In autumn 2021, Gühring presented an innovation in milling. A solid carbide high-performance milling cutter that promises full flexibility and is currently the sharpest milling cutter on the market with its higher rake angle: The RF 100 Sharp. Since then, the tool has been the cause of success stories around the world: Although the materials, applications and machining conditions were always different, the end result was always a satisfied customer who was able to generate a real advantage for their operations. We have summarised five such success stories here.
-50 % machining time
124 kg of steel machined
400 min. milling cast iron
285 %
longer tool life
-14 tools
per week
Application 1: 50 % less machining time with double the tool life
A Korean company manufactures parts for the automotive industry. However, when roughing a shank for a steel drive shaft (15CrMo5), its previous tool concept had reached its limits, as the high machining times were uneconomical over the long term.
Gühring was able to offer a significantly more efficient process here. The Gühring experts advised the customer to use the new RF 100 Sharp with a diameter of 6 mm (art. no.: 6478) with the GTC strategy (Gühring Trochoidal Cutting). This state-of-the-art milling strategy relies on a high cutting depth (ap) as well as the lowest possible and consistent tool wrap due to a reduced radial infeed rate (ae). The result is a significantly faster cutting speed, which enables high material removal rates to be achieved. The particularly easy-cutting RF 100 Sharp high-performance milling cutter unleashes its full potential here and at the same time its AlCrN coating offers a high level of wear protection – even with aggressive cutting parameters. This also pays off in the aforementioned example: Thanks to the tool change, the customer has been able to reduce its machining time by 50 percent. At the same time, the milling cutter achieves double the tool life: With one tool, 20 parts are now produced instead of the previous 10.
| GÜHRING | COMPETITOR |
| Vc = 89 m/min | Vc = 72 m/min |
| Fz = 0,08 mm/z | Fz = 0,046 mm/z |
| Ae = 0,5 mm | Ae = 0,5 mm |
| Ap = 4 mm | Ap = 4 mm |
| n = 4.722 U/min | n = 3.820 U/min |
| Vf = 1.511 mm/min | Vf = 703 mm/min |
Application 2: 124 kg machining volume – despite unstable conditions
When machining steel supporting strips (16MnCr5), a contract manufacturer faced a challenge: The very long machine components could not be clamped stably. In addition, the deep slots required a tool with a long projection length. However, both can lead to vibrations during milling, which promote rapid tool wear.
Gühring was able to offer a significantly more efficient process here. The Gühring experts advised the customer to use the new RF 100 Sharp with a diameter of 6 mm (art. no.: 6478) with the GTC strategy (Gühring Trochoidal Cutting). This state-of-the-art milling strategy relies on a high cutting depth (ap) as well as the lowest possible and consistent tool wrap due to a reduced radial infeed rate (ae). The result is a significantly faster cutting speed, which enables high material removal rates to be achieved. The particularly easy-cutting RF 100 Sharp high-performance milling cutter unleashes its full potential here and at the same time its AlCrN coating offers a high level of wear protection – even with aggressive cutting parameters. This also pays off in the aforementioned example: Thanks to the tool change, the customer has been able to reduce its machining time by 50 percent. At the same time, the milling cutter achieves double the tool life: With one tool, 20 parts are now produced instead of the previous 10.
| Vc = 140 m/min |
| Fz = 0,055 mm/z |
| Ae = 2,5 mm |
| Ap = 18 mm |
| n = 2785 U/min |
| Vf = 613 mm/min |
| Q = 25,57 cm³/min |
Application 3: 400 minutes of milling and no end in sight
Covers for gearboxes are manufactured in a medium-sized company. The gearbox housing covers are made from GGG40 with a tensile strength of 400 N/mm². The material is typical for powertrain components. However, due to its high degree of toughness, typical casting wear quickly occurs.
The RF 100 Sharp mills easily through all materials with a tensile strength of 300 to 900 N/mm². A very sharp rake angle of 12° is ideal for reducing cutting pressure and cutting forces. To manufacture the gearbox cover, the customer used the milling cutter with a diameter of 16 mm (art. no.: 6479) with the GTC strategy. The result is a high machining volume of 128.95 cm³/min. The tool lives are also impressive: After 400 minutes of use, the tool is still good to use.
| Vc = 200 m/min |
| Fz = 0,125 mm/z |
| Ae = 2,4 mm |
| Ap = 27 mm |
| n = 3979 U/min |
| Vf = 1990 mm/min |
Application 4: 285 % longer tool life than the competition
A customer from Korea manufactures particularly thin-walled support rings made of quenched and tempered steel (C45E). However, tool wear was too high when roughing these components, as the interface of a competitor’s modular tool proved to be unstable.
This was where the four-fluted version of the RF 100 Sharp with a diameter of 20 mm (art. no.: 6478) came in. The monolithic, easy-cutting tool exhibits high stability during milling, which is further reinforced by its particularly tough carbide material. As a result, the Gühring tool achieved a 285 % longer tool life in Korea than the competitor’s modular six-fluted cutter: Instead of 70, as many as 200 components can be produced with the new solid carbide milling cutter.
| Number of teeth: Z4 | Number of theeth: Z6 |
| Vc = 100 m/min | Vc = 100 m/min |
| Fz = 0,105 mm/z | Fz = 0,07 mm/z |
| Ae = 1,6 mm | Ae = 1,6 mm |
| Ap = 18 mm | Ap = 18 mm |
| n = 1591 U/min | n = 1591 U/min |
| Vf = 668 mm/min | Vf = 668 mm/min |
Application 5: Save 14 tools per week when machining titanium
A customer from Korea manufactures particularly thin-walled support rings made of quenched and tempered steel (C45E). However, tool wear was too high when roughing these components, as the interface of a competitor’s modular tool proved to be unstable.
This was where the four-fluted version of the RF 100 Sharp with a diameter of 20 mm (art. no.: 6478) came in. The monolithic, easy-cutting tool exhibits high stability during milling, which is further reinforced by its particularly tough carbide material. As a result, the Gühring tool achieved a 285 % longer tool life in Korea than the competitor’s modular six-fluted cutter: Instead of 70, as many as 200 components can be produced with the new solid carbide milling cutter.
| Vc = 58 m/min | Vc = 58 m/min |
| Fz = 0,0066 mm/z | Fz = 0,0066 mm/z |
| Ae = 2 mm | Ae = 2 mm |
| Ap = 4 mm | Ap = 4 mm |
| n = 9.231 U/min | n = 9.231 U/min |
| Vf = 244 mm/min | Vf = 244 mm/min |
To be continued!
Every two weeks, we will present a new component that our customers have successfully processed with the RF 100 Sharp. Don’t want to miss anything? Then sign up for our newsletter here.
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