Easy-cut and dynamic up to 5.2xd deep
The multi-functional MB-NVDS (MFC) tools launched last year are extremely popular. Each MFC tool enables up to 96 different applications to be handled, allowing users to achieve significant reductions in inventory and machine setup costs as well as tool change times – and reduce their production costs long-term.
Thanks to the high degree of market acceptance of MB-NVDS (MFC) tools, the MB-NVDS tool family has been expanded. While the MB-NVDS tools already available on the market are exhibiting excellent performance in finishing and conventional HPC roughing operations, the new family members are focused on HDC (High Dynamic Cutting).
That is, these tools, with their very robust cutting edge geometry, are ideally suited to penetrating and milling out the component using the entire length of the cutting edge.
The cutting profile of the new MB-NVDS tools has been designed with a more positive edge. A cutting angle of 10° and a treated cutting edge result in a soft and low-vibration cut that in turn reduces machining forces, power consumption and torque input. With the aid of the redesigned double groove and continuous polished teeth, it is now possible to absorb greater thermal and mechanical loads during HDC trochoidal machining.
The new MB-NVDS 5.2xd version can be used to make deep holes and to achieve extremely high material removal rates when HDC-S milling.
The ToolExpert MFC software developed specifically for the MFC family has been updated with the many new applications possible and now provides an outstanding overview of the broad range of uses of this truly unique MB-NVDS (MFC) tool family.
- Reduced logistics and inventory costs,
because one tool can be used for many different applications
- Shorter machine setup times
thanks to a much reduced variety of tool variants
- Reduced capital commitment
for tools and tool holders
- High process reliability
thanks to guaranteed chip removal via a central air and cooling channel
- Reduced loads and lower energy consumption
thanks to smooth cutting and optimum chip removal
- Optimized program cycles and performance
because ToolExpert MFC supplies precise application data
- Optimum life cycle
with ToolCare® tool management, ReTool® tool reconditioning and ReToolBlue recycling
Challenge and targets for production
- More productivity, better performance and longer tool life
- Greater process reliability and reproducibility
- Increased automation
- Better component quality
- Shorter machine setup times and faster use
- Fewer operating costs and investments
- Greater sustainability/sparing use of resources
- Greater application know-how
- Greater flexibility
- Simplification and standardization
MFC solution for successful production
This is where Multi-functional Cutting (MFC) comes into its own. The goal of MFC product development is to reduce these complexities without compromising on performance.
Thanks to MFC, the customer is able to focus fully on their competency in CAM programming and enhance their competitiveness even more in the process!
The technologies behind the new MB-NVDS (MFC) tools
New technologies have a clear goal: They have to offer the user a number of definite benefits. To achieve this, only as many technologies as necessary are built into the tools, in order to obtain the best price-performance ratio. This also includes the application recommendations and cutting data that FRAISA develops at the same time as the tool technology.
MFC with machining depths of up to 5.2xd
using extra-long version with cutting edge length of 5.2xd
- Penetration using the FRAISA penetration edge and central air and cooling channel
- Broader range of applications for complete machining
- Extremely high material removal rates when HDC-S machining
The component featured above was made using just one tool!
Reduced machining forces, power consumption and torque input
thanks to soft and lowvibration cutting
- Mill with a 10° cutting angle and treated cutting edge
- Up to 25% reduction in axial extraction force and up to 20% lower power consumption and torque input
- Better performance in soft structural steel and steel < 850 N/mm2
- Milling with weak chucking or thin-walled components
- Lower energy consumption and spindle load
Multifunctionality as the key factor for simplifying the entire production process
The multi-functional MB-NVDS (MFC) tools with 10° cutting angle launched autumn 2017 are extremely popular. Thanks to the expansion of the range of tools with corner radius, MB-RNVDS, up to 132 different application areas can now be covered. By combining the most productive applications, a 3D part can be finished – up to and including prefinishing – using just one tool! Inventory and machine setup costs, as well as tool change times, are significantly reduced and production costs are sustainably reduced. ToolExpert MFC is a reliable implementation aid!
The cutting profile of the new MB-RNVDS (MFC) tools has been designed with a positive edge. A cutting angle of 10° and a conditioned cutting edge result in a soft and low-vibration cut that in turn minimizes machining forces, power consumption and torque input. The double groove and the continuous polished teeth, from which the corner radius tools also benefit, enable very effective chip removal, so that the thermal and mechanical loads remain low. This relieves the load on the important corner radius at the tool face and facilitates a remarkably long tool life in 3D machining.
