Maximum performance and minimal power consumption = extreme cost reduction!

When milling aluminum, the machine tool is all too often the limiting factor. This is due to the

• reduced spindle torque at high speeds
• existing axial spindle preload and the spindle interface (example HSK-63)
• cooling lubrication and maximum coolant pressure
• tool throats and the stability of the chucking
• active spindle power
• reliable chip removal

Characteristic curves of the spindle torque and spindle power

The torque of a machine spindle decreases significantly as the speed increases. As aluminum is machined in the very highest speed range (n_ACT), the active torque in the operational area (M_ACT) is usually crucial with respect to the spindle’s performance.

One aspect that is often not taken into account but is very relevant is the bearing pretensioning of the spindle. This is why the axial tensile force must be kept as low as possible in order not to damage the spindle.

Since FRAISA has measured the power and torque requirements of the AX-FPS tools, the application data in FRAISA ToolExpert AX-FPS can be optimally positioned on the spindle characteristic to obtain maximum performance without overloading the spindle motor.

The new AX-FPS technology is systematically designed for productivity and cost effectiveness. Very positive, easy-cut geometries paired with mirror-finish flutes ensure excellent chip formation and good chip removal, supported by a central coolant supply. Small, radially mounted surfaces on the tool circumference act as vibration dampers and result in a very smooth and reliable cut. Of course, the AX-FPS cutter also has a high-performance penetration edge that further enhances the tool’s range of applications.

Descriptions of all FRAISA technologies can be found in the main FRAISA catalog.

The new FRAISA ToolExpert AX-FPS calculator is an innovative solution to determining cutting data that match your machine environment. High-performance roughing of wrought aluminum alloys is often not limited by the tool, but by the machine spindle being used and the actual machine environment.

Consequently, FRAISA ToolExpert AX-FPS lets you describe your machine environment clearly, so that you can determine the cutting data that is most efficient and reliable for your application. This option is unique and new and shows that FRAISA is continuing to “digitalize” its application knowhow. The outcome is a customer benefit in respect to cutting production costs and reducing machining times.

How does FRAISA ToolExpert AX-FPS work and what influencing factors are considered?

The functions built into FRAISA ToolExpert were developed from more than a thousand recorded measuring points. Highly productive and reliable system utilization comes about when the degree of capacity utilization of the milling cutter, the machine spindle, and the machine environment is as close as possible to maximum utilization.

Utilization of the milling cutter:
The optimum is the maximum possible chip removal rate of the cutter at the speed selected. The blue bar represents the chip removal rate with the set or recommended cutting data.

Utilization of the spindle:
The maximum is the active spindle power and the spindle torque at the corresponding speed. The blue bar shows the power and torque required by the tool in relation to the active spindle power and spindle torque.

Utilization of the machine environment:
The output variable represents the cutting data recommended by FRAISA to ensure process reliability. These were derived from the entries made with respect to the machine environment. The blue bar shows the difference when the operator adjusts the cutting data.

The goal is to utilize the system as efficiently as possible in order to achieve maximum productivity. FRAISA ToolExpert AX-FPS reveals when too large a diameter has been selected, while utilization of the spindle can be optimally adjusted by setting

reduced cutting data, the performance potential of the cutter is far from being fully utilized. Smaller diameters are therefore recommended for less powerful machines or spindle interfaces.