A range of optimised solid end mills designed specifically for profiling applications has been launched.  The new solution is said to provide high process security, productivity gains and cycle time reductions of up to 90%, making it particularly suitable for the aerospace industry and other high-demand sectors.

The CoroMill Plura barrel from Sandvik Coromant features a one-radius barrel form with up to six optimised flutes and is said to offer a new machining principal for profiling tools. The product has been added to the company’s existing range of end mill solutions for ISO S profiling applications, including CoroMill Plura ball nose, CoroMill Plura lollipop and CoroMill Plura conical ball nose.

By utilising an increased contact radius, the barrel design enables an up to 90% reduction in cycle times by increasing the step-over, which enhances machining efficiency by increasing the surface removal rate while also ensuring surface quality.

The optimised barrel design results in a reduced cusp height between passes, leading to superior surface finishes and lower surface roughness. Despite generating higher forces, the stability and process reliability of barrel end mills make them suitable for achieving precise finishes in demanding profiling applications.

“CoroMill Plura barrel’s large cutting-edge radius enables increased step-over and reduced cycle times, boosting productivity during high-volume material removal and making it ideal for machining large, complex contours and 3D shapes, while minimising scalloping for shallow depths of cut. This tool is particularly suited to demanding applications like aerospace, where components such as engine blisks involve complex geometries and challenging materials. It also enhances profiling in other high-demand sectors like medical, oil and gas and power generation,” said Sandvik Coromant product manager: solid carbide milling tools Liam Haglington.

The tool is available with the company’s material-specific grades, including T2CH for titanium alloys and R2AH for heat-resistant superalloys, both delivered by Sandvik Coromant’s Zertivo 2.0 PVD coating engineered for improved durability and wear resistance. The tool can be customized using Sandvik Coromant’s Tailor Made service, while the CoroPlus Tool Guide platform offers tooling advice.

The company also offers a recycling program for worn-out carbide tools, including CoroMill Plura barrel and other advanced milling solutions. This service allows customers to return used tools for responsible recycling, reducing industrial waste and conserving critical materials like tungsten and cobalt.