CERATIZIT’s advanced milling solutions

The machining of advanced materials presents challenges that demand specialised tooling solutions. CERATIZIT has now developed two milling systems that meet the specific requirements of difficult-to-machine materials: the MonsterMill ISO-S for nickel-based alloys and titanium, and the MaxiMill S-Power for cast iron applications.

A Monster That Conquers Nickel-Based Alloys
The machining of nickel-based alloys such as Inconel, Hastelloy, and Waspaloy present significant challenges. CERATIZIT’s redesigned MonsterMill ISO-S range addresses these challenges through a carefully engineered carbide substrate, advanced coating, and optimised geometry. The geometry has been specifically adapted to minimise heat and the polished chip flutes work in conjunction with an optimised coating to reduce friction.
The irregular cutting edge pitch, combined with a variable helix angle, effectively minimises vibration during operation. This design feature significantly enhances machining performance while helping to prevent catastrophic tool failure.
Microgeometry plays a crucial role in the tool’s performance. The precision-engineered preparation of the cutting edge reduces cutting forces while stabilising the edges. The design takes into account regrindability from the outset, offering clear advantages in the reconditioning process.
The DPX22S Dragonskin coating represents a significant technological advancement. Applied in 4 to 6 microns layers, the coating provides thermal stability through its specialised layered structure.
Four-edge cutters come in two different lengths with diameters ranging from 3 to 20mm, available with both HA and HB shank configurations. Five-edge variants offer diameters from 3 to 16mm with similar shank options, while the new six-edge configuration covers diameters from 6 to 16mm with HA shanks. Corner radii options range from 0.2 to 5mm for the four and five-edge variants, with the six-edge version providing 0.2 to 2mm radii.

Optimised Cast Iron Machining
Cast iron also presents its own set of challenges. Here, the MaxiMill S-Power series addresses these issues through a high tooth count design utilising double-sided indexable inserts.
The key innovation lies in the tool’s ability to support an optimal number of cutting edges. The 88-degree setting angle enables a high tooth count while preserving small chip spaces, accommodating 12 teeth on a 63mm diameter cutter.
The double-sided indexable inserts boast eight actual cutting edges crafted from carefully selected substrates and finished with DRAGONSKIN coatings. This design maximises insert utilisation while ensuring consistent performance throughout the insert’s lifespan. The inserts are peripherally ground to achieve precise tolerances and a superior surface finish.
Available in standard diameters ranging from 56 to 125mm, the MaxiMill S-Power accommodates maximum cutting depths of approximately 8mm while maintaining efficiency through its high tooth count. The system is optimised for GJS, GJV, and GJL cast iron grades, with recommended feed rates between 0.08 and 0.15mm.
The indexable insert range includes ISO P/K classifications with M cutting edge geometry, offering corner radii of 0.4, 0.8, and 1.2mm to meet various application requirements. Grade options encompass CTPK220, CTCP230, and ceramic variants to suit specific material and operating conditions.
While the MonsterMill ISO-S addresses the thermal and mechanical challenges of aerospace-grade superalloys, the MaxiMill S-Power tackles a completely different set of problems encountered in high-volume cast iron production.
Where the MonsterMill ISO-S utilises advanced geometry and coating technology to withstand the extreme conditions of nickel-based alloy machining, the MaxiMill S-Power leverages mechanical design advantages to improve cast iron processing.