Extended-flute cutters are placed under significant load when they remove a large material layer, and their work in such heavy-cutting conditions is characterized by high cutting forces, considerable power consumption, and substantial heat generation.
Intensive material removal requires the use of a cutter with a chip gullet of considerable volume to ensure effective chip evacuation. This decreases the number of the cutter’s flutes (effective teeth), reducing its productivity. In addition, high cutting forces acting cyclically induce serious vibrations. When using indexable inserts that have a chip splitting action, it is possible to avoid these difficulties.
Inserts featuring chip splitters have a geometry that enables the division of a wide chip into small segments.
As a result, cutting forces and power consumption are reduced, vibration is stabilized, and thermal problems are eased.
Inserts with serrated, wavy cutting edges provide efficient machining with a chip splitting (even chip crushing) action. For optimal chip crushing, it is recommended that users mount the inserts in alternative edge configurations on adjacent flutes of the tool. However, even if the inserts are mounted randomly, the tool will continue to mill effectively.
Tangential clamping creates two important advantages within the tool design. First, it enables effective use of the insert’s cross section to enable it to resist heavy loads. Second, this approach ensures strength and rigidity in the tool body.