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Milling cutters play a crucial role in mold manufacturing, as they account for approximately 80% to 90% of the total cutting operations in this field. This makes them a central focus for tool developers and manufacturers. At the exhibition, several cutting tool companies showcased complete sets of milling tools specifically designed for mold processing, often displaying the finished molds alongside the tools themselves. This interactive approach attracted a lot of attention from visitors. For instance, Sandvik Coromant presented a wide range of its CoroMill series, many of which are tailored for mold machining.
One of the key trends in milling technology is improving efficiency. Since milling cutters remove the most material during the cutting process, increasing their productivity has become a major innovation focus. The CoroMill 345, introduced by Sandvik Coromant, is a 45° positive face milling cutter with a wiper insert. Compared to standard face mills, it can increase the table feed rate by up to three times while achieving a better surface finish. Unlike traditional wiper cutters that are typically used for precision milling with shallow cuts, the CoroMill 345 can handle depths of up to 6 mm. Tegucico also showcased similar tools at the event, suggesting that these new products could set a new standard in large-depth, high-feed milling, significantly impacting the industry’s performance and efficiency.
Another notable trend was the introduction of new milling cutter designs. Some manufacturers have developed multi-functional tools capable of handling various operations like plane milling, cavity milling, and hole milling, especially useful in mold making. These tools reduce tool change time and enhance productivity. For example, ramping-capable cutters were showcased across different types, including face mills, end mills, shoulder mills, and arc angle mills. This versatility not only benefits mold processing but also offers advantages for general milling applications.
Companies such as Zhuzhou Diamond and Tungaloy have also focused on high-feed, low-depth milling tools to maximize efficiency. Tungaloy even applied this concept to turning tools, introducing the Turning X super-feeding tool, which boosts efficiency by eight times. Meanwhile, Zhuzhou exhibited FMD03, FMD04, and FMP03 series of vertical blade gravity cutters equipped with LNKT blades that offer high efficiency, deep cutting (up to 17mm), and reduced power consumption.
Improving tool economy has also been a major concern, especially for users facing financial challenges. Manufacturers are now focusing on structural improvements to make tools more cost-effective. Double-sided inserts, for example, double the number of cutting edges, while polygonal inserts increase edge count. Face mills with hexagonal, heptagonal, or octagonal inserts have become popular selling points. Dijet’s heptagonal blade face mill and Mitsubishi’s octagonal CBN insert mill are examples of such innovations. VARGUS also showcased thread inserts that double the number of cutting tips, significantly reducing blade costs.
Modular end mills and vibration-reducing tool posts further contribute to cost savings. Companies like Japan Research Institute demonstrated tool posts made from special alloys, offering lower costs compared to traditional hard alloy materials.
Solid carbide end mills remain essential in tooling, and their development continues to evolve. Key trends include anti-vibration designs, hardened die steel milling cutters, and tools for difficult-to-machine materials. Hitachi’s EPOCH MIRUS series uses optimized tooth design and unequal offset blades to reduce vibration and improve efficiency. Canon’s coated cemented carbide end mills are suitable for HRC45–HRC65 die steels, while Mitsubishi’s CoolStar series features internal cooling channels and wear-resistant matrix materials for efficient super alloy machining. OSG also displayed an end mill designed for aerospace composites, featuring a unique groove shape to prevent delamination and burrs.
Additionally, tools for graphite and aluminum alloy machining are gaining traction. These use diamond or diamond-like coatings to ensure efficient processing. OSK’s aluminum roughing cutter, for example, features an angled chip groove that reduces cutting resistance and prevents chip buildup, extending tool life.
Finally, Sandvik Coromant distributed detailed milling application guides, covering cutter selection, parameter setting, and path planning. As CNC machines become more common, traditional methods are no longer sufficient, limiting machine performance. These guides provide valuable insights into modern milling techniques, helping users optimize processes and achieve greater economic benefits. Alongside these, other technical manuals covered turning, drilling, boring, and shank handles, offering comprehensive guidance on advanced cutting technologies. These resources proved to be highly valuable for tool users, making them one of the standout features of the exhibition.