The new geometry also reveals its full performance potential in HDC and HPC milling. Supported by Tool- Expert MFC, the MB-RNVDS tool family has grown to include three new individual applications, so that the multi-functionality of the tools can be fully utilized. In addition, ToolExpert MFC now provides an excellent overview of the wide range of applications for this truly unique MFC tool family.
Thanks to reliable and applicationbased cutting data, CAM strategies can be implemented faster and setup times for the workpieces can be minimized.
The advantages of our MB-RNVDS over conventional milling cutters are compelling on all fronts
MB-RNVDS tools are available with a range of corner radii. The large r/d1 variants are particularly suitable for HFC machining. This machining strategy combines all the advantages, so that the amount of residual material in the workpiece is smaller due to the corner radius and the final contour can be approached more smoothly.
To guarantee wear resistance, all MFC tools are equipped with a single pass-ground end cutting face in the radius area and cutting edge conditioning to withstand the highest levels of mechanical and thermal load.
The new individual applications for 3D machining!
The newly added individual applications enable extremely efficient and reliable machining of 3-dimensional workpieces. Process cycles precisely matched to the tool are also suitable for replacing insert tools. The big advantage is simply the fact that the entire machining process for semi-finished products, up to and including pre-finishing, can be carried out using just a single MB-RNVDS tool!
Depending on the workpiece, the CAM programmer can cleverly combine the necessary individual applications: The main volume of the 3D part is first removed using the HDC milling strategy. The remaining material is then roughened away by means of HFC or HSC milling, after which the switch is made to pre-finishing by HSC milling. All cutting data necessary for the individual applications described below have been determined by testing and are stored in ToolExpert MFC.
New application areas for 3D machining!
The unique multi-functionality of the newMB-RNVDStools covers twelve groups of materials, each of which can be combined with eleven specific applications. Thanks to the corner radius, it is possible to use HFC (High Feed Cutting)-and HSC (High Speed Cutting)-strategies, which are the
most productive solutions for machining certain parts. In combination with HDC (High Dynamic Cutting)-, workpieces of a wide variety of materials and tempering conditions can be machined extremely efficiently.
ToolExpert MFC and application technology
Knowledge of the application
In addition to developing the new MB-NVDS-MFC mills with 10° cutting angle, we have also compiled comprehensive cutting data that we have incorporated into the new version of ToolExpert MFC. With just a few clicks, you select the material, application and tool and obtain the parameters that need to be programmed for your machine control or CAM system.
When selecting the tool you require, ToolExpert MFC provides you with information on the performance index and areas. The new MB-NVDS mills with 10° cutting angle and treated cutting edge are ideally suited to HDC milling. The existing MB-NVDS mills (8102/8202 and 8105/8205) are ideally suited to HPC milling. This allows you to match the MFC tools perfectly to your machine environment and application.
Central air and cooling channel
All MFC tools have a central air and cooling channel. In combination with the penetration edge, this channel ensures maximum process reliability and performance, because the chips are immediately removed upwards and away from the area of the penetration edge. Nevertheless, FRAISA recommends that coolant is delivered internally when making penetration depths greater than 1.5xd.
HDC (High Dynamic Cutting) milling
HDC milling offers greater productivity, process reliability and lower loads than HPC milling. However, the faster cutting speeds mean that the processing temperatures are considerably higher. Depending on the component being milled, the working length is longer or shorter and this has a direct impact on the temperature. Reduce or increase the cutting speed in order to regulate the processing temperature; this also enables you to control the amount of tool wear.
Using state-of-the-art CAD-CAM systems to gain a competitive edge
The CAD-CAM system assigns the type of application and the milling strategy to the component to be machined. State-ofthe- art CAD-CAM systems enable a multitude of different machining strategies. High Dynamic Cutting (HDC, aka trochoidal milling) has been implemented in many CAD-CAM systems recently. This process offers significant economic advantages and is a real alternative to High Performance Cutting (HPC) and High Feed Cutting (HFC).
The competitive advantage is to be found in the knowledge of which machining strategy is ideal in respect of productivity, safety, quality and the machine environment. The programmer’s own knowledge of the possibilities offered by their infrastructure also plays a crucial role.
In order to further improve coordination between the infrastructure and use of the CAD-CAM system, FRAISA includes this key element in its regular cutting seminars. Conversations with participants at these seminars reveal that there is a great deal of performance potential still to be teased out.