Modular Multi-Flute End Mill with Cutting Disc for Honeycomb Materials

Developed to provide exceptional versatility when machining honeycomb materials such as Nomex®, Kevlar® and aluminium, this modular tool combines outstanding cutting performance with maximum process flexibility.

The proven multi-flute chipbreaker milling body is integrated into a modular assembly consisting of three separate components: a steel shank, a solid carbide milling head and an interchangeable lower cutting disc.

The system can be configured with three different cutting discs to suit specific honeycomb materials and finishing requirements:

• Toothed disc (77SUPD): designed for machining high-density aluminium honeycomb.
• Smooth disc (77SUPL): ideal for all Nomex® and Kevlar® densities, as well as medium-density aluminium honeycomb.
• Flat disc (77SUPP): developed for mixed-density honeycomb materials incorporating hard epoxy bond lines.

Once assembled, the three components are securely clamped together using a high-strength retaining screw, providing rigidity comparable to that of a solid tool.

During machining, the cutting disc cleanly severs the base of each honeycomb cell while the multi-flute milling body simultaneously profiles the cell walls. This coordinated cutting action eliminates burr formation, prevents fibre fraying and protects the honeycomb structure from collapse, ensuring clean, accurate and repeatable machining results.