Circle Segment Cutters
5-Axis Milling Tooling
EMUGE-FRANKEN was the first company to introduce Circle Segment end mills for 5-Axis milling. This family of tool designs constitute a new tool class that enable machining with a larger tool path distance during pre-finishing and finishing operations. These tools are primarily used in mold-making as well as in the production of tire molds, turbine blades, impeller blades or blisks.
The technical specialty of these end mills are the large radii in the cutting area of the respective tool which offer entirely new possibilities in machining. The large radius simulates a ball-nose end mill with a cutting diameter of 12 to 3,000 mm and even larger on request.
The CAM system which has to support and compute the geometry of the circle segment end mill, plays an important role here. Emuge offers programming assistance to end users who use most popular CAM software such as hyperMILL®,, Mastercam® and others. With circle segment cutters, machining times can be reduced significantly and at the same time the surface quality of the components is increased.
There are four different types of circle segment end mills available:
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Barrel-shape
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Oval form
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Taper form
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Lens-shape
To help further understand the benefits of circle segment cutters please read the June 2018 article in Modern Machine Shop
Visit the Circle Segment Microsite to create examples that compare your current ball nose milling cutter paths and time cycles to a circle segment tool:
ADDITIONAL RESOURCES
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Modern Machine Shop Article | 06/01/2018
Understanding Circle-Segment Milling Tools
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EMUGE Circle Segment & Trochoidal Milling Strategies | 12/28/2016
A demonstration of EMUGE end mills in P20 tool steel using traditional and updated milling strategies. Finishing a surface with a standard ball end mill strategy and the new EMUGE Circle Segment strategy, showing a 90% cycle time decrease with an improved finish. Roughing a pocket with the standard Multi-Cut roughing strategy & a new Jet-Cut Trochoidal strategy with chip breaker. The Jet-Cut Trochoidal is used to finish both pockets. Roughing a pocket with a Top-Cut VAR with & without radial chip thinning.
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5-Axis / Circle Segment End Mills | 12/08/2016
Circle segment cutters are a family of carbide form cutters specifically designed for 5-axis milling. This video demonstrates the concept of 5-axis milling with 1. BARREL SHAPE, 2. LENS SHAPE, 3. OVAL FORM and 4. TAPER FORM cutters from Emuge. This new milling concept requires proper CAM software. Emuge has partnership agreements with many CAM suppliers and can help explain the application for proper results.
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OPEN MIND hyperMILL 5-Axis Milling | 12/08/2016
This video shows the possibilities of modern 5 axis milling released by Hermle, EMUGE and hyperMILL. This masterpiece of an aluminum high heel shoe model is a joint project by Hermle, EMUGE and OPEN MIND and was shown at the 2014 IMTS Show.
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Emuge Customer says Circle Segment End Mills have revolutionized the industry | 05/01/2022
Jim Walslager, Lead Programmer at RWD in Ringwood, IL is glad that he’s invested in Circle Segment cutters from high-performance cutting tool manufacturer, EMUGE-FRANKEN, of West Boylston, Mass. “Prior to this, my only alternative was to finish the conical surface with a ball-nose end mill. I didn’t even bother trying, but because the CAM system said it would have required close to five hours per part. The EMUGE cutter did it in 38 minutes.” He laughed. “The thing started out as a 100-lb. block of 6061-T6
