SX – High Dynamic
Cutting HDC
20% higher
productivity
30 % longer
tool life
FRAISA product
quality
Sustainable thanks
to FRAISA ReTool®
Process stability
that inspires
Verified application
data
With its multi-tooth SX high-performance milling cutters, FRAISA has developed a completely new milling series designed specifically for machining all stainless steels and difficult-to-machine materials. The tool technologies and application data have been specifically configured for penetration and high-performance High Dynamic Cutting (HDC) machining.
The tough, abrasive materials result in the cutting edges being subject to extremely high thermal and mechanical loads. The number of cutting edges has been increased so that the load is distributed over more teeth and the service life of the tools can be significantly extended. As a result, you benefit from high productivity and a long tool life by choosing to use the new SX tools.
With the new DURO-XI coating, stainless steels and nickel- based alloys, which effectuate the highest thermal as well as abrasive loads on the cutting edges, are able to be machined. Thanks to their optimized flute geometry and extremely light and low-vibration cut, SX milling cutters enable you to achieve the highest stock removal rates. Also new: the high-performance penetration edge for multiple
flutes enables rapid penetration – actively supported by the central cooling channel bore at the center of the end face. The new chip breaker concept additionally ensures that no machining zones or machine spaces are blocked by long chips.
Parallel to developing the tools, we also compiled the necessary application knowledge. FRAISA ToolExpert® 2.0 provides you with perfectly coordinated cutting data to ensure optimum tool use. Prerequisite for utilizing this outstanding tool technology is a CAM system that facilitates HDC programming.
The advantages
- Outstanding cost-performance ratio
- Chip removal rate (+20%), tool life (+30%), repeat accuracy and reliability
- FRAISA ToolCare® tool management, FRAISA ReTool® tool reconditioning and FRAISA ReToolBlue tool recycling
- Two different lengths with catalog cutting data
- Diameters ranging between 6 mm and 20 mm
- Two different lengths: standard and medium-long, with enlarged cutting edge lengths
- Wide range of workpiece material applications
- For replacing existing applications and as a solution for new applications
- Low force producing tools for dependable use in demanding applications
- Perfection – FRAISA ToolExpert® 2.0
- Cutting performance data and upgraded material table
- Quick, simple, and reliable cutting-data search function
- Automatic data transfer to CAM
High Dynamic Cutting (HDC) The five building blocks for successful implementation
The technologies of the SX high-performance milling cutters for HDC machining
SX high-performance tools are made of a strong-edged, ultrafine-grain carbide with excellent wear properties. The positive, easy-cut geometry with reinforced cutting-edge corners facilitates optimum chip formation, good chip removal, and excellent tool stability.
The coating plays a crucial role with respect to wear resistance. The PVD coating, which contains elements that make it a perfect match for the intended range of applications, protects the substrate from extreme thermal and abrasive stresses. FRAISA’s development engineers also recognized early on that chip breakers are essential.
The long chips and their removal place considerable demands on the machine environment – the tools can therefore have up to 24 chip breakers.
To ensure reliable and rapid penetration of the multi-toothed tools, our engineers have developed a new high-performance penetration edge with an internal cooling channel.
SX – all in all, a perfectly coordinated tool technology for HDC machining.
Detailed descriptions of each technology can be found in our “High-performance milling tools” catalog.
Higher productivity and a longer tool life thanks to multiple high-performance cutting edges
Due to the significantly lower thermal conductivity (λ) of stainless and acid-resistant steels (λ = 21 [W/(m · K)]) compared to steel (λ = 46 [W/(m · K)]), the temperatures at the cutting edge rise rapidly, which means that the cutting speed can be increased to only a very limited extent. It therefore makes sense to use tools with multiple cutting edges and the HDC-S machining strategy in these materials. In this way, wear can be spread over more cutting edges.
With the data specified in FRAISA ToolExpert®, it is possible to increase the chip removal rate by 20%. To increase tool life by 30%, the same feed rate (as for a z4 tool) can be used. This reduces the feed rate per tooth and increases tool life. The extended cutting edge also allows higher ap values to be realized, further increasing performance.
Downloads
| Brochure |
|---|
| SX – High Dynamic Cutting HDC |
The new SX high-performance milling cutter from FRAISA has been developed specifically for machining stainless and acid-resistant steels. A high degree of universality, excellent cutting performance and a long tool life are its trademarks.
