In modern mold forming and manufacturing, the increasing demands for aesthetic appeal and functional performance in new products across industries such as machinery and electronics, automotive, and home appliances have led to ever more complex parts, resulting in increasingly intricate mold cavity surfaces and a growing proportion of free-form surfaces. This, in turn, places higher requirements on mold machining technologies. Given the complex structure and stringent precision requirements of molds, coupled with significant variations in surface features and material properties across different regions, different types of mold milling cutters are employed accordingly. This paper provides a brief overview of typical machining cases involving mold milling cutters.

(1) Zhuzhou Diamond XMR01 Series High-Feed Milling Cutters

(1) Application areas. High-feed milling cutters are widely used in the mold-making industry, offering higher machining efficiency than contouring tools; among these, tools equipped with quadrilateral inserts are primarily employed for face milling, while those with W-shaped inserts are more commonly used for cavity milling.

(2) Tool Characteristics

1) High cutting efficiency: the small insert geometry and reduced principal rake angle minimize radial cutting forces, thereby significantly reducing tool vibration and enabling substantially higher feed rates.

2) In most applications, it can replace conventional round inserts; compared with round inserts, it features a smaller principal rake angle and a wider finishing land, enabling highly efficient stock removal.

3) During face milling and helical machining, the feed rate must be reduced; during drilling, the axial feed should be set to no more than 0.2 mm/rev, and care must be taken to ensure safety when long chips are produced; during helical reaming, the weekly depth of cut must not exceed the maximum allowable depth of cut ap; S-shaped inserts can also be used for plunge milling (see Figure 4-93).

Figure 4-93 Inclined Plane and Helical Machining

4) Blades are available in two types: Z-shaped and S-shaped; mounting interfaces include straight shank interfaces and sleeve-type interfaces with end keys.

(3) Description of the features of the XMR01 series milling cutters. The hallmark of high-feed tools is the distribution of the primary cutting force along the axial direction, which significantly reduces the radial component and enhances the tool’s impact resistance. Moreover, this design effectively suppresses vibration during long-overhang milling (see Figure 4-94).

Figure 4-94 XMR01 Series Milling Cutters

a) Milling cutter assembly drawing b) Cutting insert c) Machining schematic

(4) Typical Application Cases of the XMR01 Series Cutting Tools (Mold Machining)

1) Client Name: A Domestic Mold Manufacturing Plant.

2) Part Name: Punch Die.

3) Workpiece material: 45 steel.

4) Cooling method: dry.

5) Machining method: Constant-height rough machining.

6) Cutting tool: XMR01-063-A22-WP08-04; insert: WPGT080615ZSR; insert grade: YBM351.

7) Original cutting tool: TXP08-63-22 (a foreign brand); original insert: RB7025/XPKT08T516TR.

8) Cutting parameters: vc = 800 r/min, ap = 1.2 mm, vf = 4000 mm/min.

9) Trial results: The tool was used for 180 minutes, while the RB7025 was used for 157 minutes; its cutting performance outperforms that of the brand’s imported tools.

(5) Typical Application Cases of the XMR01 Series Cutting Tools (Machining Forged Steel)

1) Client Name: A Domestic Heavy-Machinery Company.

2) Part Name: Automotive Fuel Tank Guard Mold.

3) Machining material: 55 forged steel.

4) Cooling method: dry cutting.

5) Machining methods: planar milling; helical interpolation machining.

6) Pre-drilling diameter: φ45 mm, cutting diameter: 115 mm, total machining depth: 60 mm.

7) Cutting tool: XMR01-063-A22-WP08-04; insert: WPGT080615ZSR; insert grade: YBG212.

8) Original cutting tool: FCP05 X65.080AN-1 (a foreign brand); insert grade: LC280TT (a foreign brand).

9) Cutting parameters: n = 610 r/min, vc = 120 m/min, ap = 2 mm, vf = 1500–2000 mm/min.

