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The Excelerator® XF

What is High-Feed Milling? Definition: Utilizing an inserts lead angle to create a chip-thinning effect that allows the cutter to run at high feed rates and shallow depths of cut

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What’s the difference? Traditional Milling High-Feed Milling

What makes it work? The insert’s relationship to the part

What makes it work? Chip Thinning

Cutting Forces The 10 degree lead angle directs most of the cutting pressure axially.

High-Feed vs. Round Depth of cut does not affect chip thickness on the Excelerator® XF; this is not the case when using a round insert.

High-Feed vs. Round Bull Nose Cutter Excelerator® XF Diameter 1.5” 1.5” # of inserts 5 5 Insert IC 4 3 D.O.C. .040” .040” W.O.C. 1” 1” S.F.M. 800 800 I.P.M. 40 150 A.C.T. .003” .003” Cubic IPM 1.6 per minute 8.6 per minute

90° Cutter Excelerator® XF High-Feed vs. DOC 90° Cutter Excelerator® XF Diameter 1.5” 1.5” # of inserts 5 5 D.O.C. .250” .057” W.O.C. 1” 1” S.F.M. 800 800 I.P.M. 30 215 A.C.T. .003” .003” Cubic IPM 7.5” 12.26”

Feed rate is dependent on what? Power available at the spindle (to prevent stalling of the cutter) Rigidity of the machine and tooling setup (ability to withstand the tool pressure and speed) Strength of the work piece and work holding (high feed rates will collapse or warp thin wall parts) Characteristics of the material being cut The inserts composition and design

Depth of cut determines the effective diameter and SFM. Knowing Your Depth of Cut Depth of cut determines the effective diameter and SFM.

Effective Diameter Knowing your depth of cut determines SFM

Limiting Factors D.O.C.- The maximum depth of cut is determined by what factors? The bottom corner of the leading edge 1” = .032 Max DOC 1.5” = .055 Max DOC 2.0” = .076 Max DOC 3”-12” = .076 Max DOC The machine’s available horsepower Rigidity of the part and its work holding

Material Limitations Material hardness Part condition Part & fixture design Material composition

SPGN 1” SPGN-222 1.5” SPGN -322 2” SPGN-432 3”-6” SPGN432 Carbide & Ceramic Inserts SPGN 1” SPGN-222 1.5” SPGN -322 2” SPGN-432 3”-6” SPGN432

Carbide Speeds and Feeds

Carbide Wear & Chips GA-5036 insert and chips Hardened material & interruption

Diameters & Insert Sizes Ceramic Inserts Diameters & Insert Sizes 1” SPGN-222 1.5” SPGN-322 2” SPGN-432 3”-6” SPGN-432

Ceramic Edge Prep T1A edge prep – Allows for the maximum amount of edge protection and least amount of tool pressure

Ceramic Wear Ideal wear patterns: Minimal flank wear Little to no chipping Slight D.O.C. notch

Premature Insert Wear Improper speeds and feeds along with excessive entering and exiting the cut can lead to excessive chipping .

Ceramic Chips The chip’s shape, color and thickness can tell you what adjustments need to be made.

Ceramic chips The reduction of feed (.0015” ACT) in hardened materials (58-65rc) will minimize D.O.C. notching and extend tool life while making a thinner chip.

Ceramic Speeds and Feeds

Cutting Forces The limited amount of radial pressure allows for plunge milling at extended length along with high metal removal rates.

Scallop Height The scallop height is determined by the amount of programmed step over.

Maximum Step Over 1” diameter = .580” 1.5” diameter = .840” 2” diameter = 1.050”

Tool Paths To minimize vibration when machining corners, program a larger radius than the cutter radius.

Tool Paths Avoid using a drilling cycle when plunge milling.

Tool Paths Adjust tool paths to eliminate narrow widths of cut.

Tool Paths To decrease depth of cut notching and increase tool life, keep the cutter engaged to the part as much as possible.

Example Keeping the tool engaged as much as possible it can double your tool life. Before After 5/8 Excelerator 5/8 Excelerator 800 SFM 800 SFM .030” DOC .030 DOC 32 IPM 32 IPM Cut Time 15min Cut Time 1 Hour

Kennametal - KenFeed The Competition Our advantages: # of inserts per diameter Available diameters Speed and versatility # of indexes per insert

Kennametal The Competition Limited speed and DOC are also another advantage we have over Kennametal.

Sandvik - CoroMill -210 The Competition Our advantages: # of inserts per diameter Speed and versatility Available diameters

Sandvik The Competition Sandvik’s limited speed and number of inserts in a given diameter proves the Excelerator® XF has a distinct advantage.

The Competition Stellram’s 7792VXD high-feed mill tends to create excessive radial pressure, especially in hardened materials.

The Competition With half the number of inserts per diameter, the Excelerator® XF can easily out-feed Stellram’s 7792VXD.

Tools You Need to Succeed

Tools You Need to Succeed Knowing the actual cutting diameter will make your SFM calculations more accurate and allow for better performance.

Tools You Need to Succeed

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