Introduction

MOLDINO is pleased to present a cutter for the new millennium: the ASR. This addition to the Hitachi Die/Mold Tooling Line is able to achieve extraordinary feeds and metal removal rates in roughing applications on both new and old machines.

The chart below demonstrates the performance difference between standard round insert style cutters and the new ASR. In most cases we are able to increase the feed (fz) up to five times without the need to increase the cutting speed (Vc) thus stabilizing or even increasing tool life.

Features

1.Specialized Radius Cutting Edge for Highest-Efficiency Machining

Thanks to the combination of the shortened cutting edge and special angle, deflection and force during the cutting process are dramatically reduced compared to round insert style cutters. This stabilizes the load and makes high-feed machining possible.
Specialized Radius Cutting Edge for Highest-Efficiency Machining

2.Extraordinary Feed Rates

The ASR's low cut structure enables increases in feed per tooth of up to five times. When cutting steel, a feed per tooth of 0.6 to 3.5mm (0.024" to 0.138") is achievable and already being successfully used. Feed per tooth in cast iron is 0.8 to 4.0mm (0.032" to 0.160"). The data below compares shape and weight of steel chips at different feeds per tooth.

3.Programming Information

By programming R3 (theoretic) as the tool radius, the maximum difference between programming and the final shape is shown.
These small remains will be left in some corners, and will be corrected later by semi-finishing or finishing operations.

4.Direct Milling

Even though the ramp angle is limited due to the cutting edge design, both ramping and helical milling are possible. Please use the following recommendations:
  • Slant Milling
  • Helical Milling

Direct Milling

5.Reduced Radial Deflection Even With Long Overhangs

When horizontal (x,y axis) machining with the ASR, radial forces are kept to an equal level to slant or helical milling, where the main force is in the z axis. This allows the ASR to achieve higher feed rates with less deflection and vibration. This table shows the directional forces.

6.Two to Five Times Greater Efficiency Compared to Conventional Radius Cutters

The ASR is capable of achieving 4 to 5 times greater efficiency in deep milling with an overhang of 3D or more, and 2 to 3 times for shallow milling of 3D or less. This enables faster production resulting in quicker turnaround of components. The chart below compares metal removal rates and overhang lengths for ASR and conventional radius cutters. Two to Five Times Greater Efficiency Compared to Conventional Radius Cutters

Catalog Download

Item ListDownload a PDF file Cutting ConditionsDownload a PDF file Catalog DownloadDownload a PDF file
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