The Next Era of Performance and Versatile End Mills has arrived: Data Flute's SSI-5plus & SSI-72/21/2024 As machine shops seek precision, tool life, and versatility in a wide variety of materials, the SSI-5plus and SSI-7 have emerged as the performance leader in a lot of categories! written and edited by Bernard Martin  Dataflute introduces SS-5plus and SS-7 End Mills Data Flute, the renowned end mill manufacturer who pioneered the adoption of the 3 and 5 flute end mills for stainless steel and exotic alloys nearly 30 years ago, has recently introduced two new groundbreaking end mills— the SSI-5plus and SSI-7. These cutting-edge tools are designed to set the standard for versatility and performance in (P)steel, (H)hardened steels, (M)stainless steels, (S)super alloys and even (K)cast iron. The SSI-5plus End Mill For many years the SSI-5 has been the mainstay of Datflute's variably indexed, ferrous alloy rougher/finisher. It's truly the all-terrain vehicle of their ferrous alloy series. Now, Datflute has updated the already impressive SSI-5 with a new, advanced substrate, formerly only offered in their SSI-7 series, an even higher-performance coating and field tested micro-geometry. The result is a tool that provides outstanding cutting performance and substantially greater tool life. The SSI-5plus will appeal to machinists who demand high performance endmills, but seek to minimize tool changes, or tool inventory, over a wider range of milling operations. This offering mirrors the SSI-5 with regard to diameters, lengths of cut, overall lengths and radii offered. Dataflute is transitioning their 5 flute, variably indexed, ferrous alloy rougher/finisher from the SSI-5 to the SSI-5plus.  SSI-5 plus vs Leading Competitors. All Tool life results are from accelerated wear test. With five flutes featuring an unequal index and a variable helix, this end mill is designed to optimize chip evacuation and reduce cutting forces, ensuring efficiency in a variety of machining scenarios. The SS-5plus is a non-center cutting tool available in both RH-C and RH-H configurations, with a continuous cutting edge for seamless performance. The tool adheres to strict tolerances, featuring a shank diameter held to h5 specifications, while the cutting diameter boasts precision within -0.001"/-0.002". The corner radius is equally refined, offering +0.001"/-0.001". Whether used for roughing or finishing, the SS-5plus from Data Flute delivers exceptional results, promising machinists a combination of accuracy, versatility, and reliability in their machining endeavors. SSI-7 End Mill Data Flute unveils the SS-7 end mill, a cutting-edge solution designed for high-efficiency machining in ferrous alloys. This finisher showcases a new carbide substrate, ensuring superior durability and outstanding tool life, even in demanding applications. Engineered with specific geometry tailored for titanium alloys and stainless steels, the SS-7 features seven flutes with an unequal index and a constant helix, promoting efficient chip evacuation and reduced cutting forces. This non-center cutting tool, available in both RH-C and RH-H configurations, boasts a continuous cutting edge for seamless machining. The SS-7 end mill sets a standard with its tight tolerances, including a shank diameter held to h5 specifications and a cutting diameter precision within -0.001"/-0.002". The corner radius further enhances precision, offering +0.001"/-0.001". Machinists can expect not only high efficiency but also superior surface finishes, making the SS-7 a standout choice for those seeking precision, longevity, and exceptional performance in ferrous alloy applications. Tech spec overview
A Leap FOrwardData Flute's SSI-5plus and SSI-7 end mills signify a significant leap forward in cutting tool technology. With their meticulous design, superior materials, and advanced coating technologies, these end mills are poised to meet the diverse needs of modern machining processes. As machinists seek precision, tool life, and versatility in materials, the SSI-5plus and SSI-7 emerge as compelling choices, ready to cut their place in the new era of cutting tools.
