Hollow mill with PCD blades for the external machining of aluminum die cast parts. 10 tolerances within 10µm with 100% tolerance utilization achieved in a work cycle without preparation. Within the IMPC network, we sought to find a solution to increase the reliability of the production process. The goal was to attain a highly stable process for tolerance overlapping with fixed, nonadjustable tools and multiply variable machine utilization.

The solution consisted of:
Radial runout: adjustable solution to compensate a variety of machine interfaces and varying spindle runouts.

Cut: distribution of diameter and margins to reduce reciprocal reaction between component and machine and to achieve more constant machining situations.

The cut distribution allowed for a more stable and constant cutting force distribution, even at higher cutting speeds.