2-FLUTE END MILL FOR ROUGHING AND POCKETING ALUMINUM

Helical Solutions LLC (Gorham, ME) introduces a new, two-flute high-performance, non-serrated end mill for roughing in aluminum applications that has improved the design of three existing rough and finish aluminum-cutting tools. Each of the previously available tools has been special-order products, but now are standard and available from stock.

The new end mill is designated the H35AL-2R and features a two-flute, high-performance design that allows for heavier material removal rates in roughing and pocketing applications as its generous flute configuration allows more room for chips. The H35AL-2R maintains the manufacturer?s reputation for producing one of the tightest cutting tolerances in the aluminum-cutting industry (-.0001/-.0004) and the result will be significantly reduced chatter, fewer programming errors and optimum tool performance.

It also features enhanced strength with a 35 deg helix angle and a choice of two corner radii for each cutter size from 1/8 in to 1 in diameter. The tool is available uncoated or with a ZrN (zirconium nitride) coating that provides improved lubricity for maximum chip evacuation and resistance to abrasion for extended tool life.

Crafted of certified premium sub-micron grain carbide, the H35AL-2R is ideal for roughing and slotting applications and is available in stub and regular lengths. In testing with tool path optimizing software cutting 6061-T6 aluminum, this end mill achieved 1,000 ipm, compared to the 300 ipm for aluminum cutting tool designs previously available in the marketplace.

The test conditions were 1 in depth of cut, ½ in width of cut, 12,000 rpm and .0277 in chip load per tooth. This 100 cu ipm metal removal rate was achieved with a mere 10 percent load on a 20 hp (14.9 kW) vertical machining center. Over time, putting less stress on the machine results in longer machine life and longer tool life.

?The H35AL-2R design and the other three aluminum end mill designs have been performing well in the real world for many years as special-order products,? says national sales manager Scott Thiehen. ?Now, with the launch of the new H35AL series, these tools will be available immediately and at standard tool pricing.?

Three other aluminum end mills have received redesigns for improved strength and compliance with aerospace industry specifications, and now are available as standard. First is the H35AL-RN-R2, which is similar in design and function to the H35AL-2R. The difference is that this tool has a reduced neck diameter with a relatively short flute length, allowing for longer reach into deep pockets while maintaining maximum tool rigidity. Additionally, the tool now includes corner radii for corner strength.

For finishing applications, Helical revised the three-flute H35AL-3R with complete corner radii for improved strength. The H35AL-RN-3R, which also now has corner radii for improved strength, is the longer-reach version of the H35AL-3R. All three of the updated tools are available in shank diameters ranging from 1/8 in to 1 inch, and are made from certified premium sub-micron grain carbide.

Helical Solutions supplies high-quality, high-performance cutting tools for aerospace, energy, medical and every other industry and application. Founded in 2001, Helical specializes in tools for hard-to-cut materials like aluminum and titanium, and in tools customized for particular customer applications. Among the tools offered are coolant-thru tools, form tools, chamfer end mills, corner-rounding end mills, double-angle cutters, dovetail cutters, lollipop cutters, radius end mills and taper end mills.

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Helical Solutions LLC, 29 Sanford Drive, Gorham, ME 48038, 866-543-5422, Fax: 866-350-5968, www.1helical.com .