Five-axis machining equipment allows multi-directional processing in a single workpiece setup. By eliminating the need for workpiece re-clamping, it significantly reduces production auxiliary time spent on repositioning and tool setting, substantially decreases operation stages, and prevents tool-workpiece interference. The shortened relative distance between the workpiece and the machine tool spindle enables the use of shorter tools with higher rigidity, more stable performance, and improved tool life. Therefore, the application of five-axis machine tools has overcome a bottleneck in digital intelligent manufacturing, and the R&D and utilization of 5-axis dedicated tools are increasingly widespread.
However, since traditional 3-axis machines still dominate production floors, currently available tools specifically developed for five-axis machines exhibit very limited applicability or significant constraints when used on 3-axis equipment.
Addressing these shortcomings of five-axis tools, the Mirror-finished Spherical Drum Cutter TNM Type delivers high efficiency, precision, and extended service life as a five-axis machining tool, while simultaneously offering unparalleled adaptability in 3-axis machining operations.
Drum-shaped tools operate on the fundamental concept of incorporating a large-radius cutting edge on the tool. Compared to ball nose end mills of identical diameter, they enable larger stepover while maintaining equivalent machined surface accuracy — specifically by controlling theoretical cusp height (commonly referred to as tool marks) — thereby achieving higher machining efficiency.
The geometry of drum tools is engineered through comprehensive consideration of both the R-dimension (radius) of the cutting edge and its positional characteristics, resulting in various configurations. The four most common types are illustrated below:Peripheral Drum Cutter、Tangential Drum Cutter、Tapered Drum Cutter、Face Drum Cutter
The Mirror-finished Spherical Drum Cutter TNM Type features a large-radius drum edge exceeding twice the tool diameter at the front end of its peripheral straight cutting edge. This drum edge transitions into a ball nose cutting edge at its tip. All edge segments maintain tangentially blended transitions, ensuring precise geometric definition along the entire cutting contour.
TNM Type Characteristics：
1.The TNM Type Multi-Arc Mirror-finished Spherical Drum Cutter belongs to our flagship BNM/RNM Mirror Series. Despite being an indexable tool, it delivers cutting edge precision that matches or exceeds that of solid tools.
2. The TNM Type Mirror-finished Spherical Drum Cutter integrates three distinct edge geometries – straight peripheral edge, drum edge, and ball nose edge – with tangentially continuous transitions. This enables seamless handling of all surface contouring requirements in 5-axis machining operations.
3. For conventional 3-axis machining, it delivers full 180-degree accessibility for high-efficiency, high-precision applications. The peripheral cutting edges function as a standard end mill at full diameter, while the drum profile facilitates efficient angular surface machining. The front ball nose section handles all 3D contouring tasks with ball-end mill capability.
4. The extended-length ball nose design exceeds the engagement range required for most 3-axis applications, effectively performing as a dedicated solid ball nose cutter in practice.
5. Two diameter specifications are available:
Proprietary Engineering Innovations of the TNM Type：
1. Tri-Edge Tangential Integration
The tangential convergence of straight, drum, and ball nose edges pioneers the simplified deployment of complex-geometry tools. This innovation enables both intuitive toolpath alignment in 5-axis setups and ultra-precision machining through exceptional edge-tracking accuracy and geometric fidelity. Crucially, it achieves full 180° machining capability for high-efficiency 3-axis operations – an unmatched feature among contemporary 5-axis dedicated tools.
2. G² Continuous Edge Transitions
Seamless tangential blending (G² continuity) between all edge segments maintains precise geometric definition across the entire cutting contour. This ensures sub-micron process stability during dynamic tool-work engagement in 5-axis machining , where contact points continuously migrate.
3. Sub-μm Convexity Retention
The ball nose apex zone incorporates sub-micron convex preservation technology, eliminating undercut defects during machining while enabling ultra-precision surface generation (Ra ≤0.8μm).
Machining Case Studies：
Using a φ16 TNM Type tool in 5-axis simultaneous machining, vertical wall surfaces are machined with the full tool diameter (Ø16) while varying the cutting edge position. Comparative data is provided for:
Gradual cutting point shift method (from top to bottom of wall)
Fixed cutting point position method
Workpiece Material: SKD61 (48 HRC)
Cutting Conditions:
Rotational speed: n=4,974 min⁻¹
Cutting speed: Vc=250 m/min
Feed rate: Vf=1,492 mm/min
Feed per revolution: f=0.3 mm/rev
Radial depth of cut: ae=0.1 mm
Stepover distance: 1.0 mm
Tool overhang: 110 mm
Process: Reciprocating contour machining with internal through-tool coolant
Machining Results:
In the fixed cutting point method, when the machining length exceeded 150m, tool wear reached 0.05mm, after which flank wear rapidly accelerated. Conversely, with the gradual cutting point variation method, flank wear remained below 0.05mm even at 500m machining length.
Conclusion:
By leveraging 5-axis machine tools with the Mirror-finished Spherical Drum Cutter TNM Type, high-efficiency and high-precision machining requirements can be achieved while significantly extending tool life.
User Feedback:
"The Mirror-finished Spherical Drum Cutter TNM Type demonstrates extensive applicability, effectively machining diverse materials including carbon steel, pre-hardened steel, stainless steel, heat-resistant alloys, aluminum alloys, and even welded overlay materials – which are most prone to edge chipping."
Application Case:
For machining an AM (Additive Manufacturing) mold from welded SKD61 material (55 HRC), multiple tools were tested. All conventional tools suffered premature catastrophic edge chipping due to the extreme machining conditions.
[Mirror-Finish Ball Nose TNM Type Cutter] not only performed steadily during cutting with exceptional chipping resistance, but also delivered superior machined surface quality, earning high praise from users!