During countless cutting trials, the cutting-edge geometry has been optimized in such a way that maximum stability and very low-friction chip discharge have been achieved at the same time. The result is silky smooth running of the cutter with low cutting forces. Very tough but also abrasive rustproof and acid-resistant materials pose a challenging complex of loads for tools. Ultrafine- grain carbides have a high hardness and considerable edge strength.
Ultrafine-grain carbides form the basis of SX highperformance milling cutters. To protect the carbide from high temperatures and abrasive wear, an extremely smooth DURO-Si hard coating was chosen. As a result, the hardware of the cutters is made up of perfectly coordinated components.
In addition to FRAISA’s innovative tool and production technology, another point is fundamental to the success of SX tools: The expertise of the cutting data matched to the materials of the “INOX” group. This knowledge is integrated in the new ToolExpert 2.0 cutting data calculator and guarantees simple, reliable, and fast implementation in production. This makes milling difficult stainless and heat-resistant steels easy.
The wide range of applications SX high-performance milling cutters are capable of is another big benefit of this new technology. In addition to the main purpose for which they were designed, namely, HPC processes, these cutters are also ideal for HDC machining. After use, the tools can be restored to their original condition by the FRAISA ReTool® reconditioning service and later recycled by means of ReToolBlue service at the end of the service life.
The advantages
- Excellent cost-performance ratio:
- High performance, long tool life, repeat accuracy and reliability
- ToolCare® tool management, FRAISA ReTool® tool reconditioning and ReToolBlue tool recyclinge
- Application know-how for stainless, acid- and temperature- resistant steels
- Comprehensive range with catalog cutting data
- Diameters between 3 mm and 20 mm
- Two different lengths: standard and medium-long
- Specially developed catalog cutting data for HPC machining
- Tools with a corner radius available on request (custom-made)
- Wide range of applications
- For replacing existing tools and as a solution for new applications
- HPC machining with 65% ae and 1.5xd ap, ToolExpert 2.0 with HDC machining
- Maximum performance thanks to the perfect combination of tool type and cutting data
- Soft-cutting tools for dependable use in demanding applications
- Perfection – FRAISA ToolExpert® 2.0
- Completely revised cutting performance data and revised material table
- Quick, simple, and reliable cutting-data search function by entering the material number
- Automatic data transfer to CAM
The technologies of the SX high-performance tools
The new SX technology was developed in FRAISA’s Production department and Test Center, while the FRAISA ToolSchool was responsible for developing and validating the cutting data. All product development measures were focused on achieving high productivity, a long tool life and cost efficiency.
A strong-edged, ultrafine-grain carbide with excellent wear properties forms the basis of the SX high-performance tools. A positive, easy-cut geometry was combined with optimized flutes and an increasing tool core diameter. The result: Optimum chip formation, good chip removal, and high tool stability.
To ensure the SX tools can withstand high mechanical and thermal stresses, the exposed cutting-edge corner has been equipped with a special, robust, polished tooth edge and a small corner radius.
The high-performance DURO-Si coating protects the tools against high temperature loads and ensures maximum performance and tool life by means of its high wear resistance. The SX high-performance tools are ideally suited to HPC and HDC machining and consequently cover a wide range of applications and materials.
Detailed descriptions of each technology can be found in our “High-performance Milling Tools” catalog.
FRAISA tool technology for maximum competitiveness!
FRAISA carries out extensive tests with its own high-performance milling cutters and milling tools made by competitors. We do this to keep a constant eye on the status quo in tool and application technology. These tests involve using the milling cutters in different materials with different milling strategies.
A special focus is placed on HDC milling: Due to the high mechanical and thermal loads, testing with this milling process is particularly intensive. This ensures that the tools can be used for a wide range of materials and applications – while also providing maximum performance and a long service life.
Application expertise for optimum results
Machining stainless, acid- and heat-resistant steels is a
particular challenge. Using the right high-performance tool and the appropriate cutting data for the job is crucial. But it’s also essential to monitor other factors and make optimizations if necessary.
FRAISA performance guarantee through industrial reconditioning
FRAISA ReTool® guarantees 100 % of the machining performance and service life of a new tool. Industrial reconditioning is already being considered during tool development. Our automated production processes ensure maximum performance stability.
Cost savings thanks to FRAISA performance guarantee
Thanks to the FRAISA performance guarantee, you benefit from the reliable 100 % performance of the reconditioned tools. Your machines can produce at an output of 100 % – with new tools as well as after the first, second or third reconditioning.
