Milling challenging materials like tough steels, stainless steels, superalloys and titanium cause built-up or notched edges and broken inserts that increase tooling costs and cause unexpected downtime. To overcome these challenging ISO P, M and S materials, the new next-generation Seco High Feed SP milling system features a combination of dedicated cutting geometries and insert grades, as well as optimized lead angles, that combine to boost material removal rates, maximize chip evacuation and extend tool life.

Reduce tooling inventories
Packed with versatility, one High Feed SP tool handles a complete range of high-feed milling operations and materials. The tool optimizes such operations as copy milling, ramping, pocketing, face milling and plunging to further reduce tooling inventories. Users optimize milling performance while eliminating the need to switch among numerous tools to implement various machining strategies and part materials.

“Premature tool wear increases job costs and leads to unexpected machine downtime that lengthens production time,” said Benoît Patriarca, Global Product Manager High Feed Milling at Seco Tools. “The combination of dedicated cutting geometries and grades with optimized leading angles of the High Feed SP system allow for faster machining to shorten job turnaround times, while also providing a superior price-to-performance ratio.”

Avoid downtime and scrapped parts
Designed for ease of use, the robust High Feed SP milling tools provide simple foolproof insert indexing that prevents operator mistakes, unexpected machine downtime and scrapped parts. Plus, users can quickly access product information through the Seco data matrix code scanning.

Seco offers a comprehensive range of High Feed SP tool sizes. The range includes:

•  SP10: two geometries, 10 grades, dia 32 to 63mm + inch equivalents
•  SP14: two geometries, 10 grades, dia 50 to 100mm + inch equivalents
•  SP18: two geometries, 10 grades, dia 63 to 160mm + inch equivalents

Seco Tools has expanded its family of PCBN insert grades to cover the entire spectrum of hard part turning applications. Using a new bimodal substrate and coating process, these new inserts extend tool life and increase productivity in a broader range of applications.

Seco’s PCBN grade chain for materials ranging from ISO H05 to H35 consists of CH0550, CBN060K, CH2540 and CH3515 and is designed specifically for turning case hardened steels. They incorporate advanced coatings and a bimodal substrate with coarser grain materials, along with optimized cutting edge profiles for long and predictable machining performance.

CH0550 provides high speed continuous cuts in H05 materials. CBN060K excels in continuous to medium-interrupted cuts in H15 materials. CH2540 offers strong performance in light-to-heavy interrupted cuts in H25 materials. CH3515 handles heavy interruptions in H35 materials.

Each of Seco’s PCBN grades is available in common ISO insert geometries in both metric and imperial specifications. Wiper geometry options are available to further enhance performance.

Seco Tools continues to develop solutions that keep pace with the natural progression of the metalcutting industry. Two of the company’s latest tooling systems that set new standards in precision and performance are the EPB 5831 Slim Hydraulic Chucks and the ER-to-Combimaster holders.

EPB 5831 Slim Hydraulic Chucks
Seco has expanded its line of hydraulic chucks to include the new EPB 5831 with a slender profile that makes it easy to perform semi finishing and finishing operations in confined spaces such as narrow mold cavities. In addition to their slim designs, the chucks are available in long projection lengths of 150 mm and 200 mm to reach deep into workpiece cavities.

These new hydraulic chucks use high pressure and a single pressurized screw to uniformly grip small-diameter cutting tools. This secure clamping results in extreme precision and high repeatability along with a run out of less than 5 µm at 3xD for excellent surface finishes.

The EPB 5831 accommodates 6-mm, 8-mm, 10-mm and 12-mm tool diameters, and with the use of reduction sleeves, the chuck holds various shank types and diameters. For example, with a reduction sleeve, the 12-mm hydraulic chuck can hold 3-mm, 4-mm, 5-mm, 6-mm, 8-mm and 10-mm tools. The chucks are available in HSK-A63, HSK-A100, BT 40 and Seco-Capto C5 machine side connections.

ER-to-Combimaster holders
Seco’s new ER-to-Combimaster holders bring ease of use, stability and unlimited possibilities to multi-tasking machines. This unique system combines ER taper, ER clamping nuts and a ball bearing interface that allows for unmatched tool positioning and tightening during setup.

Highly adaptable, the ER-to-Combimaster tooling system performs face, side and disc milling operations via insert-based milling cutters, as opposed to solid end mills. This allows for higher material removal rates due to larger cutting diameter capacities. Plus, the system’s compact design with short overhangs saves space in the machining area for improved safety and reliability.

