February 22, 2017
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Solutions for the Automotive Industry

Demonstrate a multi-tool milling process to machine a corner cube array and automotive reflector applications

Freeform 4-Axis XYZC milling with HSK25 Quick Change Tooling System. The tools required to complete the machining process are mounted in individual tool holders. The balance quality and run-out of the tool holders allow them to be changed without having to redo the tool setting process.

Part Details:

• Material: Aluminum

Tool Details:
• Four carbide ball-end mills ranging
    from 0.3 to 0.75 mm in radius to
    progressively deepen the corner
    cube pattern
• One 0.3 mm radius diamond ball-end mill    
    for finishing

Process Details:

• Spindle Speed: Four roughing passes
    16,000 - 50,000 rpm (increasing each step)
    One finishing pass at 60,000 rpm
• Feed Rate: 200 mm/min

Machining Time:
• Four roughing passes 800 min.
   Total 2170 min.

• Optical quality surface and sharp corners
    on cube