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Milling cutters play a crucial role in mold manufacturing, with their cutting volume accounting for approximately 80% to 90% of the total machining work. As a result, they have become a key focus in the development of mold processing tools. At this exhibition, several cutting tool companies showcased complete sets of milling cutters specifically designed for mold processing, displaying both the tools and the finished molds side by side. This attracted significant attention from visitors. For instance, Sandvik Coromant presented a wide range of CoroMill series milling cutters, many of which are tailored for mold machining.
One of the main innovations in milling cutter technology is improving machining efficiency, especially since these tools remove the most material during the cutting process. The CoroMill 345, introduced by Sandvik Coromant, is a 45° positive face milling cutter featuring a wiper blade. Compared to standard face mills with parallel-edged inserts, it can increase the table feed rate by up to three times while achieving a better surface finish. Traditionally, wiper blades were used in precision milling with small depths of cut, but the CoroMill 345 can handle depths of up to 6 mm. Tegucico also showcased similar tools, suggesting that these new products could set a new benchmark for large-depth, high-feed milling, significantly impacting the industry and enhancing the efficiency and quality of large-scale flat milling.
New cutter structures were also on display at the event. Some recently developed designs have been widely adopted in various milling tools. For example, the ramping-capable milling cutter is ideal for processing mold cavities or closed grooves, offering multiple functions such as planar milling, cavity milling, and hole milling. This reduces tool change time and enhances flexibility. These features were applied across different types of milling cutters, including face mills, end mills, shoulder mills, and arc angle mills, making them more versatile for both mold and general machining applications.
Companies like Zhuzhou Diamond and Tungaloy have also introduced high-feed, low-depth milling cutters, aiming to maximize efficiency. Tungaloy even extended this concept to turning tools with its X-Feeding Turning Tool, which boosts processing speed by eight times. Meanwhile, Zhuzhou exhibited the FMD03, FMD04, and FMP03 series of vertical blade gravity-cutting face mills, equipped with LNKT inserts that offer high efficiency, deep cutting (up to 17mm), and reduced power consumption.
Improving tool economy has become a major focus for manufacturers, especially in the wake of financial challenges. One common approach is to design indexable inserts that can be used on both sides, effectively doubling the number of cutting edges. Hexagonal, heptagonal, and octagonal double-sided inserts have become popular selling points. For example, Dijet’s face mill with a heptagonal blade and Mitsubishi’s face mill with an octagonal CBN insert highlight this trend. VARGUS also introduced thread inserts that increase the number of cutting tips from three to six, reducing blade costs by over 50%.
Modular interchangeable end mills were another highlight, as they reduce tool change time and minimize the need for multiple arbors, lowering overall tooling costs. A vibration-reducing tool post made from a special alloy was also showcased, offering cost-effective performance compared to traditional hard alloys.
Solid carbide end mills continue to evolve rapidly. Their main trends include:
1. **Anti-vibration milling cutters**: Hitachi’s EPOCH MIRUS series optimizes tooth design and uses unequal offset blades to reduce vibration and improve machining efficiency.
2. **Milling cutters for hardened die steel**: Tools like Canon’s coated cemented carbide end mills can process materials with hardness up to HRC65, even reaching HRC70 in some cases.
3. **Cutters for difficult-to-machine materials**: With the rise of aerospace and energy sectors, tools like Mitsubishi’s CoolStar series feature enhanced chip evacuation and internal cooling systems, allowing efficient machining of super alloys.
4. **Cutters for graphite and aluminum alloys**: Diamond-coated tools support high-efficiency machining of graphite electrodes and aluminum parts. OSK’s aluminum roughing cutter, for example, features an oblique swarf groove to prevent chip buildup and extend tool life.
Finally, Sandvik Coromant distributed two comprehensive “milling application guides†at the exhibition, covering cutter selection, parameter settings, and path planning. These guides are essential for modern CNC milling, helping users fully utilize machine capabilities. Alongside, technical manuals for turning, milling, drilling, and boring were also available, providing valuable insights into modern cutting technologies. These resources proved to be more valuable than new tool exhibits, becoming a standout feature of the event and offering great benefits to tool users.