Milling cutters and new processing technology

Product Development Technologies (PDT), based in Lincoln, Illinois, USA, is a global company specializing in new product development, including tool design and manufacturing. Since its establishment, PDT has focused on researching advanced processing strategies to reduce production time and costs. The company has conducted innovative research on high-feed tooling using surface-coated TiAlN milling cutters with APKT square inserts. In August 2004, PDT collaborated with LMT-Fette USA to develop the Twincut Vario high-feed milling cutter, using the LC280TT insert. This tool was applied in high-efficiency mold processing studies. In the final process test, PDT used the modified Twincut Vario cutters along with patented scraping technology to machine the exhaust nozzle core box mold base of a specific car model. The mold base measured 914 x 711 x 127 mm, made from 4140 steel (30HRC). The machining was performed on a Makino MCB 1210 horizontal machining center with a 25 hp power and a No. 50 spindle. The tool had a 178mm overhang. The results were impressive: the machining cost dropped from $12 per cubic inch to $6, tooling cost decreased from $31 to $2, and total production cost fell from $42 to $8 per cubic inch, saving 81.6% compared to the original process. Sarullo, a manufacturing engineer at PDT, noted that processing time was reduced from 17 hours to 5 hours for efficient mold machining. Previously, PDT used tools from another supplier, where replacing 20 blades was necessary. With the Vario cutter, this was reduced to only 5 blades. Sarullo highlighted that the Vario LC280TT blade significantly reduced insert usage. Previously, expensive blades could only last 0.5 hours due to excessive heat, causing wear and damage. Now, the tool life extends to 1 hour and 40 minutes, with 8 cutting edges per blade, greatly reducing indexing time and overall costs. PDT also uses a 69mm diameter Vario milling cutter for different mold bases, operating at 139.3m/min cutting speed, 640rpm spindle speed, 3m/min feed rate, and 3mm depth of cut. Compared to previous 50.8mm conventional cutters, which operated at 122m/min, 764rpm, 0.78m/min, and 5.08mm depth, the Vario cutter’s patented chip technology and 23° positive rake geometry reduced cutting forces by 50%, lowering tool wear and temperature. The key feature of the high-efficiency chip-cutting technology is achieving high feed speeds. “This is the perfect application of the Vario tool,” said Sarullo. “It represents the biggest quality leap for PDT since its founding.” As a result, mold cavity processing time dropped from 17 to 5 hours. The Twincut Vario high-feed milling cutter features a unique patented geometry with two misaligned cutting edges in axial and radial directions. This allows for composite machining, adjusting cutting angles and depths according to part requirements. The width-to-height ratio of the chip cross-section is only 1/4 of previous designs, significantly reducing cutting forces and maximizing tool performance. The tool body is designed to accommodate TC280TT inserts with various materials and 8 cutting edges, each with different rake angles. “The blade doesn’t crack or break,” said Sarullo. “Even under interrupted cutting, the edge remains intact. The LC280TT blade demonstrates exceptional durability, keeping the edge sharp and enabling continuous, uninterrupted cutting.” Unlike traditional methods that extrude metal slowly, the Vario cutter “chops” metal, producing smaller chips—about one-third the volume of before. This makes chip removal easier, requiring only air blow to clean the workspace and maintain a safe environment. Previously, operators had to closely monitor the spindle during machining. Now, with Vario cutters, they can focus on other tasks without stress, as the tool performs reliably within expected wear limits. LMT-Fette’s Vario cutter also addresses noise and vibration issues common in older tools. “Our CMM studio is next door, so reducing interference is crucial,” said Sarullo. The Vario cutter minimizes vibration, maintaining a quiet working environment. Another advantage is that after tool adjustment, parts can be machined without reprogramming, saving time. “With Vario, we can use the same program even if conditions vary slightly, ensuring consistent quality,” said Sarullo. “We don’t have to worry about differences caused by material length or tool overhang.” In summary, Twincut Vario cutters and swarf cutting technology offer exceptional productivity, reducing processing time, tool wear, and costs, while improving safety and enabling unmanned operations. This makes it a highly promising and efficient machining solution for the future.

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