality results, especially when machining titanium and other heat-resistant materials. Ceratizit says it is here where the patented shoulder mill shines, thanks to precision coolant placement on the milling indexable insert flanks.

“Additive manufacturing processes are no longer mere nice-to-haves, they are essential to achieving results that would be impossible with conventional strategies,” explains Frei.

Ceratizit’s team of engineers sought to optimise the flank cooling process. The objective was to funnel the maximum amount of coolant directly on the flank, which sounds straightforward enough. However, pulling it off required a very complex construction process, which was only made possible by additive manufacturing. In doing so, Ceratizit is able to guarantee full coverage wetting of the coolant on the indexable insert cutting surface. 

Despite the complexity of the numerous coolant holes present inside the tool body, the MaxiMill-211-DC is compatible with standard adapters with through-coolant supply, without requiring any standard coolant on the chip breaker.

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