5 Things to Know About Helical’s High Feed End Mills

Helical Solutions‘ High Feed End Mills provide many opportunities for machinists, and feature a special end profile to increase machining efficiencies. A High Feed End Mill is a High Efficiency Milling (HEM) style tool with specialized end geometry that utilizes chip thinning, allowing for drastically increased feed rates in certain applications. While standard end mills have square, corner radius, or ball profiles, this Helical tool has a specialized, very specific design that takes advantage of chip thinning, resulting in a tool that can be pushed harder than a traditional end mill.

Below are 5 things that all machinists should know about this exciting Helical Solutions product offering.

1. They excel in applications with light axial depths of cut

A High Feed End Mill is designed to take a large radial depth of cut (65% to 100% of the cutter diameter) with a small axial depth of cut (2.5% to 5% diameter) depending on the application. This makes High Feed End Mills perfect for face milling, roughing, slotting, deep pocketing, and 3D milling. Where HEM toolpaths involve light radial depths of cut and heavy axial depths of cut, High Feed End Mills utilize high radial depths of cut and smaller axial depths of cut.

2. This tool reduces radial cutting forces

The end profile of a High Feed End Mill is designed to direct cutting forces upward along the axis of the tool and into the spindle. This reduces radial cutting forces which cause deflection, allowing for longer reach tools while reducing chatter and other issues that may otherwise lead to tool failure. The reduction of radial cutting forces makes this tool excellent for use in machines with lower horsepower, and in thin wall machining applications.

3. High Feed End Mills are rigid tools

The design and short length of cut of High Feed End Mills work in tandem with the end geometry to produce a tool with a strong core, further limiting deflection and allowing for tools with greater reach lengths.

4. They can reduce cycle times

In high RDOC, low ADOC applications, High Feed End Mills can be pushed significantly faster than traditional end mills, saving time and money over the life of the tool.

5. High Feed End Mills are well suited for hard materials

The rigidity and strength of High Feed End Mills make them excellent in challenging to machine materials. Helical’s High Feed End Mills come coated with Tplus coating, which offers high hardness and extended tool life in high temp alloys and ferrous materials up to 45Rc.

In summary, High Feed End Mill tools with specialized end geometry that utilizes chip thinning and light axial depths of cut to allow for significantly increased feed rates in face milling, slotting, roughing, deep pocket milling, and 3D milling applications. The end profile of a High Feed End Mill applies cutting forces back up into the spindle, reducing radial forces that lead to deflection in long reach applications. Combining this end geometry with a stubby length of cut results in a tool that is incredibly rigid and well suited for harder, difficult to machine materials.

High Efficiency Milling for Titanium Made Easy With Helical’s New HVTI Cutter

Titanium is a notoriously difficult material to machine, especially in aggressive toolpaths, such as those associated with High Efficiency Milling (HEM). Helical Solutions’ new line of tooling, the HVTI-6 series of end mills, is optimized specifically for this purpose, and proven to provide 20% more tool life than a competitor’s similar tool.

At face level, these new Helical end mills feature corner radius geometry, 6 flutes, and are Aplus coated for optimal tool life and increased cutting performance. But there is much more to these end mills than the typical geometry of standard 6 flute tools. The HVTI-6 was designed with a combination of a unique rake, core, and edge design that give it a leg up over standard 6 flute tools for Titanium while cutting HEM toolpaths. Click here to watch the HVTI-6 in action!

End Mills for Titanium

The design of the HVTI-6 was the result of significant testing by the Harvey Performance Company Innovation and New Product Development teams. These teams spent many months testing tools, doing in-depth analysis on materials and tool geometry, and pushing these tools through dozens of hours in the cut at testing sites across the country.

The new HVTI-6 cutter experienced higher metal removal rates (MRR) and 20% longer tool life while performing HEM in Titanium when compared to a standard 6 flute tool offered by a Helical Solutions competitor. This type of tool life improvement will produce huge cost savings on tooling, as well as shortened cycle times and lower cost per part.

Helical HVTI Titanium

The Harvey Performance Innovation team targeted Titanium grade Ti6Al4V for their testing, which accounts for the vast majority of the Titanium being machined in North America. The test part was designed and programmed to allow for a more defined agility test of the tool, taking the tool into key geometry cutting exercises like tight corners, long straight line cuts, and rapid movement.

