With the CrazyMill Cool SF, Mikron Tool has developed a superfinish milling cutter that mills surfaces to a grinding or polishing level of less than Ra 0.2 µm. To achieve this high surface quality, the CrazyMill Cool SF was designed with specially developed micro and macro cutting edges.
The CrazyMill Cool SF is suitable for use in the medical, aerospace and watchmaking industries, where the highest demands are placed on surface quality.
With the new CrazyMill Cool SF, the focus is solely on the surface quality to be achieved. Alberto Gotti, Head of Development, Mikron Tool: "Both in medical technology, the watchmaking industry and in the aerospace industry, components often have to be ground and polished after the milling process. As it is now possible to mill surfaces in grinding quality with the CrazyMill Cool SF, the subsequent finishing processes can either be replaced or significantly reduced, which ultimately saves costs."
Vibrations are Consistently Suppressed
The decisive factor in superfinish milling is that vibrations are completely suppressed during the milling process. To achieve this, the CrazyMill Cool SF was not only designed with an unequal teeth division, but also with different helix angles for each individual cutting edge. The helix angle itself is quite large. The main cutting edges have been designed to generate an extremely soft cut. This is only possible through the use of a new type of ultra-fine grain carbide substrate, with which an extremely sharp and homogeneous cutting edge can be ground.
VIDEO: 2 End-mills for a Perfect Surface Without Chattering
Ideally, the entire cutting-edge length of the milling cutter can be used. This has the advantage that with full axial engagement, the entire cutting-edge area is worn evenly, resulting in a very long tool life in relation to the machined surface.
Full Axial Engagement Length of the Cutting Edges Can be Used
With the new CrazyMill Cool SF, particular attention was paid to finding the perfect balance between helix angle, clearance angle and cutting-edge conditioning. The extremely high cutting speed ensures a very low cutting pressure so that the end mill can cut reliably even with maximum axial engagement (4xd).
This is crucial to limit the deflection of the milling cutter to a minimum and thus ensure shape tolerances and squareness in accordance with the required tolerance values, even at the maximum depth of engagement of the milling cutter.
Strikingly Large Helix Angles
The relatively large helix angles are striking, as Alberto Cotti explains: "The large helix angle further reduces the already low radial cutting forces. The axial cutting forces, on the other hand, increase, which has a beneficial effect on the resulting cutting forces acting on the workpiece. The deflection of the milling cutter is also reduced. The result is an extremely smooth, virtually vibration-free milling process. We achieve surfaces with a roughness of less than Ra 0.2 both parallel and transverse to the milling direction. That is sensational. For the user, this means that subsequent finishing operations are either completely unnecessary or require significantly less effort."
Patented Cooling Integrated into the Shank
The patented cooling channels of the CrazyMill Cool SF, which run through the shank, ensure constant and massive cooling of the cutting edges. The excellent cooling performance directly in the cutting zone enables a significantly higher cutting speed and also reduces wear enormously. The massive coolant jet (from just 15 bar) also guarantees a chip-free machining zone and prevents chips from sticking in the cutting zone, an important aspect for achieving high surface qualities.
Also, for Brass, Copper,Cobalt-Chrome, Inconel
The CrazyMill Cool SF is now available in the diameter range d = 1.0 - 8.0 mm in two different cutting-edge lengths 3 x d and 4 x d for all materials. Initial tests at Mikron Tool's Technology Center have shown that the CrazyMill Cool SF also produces excellent surfaces in lead-free brass, copper, cobalt-chrome and Inconel.
The CrazyMill Cool SF is one of three new tools introduced by Mikron Tool. The high-performance bit, CrazyDrill Titanium TN / TK, for all types of titanium, and the CrazyMill Cool CF have also debuted.
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