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Mitsubishi Materials awarded the 2006 CCMA Awards

Development of the BXD end mill for high efficiency machining of aluminum alloy

1.Technical features
• Mainly targeted for use in the aerospace industry for high speed, high performance machining of aluminum alloy, the BXD offers a large increase metal removal rates to allow improved customer productivity to be achieved.

2.Novelty / Originality
• The BXD uses a double phased helical rake angle to reduce the contact area with the chips to reduce cutting resistance, a helical flank to maintain cutting edge strength and a concave cutting edge line for improved chip control. The inserts used in combination with the BXD use a newly developed DLC coating method that leads to reducing the friction on the insert surface, this in conjunction with a substrate the provides high wear resistance leads to longer and more stable tool life.

3.Contribution / Benefits for the Association
• It is possible to achieve a metal removal volume of up to 8,000cc/min, making the BXD a leader in the area of high efficient machining of aluminum alloy. Additionally by using a DLC coating it is possible to carry out dry machining and as such also aids in improving environment awareness.

Development of CBN end mills

1.Technical features
• Conventional CBN end mills did not include long neck versions as problems such as the brazed section breaking occurred. However by using a new bonding method it is now become possible to create long neck CBN end mills. Therefore offering the chance to be used for applications that require longer reaches.

2.Novelty / Originality
• Previously brazing was the mainstream method of joining the CBN piece to the end mill body, but due to the fact that this is weak when used on long neck end mills it could not be put to practical use. With the use of a unique diffusion method that creates no brazed layer, higher adhesion strength between the CBN and end mill body can be achieved and the long neck type end mills can now be put to practical use.

3.Contribution / Benefits for the Association
• Enables stable machining of high hardness materials for long periods to ensure a reduction in the time needed for polishing operations of moulds. In addition, machining with long reaches has become possible. Offering the chance to machine a wider application range.