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2. The Excelerator® XF

3. 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

4. Video!!!!!!!!

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

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

7. What makes it work?
Chip Thinning

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

9. 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.

10. High-Feed vs. Round Bull Nose Cutter Excelerator® XF
Diameter ” ”
# of inserts
Insert IC
D.O.C ” ”
W.O.C ” ”
S.F.M
I.P.M
A.C.T ” ”
Cubic IPM per minute per minute

11. 90° Cutter Excelerator® XF
High-Feed vs. DOC
90° Cutter Excelerator® XF
Diameter ” ”
# of inserts
D.O.C ” ”
W.O.C ” ”
S.F.M
I.P.M
A.C.T ” ”
Cubic IPM ” ”

12. 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

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

14. Effective Diameter
Knowing your depth of cut determines SFM

15. 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

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

17. 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

18. Carbide Speeds and Feeds

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

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

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

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

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

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

25. 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.

26. Ceramic Speeds and Feeds

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

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

29. Maximum Step Over
1” diameter = .580” ” diameter = .840”
2” diameter = ”

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

31. Tool Paths
Avoid using a drilling cycle when plunge milling.

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

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

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

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

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

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

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

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

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

41. Tools You Need to Succeed

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

43. Tools You Need to Succeed

44. The End