At the cutting edge
Successful pocket milling in grade 5 titanium
It may just be a small battery case, but it’s crucial for many people’s lives. That’s because it is installed in a pacemaker and keeps our internal motor running. However, only perfectly machined parts can guarantee the durability and efficiency required. So, it’s good that, here at Gühring, our hearts beat for precision machining.
Like many companies in the medical field, the Japanese company Microcut Co.,LTD also relies on the material grade 5 titanium (Ti6Al4V). A battery case made of this material does not feel heavy when installed in the body, yet is extremely durable. What is more, the titanium alloy is biocompatible, does not cause reactions or allergies, does not corrode and is not magnetic. But grade 5 titanium also has its pitfalls – especially when it comes to machining.
Goal
Faster milling with less wear
Microcut could not ignore this when milling pockets into the components. After just 32 workpieces, a competitor’s tools were worn out despite being coated. For this reason, the company approached Gühring with the challenge of delivering a tool solution for better tool lives and machining times.
73 times longer tool life
Even after the first tests using the previous cutting parameters, the result was impressive: The tool life of the G-Mold 65 HF was 15 times longer than that of the competitor’s tool. But that was just the beginning. After the customer had adapted their cutting parameters to the new high-performance tool, they increased the tool life 73 times over with the G-Mold 65 HF compared to the competitor’s tool.
Information on the machining setup
- horizontal machining centre MAKINO a61nx
- tool clamping: HSK A63
- cooling: Internal cooling, oil-based coolant
| G-Mold 65 HF, high-feed milling cutter, 4-fluted with internal cooling | Competitor’s 4-fluted cutter |
|---|---|
| Vc = 100 m/min | Vc = 80 m/min |
| ff = 0, 1 mm | ff = 0, 05 mm |
| Vf = 3184 mm/min | Vf = 1273 mm/min |
| n = 7961 U/min | n = 6368 U/min |
| ae = 4,0 mm | ae = 4,0 mm |
| ap = 0,3 mm | ap = 0,3 mm |
| Parts / milling cutter = 2336 | Parts / milling cutter = 32 |
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