Knowledge

MonsterMill FRP & FRP CR - solid carbide milling cutters for machining carbon-fibre reinforced plastics

In times of growing awareness regarding the subject of energy, energy savings and energy efficiency, the lightweight construction segment is becoming increasingly important. Composite materials are gaining larger market shares at a rapid pace.

However, outstanding material properties also present challenges for precision tool manufacturers. The extreme tensile strength and complex structure of the materials pose new challenges in terms of the tools: the high abrasiveness means tool lives of only a few metres are achieved during conventional milling.

This demand has resulted in the MonsterMill FRP milling range for machining carbon-fibre reinforced plastics, featuring an innovative geometry for optimum process security, cutting quality and performance.

MonsterMill FRP: solid carbide milling cutters featuring a special diamond coating for machining carbon-fibre reinforced plastics

The MonsterMill FRP's fine chip breakers enhance the quiet running and therefore also the component quality. The large grooves safely clear away any dust that may develop, permitting an optimal process temperature to prevent damage such as smearing on the cutting edge. A special diamond coating ensures a long tool life despite the high abrasiveness of carbon-fibre reinforced plastics.

  • Left-hand helix: Push cut for reducing delamination on the top side
  • Without helix: Neutral cut
  • Right-hand helix: Pulling cut for reducing delamination on the underside 

Four end cutting edges provide the option of pocket milling by means of angled or circular ramping.

Left-hand helix

Without helix

Right-hand helix

MonsterMill FRP CR: solid carbide milling cutter with special diamond coating and length-independent compression zone for machining carbon-fibre reinforced plastics

The patent-pending geometry of the MonsterMill FRP CR delivers compression across the entire cutting length (length-independent compression zone).

This results in:

  • Reduction in delamination
  • Prevention of projecting fibres
  • Increase in tool life
  • Multiple use option
  • Optimum cutting quality due to large chip flutes and excellent dust removal
  • Simpler and more economical programming of the machine

Available in two versions:

  • Two end cutting edges (fine teeth) for angled or circular ramping
  • One end cutting edge (coarse teeth) for angled or circular ramping

Fine-toothed with two end cutting edges

Coarse-toothed with one end cutting edge

MonsterMill FRP CR: length-independent compression

Clean cutting edges in all fibre directions

The unique geometry with regular left and right-hand cuts on each cutting element and the accompanying fibre compression across the entire cutting length result in fibres being cut off cleanly in all directions, without damaging the component.

Maximum utilisation of the cutting length

Depending on the component thickness and the fixture, you can use our MonsterMill FRP CR multiple times. You therefore receive the best cost-benefit ratio for the tool.

Example: depending on the component thickness and the fixture!

Tool life extension through oscillation

Depending on the component thickness and shape, it is possible to significantly extend the tool life of the FRP CR. The length-independent compression zone enables oscillation and thereby supports dust extraction and helps to cool the cutting edges. This is a major advantage in comparison to standard market routers with a defined compression zone. 

Cutting edge cooling phase by means of oscillation

Less time and effort spent programming your machining centre

When it comes to programming, save time and money compared to conventional milling cutters that have only one compression zone.

In the case of formed components, thanks to our patent-pending length-independent compression geometry you do not have to align the milling cutter on the component.

See the advantages of the MonsterMill FRP CR for yourself in our product video:

Optimum product selection

● = suitable, ○ = suitable under certain circumstances

Application FRP FRP CR fine FRP CR coarse
Reduction in delamination
Reduction in projecting fibres
Tool life optimisation
Thin components
(material thickness < 0.5 x d)
Thick components
(material thickness = 0.5 – 1.0 x d)
Very thick components
(material thickness = 1.0 – 1.5 x d)

⚠️ The optimum usage recommendations may differ from those provided here depending on the machining process and application.

Please get in touch with your contact to determine the best recommendation for your application.

Discover our range now!

Do you need special dimensions for your application?

If you cannot find a suitable version for your application in our product portfolio, our team for special solutions would be happy to help!

Simply give us a call, send us an e-mail or get in touch with your contact directly. We look forward to hearing from you!

📞 +359 66 812 349
📧 sales.bulgaria@ceratizit.com

Usage recommendation for MonsterMill FRP / CR

MonsterMill FRP · straight, left and right-hand helix · conventional milling 

vc [m/min] ae max. ap max. fz [mm]
200 1.0 x d 1.0 x d Ø 6 Ø 8 Ø 10 Ø 12
0.018 0.022 0.025 0.03

MonsterMill FRP CR · fine-toothed · conventional milling 

vc [m/min] ae max. ap max. fz [mm/U]
200 1.0 x d 1.0 x d Ø 6 Ø 8 Ø 10 Ø 12
0.125 0.15 0.175 0.2

MonsterMill FRP CR · coarse-toothed · conventional milling 

vc [m/min] ae max. ap max. fz [mm/U]
200 1.0 x d 1.5 x d Ø 6 Ø 8 Ø 10 Ø 12
0.1 0.12 0.14 0.16

⚠️ The optimum usage recommendations may differ from those provided here depending on the machining process and application.

Please get in touch with your contact to determine the best recommendation for your application.