More profitable contour milling with indexable, high-feed tooling

High-efficiency (Dynamic) milling with a solid carbide end mill is all the rage, but you may be able to match – or beat – those removal rates and save significant money on tooling by ramping with an indexable high-feed tool. In this quick demo, we high-feed ramp an outside profile to 3.5" depth. Our Heavy-Feed shell mill cuts the 4140PH material at 287 IPM, even at 4.5" gage length, and on a Haas 40-taper machine!

This common contour milling application demonstrates several advantages of high-feed ramping over high-efficiency milling:

  • Equal or even better metal removal rates
  • Substantially lower tooling cost
  • Index inserts quickly with no change in tool size
  • Axial tool pressure for better cutting stability
  • Mill to deeper depths without compromising productivity

Dapra is more than just a tooling provider. We work closely with shops of all sizes to help optimize milling efficiency and profitability, from their tooling choices to the way they attack critical applications. If you'd like to determine if an approach like high-feed ramping is a good fit for your shop, contact us for a free application review!

Want to learn more about the benefits of high-feed ramping? Check out these in-depth resources:

High-feed ramping for outside profile contour milling

High-Feed Ramping for Outside Profile Contour Milling

Detailed instructional video comparing three methods for outside profile contour milling: high-feed ramping, high-efficiency milling and 2D step-down profile milling. See how to program each method, compare cycle times, and view demo footage of high-feed ramping on a Haas 40-taper VM2. Check out the results.

Pocket roughing comparison: high-feed ramping vs. high-efficiency milling

Pocket Roughing Comparison: High-Feed Ramping vs. High-Efficiency Milling

This detailed instructional video compares several approaches to a typical pocketing application: high-feed constant profile ramping with indexable tooling (with both an end mill and shell mill) and high-efficiency milling with a solid carbide end mill. This video shows you how to program the approaches and comparing actual cycle times for these three tool options. Check out the results.

High-feed mold core roughing with a button cutter

High-Feed Mold Core Roughing with a Button Cutter

Mold core roughing can be very effectively done using high-feed ramping – even with a button cutter! Check out this video to see when it makes more sense to use a button cutter versus traditional high-feed tooling using this process. As a bonus, see why plunge finishing with small-diameter bull nose tool is also a worthy approach for mold core finishing. View the demo.

High-feed ramping & plunge finishing on tapered or deep walls

High-Feed Ramping & Plunge Finishing for 30-50% Cycle Time Reduction on Tapered or Deep Walls

This detailed instructional video shows you how to take advantage of plunge finishing utilizing the diameter of a tool – rather than the corner radius of a tool – to dictate the stepover needed to achieve a certain scallop height. By using plunge finishing, you can save 30% to 50% of the cycle time. Check out this approach.

High-feed contour ramping vs. high-efficiency milling

High-Feed Contour Ramping vs. High-Efficiency Milling

When combined with high-performance indexable milling tools, constant ramp profiling (contour ramping) can be a highly effective alternative to dynamic/high-efficiency milling – at a tooling cost that is much lower than solid carbide round tools. In this demo, we examine three approaches for machining a 1" deep x 3.5" wide x 6" long pocket in 4140PH (28 Rc), comparing both cycle time and tooling cost. View the demo.

Let's Discuss Your Application!

Our applications specialists are always available to help you choose the best tooling and processes to maximize your shop's profitability.