Combimaster is available in three ER sizes – 25, 32 and 40 – and five different Combimaster thread-size connections ranging from M8 to M20. The system supports a wide range of interchangeable milling cutter heads, especially those in Seco’s Turbo line

Seco has further expanded the industry’s widest selection of disc milling inserts and cutter bodies. In response to customer demands, Seco has introduced the 335.14 small-diameter exchangeable head system, 335.16 cutter for T-slot operations and cassette versions of the 335.25 cutter that incorporate round inserts.

Incorporating small-diameter exchangeable carbide heads, the 335.14 offers a versatile, precise cutting profile that easily tackles any type of material. These cutters are ideal for groove milling, circlip grooves, full radius profiles and chamfering. Reliable exchangeable head systems control machining costs. The 335.14 product line comes in a wide variety of cylindrical and integrated collet chuck shanks in diameters from 9.7 mm to 34.7 mm that cut widths from 0.7 mm to 5.15 mm.

The highly stable 335.16 cutters incorporate 4-edged inserts to economically perform demanding T-slot operations. Modern insert geometries reduce machining forces and noise for optimum tool life. Centralised cooling channels effectively remove chips and provide excellent surface finishes and finished part quality. Cutters come in diameters from 25 mm to 50 mm based on standardised T-slot dimensions. The wide selection of insert geometries and grades cut many materials in widths ranging from 11 mm to 21 mm.

The expanded line of 335.25 disc mill cutters now includes new cassettes for 16-mm and 20-mm round insert diameters. These cutters perform well in various full side, face or half side and face operations for applications involving corner radii. The exchangeable cassettes ensure long, reliable cutter performance. The large choice of insert geometries and grades provide freer cutting operations and increase cost-efficiency in any type of material. Regular and extra-large cassette sizes accept 16-mm and 20-mm round insert diameters. Cutter diameters range from 100 mm to 315 mm.

Seco Tools has expanded its solutions for achieving high performance and long tool life with the introduction of the Highfeed 6—the latest addition to the Highfeed series of indexable-insert milling cutters. This new cutter features a design created specifically to boost material removal rates and handle high chip loads, resulting in substantial productivity increases and exceptional tool life.

The Highfeed 6 milling cutter offers exceptional performance in steels and cast irons, making it particularly valuable to the mold and die segment. It can also be applied to a variety of difficult-to-machine materials from stainless steel to heat-resistant superalloys. The tool performs equally well in all high feed applications, including face milling, slotting, contouring, plunging and helical interpolation. The large-diameter cutter bodies are capable of 1.8 mm (0.070”) axial depths of cut and feature double-sided inserts with six cutting edges for unsurpassed material removal and low operating costs.

Highfeed 6 inserts mount at low lead angles to direct machining forces up into the machine tool spindle rather than radially against the side of the tool. As such, the tool experiences less vibration and provides long, predictable performance.The flexible Highfeed 6 is available in 13 metric cutters with outer diameters from 50 mm to 160 mm and nine imperial cutters ranging from 2 to 4 inches in diameter, as well as both normal and close-pitch versions. Inserts are available in three cutting geometries. A wide variety of advanced grade and coating options are available.For more information on the Highfeed 6, please contact a local Seco representative or visit www.secotools.com/highfeed6.
Highfeed 6 inserts mount at low lead angles to direct machining forces up into the machine tool spindle rather than radially against the side of the tool. As such, the tool experiences less vibration and provides long, predictable performance.The flexible Highfeed 6 is available in 13 metric cutters with outer diameters from 50 mm to 160 mm and nine imperial cutters ranging from 2 to 4 inches in diameter, as well as both normal and close-pitch versions. Inserts are available in three cutting geometries. A wide variety of advanced grade and coating options are available.For more information on the Highfeed 6, please contact a local Seco representative or visit www.secotools.com/highfeed6.

Headquartered in Fagersta, Sweden and present in more than 50 countries, Seco Tools is a leading global provider of metal cutting solutions for milling, turning, holemaking and toolholding. For more than 80 years, the company has provided the technologies, processes and support that manufacturers depend on for maximum productivity and profitability. For more information on how Seco’s innovative products and expert services bring success to manufacturers across all industry segments,

The Jabro^®-Solid² JS554 range of solid-carbide end mills gains further utility and versatility with smaller neck diameter options. These latest tools provide greater clearance when machining complex components, such as those found in aerospace, medical and general machining applications.

Smaller neck dimensions make it easier to access parts clamped in complicated fixturing arrangements, as well as enable users to take full advantage of 4-axis and 5-axis machining capabilities. The neck sizes are optimised to retain tool rigidity while providing full compatibility with standard toolholder connective systems. The tools maintain their ability to productively machine materials in the ISO P, M, S and other material groups.