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Heritage Cutter is the parent company to the iconic metalcutting industry names Brubaker, Data Flute, Decatur Diamond and Weldon Tool each with their own specialization in cutting tools Written & edited by Bernard Martin  Heritage Cutter is the parent company to the iconic metalcutting industry names Brubaker, Data Flute, Decatur Diamond and Weldon Tool. Each of these companies names reflect their longstanding reliability, quality and commitment to industry has made them a trusted source to distributors and manufacturers for generations. Each of these companies has had a niche place in the market as well as some product overlap over over the last few decades. In order to clarify where each brand fits under the Heritage Cutter umbrella, and to set a strategic outlook, Heritage Cutter has outlined the speciality areas that each of the brands it taking moving into the future. Data Flute: Pioneering High-Performance Carbide Round Tools Since 1976 Data Flute, a distinguished brand under the Heritage Cutter umbrella, has been a stalwart leader since its inception in 1976. Known for its unwavering commitment to excellence, Data Flute has carved a niche as a premier designer and manufacturer of both standard and special high-performance solid carbide cutting tools. The mantra, "The most demanding machinists demand Data Flute!" encapsulates the brand's dedication to meeting and exceeding the expectations of machinists who demand nothing but the best. Over nearly five decades, Data Flutee has established itself as a trusted name synonymous with high-performance, application-specific carbide cutting tools.  Data Flute's product portfolio is a testament to its expertise, offering a comprehensive range of carbide round tools meticulously crafted to cater to diverse machining needs. From end mills tailored for aluminum and non-ferrous alloys to those designed for steel and ferrous alloys, Data Flute's offerings span roughing, semi-finishing, and finishing applications.The brand goes even further with its CVD Diamond Coated Tools, encompassing routers, end mills, and drills, showcasing its commitment to cutting-edge technologies. Additionally, Data Flute provides specialty tools and miniature end mills, catering to intricate and specialized machining requirements. The cornerstone of Data Flute's success lies in its state-of-the-art manufacturing facility in Pittsfield, MA. This facility serves as the epicenter of innovation, housing not only the manufacturing operations but also the brand's R&D machining test center and customer support. This consolidated setup enables Data Flute to provide a seamless experience to its customers, ensuring that design, testing, and support are all under one roof. At Data Flute, the commitment extends beyond the production line. The brand is dedicated to high-performance machining, a philosophy reflected in its comprehensive suite of tools, factory support, and field support. The team at Data Flute is driven by a shared desire to collaborate with customers, understanding their unique challenges, and working together to maximize cutting tool productivity. Brubaker: Brubaker Tool: A Legacy of Excellence in Taps and Threading Products Since 1881 For over 140 years, Brubaker Tool, a distinguished member of the Heritage Cutter family, has been a cornerstone in the industry, proudly serving with high-performance, special, and standard taps & threading tools. Established in 1881 in Millersburg, PA, Brubaker Tool began its journey by supplying taps to the burgeoning railroad industry, laying the foundation for a legacy that has endured for over a century. The commitment to excellence is etched in the very fabric of Brubaker Tool. With a wealth of experience, the brand has evolved to become a leading source of American-made industrial cutting tools. Over the years, Brubaker has built upon its enduring stability, reliability, and unwavering commitment to quality, earning its status as a trusted source for distributors and manufacturers for generations.  Brubaker Tool's extensive product offerings include an array of high-performance taps, showcasing versatility and precision. From spiral flute, spiral point, straight flute, forming, to carbide taps, Brubaker Tool caters to the diverse needs of the industry. The brand also specializes in pipe taps, covering NPT, NPS, interrupted thread, and short projection variations. General-purpose taps, including spiral flute, spiral point, straight flute, forming, and STI, further demonstrate Brubaker's dedication to meeting the threading requirements of various applications. Carrying the torch of tradition into the modern era, Brubaker Tool continues to innovate with carbide thread mills, available for special orders, showcasing the brand's adaptability to evolving industry needs. Despite the significant changes witnessed over the last 140 years, Brubaker Tool's steadfast commitment to providing the finest taps and threading tools remains unwavering. The brand's long-standing stability, reliability, and quality have positioned it as a reliable partner in the ever-evolving landscape of industrial cutting tools. Brubaker Tool's legacy is not just a chronicle of the past, but a testament to its enduring commitment to excellence. With a rich history and an eye on the future, Brubaker Tool remains a trusted name, embodying the values of stability, reliability, and quality that have defined it for over a century. Weldon: Blending Tradition and Innovation in Quality Cutting Tools Since 1918 In the specialized tapestry of Heritage Cutter's family of companies, Weldon Tool stands as a beacon of craftsmanship, quality, and a commitment to customer service that has endured since its founding in 1918. Rooted in a legacy that spans over a century, Weldon Tool has evolved into a trusted source for quality high-speed steel (HSS), cobalt, and carbide round tools, with a distinct emphasis on engineered specials. From its humble beginnings as a two-man shop in downtown Cleveland, Ohio, Weldon Tool has grown into a powerhouse, designing, manufacturing, and delivering a diverse range of cutting tools. The original dedication to craftsmanship and quality that marked its inception remains a constant thread woven into the fabric of the company.  