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Nesting of solid core panels: Application data and tips

Solid core panel nesting is challenging, because the panels react in particular to the frictional heat during milling and thus have a highly abrasive effect on the milling cutters. The diamond-tipped LEUCO DP solid core panel roughing cutter (left) and the LEU-CO DP solid core panel cutter Z=2 or Z=3 are ideal tools when the above application parameters are taken into account.
Solid core panel nesting is challenging, because the panels react in particular to the frictional heat during milling and thus have a highly abrasive effect on the milling cutters. The diamond-tipped LEUCO DP solid core panel roughing cutter (left) and the LEU-CO DP solid core panel cutter Z=2 or Z=3 are ideal tools when the above application parameters are taken into account.

With their continuous alternating shear angles and application-oriented cut-ting edge geometry as well as PCD quality, LEUCO DP shank-type cutters for machining solid core panels achieve clean, chip-free cuts when parting and formatting. When used together with LEUCO's expert tips, clean and econom-ical machining is guaranteed.


Part in a single pass with finish-cut quality at an appropriately reduced feed rate. As an alternative, you can pre-size the workpieces in order to then finish-cut with a lower removal volume at a correspondingly higher feed rate. The significantly reduced machining needed by the finish cutter greatly extends the edge life of the quality-enhancing tool.
In addition to the familiar finish cutters, LEUCO offers for this purpose a dia-mond-tipped roughing cutter with which correspondingly high material removal rates can be achieved.



The main objective: Avoid high temperatures

Particularly with nesting and the associated limited chip ejection possibilities, excessively high speeds and overly low feed rates can lead to severe heating of the material (lumpy chips!) and the tool.


The known effects of heat are

  • high cutting edge wear: short edge lives
  • loss of teeth: tooth replacement and lower overall life
  • poor cutting surfaces/lubrication: rework required or rejects
  • fire hazard in the extractor hood due to the possibility of extremely hot / glowing chips

It is therefore even more important to avoid multiple cutting in solid-core ma-terials than in conventional wood-based materials.
The speed should generally not be set too high.


The number of teeth must be matched to the feed rate. Note: The feed rate value entered into the control often is not the actual average feed rate, since this is frequently not reached at all. This is particularly the case with relatively small-format workpieces and narrow, nested structures. Here, a two-flute cut-ter instead of a 3-flute cutter is often the better and more economical choice.



These feed rates are to be regarded as max. values for guidance. They also depend, among other things, on the required cut quality and the nature of the material to be processed. In some cases, there are relevant differences in terms of hardness and temperature sensitivity. The data refer to the processing of panel thicknesses of up to 10 mm. For higher material thicknesses, feed rates must be reduced accordingly. Higher speeds are possible, but resulting higher temperatures can greatly reduce single edge lives and also the overall life of the tool, especially at n>18,000.
These feed rates are to be regarded as max. values for guidance. They also depend, among other things, on the required cut quality and the nature of the material to be processed. In some cases, there are relevant differences in terms of hardness and temperature sensitivity. The data refer to the processing of panel thicknesses of up to 10 mm. For higher material thicknesses, feed rates must be reduced accordingly. Higher speeds are possible, but resulting higher temperatures can greatly reduce single edge lives and also the overall life of the tool, especially at n>18,000.


High-precision clamping elements

And the following applies not only to all diamond-tipped tools: Tools should only be used in highly precise clamping elements: hydro expansion chucks, TRIBOS power shrink chucks or heat shrink chucks. A proven means of effectively avoiding multiple cutting can relatively often also be the use of suction turbines with hydro expansion chucks. The ideal application parameters and the achievable results can be determined within the framework of a test carried out together with the tool supplier on the customer's machine under real-world conditions. An appointment can be made at any time.



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