Tooling Strategy¶

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Each DVF 5000 carries an identical 120-tool HSK-A63 magazine, purpose-built for high-mix 6061 aluminum with zero tapping. All cutting tools held in Haimer shrink fit holders.

Endmills (Slots 1-30)¶

Helical 3-flute aluminum endmill

Helical (Harvey Performance) 3-flute aluminum-specific endmills at every diameter from 1/16 to 1/2 inch in corner radius roughers, square finishers, and ball nose, each in standard reach (~80mm) and long reach (ZG130, ~130mm).

Face Mills (Slots 31-32)¶

Seco R220.53 face mill

Seco R220.53 series: 2 inch (5 inserts) and 3 inch (7 inserts), 45 degree lead angle
Seco XOMX 120408TR-ME08 F40M aluminum-specific inserts

Holemaking: Valor Drills (Slots 37-56)¶

Valor 5xD carbide drill with through-coolant

Imperial tap drills: #4-40 through 1/2-13 (8 sizes)
Metric tap drills: M3 through M12 (7 sizes)
Spot drills: 90 and 120 degree carbide
10 reserved slots for customer-specific needs

Threading: Emuge Hybrid Strategy (Slots 57-78)¶

Tier 1: Emuge Thriller Drill-Thread Mills (10 tools)¶

Combined drill + thread mill in one tool, covers 80%+ of common thread sizes
#4-40, #6-32, #8-32, #10-32, 1/4-20, 3/8-16, M4, M5, M6, M8

Tier 2: Emuge Threads-All Single Profile (12 tools)¶

One tool per pitch covers all diameters: 6 imperial TPI + 6 metric pitches
Complete coverage from #4 through 1/2 inch and M3 through M16

Why Thread Milling Over Tapping¶

Broken thread mill does not seize in hole: part is salvageable
Thread mills run in standard Haimer shrink fit holders: no tapping chucks
AI-CAM controls thread depth, class of fit, and handedness in code

Holders: Haimer HSK-A63 Shrink Fit¶

Haimer HSK-A63 shrink fit holder

Standard Shrink Fit (A63.140/A63.144), Power Mini Shrink (A63.184), Face Mill Arbors (A63.050)
~52 unique holders per machine, ~260 across a 5-machine fleet