Weldon Tool's product offerings reflect a comprehensive understanding of the diverse needs of the industry. The range includes HSS, cobalt, and CPM end mills for both roughing and finishing applications, underscoring the brand's commitment to versatility. Carbide end mills designed for ferrous and non-ferrous materials showcase Weldon's expertise in adapting to evolving machining requirements. Specialty tools such as countersinks, hole saws, and core drills further demonstrate the brand's dedication to providing a holistic solution for cutting challenges. Weldon Tool's focus on engineered to order solutions, including end mills, round tools, and other specials, positions it as a go-to partner for those seeking customized cutting tools. For the past two decades, Weldon Tool has been co-located with Brubaker Tool in Millersburg, PA, reflecting a strategic alignment within the Heritage Cutter family. The synergy between these companies has not only provided operational efficiency but has also allowed Weldon to maintain its traditional commitment to quality while embracing the demands of modern manufacturing. In many ways, Weldon Tool represents a harmonious blend of the old and the new. While remaining steadfast in its dedication to traditional end mills and specialty products in HSS, cobalt, and CPM, Weldon is simultaneously steering towards the future with a pronounced focus on custom tools and engineered specials. This forward-looking approach ensures that Weldon Tool continues to be a dynamic force in the cutting tool industry, adapting to the ever-changing needs of its customers and the evolving landscape of precision machining. Decatur Diamond: Your Trusted Source for Diamond and PcBN Tools Nestled within the Heritage Cutter family of companies, Decatur Diamond is the home of innovation and expertise in diamond-based cutting tools. The brand's lineage is intricately tied to some of the earliest adoptions of diamond-based technologies in the cutting tool industry, showcasing a history marked by success and innovation. Under the banner of "When every cut counts, count on Decatur Diamond," this brand is dedicated to delivering diamond and PcBN-based cutting tools. With a comprehensive range covering indexable milling cutters, fixed pocket brazed tools, complex monobloc solutions, and CVD diamond-coated tools. At the forefront of Decatur Diamond's contributions is the Ultra-Mill, an early and remarkably successful indexable platform for diamond tools. This innovation underscored the brand's commitment to pushing the boundaries of what was possible in the realm of cutting materials. Similarly, the DIAbide line emerged as one of the original CVD diamond carbide round tool brands, solidifying Decatur Diamond's reputation as a trailblazer in the industry.  As the landscape of cutting tools evolved, so did Decatur Diamond's portfolio. The addition of fixed-pocket brazed tools and complex monobloc solutions further expanded the brand's capabilities, offering a comprehensive suite of options to meet the diverse needs of precision machining. Decatur Diamond not only focuses on advancing technology but also places a significant emphasis on service. The brand goes beyond the design and manufacture of new tools, offering reconstruction services with an equal measure of dedication and enthusiasm. This commitment to providing comprehensive solutions showcases Decatur Diamond's holistic approach to meeting the varied demands of its customers. Being a full-service diamond tooling company, Decatur Diamond houses all its engineering, product support, customer service, and reconstruction services in its Decatur, IN facility. This centralized hub ensures seamless collaboration between different facets of the operation, promoting efficiency and excellence in every aspect of service delivery. Decatur Diamond's rich history and ongoing commitment to innovation make it a vital component within the Heritage Cutter family. Its legacy of pushing the boundaries of diamond-based technologies, coupled with a dedication to comprehensive service offerings, positions Decatur Diamond as a dynamic force in the cutting tool industry. As the industry continues to evolve, Decatur Diamond remains at the forefront, ready to shape the future of precision machining with its cutting-edge solutions and unwavering commitment to excellence.  Heritage Cutter's strategic approach to housing these specialized brands showcases its unwavering dedication to providing cutting-edge solutions to an array of industries. With a legacy spanning over a century, Heritage Cutter continues to lead the way in the ever-evolving landscape of cutting tool technologies.