JS554 end mills provide high stability and low deflection. They also bring an excellent price-performance ratio to a range of applications, and these latest additions further expand the line’s advanced capabilities.

The range of JS554 end mills covers tool diameters from 3 mm to 20 mm and typical cutting lengths 2xD + 2 mm. Reach lengths are 3xDc. The range also includes corner radius and 45˚-chamfer versions, for both Cylindrical and Weldon shanks

Seco has added a new range of taper-face toolholders to meet machinists’ increasing needs for higher production and process reliability. These new options provide two surfaces of contact to offer increased rigidity and consistency compared with standard holders when machining complex parts at high cutting parameters.

The new taper-face toolholders are designed for use with dual-contact spindle systems. They use plastic deformation of the machine spindle to achieve simultaneous fit of both the taper and the flange face from the holder to create a highly rigid connection and prevent the toolholder from being pulled into the machine spindle. This results in higher run-out precision and better machining accuracy. It also makes it possible for machinists to use higher machining parameters for substantial increases in productivity.

In addition to complex part machining, the taper-face toolholders excel in situations involving long tool overhangs, deep-hole boring and exotic workpiece materials that magnify cutting forces. They are available for spindle connections BT30 TF, BT40 TF, BT50 TF, CAT40 TF and CAT50 TF in both metric and inch programs.

Seco’s new Multi-Directional Turning (MDT) interchangeable heads for use with the Seco Steadylineâ modular vibration-damping tool bar system now incorporate the company’s recently developed GL Connection. Together, the GL Connection and Steadyline bars ensure precision and superior surface finishes for grooving and turning with the new MDT heads in long-reach applications as well as those with high risk of cutting vibrations.

The extremely high-precision GL Connection allows users to quickly, easily and accurately exchange MDT heads and other types on the Steadyline bars. Once the bar is set, tool heads can be mounted and remounted without having to reset the system. The polylobe tapered interface of the patented GL Connection features two positions so that MDT insert cutting edges can be oriented to face either up or down for effective chip control.

Seco recently expanded its successful range of face milling cutters to include an innovative new Double Octomill Cassette Cutter. The new cassette cutters use Seco’s advanced pinlocating technology and high-speed steel pins, to ensure fast, easy and precise insert positioning. Equally important, cassette pockets are adjustable to virtually eliminate axial runout.

The Double Octomill Cassette Cutter incorporates Seco’s patented pocket design and features cassettes that are adjustable in the Z-axis or axial direction. Inserts can be mounted and setup in cassettes separately before they are assembled into the cutter body. Each individual cassette can then be adjusted so that all cassettes are cutting on the same plane. This exact insert positioning allows for increased feedrates while ensuring the best possible surface finishes and the longest tool life. Cassettes are combined with new close-pitch cutter bodies that accommodate Seco’s cost-effective Double Octomill inserts. They are double-sided and provide a total of 16 cutting edges for both economy and high performance. Presently, the Double Octomill Cassette Cutters are available from 125 mm to 315 mm standard, and up to 500 mm as custom. Because the cassettes are modular and removable, they can be quickly and inexpensively replaced if damaged. Users can avoid the expense of replacing an entire cutter body.

Seco recently added new JPD and JC end mills to its line of Jabro products developed specifically for cutting composite materials. These end mills consist of four new geometries that bring fast, efficient cutting to applications involving workpiece materials such as carbon and glass fibre composites as well as carbon reinforced plastics (CRFP).

The JPD group of solid-carbide end mills, which consists of the JPD880 square end mill, JPD850 ball nose end mill and JPD840 compression-type end mill, features brazed polycrystalline diamond plates to achieve fast, efficient cutting and long tool life. Main PCD-plated bodies include through-coolant channels for highly effective chip and dust evacuation. The JPD880 and JPD840 end mills are available in diameters that range from 6 mm to 16 mm, while the JPD850 covers diameters from 4 mm to 16 mm. Two PCD plate lengths – normal and long – are also available for the JPD880.

The JC solid-carbide end mill group, which includes the JC875 solid-carbide router, delivers superior surface finishes via a special edge treatment that prevents wear and ensures the longest possible tool life. An added diamond coating further boosts the tool’s wear resistance, allowing it to withstand the highly abrasive properties of composite materials. Seco also imparted a special chip-splitting design to the end mill for clean cutting actions. Diameter ranges for the JC875 are from 3 mm to 12 mm, with .250″ to .500″ imperial sizes also available.

Overall, all four of these geometries incorporate special advanced designs so that composite workpiece materials remain undamaged during the machining process. As a result, users of these end mills can expect clean, controlled cuts for high surface finish quality.