Three new "crazy" high-performance tools

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Mikron Tool—a global leader in the machining of difficult-to-machine materials in the micro range—presented three new solid carbide tools at AMB 2024: a high-performance drill for all types of titanium and two efficient precision milling cutters tailored to delicate components. With these three new developments, Mikron Tool sets benchmarks in high-performance micro machining.

The "Crazy Ones from Agno" have gone full throttle again: "CrazyDrill Titanium TN/TK", "CrazyMill Cool CF", and "CrazyMill Cool SF" are the latest high-performance micro tools from the Ticino toolmaker Mikron Tool, which has set benchmarks in the machining of delicate materials over the last 25 years and has won several industry awards for their "Crazy Tools".

The tool specialists from Ticino consistently focus on two key factors in their tool developments: Firstly, the highest productivity and, secondly, very long tool life, with a focus on the micro-manufacturing sector in processing complex materials such as titanium, chrome-nickel steels, cobalt-chrome, or high-temperature-resistant alloys like Inconel. These materials are typically used in medical technology, the watch industry, aviation, the automotive industry, and the chemical industry.

In addition, aspects such as the required surface quality and precision on the component throughout the entire lifespan of the tools are in focus. Speaking of surface quality: particularly high attention is given to it with the two high-performance milling cutters, "CrazyMill Cool CF" (Chatterfree) and "CrazyMill Cool SF" (Super Finishing). The range of possible materials that can be processed with the new milling cutters is significantly expanded; more on that below.

The micro drill "CrazyDrill Titanium TN/TK" was specifically developed for drilling all titanium alloys (!) and pure titanium (!) with diameters ranging from 0.2 to 2 millimeters and drilling depths of 3 × d and 6 × d. The TK version can be used with internal cooling from 15 bar, meaning a high-pressure coolant system is not strictly necessary.

Alberto Gotti (Head of Development, Mikron Tool): "We have designed the micro and macro geometries of the 'CrazyDrill Titanium TN/TK' in such a way that it generates high performance for all titanium materials. This is anything but trivial, as the machining behavior of the different types of titanium varies quite significantly. However, there are also similarities in the machining behavior. It is precisely here that we started with the development of the 'CrazyDrill Titanium TN/TK'."

An example: A critical aspect of drilling titanium is that the edge zones in the machining area elastically deform, essentially dodging the tool's cutting edge. As a result, the diameter is tapered again during the drilling process, which typically leads to an increase in torque and, in the worst case, can cause the drill to break.

Alberto Gotti: "This knowledge is crucial in the development of the micro and macro geometries of the drills, which must be tailored to this material behavior to ensure the drilling process is reliable."

Another common feature of all titanium alloys is the high energy input required for machining titanium, which ultimately leads to high heat generation in the cutting zone at the main cutting edges. This heat cannot be sufficiently dissipated through the chips due to titanium’s poor thermal conductivity. Excessively high temperatures at the cutting edges lead to micro-chipping and faster wear of the tools.

Here, the key is to cool, cool, cool, and/or use carbide substrates that have high heat resistance. Moreover, it is crucial to select a high-performance coating that protects the carbide substrate from excessive heat input.

Regarding cooling, Mikron Tool relies on their patented cooling system integrated into the shank, whose kidney-shaped cooling channels already provide highly efficient and targeted cooling from 15 bar coolant pressure and ensure safe chip removal.

The aspects mentioned above were comprehensively taken into account in the design of the micro drill "CrazyDrill Titanium TN/TK." The following design features characterize the new "CrazyDrill Titanium TN/TK" micro drills:

A tip geometry tailored for titanium.

A drill outer profile specifically designed for drilling titanium.

Polished flutes for secure chip evacuation.

A coating specifically designed for titanium materials and drilling.

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Thus, the high-performance drill "CrazyDrill Titanium TN/TK" is capable of drilling all titanium alloys as well as pure titanium with process reliability. The "CrazyDrill Titanium TN/TK" delivers maximum feed rates, very long service life, excellent process reliability, and ultimately very high drilling precision. It expands the titanium drill series "CrazyDrill Cool Titanium ATC/PTC" launched last year.