10) Machining Performance: Face Milling: The tool demonstrates excellent performance during trial cutting, with minimal insert wear, no chipping, and good rigidity and toughness. Helical Interpolation Milling: Also performs well during trial cutting, particularly excelling in helical interpolation milling operations, with uniform insert wear and superior rigidity and toughness.

11) In face milling and helical interpolation milling, the overall performance of the XMR tool outperforms that of the brand’s imported tools.

(2) Oushi Precision Machining Ball-Nose Mold Milling Cutter

Oushiji has developed the indexable fine-finishing ball-end mill PFB (see Figure 4-95) to meet the ever-evolving machining demands of the mold industry. The PFB is available in three distinct shank configurations: a steel shank, a short-shank carbide shank, and a long-shank carbide shank, with shank diameters ranging from φ8 to φ32 mm.

Figure 4-95 Ball-end Mill PFB

In addition, four different insert materials are available, allowing customers to select the most suitable insert body and insert based on specific machining conditions and workpiece materials, as shown in Tables 4-22 and 4-23.

Table 4-22 Blade Performance

Table 4-23 Specific Processing Results of PFB

(3) High-speed feed milling cutter for steep slopes

When using high-feed milling, the tool has a small principal rake angle, resulting in lower radial cutting forces and higher axial cutting forces; consequently, the risk of vibration during machining is reduced, leading to stable and smooth operation. Particularly when the tool overhang is long, the reduced vibration allows for the use of relatively higher cutting parameters. High-feed milling tools feature a small principal rake angle and a shallow depth of cut, but a longer effective cutting edge length, which enhances edge strength. This machining method employs a larger feed per tooth and a faster feed rate, which helps minimize work-hardening and reduces the sustained accumulation of cutting heat in the tool body; therefore, it is well suited for machining difficult-to-cut materials such as high-temperature alloys.

1. Jabro solid-carbide high-feed milling cutters—a perfect tool series for small workpieces and shallow cavities (see Figures 4–96). The JHF980 is suitable for machining steel, stainless steel, cast iron, and superalloys, while the JHF180 is designed for machining quenched and hardened steels.

Figure 4-96 Jabro Solid Carbide High Feed Milling Cutter

2. The Minimaster “Little Demon” high-feed milling cutter, in the φ8–φ12 mm range, benefits from the superior rigidity of Jabro solid carbide end mills and is therefore best suited for applications with small depths of cut.

The Minimaster “Little Demon King” (see Figure 4-97) offers excellent flexibility, with different shank configurations available for each diameter, allowing you to select the optimal tool length for your specific application.

Figure 4-97 Minimaster “Little Demon King” High Feed Milling Cutter

3. R217/220.21 Convex Triangular Series High Feed Milling Cutters—Fixed Insert Holder Series, comprising shank-type and disc-type end mill bodies. Suitable for applications such as face milling, cavity milling, helical interpolation milling, and plunge milling.

R220.21: Cutter body for disc-type end mills.

R217.21: Various types of tool holders.

218.19 Inserts: Available in four different specifications, covering a diameter range of φ16 to φ208 mm. A wide selection of cutting-edge geometries and insert grades makes them suitable for all types of materials (see Figure 4-98).

Figure 4-98 R217/220.21 Convex Triangular Series High Feed Milling Cutter

4. SC12 Square High-Feed Series: SCET120630T Insert—6.35 mm thick, with a nose radius of 3.0 mm. Primarily intended for heavy-duty roughing operations under stable machining conditions. Suitable for milling operations in which the tool is oriented horizontally relative to the workpiece (see Figure 4-99).

