AE-VML long carbide end mill accelerates performance in clamping system production
Founded in 1998, Maskinfabrikken Polund A/S (Polund) is a manufacturer of clamping systems for CNC machines and a subcontractor for metalworking. Employing 10 staff, Polund is located in the town of Otterup in central Denmark, with an estimate production floor space of 1,600-square-meter.
Located in the town of Otterup in central Denmark, Maskinfabrikken Polund A/S (Polund) is a manufacturer of clamping systems for CNC machines and a subcontractor for metalworking.
Initially, Polund was primarily involved with subcontractor work especially for milling and surface grinding. Today, however, Polund’s own brand – PRO-CLAMP Systems – has become the core product of the company. The PRO-CLAMP Systems was invented more than 14 years ago to optimize Polund’s own production. At the time, Polund felt that its advanced machinery could be better optimized if less time was spent on adjustments and chip removal during production. Thus, the PRO-CLAMP Systems – a fast and flexible clamping solution – was created where cleaning, adjusting and clamping of many items can be done in minimal time.
The PRO-CLAMP Systems was invented more than 14 years ago to optimize Polund’s own production.
Today, the PRO-CLAMP Systems has advanced considerably. In addition to the standard lineup, Polund also offers customized solutions to help customers maximize production capacity. Currently, 10 CNC machines at Polund are used to produce PRO-CLAMP standard vices and customer specific clamping systems. About 70 percent of the production is standard and 30 percent is custom. Moreover, approximately 50 percent of the production is exported overseas to countries such as Germany and the United States.
A PRO-CLAMP 5-Axis vice made by Polund, which has a long clamping distance and is ideal for all kinds of clamping associated with 5-Axis machining.
Recently, Polund was looking to enhance productivity on the production of a custom clamping system that requires the milling of deep pockets and a high amount of metal removal. Six parts made of Uddeholm Holdax (DIN 1.2311; prehardened steel) are needed to be milled. The parts are machined using a Mazak VTC 830 SR machining center (BT40 spindle). MST’s shrink fit tool holder is employed for the processing.
One of the six parts of a custom clamping system.
As an existing customer, OSG was called in to offer a solution. OSG Scandinavia sales representative Morten Larsen visited Polund’s facility to inspect the cutting condition. Upon a detail evaluation of the application, Larsen recommended the AE-VML anti-vibration long carbide end mill (EDP# 8556378, 16 x 64, 5-flute).
The AE-VML long type end mill is a part of the AE-VM anti-vibration carbide 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.
The AE-VML long carbide end mill is a part of OSG’s AE-VM anti-vibration carbide 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. The AE-VM’s 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-VM’s unequal spacing of teeth and variable-lead geometry. Furthermore, its unique flute form helps facilitate trouble-free chip evacuation to enable stable and consistent performance. 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. Available in a wide variety of styles and specifications, the AE-VM series is designed to accommodate a wide range of milling operations in stainless steel, cast iron, carbon steel, alloy steel and hardened steel.
Polund was originally using a 16 mm diameter 5-flute competitor solid carbide end mill with TiCN coating for the application. The competitor end mill was used at a cutting speed of 251.2 m/min (5,000 min-1), a feed of 3,500 mm/min (0.14 mm/t), feed per revolution of 0.7 mm/rev, an axial depth of cut of 40 mm, and a radial depth of cut of 0.5 mm. Water-soluble coolant (8 to 18%) was applied. The competitor end mill achieved a metal removal rate of 70 cm3/min. OSG’s AE-VML carbide end mill was tested at a cutting speed of 140.7 m/min (2,800 min-1), a feed of 7,000 mm/min (0.5 mm/t), feed per revolution of 2.5 mm/rev, an axial depth of cut of 40 mm, and a radial depth of cut of 1 mm. Air-blow was used for the coolant. The AE-VML achieved four times the metal removal rate of 280 cm3/min versus the competitor tool.
Left: OSG’s AE-VML end mill in a MST shrink fit chuck.
Right: Photograph of the AE-VML end mill after 500 minutes of milling in Uddeholm Holdax (DIN 1.2311). The AE-VML exhibited normal wear and could continue to be used.
The competitor end mill reached its tool life after milling 250 minutes. The AE-VML, on the other hand, was able to complete 500 minutes of milling, exhibited normal wear, and could continue to be used. Test results have demonstrated that an estimate of 10 hours could be saved by switching to the AE-VML for milling the six custom parts. The AE-VML has outperformed the competitor tool in both machining efficiency and tool life. With the satisfactory result, Polund will look to apply the AE-VML in other applications to further optimize productivity and maximize performance.
From left, Polund founder Ole Tolderlund, OSG Scandinavia sales representative Morten Larsen and Polund founder Lars Pors pose for a photograph at VTM Summit in April 2023. Held in Odense, VTM Summit is an important trade fair for machine tools, tools and equipment for the metalworking industry in Denmark. Polund’s PRO-CLAMP vise was used at the OSG booth for demonstrations during the exhibition.
For more information on OSG’s AE-VML anti-vibration long carbide end mill series, OSG Scandinavia and Polund