Aluminum is relatively easy to machine, especially when compared to heat-resistant superalloys and titanium, but as the silicon content increases or if the material is inherently gummy, controlling chips and economically cutting aluminum can be a challenge. To meet that challenge, toolmaker Lach Diamant, Hanau, Germany, combined its »Cool Injection« coolant-delivery system with the »Plus« chipbreaker to introduce »Cool Injection-Plus« PCD monoblock milling cutters.

According to the company, the combination cutter maximizes tool life, imparts mirror surface finishes, reduces cycle times up to 50 percent and provides high machining parameters, with a feed rate up to 40.000 mm/min. (1.575 ipm) and a cutting depth up to 8mm (0.315 ") at the maximum cutting speed.

The »Cool Injection« system delivers coolant directly through the PCD cutting face. All images courtesy Lach Diamant.

Audi developed the »Plus« chipbreaker.

The through-coolant system delivers coolant directly through the base of the substrate and PCD cutting face, so cooling occurs at the cutting edge, explained Randy Prafke, operations manager for Lach Diamond Inc. "This keeps the heat stable right at the cut."

In addition to emulsion and oil, the tool is also suitable for cryogenics, such as liquid nitrogen and liquid CO2. However, Prafke noted it has to be a special application, such as machining difficult-to-cut materials like cobalt chrome or hard metal-matrix composites, for that to be necessary.

German automaker Audi AG developed and patented the laser-machined chipbreaker, which Lach Diamant incorporated into the cutter design through a licensing agreement. "The chipbreaker is developing the chip and getting the chip to go in the direction you want it to go so you can deal with it," Prafke said.

The cutter concept is suitable for all aluminum processors, particularly Tier 1 and 2 automotive suppliers, but he noted potential applications are more widespread. "Cutting aluminum is what it was built to do, but I know that our mother company, Lach Diamant, has taken this tool to a lot of places. Some of the uses include facing and decking of aluminum engine blocks, heads, transmission components—basically, anywhere in which chip control and high production is in demand."

The toolmaker reports that it assembles a »Cool Injection-Plus« PCD cutter with the adapter of the customer's choice and balances the assembly to G2.5 grade, allowing users to mount the tool on a machine after adjustment. For more information about Lach Diamond Inc., Grand Rapids, Mich, call (800) LACH-USA or visit www.lach-dia mond.com.

About the Author: Alan Richter is editor of CTE. Contact him at (847) 714-0175 or [email protected].