Data Flute CVD coated diamond tools are a perfect match for machining glass fiber composites. The very abrasive characteristics of composite materials severely limit the life of both carbide and PCD diamond tools.  Data Flute carries a large variety of high performance cutting tools optimized for machining composite materials such as carbon fiber reinforced polymer (CFRP), glass fiber reinforced polymer (GFRP), and metal matrix composites (MMC). Tools with diamond on the surface wear longer and have a lower coefficient of friction. These characteristics provide substantial benefit to machining operations. Because CVD diamond tools last 10-50 times longer than carbide tools, and 3-4 times PCD diamond tools they:
The low friction of CVD diamond tools permit using speeds higher than both carbide and PCD – again contributing to higher productivity – with no degradation of the surface quality or tool life. The consistently sharp edge and lower friction allows delicate, thin wall sections to be machined quickly and precisely. The sharp and long wearing edge also puts lower stresses on the part, fixturing, and equipment. Since CVD diamond has no cobalt binder to break down or abrade away they offer the longest possible tool life. Glass fiber composites can be machined successfully with diamond coated endmills if resin melting and chip evacuation are carefully controlled. Observance of the following guidelines should yield tool lifetimes of approximately 10 times the equivalent carbide tool. Resin MeltingSpeeds and feeds must be adjusted to avoid melting or softening the resin in composite materials. This means that feeds must be 0.001” ipt or greater with larger diameters and speeds should be kept at 400-500 sfm for G10 or FR4 type materials. As the depth of cut increases the cutting speeds should be reduced to below 400 to minimize heat buildup in the chips. For shallow depths of cut, feeds can be up to 0.010” ipt for 1/2” diameter tools. Maximum feed rates are a function of the depth of cut and limited by the tool strength for a given diameter. Chip evacuationFor slot depths exceeding more than 1/2 the diameter of the endmill the evacuations of chips from the slot becomes extremely important. Failure to adequately remove chips can cause breakage of the carbide under the diamond film on the flute edge and subsequent catastrophic failure of the tool. The use of 2-flute tools and moderate-to-high feed rates is highly recommended to insure good chip flow. Air flow into the cut and vacuum evacuation of chips from the cutting area are also recommended. Additional life improvements can be obtained by using a corner radius or ball end tool for the initial cut and then following up with a square end tool with a much shallower cut to achieve the final dimensions. For side cutting applications there is also an issue with chip evacuation if the radial depth of cut exceeds 1/4 of the tool diameter for a 4-flute tool or 2/3 the diameter for a 3-flute tool. Maximum tool life and production rates are generally achieved with 2-flute tools operated at high feed rates for most side cutting applications. Machining Parameters: recommended parameters for sidecutting are listed in the following chart for various flute configurations. Recommendations are based on a cutting speed of 400- 500 sfm and a diameter of the tool greater than or equal to the material thickness. Larger radial depth of cuts are possible if the material is substantially thinner than the tool diameter.  Machining Parameters: recommended parameters for slotting are listed in the following chart for various flute configurations. Recommendations are based on a cutting speed of 400-500 sfm and a full width slot which does not penetrate the full thickness of the material thickness. See sidecutting chart for slots which penetrate the full material thickness.  Note: VDOC’s greater than 100% of the tool diameter are listed for informational purposes only and are not recommended for normal operation Data Flute carries a large variety of high performance cutting tools optimized for machining composite materials such as carbon fiber reinforced polymer (CFRP), glass fiber reinforced polymer (GFRP), and metal matrix composites (MMC).
Data Flute products provide the opportunity to machine large parts while minimizing tooling changeovers and ultimately reducing your costs. They can tailor our super hard materials for the challenges at hand with coated CVD, CVD and PCD fabricated tools. Contact us with quesitons! |
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