Next Gen Technology Integrating the Benefits of Both Finish Milling and Grinding  

Replace expensive, complex indexable tungsten carbide or PCD milling cutters in high volume production finishing applications.

High strength alloys Stainless steel Ceramics Cast Iron Fiberglass  Composite Materials Aluminum Composites Powdered Metals

The flat machining of bi‐metal surfaces or milling applications involving an interrupted cut can present daunting challenges to PCD or carbide milling cutters.   The inserts may chip during the milling process, resulting in high machining costs and elevated levels of sub‐standard or rejected parts.    The Engis ElectroMill is designed to produce high quality, flat milled surfaces, even if an  interrupted cut is present or multiple materials need to be machined simultaneously.

The ElectroMill, combined with high pressure coolant, can machine these materials to an extremely accurate value of flatness with very low tooling costs.  This hybrid tool can achieve flatness up to 20 µm and surface finishes as smooth as 8 Ra over a single, continuous length of 25 inches on cast iron.   In some cases customers have been able to reduce scrap and reworks significantly; this contributes to increased productivity and an improved bottom line.

Significant advances in part quality, as well as cost savings, have been realized with the use of the ElectroMill in the final machining of cast iron hydraulic valve bodies and aluminum engine blocks fitted with cast iron cylinder inserts.  

ElectroMill is used successfully in marine, small-engine, automotive, off-road, agriculture, aerospace, defense and other industries - across a wide variety of components as well as ferrous, non-ferrous and exotic materials.

		Challenge: A major manufacturer of marine engines was unable to achieve the desired flatness, parallelism and finish requirements which resulted in an unacceptable level of rejected components and reworks.
		Challenge: Customer requested optimal speeds and feeds to achieve a surface finish of 48 Ra or better and a flatness of 0.0005" or better within their working zone.
		Challenge: To achieve a surface finish of 32 Ra and a flatness of 0.0005" or better with low coolant pressure and lower RPM.

• The Mills can be sent back to Engis for strip and replate.  Tool quality, dimensional accuracy and life repeatability are the same as the original mill.  

Learn more about Engis Re-Plating/Reconditioning Service; click here.