Tom Wilkins, general manager of Alexandria Pro-Fab Co Inc, recently switched to the Accelerator Series
1255 TiCN-coated roughing end mills.

He received two surprises: tool life tripled, and the machined-part finish improved from 250 rms to 100 rms.

“tool life tripled, and the machined-part finish
improved from 250 rms to 100 rms.”

This is significant because Tom machines a 1018 welded bracket in lots of 2000, and the previously used
corncob-style TiCN-coated rougher required 50 cutters for the batch.

The special chipbreaker design made it possible to do the same amount of work with only 17 cutters. Not only
were tool costs reduced by more than $1,300, but the number of tool changes had dropped by 33, which of
course adds to productivity.

The part is in the form of a match box, with outside overall dimensions of 5"x6"x2.5" high, and open on both
6" sides. The side walls, top, and the bottom are fabricated from 5/16" hot-rolled 1018. The depth of cut (DOC)
is 0.310", and the cutting speed is 5 ipm.

The top side requires milling a 2.500"x2.500" square hole through it. Here, cutting-tool rotation is 1600 rpm,
producing a cutting speed of 157 sfm. Tom uses an OKK PCV60 vertical mill with a 10-hp drive and a #40
taper toolholder. The parts are machined with flood coolant.

Tom conducted a test with a corncob-style roughing end mill and IMCO's Accelerator model running side by side.
Wilkins reports the results: “The Accelerator's unique chipbreakers along the flutes reduce cutting forces, and
this is critical because of the fragile configuration of the work piece, which also limits clamping pressure.”

Tom adds, “We've enjoyed rapid growth because we try to be progressive. Switching to the Series 1255 TiCN
cutter is a good example of how progress can benefit our customers as well as ourselves.”

Reprinted from Metlfax magazine.

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