Next generation AE-VMS anti-vibration carbide end mill
Ikuo Takikawa, OSG Corporation Applications Engineer
The AE-VMS anti-vibration carbide end mill is the latest addition to OSG’s milling tool lineup. It is a next generation end mill series designed to attain an all new level of milling efficiency coupled with superb finish quality suitable for a variety of milling applications.
In the past, OSG has developed end mills based on specific application needs. As machining requirements evolved over time, the need for versatile milling solutions has become increasingly vital. As a result, the AE-VMS development project was introduced to create a new standard for milling solutions.
Enhancing processing efficiency was one of the key objectives of the AE-VMS development project, which could lead to various cost savings due to machining time reduction. An additional focus was to ensure high quality surface finish.
OSG has accumulated a tremendous amount of data over the years and has analyzed in detail the performance of existing products versus other competing products in the market. These data and customer feedback are the fuels to innovation such as the AE-VMS series.
Innovation from trial and error
The hardest part of the development process was to add originality to the product. There were already a wide variety of high efficiency end mills in the market. It was a great challenge to create unique characteristics that can differentiate the new end mill from competing products. Consequently, the concept of the AE-VMS focused on the problem of burrs generated during metal processing. Because many conventional end mills have this problem, OSG’s development team spent many hours seeking for a new method to eliminate burrs.
Addressing a new challenge means a succession of failures. OSG’s product development team seek the cause of the existing problem, developed countermeasures, and solved them in a step-by-step manner. To patiently repeat this process is the work of product engineers. To succeed, each and every challenge has to be addressed honestly and earnestly.
Reduction of Cutting Vibration and Burrs
As illustrated in figure 1, the AE-VMS’ sharp positive rake angle geometry significantly reduces cutting force to minimize tool wear and potential damage to the workpiece even under aggressive cutting conditions. Cutting vibration is minimized with the AE-VMS’ unequal spacing of teeth and variable-lead geometry (figure 2). Furthermore, its unique flute form helps facilitate trouble-free chip evacuation to enable stable and consistent performance. As depicted in figure 3, the AE-VMS is able to achieve stable performance even when the overhang length is L/D=4. With the AE-VMS’ high tool rigidity, the occurrence of burrs can be suppressed to ensure high milling accuracy.
With the addition of OSG’s original DUARISE coating, tool life can be enhanced by its excellent lubricity, superior friction-resistance and high oxidation temperature qualities. As illustrated in figure 4, the AE-VMS is able to consistently suppress cutting heat generation, resulting in stable surface roughness, less tool wear and longer tool life versus other competitor tools. Moreover, the DUARISE coating’s multi-layer construction minimizes thermal cracks, allowing the AE-VMS to excel even in water-soluble oil.
The AE-VMS is designed to accommodate a wide range of milling operations including slotting, side milling, helical milling, contour milling and ramping in stainless steel, cast iron, carbon steel, alloy steel and hardened steel (up to 40 HRC). The cutting trial in figure 5 highlights the AE-VMS’ capability to achieve superior surface finish with no vibration and minimal burrs even in stainless steel. Tested repeatedly to guarantee consistent performance and quality even in difficult-to-machine materials, the AE-VMS is the new standard for milling.