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Challenge: How to machine a 125 mm deep cavity with an end mill on challenging aerospace parts with a base corner radius of 15 mm?
Solution: Try an oversized EH interchangeable head mill made of heavy metal cylindrical adapters.
The principle of a modular tool system is essentially a choice of a limited number of accessories to achieve flexibility in processing applications. The standardized interface streamlines tool inventory and delivers versatility without sacrificing the rigidity of the tool system.
Sandvik Coromant Capto and interchangeable heads (EH) are based on the principle of using preloaded taper and flange end faces for extremely high rigidity and strength, resulting in two levels of modularity. The EH system is available in a range of 10 to 32 mm medium diameters with solid carbide tips, machine clamps and boring systems ranging from the typical size range of conventional carbide and indexable insert tools.
The compact construction of the EH tool benefits two very different applications: applications requiring long overhang machining, such as machining on 10-32mm tool diameters on large machining centers (MC), and demanding gauge lengths for tool systems For example, in small and medium-sized machining centers and power head holders for turning centers. Typical interface sizes for turning center turrets include Coromant Capto C3 to C5, while small machining centers that have production efficiency as a core requirement typically have typical interfaces such as BT30 and HSK40/50.
Highly accessible machining requires the tool system to be slender and highly rigid. The EH system meets the requirements by using an oversized shank with a smaller diameter than the tip, so that sufficient space is available between the shank and the part in deep cavity machining.
Deep cavity milling in the aerospace industry is a good application for modular EH systems, combined with carbide or heavy metal adapters to provide the required accessibility without limiting process safety. It is of course also possible to use non-standard custom tools instead of EH systems, but this will involve additional costs and longer lead times, as well as high costs due to tool damage.
Another important feature of the EH system is its compactness: from the spindle end of the machine to the cutting edge, the entire tool assembly consists of only two parts: the adapter and the cutter head, so that a separate tool holder is no longer required. This is exploited in applications that require a short gauge length of the tool, such as the power head holder in the turning center, where the tool length is limited by the diameter of the revolution, ie the required safety distance around the rotating turret.
These applications can have a significant impact on productivity due to the short, rigid EH tool: the depth of cut can be increased by a factor of 10.
to sum up
The modular system offers operational flexibility, safety and the feasibility of standardization. Modular tools with interchangeable heads provide the high accessibility required for deep cavity machining, as well as shanks with short gauge lengths for turrets in tight spaces, and good rigidity for both cases The processing underneath brings productivity.
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Sandvik Coromant EH cutters: flexible and compact