FRAISA Annual Report 20/21

Innovations are the backbone of a company: they ensure long- term competitiveness, secure jobs and guarantee positive fu- ture prospects. With its corporate culture, FRAISA offers an elementary basis for the continuous implementation of highly innovative ideas. Face finishing cutter for surface finishes below Ra 0.1 µm Since surface finishes are subjected to higher loads and tighter tolerances, they play an increasingly important role in compo- nents. The customers' wishes for smooth component floors spurred the product developers at FRAISA to think about com- pletely new concepts. The revolutionary result is a tool with four face cutting edges – three cutting edges primarily for power cutting, and a slightly radially and axially offset cutting edge for the finishing process. The task was to precisely adjust the chip cross section of the finishing cutting edge so that bril- liant surface characteristics of Ra < 0.1 µm could be achieved and long tool lives guaranteed. The design of the finishing cutter had to take into account that process-related radial tool deflections have no negative effect on the machining result. Revolutionary Support Chamfer Technology for the Aluminum Machining The machining of thin and high webs has always been a special challenge. Thin webs deform under cutting forces and tend to vibrate like violin cases. The dilemma of vibration susceptibility and high chipping rates seemed unsolvable for a long time – until the Research & Development department of FRAISA ad- dressed this problem. First, the vibrations on the component had to be reduced. For this purpose, tiny supporting chamfers were ground on the main cutting edge – these had almost no relief angle and thus provided a damping function in the cut. Used for the first time in the AX-FPS aluminum roughing cut- ter, this patented technology has been extremely well received by the market. In addition to the surface quality, the form deviation on the component is also of essential importance in finish milling op- erations. The development of a new range of finishing cutters with machining depths up to 5.2xd was also based on the damping property of narrow support chamfer elements. In or- der to achieve minimal shape deviation at high and thin webs, the very delicate damping support chamfers were continuously reduced towards the end of the shaft. Thus, a constant cutting pressure could be guaranteed over the entire axial engagement length of the tool. This technology feature has also been pat- ented and deeply impresses with its innovative mode of oper- ation. With the newly developed AX finishing tools, thin webs with a height of 5.2xd can be machined in one pass without vibration or loss of shape. Innovations Basis for positive future prospects NX face finishing cutter for highest surface quality Surface material: Inox 1.4301, Ra: 0.11 µm, Rz: 0.62 µm [ 38 ]