Overview

This document provides a comprehensive technical guide for the HCM/ACM/SC St SRA Milling Cutter Series, designed for high-speed, precision milling in sectors such as aerospace, automotive, mold making, and electronics. It highlights advanced cutting edge technologies, dynamic balancing, and cooling systems to optimize performance and tool longevity.

1. Product Specifications

• Speed Capability: Cutters support spindle speeds up to 33,000 rpm for smaller diameters, with speed decreasing as diameter increases.
• Material Compatibility: Suitable for aluminum, copper alloys, plastics, carbon fiber reinforced composites, and other industrial materials.
• Insert Types: Utilizes polycrystalline diamond (PCD) and single crystal diamond inserts known for high hardness and wear resistance.
• Insert Seat Design: Precision-engineered seats ensure stable insert positioning and prevent detachment during high-speed rotation.
• Dynamic Balancing: Radial and axial adjustments reduce vibration and improve cutter stability.
• Through-Tool Coolant: Enhances chip evacuation and cooling, extending tool life and maintaining surface finish quality.

2. Cutter Models and Parameters

The series includes cutters ranging from 50 mm to 400 mm diameter, each with specified maximum spindle speeds and tooth counts. Examples include:

• HCM-50-FMB16-6T: 50 mm diameter, max 33,000 rpm, 6 teeth
• HCM-100-FMB32-14T: 100 mm diameter, max 29,500 rpm, 14 teeth
• HCM-400-FS60F-58T: 400 mm diameter, max 9,000 rpm, 58 teeth

Each model details spindle speed limits, tooth count, and weight for precise selection.

3. Insert and Seat Details

• PCD Inserts: Available in multiple geometries (45°, 73°, 75°) with optional wiper edges to enhance surface finish.
• Insert Seats: Interchangeable seats (e.g., ACM-SE12, ACM-AP16, ACM-RP12) tailored for different materials and cutting conditions.
• Adjustability: Micro-adjustments of insert edge height and position within 0.005 mm enable optimal cutting precision.

4. Cutting Technology and Recommendations

• Cutting Edge Angle: Recommended angles (e.g., 45°) balance chip thickness and cutting resistance to maximize tool life and surface quality.
• Engagement Ratio: Suggested cutting width engagement is 70-80% of cutter diameter, adjustable based on machine rigidity and workpiece characteristics.
• Force Components: Radial and axial cutting forces vary with edge angle; smaller angles favor axial force for long-length machining, larger angles favor radial force for thin-walled parts.
• Wiper Inserts: Should be installed 0.03-0.05 mm higher than PCD inserts to ensure proper surface finishing.

5. Material Cutting Conditions

• Recommended cutting speeds (Vc), feed rates (f), and depths of cut (Ap) are specified for materials such as aluminum alloys, copper alloys, plastics, graphite, and CFRP/GFRP.
• Examples: Aluminum alloys at Vc up to 700 m/min, Ap 1-2 mm; CFRP at Vc 100-300 m/min, Ap 0.1-0.4 mm.

6. Tool Assembly and Maintenance

• Balancing must comply with ISO 1940-1/8821 standards, especially for speeds above 10,000 rpm.
• Maximum spindle speeds must not be exceeded to avoid insert detachment and safety hazards.
• Torque specifications for screws and adjustment tools are provided to ensure correct assembly.
• Insert and wedge parallelism must be maintained with general accuracy of 0.01 mm and precision between 0.003-0.005 mm.

7. Accessories and Options

• Standard accessories include adjustment wedges, screws, torque drivers, and various insert holders.
• Interchangeable cartridges and insert seats allow customization for specific applications.
• Options for cutter bodies made from aluminum alloy, copper alloy, and alloy steel with anodized surfaces enhance rigidity.

Additional Technical Details

1. Product Identification and Components

Lists ACM and SCM series components such as aluminum changeable insert seats, converter keys, washers, water screws, and converter kits with detailed model numbers, dimensions, thread sizes, torque values, and weights.

2. Standard and Optional Accessories

Includes adjust screws, fixed screws, G-type rings, shims, PL-type wrenches for cutter height adjustment, cartridge fixing, and screw fastening. Optional accessories like spring pliers and assembly rings are also described.

3. Application Inserts and Cutting Conditions

Details inserts suitable for alloyed steels, stainless steels, cast irons, aluminum, refractory alloys, and hard materials. Inserts are classified by ISO standards and feature coatings such as ultra-micro, polycrystalline diamond, and ultra-hard microprogram coatings.

Cutting conditions specify speeds (Vc), feed per tooth (fz), and depth of cut (Ap) tailored to material type and hardness, differentiating continuous, general, and interrupted cutting.

4. Layer Coatings and Material Compatibility

Coatings like CHF, DP, and ultra-micro are matched to insert types and machining applications. Polycrystalline diamond coatings are emphasized for ultra-hard materials to optimize performance and tool life.

5. Cutting Parameters Tables

• Low-Alloy Steels: Speeds 180-300 m/min, feed 0.10-0.35 mm/rev, depth 0.5-3.0 mm.
• Stainless Steels: Speeds 80-160 m/min, feed 0.06-0.30 mm/rev, depth 0.5-3.0 mm.
• Cast Iron: Speeds 200-300 m/min, feed 0.06-0.30 mm/rev, depth 1.5-3.0 mm.
• Aluminum and Alloys: Speeds 400-1200 m/min, feed 0.05-0.30 mm/rev, depth 1.5-3.0 mm.
• Hard Materials (CBN, PCD): Speeds up to 2000 m/min, feed 0.04-0.10 mm/rev, shallow depths 0.05-0.50 mm.

6. Manufacturer and Contact Information

Contact details for Chain Headway Machine Tools Co., Ltd. are provided, including phone numbers, website, and social media for sales and technical support.

Critical Information and Best Practices

• Perform dynamic balancing adjustments for high-speed operation to minimize vibration and extend tool life.
• Use cutting parameters tailored to material and cutter size to optimize machining efficiency and surface finish.
• Install wiper inserts with the specified height offset relative to PCD inserts for optimal finishing.
• Maintain insert edge alignment and tool assembly precision regularly.
• Strictly adhere to maximum spindle speeds to prevent mechanical failure and ensure operator safety.

This document serves as an essential reference for selecting, assembling, and operating the HCM/ACM/SC St SRA Milling Cutter Series, ensuring high precision, efficiency, and safety in advanced milling applications.