Figure 4-99 SC12 Square Rapid Feed Series

5. HF2 and HF4 series high-feed milling cutters with L-shaped inserts represent a new family of small-diameter, high-feed tools designed to deliver exceptionally high productivity on modern CNC machines. The large insert cross-section and thickness enhance strength, while the external arc geometry helps prevent chipping of the cutting edge. The tool body’s “excellent dynamic balancing design” ensures smooth chip evacuation during cavity contour milling, particularly when using long overhang tool holders. Double-sided LO-type inserts further boost machining efficiency and cost-effectiveness. In addition, the product line offers corresponding imperial-size options and a comprehensive range of insert grades and geometries, covering a broad spectrum of materials—including case-hardened steels, stainless steels, and high-temperature alloys (see Figures 4–100).

Figure 4-100 HF2 and HF4 Series High-Speed Feed Milling Cutters

6. The HF6 double-sided convex triangular series features a design with six effective cutting edges and three groove geometries—ME13, M15, and MD17—combined with various insert materials to suit different workpiece materials (see Figure 4-101).

Figure 4-101 HF6 Double-Sided Convex Triangle Series

7. The Double-Sided King quick-feed cutter features the ON09 series with 16 effective cutting edges. Thanks to its unique insert holder design, it delivers high axial and radial accuracy, longer and more predictable tool life, and outstanding cost-effectiveness by using the same R220.48-ON09 inserts as the Double-Sided King face mill—16 effective edges in total. This also reduces insert inventory since the same insert type is used across both the cutter body and the insert. Furthermore, the nickel-plated cutter body extends tool life (see Figure 4-102).

Figure 4-102 ON09 Series

a) Partial assembly drawing of the milling cutter b) Assembly drawing of the milling cutter

(4) TECO Milling Cutters

1. DoFeed High-Feed Milling Cutter

(1) Product Overview. Since its introduction, the DoFeed high-feed milling cutter (see Figure 4-103) has been widely used in mold manufacturing, aerospace, power generation, and other industries. It is suitable for high-efficiency rough machining operations such as face milling, slot milling, cavity milling, ramp milling, plunge milling, and helical milling of materials including steel, stainless steel, cast iron, titanium alloys, nickel-based alloys, and quenched steels.

Figure 4-103 DoFeed High-Feed Milling Cutter

(2) Product Features: The highly economical four-cutting-edge insert design, combined with coolant-hole-equipped tool bodies to ensure smooth chip evacuation, and a low-force geometry that guarantees vibration-free machining, make the EXN03 milling cutter ideal for high-efficiency machining on medium- and small-power machine tools, while the EXN06 milling cutter is suited for high-efficiency machining on medium- to large-power machine tools. Furthermore, four different insert materials are available to meet the machining requirements of a wide range of workpiece materials.

(3) Application Examples

1) Workpiece Name: Aerospace Structural Component (see Figure 4-104).

Figure 4-104 Aerospace Structural Components

2) Workpiece material: titanium alloy.

3) Application: Cavity milling.

4) Machine tools: MC machining center, BT50 high-power tool holder.

5) Cutting fluid: water-soluble.

6) Tool holder: EXN03R025M25.0-05; insert: LNMU06X5ZER-ML AH725.

7) Cutting parameters: vc = 40 m/min, fz = 0.7 mm/z, vf = 1790 mm/min, ap = 0.5 mm.

8) Cutting performance: Machining efficiency is 3.3 times that of the original cutting tool.

 

2. TECOLO Ball-Finish Nose High-Precision Mold Contour Milling Cutter

(1) Product Overview. The BallFinishNose high-precision indexable mold milling cutter (see Figure 4-105) features a unique clamping mechanism and a completely new coolant delivery system, making it the recommended tool for machining in the mold industry. Its asymmetrical insert positioning geometry ensures secure clamping, which contributes to excellent surface finish and long, stable tool life.

Figure 4-105 BallFinishNose High-Precision Indexable Mold Milling Cutter

(2) Product Features

1) Asymmetric inserts enhance the repeat positioning accuracy of indexable inserts, ensuring minimal runout and high precision.

2) Two series of inserts—ball-nose inserts and rounded-corner inserts—are available to meet the machining requirements of the mold-making industry.

3) High-precision ball-nose inserts can be used for high-precision 3D machining.

