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Moldmakers and other users who apply small-- diameter solid carbide mills for finish and semifinish machining operations now have an alternative: systems that can provide application flexibility, reduced procurement cost, and, in many cases, productivity improvements versus solid carbide.
The systems consist of steel, heavy metal, or carbide tool shanks to which interchangeable carbide tool inserts can be attached. Multiple insert geometries and carbide grades are available depending on the system, but ball nose configurations popular for mold finishing applications are offered by all suppliers.
Modular systems can save money up front compared with solid carbide tools by allowing use of relatively expensive carbide only where it's needed most-- in the cutting tool itself.
"Carbide, when you come right down to it, is sold by the gram-the amount of material you put into a tool," says Michael Gadzinski, training coordinator, Iscar Metals Inc. (Arlington, TX). "A premium, brand-name solid carbide tool is about 30% more expensive" than Iscar's Multimaster modular tooling, according to Gadzinski.
Mathieu Tapp, product manager for the Fraisa Novosys modular milling system at US importer Fischer USA Spindles (New Brighton, MN), agrees with this assessment. "The material cost share of solid carbide mills can be more than 50% at larger diameters. But only 10% of the carbide is really used for the cutting process. The rest is distributed among the shank and noncutting parts of the tool, and 90% of the carbide is wasted," he says.
But material savings are not the only advantage of modular systems. The real cost reductions, say suppliers, come in improved productivity resulting from higher speeds and feeds than solid carbide tools at the relatively long tool lengths often needed for machining deep cavities.
"The tools give you a longer reach, which is especially important in mold and die applications," says Patrick Sheppard, segment development manager/mold and die for Seco Carboloy (Warren, MI). "For example, it can be difficult to find a 1/4" diam end mill that's 5" long. With [Carboloy's Minimaster] you can get that, and it will run faster than solid carbide."
Modular systems such as the Press Fit from HPI Nikken (Elk Grove Village, IL) can also alleviate clearance problems at longer reaches, according to the company's Preben Hansen. "There are many long tools...