High-volume milling: Solid carbide milling cutter eliminates vibrations

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Experiencing vibrations during milling? This was a huge problem for a Japanese manufacturer of guitar parts: The long protruding tools started rattling during machining and led to a poor component finish. Gühring had the solution: The RF 100 Speed does not only stand out thanks to its high running smoothness, but also thanks to 25 percent longer tool lives.

Heartache, regret and a bed full of roses – this is Jon Bon Jovi lamenting his love life. Meanwhile, an electric guitar is screaming in the background: The notes are vibrating, resulting in quite a painful sound. Guitarists create this special lamentation effect by pulling a metal lever on the instrument’s lower tailpiece. This small movement changes the tension of the guitar strings, thereby adjusting the pitch.

Protruding tools rattle during roughing

At Gotoh, the component’s lateral contour is finished on a vertical machining centre with external cooling, requiring a very high cutting depth of 42 mm. This can only be achieved with a long protruding tool– but this presents it own problems: During machining, the tool starts rattling, resulting in a poor component finish. A competitor relied on a five-fluted milling tool, but the rattling was too strong and machining had to be stopped. “The surface quality was not good due to the long tool length and the slight occurrence of rattling marks”, recalls Yoshiyuki Yamada, a Gühring sales representative. “The customer asked us to solve this problem.”

Solid carbide milling cutter from Gühring with optimised geometry

Gühring has the perfect solution to vibrations during milling: the RF 100 Speed. The solid carbide end mill is particularly well known for its high rigidity, which Gühring achieves through a coordinated flute profile with a high core factor. This enables the milling cutter to absorb the vibrations when milling. The RF 100 Speed also features a high helix of 48° and an unequal blade pitch – both of which promote a smooth, quiet cut.

Because only four cutting edges are used, there a fewer cutting edges in contact with the workpiece than in the competitor’s five-fluted concept; this significantly reduces radial forces and thus the creation of vibrations. The long design of the tool features chip breakers to cut the chips down to short lengths, ensuring smooth chip removal during high-performance machining.

Outdoing the competition in high-volume milling

This was made possible by an innovative combination of optimised micro-geometry and the high-temperature-resistant SuperA coating, which has an excellent combination of hardness and oxidation resistance. With the RF 100 Speed, Gühring has succeeded in bringing stability into the machining process. And, most importantly: The surface quality of the manufactured components is very high. Yoshiyuki Yamada is satisfied: “Gotoh was facing problems that could not be solved with competitors’ tools. However, the tool we proposed immediately ensured a reliable process.”

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