4) The insert features three directional coolant channels that deliver ample cutting fluid to the cutting edge.

(3) Application Examples

1) Workpiece Name: Automotive Parts Mold (see Figure 4-106).

Figure 4-106 Automotive Parts Mold

2) Workpiece material: SKD11 (60 HRC).

3) Applications: Contour machining.

4) Machine tool: horizontal machining center, BT50 tool holder.

5) Cutting fluid: Internal cooling.

6) Tool holder: EBFM20S20C220; insert: ZFBM200R00-MJ AH710.

7) Cutting parameters: vc = 283 m/min, fz = 0.39 mm/z, ap = 0.15 mm.

8) Machining performance: Tool life increased by 1.3 times.

 

(5) Arrow-shaped milling cutter

High-feed milling cutters, also known as high-feed end mills, operate on the principle of optimizing the geometry of the cutting edges to reduce radial cutting forces while increasing axial cutting forces. By leveraging the high compressive strength of cemented carbide, these tools achieve rapid stock removal. Consequently, compared with conventional milling cutters, they offer greater overhang and a larger per-tooth feed rate.

1. Indexable High-Speed Milling Cutter

(1) Product Overview. Indexable end mills with replaceable cutting inserts (see Figure 4-107) represent one of the key development trends in carbide milling tools. Many of the world’s leading tool manufacturers have introduced similar products. Owing to the characteristics of high-speed milling cutters, they are less sensitive to machining depth than conventional milling cutters, making them suitable for machining slots or surfaces with large overhangs. Available sizes: φ8 mm, φ10 mm, φ12 mm, φ16 mm, φ20 mm, and φ25 mm.

Figure 4-107 Indexable-Insert High-Speed Milling Cutter

a) Milling cutters and cutter heads b) Standardization of milling cutter series

(2) Product Features

1) High production efficiency, with a feed rate of 1 to 1.6 mm/rev.

2) Short taper with T-shaped thread positioning is employed, ensuring reliable connection, high positioning accuracy, and coaxiality ≤ 0.015 mm.

3) The tool holder is compatible with a variety of tool heads.

4) Low cost—simply replace the cutting head when it wears out.

5) The maximum machining depth can exceed six times the diameter.

(3) Application Examples

1) Part: Non-freeform integral impeller (see Figure 4-108).

Figure 4-108 Integral Impeller with Non-Freeform Surface

a) Impeller workpiece b) On-site machining diagram

2) Part material: FV520B.

3) Part dimensions: φ16 mm high-speed milling cutter for rough milling the impeller flow passages.

4) Machining parameters: vc = 100 m/min, ap = 1 mm, ae = 16 mm, f = 1.6 mm/rev.

5) Machining life: continuous machining for 90 minutes.

2. YESTOOLS Solid Carbide High-Speed Milling Cutter

(1) Product Overview. This product utilizes ultra-fine-grained, imported European carbide rod stock, combined with an appropriate nano-scale PVD coating, stringent process control during manufacturing, and a meticulous edge-post-treatment procedure, all of which significantly reduce the likelihood of chipping and breakage at the cutting edge, thereby enabling high-speed, high-feed machining (see Figure 4-109).

Figure 4-109 Solid Carbide High-Speed Milling Cutter

a) Milling cutter b) Top view of the milling cutter

(2) Product Features

1) High production efficiency.

2) High rigidity, large core diameter design.

3) Unequal tooth spacing vibration-reduction design for stable machining under large overhang and high feed rates.

4) Top-grade TiAlN coating, combining high wear resistance, a low coefficient of friction, and excellent adhesion.

(3) Application Examples

1) Machined part: a certain military product.

2) Part material: 42CrMo, quenched and tempered to 280–300 HBW.

3) Tool specifications: φ10 mm, machining depth 50 mm.

4) Machining parameters: vc = 180 m/min, ap = 0.8 mm, ae = 10 mm, f = 1 mm/rev.

5) Machining life: 325 m.