The new product, dubbed "Anatomy of an End Mill for Aluminum," is designed to overcome the four significant barriers to aggressively milling aluminum. These barriers include chatter, chips adhering to the tool, the abrasiveness of the material, and controlling the large volume of chips.
One of the most pressing problems in milling aluminum is chatter. This is caused by the uneven spacing of the cutting flutes that prevents regular flute impacts from creating harmonic vibration. The vibration can cause chatter in the walls and floors of the cut, leading to poor surface finish and even tool breakage. To overcome this, Xinfa has developed a unique flute geometry that ensures even flute impact, resulting in a smoother cutting process.
Another challenge in milling aluminum involves chips adhering to the tool. The material's ductility and the high levels of heat generated during the milling process can cause the chips to adhere to the cutting edges, leading to a buildup that can affect the tool's performance. In response to this, Xinfa has developed a specialized coating that reduces the material's adhesion to the tool, preventing chip buildup and allowing for uninterrupted cutting.
The abrasiveness of the aluminum material itself poses yet another challenge. Cast grades of aluminum can contain aluminum oxides left over from the sand-cast process and can also contain the more aggressive silicon oxide. This poses a challenge in ensuring that the tool remains sharp and resists wear during the milling process. To overcome this, Xinfa has developed a carbide material that is specifically designed to withstand the abrasive properties of aluminum, ensuring that the tool remains sharp and performs optimally even under high-stress conditions.
Finally, controlling the large volume of chips generated during the milling process can be a significant challenge as the chips can cause damage to the tool and the workpiece, reduce surface finish, and even pose a safety hazard. To address this, Xinfa has developed a unique chip evacuation system that quickly and efficiently removes the chips generated during the milling process, allowing for uninterrupted cutting and reducing the risk of damage to the tool and workpiece.
The new product is part of Xinfa's commitment to providing innovative and quality mechanical and engineering solutions to its clients. The company's reputation in the market has been built on its ability to provide a comprehensive range of services, including product development, production, and sales, to clients in various industries. Its focus on research and development ensures that the company remains at the forefront of technological advancements, providing solutions that are tailored to its clients' unique needs.
In conclusion, "Anatomy of an End Mill for Aluminum" is an innovative solution to the many challenges associated with aggressively milling aluminum. Xinfa's development of a specialized carbide material, unique flute geometry, a specialized coating to reduce material adhesion, and a unique chip evacuation system all make for a product that ensures optimal performance, reduces waste, and ultimately, improves productivity. As such, the product is set to be a game-changer in the milling industry, providing a much-needed solution to the many technical challenges associated with milling aluminum.