Optimized production conditions are an important factor for manufacturing cutting tools that are intended to meet not only the current challenges in metal processing, but also future ones as well. Tool manufacturer InovaTools from Kinding-Haunstetten, Germany, has reacted. The Bavaria-based company has invested around € 15 million to expand its production capacities and bring its grinding technology up to the latest technology standards. This is paying dividends. One example of this is the Starmax series for HPC end milling of steel materials. Following modifications to the design, the 3^rd generation – the Starmax 3G – is now even more productive.

HPC end milling of steel materials is not for the faint-hearted, as the tools used must achieve high chip removal rates across large engagement widths and depths within a very short time. Despite the moderate cutting speeds, the cutting edge is subjected to enormous cutting forces and suddenly changing loads. The high levels of heat and huge chip volumes that have to be removed quickly and safely from the engagement zone also make life difficult for the tool.

With the VHM-HPC universal end mill concept Starmax (diameter: 3-25mm), tool manufacturer InovaTools from Kinding-Haunstetten has recently made the HPC end milling of steel materials – contour milling, angular infeed milling and pocket milling – quick and cost-effective. Jochen Eckerle, Head of Production at InovaTools: "Thanks to the numerous design advantages, our VHM-HPC Starmax end mills have been the leader of the pack in terms of service life, cutting volume and productivity for many years now compared to similar tools on the market. We have now upped our performance again. Because thanks to our investments in state-of-the-art production technologies as well as development capacities and manpower, we can offer a quick and targeted response to market requirements. The result is the latest-generation Starmax 3G end mill, which now offers even better performance."

InovaTools invests considerably in development and has a dedicated technology center for this purpose at its headquarters in Kinding-Haunstetten. Not only does this offer quick access to combined areas of expertise, it also shortens paths and development times. These advantages also bore fruit in the optimization of the current Starmax end mill, where the tool specialists have increased the core diameter. In addition, there are now four cutting edges with an unequal spiral pitch as well as a defined support chamfer for an even softer cut with even fewer vibrations than before. During the development, particular attention was paid to optimal chip control and removal. This is ensured by a special groove profile with extremely smooth chip grooves in a 40° spiral angle.

Jochen Eckerle: "Ultra-modern technology is required so that our Production department can implement the specifications of our Development department in the best possible way." To achieve this, InovaTools made high investments in new, ultra-modern technology for circular and tool grinding. This was complemented by new, innovative KSS ultra-fine filtration systems as well as progressive testing and measurement technology. Jochen Eckerle: "Once a tool has been well ground and pre-treated, it is completed with a first-class coating. It is therefore only logical that we, as an exacting tool manufacturer, guarantee this end quality ourselves, placing particular emphasis on our own areas of expertise and competence in the process." In keeping with this, the tools from InovaTools receive their high-performance coatings in the dedicated coating center using processes, including nano-composite coating.

This top class standard in coating technology is also used on the new Starmax 3G. Manufactured under temperature-stabilized conditions and using the very latest grinding machines, the special VAROCON smooth coating and the additional end finishing also help to promote the rapid removal of the very high chip volumes during HPC end milling. The high-performance coating also ensures a long service life for the tool.

The new Starmax 3G end mills are available as VHM tools in a short and long version and also as a long shank version with a release. The shank designs are based on DIN 6535 HA/HB, and there is also a special shank design to ensure additional hold. All tools can be used in dry as well as wet machining.

In practical applications, the new generation of the VHM-HPC Starmax 3G end mill really shows off its strengths over its competitors. An example of this can be seen in the manufacturing of a component for machine construction. During full grooving in the hardened and tempered tool steel 1.2312 (tool design z = 4 / Ø 12mm; a_p = 12mm; a_e 12mm; f_z = 0.06mm), the Starmax 3G was operated (compared to the reference tool) with v_c = 130 m/min instead of v_c = 100 m/min and a feed of v_f = 827mm/min compared to v_f = 636mm/min. In the special application, the machining volume (Q) was 120 cm³/min, which is much higher than that of the reference tool (91.7 cm³/min). Jochen Eckerle: "With the Starmax 3G, feed motions up to 1.5×d can be achieved reliably, even during HPC end milling, and even during full grooving. The tools have such a precise concentricity that roughing and finishing is possible with the same end mill. The bottom line is that the new generation of Starmax 3G offers a potential increase in productivity of up to 30 percent in different applications."