In the area of milling, two new high-performance cutters have been developed. One is the "CrazyMill Cool CF" Chatterfree and the other is the Super Finishing cutter "CrazyMill Cool SF." A primary goal in the development of these cutters was to mill delicate components with extremely high-quality surface finishes. Applications for such components are commonplace in the fields of medical, aerospace, and watch manufacturing.

Both cutters were designed with specific macro and micro geometries that consistently suppress vibrations during the manufacturing process. The main cutting edges are designed to have an extremely smooth cut. But that's not all. To consistently avoid resonance frequencies during the milling process, both high-performance cutters "CrazyMill Cool CF and SF" feature unequal tooth spacing. Additionally, the individual cutting edges have different helix angles.

Alberto Gotti: "In delicate components such as bone plates, watch components, or aerospace parts with narrow, cantilevered webs, resonance frequencies can occur during the milling process. This significantly hinders the milling process. To avoid this during milling, we need to integrate asymmetry into the cutter geometry, which prevents resonances. For this, we apply mathematical models with which we determine the ideal pitch angles and the variable helix angles of the cutting edges. Ultimately, however, our production must also be capable of grinding these complex geometries in series."

The "CrazyMill Cool CF" is a high-performance micro-milling cutter, designed for a very high material removal rate. Its capabilities can be utilized even with very demanding, delicate component structures, including generating outstanding surfaces without chatter marks. To achieve such results, the latest generation of cutters operates with minimal cutting pressure and completely without vibration.

With its specific cutting geometry and the application of a dynamic milling process, it is the ideal cutter for delicate, thin-walled parts or for parts in unstable clamping. Particularly in the field of medical technology (bone plates), as well as in aerospace (structural components) and the watch industry, the demand is high. The "CrazyMill Cool CF" also efficiently, precisely, and with very smooth operation performs milling operations such as slots, pockets, or other volume-intensive machining.

The mill is available immediately in diameters ranging from 1 to 8 millimeters in two different full cutting lengths (3 × and 4 × d).

The "CrazyMill Cool SF" is a superfinishing mill developed to elevate milled surfaces to a grinding or polishing quality level. The "CrazyMill Cool SF" also features the macro-geometries described above. Additionally, it has a very flat helix angle.

Alberto Gotti: "The shallow helix angle significantly reduces the radial cutting forces while increasing the axial cutting forces. This has a beneficial effect on the resulting machining forces that act on the workpiece and also positively affects the deflection of the cutter, leading to a smooth cut. The result is an extremely quiet milling process, practically vibration-free. We achieve surfaces with a roughness less than Ra 0.3, measured both parallel and perpendicular to the milling direction. That is sensational. For users, this means that subsequent finishing operations, such as grinding or polishing, are either completely eliminated or require significantly less effort."

The "CrazyMill Cool SF" is available in diameters ranging from 1 to 8 mm and in two full cutting lengths of 3 × d and 4 × d. This new super-finishing mill has the perfect ingredients to achieve amazing surface quality: the carbide substrate, the highly efficient cooling concept, the perfect cutting edge treatment, the variable helix angle, the unequal tooth spacing, etc.

Due to the extremely smooth milling behavior of the two high-performance cutters, their tool life has increased significantly compared to the benchmark. Alberto Gotti: "With the 'CrazyMill Cool CF', a very high material removal rate can be achieved while simultaneously obtaining an excellent surface finish on the workpiece. The 'CrazyMill Cool SF' is designed as a finishing cutter, where our focus is on the fastest surface finishing. Here too, due to the extremely smooth, vibration-free milling process, there is a substantial increase in tool life compared to traditionally designed cutter geometries."

Initial trials at Mikron Tool's Technology Center showed that the "CrazyMill Cool SF" generates excellent surface quality in lead-free brass, copper, cobalt-chrome, and Inconel. For all the above-mentioned materials, the "CrazyMill Cool SF" was able to achieve Ra values below 0.3 µm.

At the AMB, visitors at the Mikron Tool booth could get a firsthand look at the latest developments and also inspect test pieces. And the "Crazy Ones from Agno" were, as always, pleased to welcome visitors looking for "crazy" manufacturing solutions.

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