Profielfrezen

Profielfrezen, also known as profile milling, is a milling process in which a cutting tool removes material to create a defined external or internal contour along a programmed path. It covers two-dimensional and three-dimensional contouring and is typically performed with end mills or ball-nose cutters. In 2.5D profilfrezing the tool follows a single working plane with limited variation in the vertical direction, while true 3D profilfrezing uses multi-axis motion to follow complex surfaces.

Tooling and technique: common tools include solid carbide end mills and ball-nose cutters. Tool selection depends on the profile geometry, required surface finish, and fillet radii. Machining strategies include peripheral milling along the contour, sometimes combined with plunge or face milling. The stepover and stepdown influence surface roughness, material removal rate, and tool wear. CAM programs generate the profile path, and process parameters are chosen to balance accuracy, productivity, and tool life.

Applications: profielfrezen is widely used in mold and die making, aerospace and automotive components, architectural detailing, and the fabrication of wooden, plastic, and soft-metal profiles where precise contours are required, such as slots, grooves, and complex curves.

Process considerations: material properties, cutter diameter and geometry, spindle speed, feed rate, and cooling affect results. Proper workholding and machine rigidity are essential for achieving tight tolerances. Typical tolerances for profile milling range from tenths to a few hundredths of a millimeter depending on equipment and setup.

Advantages and limitations: it enables accurate production of complex contours with good surface finish and design flexibility. Limitations include tool wear, higher programming complexity, and potentially longer cycle times for very intricate profiles.