Many hours were spent with Lyndex-Nikken, manufacturers of high-quality rotary tables, tool holders, and machining accessories, at their Chicago headquarters. By working with the team at Lyndex-Nikken, the Harvey Performance Company team was able to test under optimal conditions with top-of-the-line tool holders, work holding, and machining centers. Lyndex was also available to provide their expert support on tool holding techniques and were an integral part of the testing process for these tools. Video of the impressive test cuts taken at the Lyndex facility can be seen below.

WATCH THE HVTI IN ACTION

In these tests, the HVTI was able to run HEM toolpaths at 400 SFM and 120 IPM in Ti6Al4V, which served as the baseline for most of the testing.

While the standard 6 flute tools offered by Helical will still perform to high standards in Titanium and other hard materials (steels, exotic metals, cast iron), the HVTI-6 is a specialized, material-specific tool designed specifically for HEM toolpaths in Titanium. Advanced speeds and feeds for these new tools are already available in Machining Advisor Pro, and the complete offering is now available in the Helical CAM tool libraries for easy programming.

To learn more about the HVTI 6 Flute End Mills for Titanium, please visit the Helical Solutions website. To learn more about HEM techniques, download the HEM Guidebook for a complete guide on this advanced toolpath.

Helical Solutions: Behind the Scenes

We have shown our end users bits and pieces of our manufacturing process on our website and via social media, but for the first time we decided to open our own doors to the public and show you every step behind how we manufacture and fulfill the Helical Solutions product. We partnered with John Saunders from NYC CNC to create a “Factory Tour” video, covering topics like our CNC grinding machines and setups, tool manufacturing, and our warehouse organization and fulfillment procedures.

In the video below, we first toured our Gorham, Maine manufacturing plan with Plant Manager Adam Martin. Then, we ran a few tests with the Helical tools on our Haas machine, before heading back to our warehouse in Massachusetts to talk about fulfillment and new products with Fulfillment Manager Megan Townsley.

 

 

7 Facts Revealed in Our Factory Tour (Plus 3 More That Didn’t Make the Cut)

We know you’re busy making amazing parts, and might not have time for the entire video. To save you time, here are some of the most important facts you should know about Helical.

We Take Quality Control Seriously

Our high performance end mills go through an extensive inspection and quality assurance process before they end up in your machine, with multiple inspection points along the manufacturing journey. At the 17 minute mark of the video, you can learn more about how we monitor the quality of the tools in batches as they are manufactured. If you skip ahead to the 29 minute mark, you can see some of our more advanced inspection machines in action.

We Stand Behind Our Tools with Our Renewal Services

Our Tool Renewal service is a great way to maximize your cost-savings and avoid having to re-purchase new tools without sacrificing any aspects of the original design. At Helical, we do not re-sharpen tools. Rather, we restore your tools to their original geometry. We will review the condition of your used tools and return the cutting edge to its original sharpness and strength, allowing the tool to retain its outstanding performance. The renewed tools go through the same rigorous inspection, edge prep, and coating process that we follow for all our of our new tools. To learn more about our Tool Renewal services, head to the 23:30 mark in the video.

Our Tool Coating Is Done In-House

We have multiple tool coating machines in-house which allow us to take the ground tools right off the line and transfer them to our coating room to have Aplus, Zplus, or Tplus coatings added. These machines also have the capability to create roughly 20 different coatings, which are reserved for specials and custom orders. If you want a close-up look at the coating room and learn how the PVD coating process actually works, head to the 35 minute mark.

Our Standard Catalog Items Are Stocked and Ready for Your Machine

We don’t make our standard catalog tools to order. All of our standard tools are stocked and ready to make some chips in your machine. We also introduce hundreds of new tools to our annual catalog to keep providing our customers with the latest in high performance tooling technology. You can check out our new tools for 2018, including our new High Balance Tools and Metric Tooling, by heading to 52:20, or take quick look at our rows of stocked tools in our warehouse by jumping to 56:55.

Diamond Wheels Grind Carbide Tools

Diamond grinding wheels are the essential tool (outside of the machine) when it comes to grinding carbide. We have a unique management system for our diamond wheels, and a redressing process which can see these wheels last up to a year or more before they need replacement. Adam goes through our “frozen wheel” room with John at the 32:45 mark in the video above.

We Track Every Batch of Tools With Laser Etching

Our tools are all laser etched on-site with our logo, phone number, and tool description, but also with a specific batch number. These batch numbers allow us full track-ability of every tool so we can quickly asses any questions or concerns a customer may have about a tool. With these numbers, we are able to track the tool’s journey all the way back to which machine it was made on, which grinding wheel was used, and who ran the program. We have a couple of these laser etching machines in Maine, which you can see in action at the 42 minute mark.

