The flat machining of bi‐metal surfaces or milling applications involving an interrupted cut can present daunting challenges to PCD or carbide milling cutters. The inserts may chip during the milling process, resulting in high machining costs and elevated levels of sub‐standard or rejected parts. The Engis ElectroMill is designed to produce high quality, flat milled surfaces, even if an interrupted cut is present or multiple materials need to be machined simultaneously. It effectively replaces expensive, complex cutters in high volume applications such as high strength alloys, stainless steel, ceramics, cast iron, fiberglass pipe, composites and aluminum.
Features and benefits include high stock removal rates, stress-free cutting action, extended tool life, industry standard adapter mountings and milling cutting dimensions. Additionally, superabrasives deliver longer tool life than conventional milling technology.
Combined with high pressure coolant, the ElectroMill can machine several materials to an extremely accurate value of flatness with very low tooling costs. On cast iron, this hybrid tool can achieve flatness of up to 20 µm and surface finishes as smooth as 8 Ra over a single continuous length of 25,000 inches. In some cases, customers have been able to reduce scrap and reworks significantly; this contributes to increased productivity and an improved bottom line.