Application of End-Face Annular-Spray High-Performance Tool Holders in HPC Milling

To effectively address the machining challenges posed by these “difficult-to-machine materials,” Diebold has specially developed the UltraJet™ 3.0 face-ring, high-force collet. This new UltraJet™ 3.0 high-force collet is an innovative combination of the JetSleeve™ 2 collet—marketed for many years—and the UltraGrip™ 3.0 face-ring, high-force collet. Designed specifically for HPC milling, it delivers high cutting speeds, extremely high cutting forces, low runout, ultra-high clamping force, and superior cooling performance. As a result, it effectively resolves common issues associated with hard materials such as titanium and nickel-chromium alloys, including poor chip evacuation, frequent tool breakage, low machining efficiency, and poor surface quality when machining deep holes and deep cavities.

Release time:

2023-07-01

In recent years, the demand for higher strength and lighter weight in aerospace components has continued to rise. Consequently, the use of materials such as titanium and nickel alloys in these components has been steadily increasing, with titanium alloys being increasingly adopted for aircraft airframe parts and compressor components of jet engines.

Due to their light weight, excellent corrosion resistance, high specific strength, high thermal strength, and high chemical reactivity, titanium alloys generate relatively high and concentrated cutting forces during machining, which can easily induce vibration and result in chatter. Consequently, they exhibit poor machinability, leading to their classification as “difficult-to-machine materials.”

To effectively address the machining challenges posed by these “difficult-to-machine materials,” Diebold has specially developed the UltraJet™ 3.0 face-ring jet high-performance tool holder. This new UltraJet™ 3.0 high-performance tool holder represents an innovative combination of the JetSleeve™ 2 tool holder, which has been on the market for many years, and the UltraGrip™ 3.0 face-ring jet high-performance tool holder. Specifically for HPC milling and design, featuring High cutting speeds, extremely high cutting forces, low runout, ultra-high clamping force, and superior cooling performance. and other characteristics, effectively addressing the challenges associated with machining hard materials such as titanium and chromium-nickel alloys, including low chip evacuation rates, frequent tool breakage, low machining efficiency, and poor surface quality in deep-hole and deep-cavity operations.

The all-new UltraJet™ 3.0 power tool holder delivers coolant directly to the tool-holder face, with high-pressure nozzles that blow chips out of the cutting zone using coolant, compressed air, or an air–oil mist. In heavy-duty machining, chip accumulation is virtually eliminated, enabling higher cutting parameters and significantly extending tool life—resulting in substantial savings on tool costs.

The Venturi effect keeps the mixture precisely at the cutting edge at all speeds, ensuring optimal cooling and effectively flushing away chips within just a few milliseconds. As a result, milling deep holes and deep cavities has become straightforward—there’s no need for tools with internal coolant delivery. Milling cutters without internal coolant are not only more affordable but also more stable. In summary, this leads to greater process reliability (making unmanned operation possible), longer tool life, improved surface quality, lower tool costs, higher chip evacuation rates, and a significant reduction in the consumption of coolant and compressed air.

The UltraJet™ 3.0 face-ring high-force tool holder delivers maximum clamping force, vibration-damping performance engineered for optimal stability, and exceptional concentricity, ensuring reliable performance at large depths of cut. HPC Milling In this context, it delivers maximum chip evacuation performance through high feed rates and extreme cutting forces.

Diebold UltraJet™ 3.0 Face-Contact Annular Jet High-Performance Tool Holder Features:

■ Low vibration, vibration accuracy < 5 µm

■ Maximum clamping force: up to 4,000 Nm, ensuring the tool is securely held and will not be pulled out.

■ Three-piece system, high seismic resistance, dynamic balancing: G 2.5 at 20,000 min⁻¹

■ Unique Cooling System

Nozzle Design
The Venturi effect ensures that the coolant remains in constant contact with the cutting tool, delivering superior cooling performance.
Instant chip evacuation
No internal cooling required (more affordable and more stable).

■ Multiple specifications available: SK40 / SK50, BT40 / BT50, D-BT40 / D-BT50, HSK63 – HSK100

Face-ring coolant nozzle tool holder, HPC milling tool holder

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Applications of RTCP Ballbar/Probe for Five-Axis Machine Tools

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Applications of RTCP Ballbar/Probe for Five-Axis Machine Tools

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