If You Can Dream It, We Have Probably Made It

We have had some crazy tool drawings come in to our custom tool program over the years, including oddly shaped form tools, tools with a crazy long length of cut, “paper cutters”, and more. You can see some cool examples of custom tools we have manufactured by jumping to the 20 minute mark. If you are more interested in how we actually make them, head to the 27 minute mark to see one of our large custom tools being ground on our Walter machines.

Our Technical Resources Are Second To None

We don’t leave you hanging after your purchase of Helical tools. We have a multitude of technical resources and How-Tos available here on our blog, and we also offer the HEM Guidebook, a complete guide to High Efficiency Milling techniques.

If you are looking for information on speeds and feeds, we suggest you try our Machining Advisor Pro application. This application is designed to increase metal removal rates and shop productivity by generating customizable running parameters optimized for your Helical Solutions end mills. You can click here to get started with Machining Advisor Pro today.

You Will Always Get a Real Person When You Call Helical

If you have technical questions about an upcoming job, a special application, or tooling selection, you can contact Helical by phone at 866-543-5422. Our technical experts are available over the phone Monday-Friday from 8 AM to 5 PM EST, and you will always get a real person to talk to with no automated systems to navigate through. You can also reach our team by email at [email protected].

Questions about where to buy Helical tools? You can give our team a call, or you can find your local distributor by using the “Find a Distributor” tool on our website. Simply choose your state to see a complete list of authorized distributors in your area.

We’re Hiring!

We have a current list of our open opportunities on our website! Open jobs include CNC Machinist, Quality Control Inspector, and Customer Service Representative.

The Advances of Multiaxis Machining

CNC Machine Growth

As the manufacturing industry has developed, so too have the capabilities of machining centers. CNC Machines are constantly being improved and optimized to better handle the requirements of new applications. Perhaps the most important way these machines have improved over time is in the multiple axes of direction they can move, as well as orientation. For instance, a traditional 3-axis machine allows for movement and cutting in three directions, while a 2.5-axis machine can move in three directions but only cut in two. The possible number of axes for a multiaxis machine varies from 4 to 9, depending on the situation. This is assuming that no additional sub-systems are installed to the setup that would provide additional movement. The configuration of a multiaxis machine is dependent on the customer’s operation and the machine manufacturer.

Multiaxis Machining

With this continuous innovation has come the popularity of multiaxis machines – or CNC machines that can perform more than three axes of movement (greater than just the three linear axes X, Y, and Z). Additional axes usually include three rotary axes, as well as movement abilities of the table holding the part or spindle in place. Machines today can move up to 9 axes of direction.

Multiaxis machines provide several major improvements over CNC machines that only support 3 axes of movement. These benefits include:

  • Increasing part accuracy/consistency by decreasing the number of manual adjustments that need to be made.
  • Reducing the amount of human labor needed as there are fewer manual operations to perform.
  • Improving surface finish as the tool can be moved tangentially across the part surface.
  • Allowing for highly complex parts to be made in a single setup, saving time and cost.

9-Axis Machine Centers

The basic 9-axis naming convention consists of three sets of three axes.

Set One

The first set is the X, Y, and Z linear axes, where the Z axis is in line with the machine’s spindle, and the X and Y axes are parallel to the surface of the table. This is based on a vertical machining center. For a horizontal machining center, the Z axis would be aligned with the spindle.

Set Two

The second set of axes is the A, B, and C rotary axes, which rotate around the X, Y, and Z axes, respectively. These axes allow for the spindle to be oriented at different angles and in different positions, which enables tools to create more features, thereby decreasing the number of tool changes and maximizing efficiency.

Set Three

The third set of axes is the U, V, and W axes, which are secondary linear axes that are parallel to the X, Y, and Z axes, respectively. While these axes are parallel to the X, Y, and Z axes, they are managed by separate commands. The U axis is common in a lathe machine. This axis allows the cutting tool to move perpendicular to the machine’s spindle, enabling the machined diameter to be adjusted during the machining process.

A Growing Industry

In summary, as the manufacturing industry has grown, so too have the abilities of CNC Machines. Today, tooling can move across nine different axes, allowing for the machining of more intricate, precise, and delicate parts. Additionally, this development has worked to improve shop efficiency by minimizing manual labor and creating a more perfect final product.