Machining hardened materials with complex 3D surfaces is a direct test of process stability. When the material reaches 50 HRC, the cutting system must control vibration, heat, and tool runout consistently—especially during long-cycle finishing where even small instability can translate into visible tool marks or dimensional drift.
This case study shares a real production-style example completed on a ChangZhun (e-850) machining center, using our own Milling Cutter together with a Hydraulic Holder to finish a 3D surface on SUS630 hardened to 50 HRC. The process ran for 12 hours, targeting stable surface quality and repeatable results.
I. Workpiece Overview (Based on Photo Features)
Processing case diagram
From the provided photo, the workpiece is a feature-dense sample with:
- 1. Large reference flats and multiple step levels
- 2. Complex 3D transitions and blended surfaces
- 3. Curved grooves and circular features
Local narrow regions where toolpath engagement changes frequentlyThese features are common in mold components, functional fixtures, and high-value structural parts. The 3D surface areas in particular require a stable finishing strategy to maintain consistent texture and avoid visible step lines or vibration patterns.
II. Machine Platform: ChangZhun e-850 for Stable Multi-Feature Machining
E850
This job was completed on a ChangZhun e-850 platform. For complex parts with multiple surface and cavity features, a stable machining center helps deliver:
- 1. Smooth interpolation for 3D finishing paths
- 2. Consistent performance during long cutting cycles
Reliable repeatability for future process replicationEven when only one main orientation is required, this kind of platform supports a standardized workflow and consistent quality output.
III. Tooling System: Our Milling Cutter + Hydraulic Holder
All the tools used are produced by Meiwha.
Milling Cutter
- · Tool Name: MW-MS2R-12.0R624H*100L
- · Application focus: 3D surface finishing on hardened SUS630 (50 HRC)
Hydraulic Holder
A Hydraulic Holder is a strong choice for surface finishing because it provides:
- · Uniform 360° clamping for stable tool holding
- · Improved runout control (critical for consistent surface texture)
- · Added damping behavior that helps reduce micro-vibration during finishing
For long-cycle finishing, these attributes directly support stable results and help prevent surface defects caused by minor runout or chatter.
IV. Material and Cutting Conditions
Work Material: SUS630
Hardness: 50 HRC
Machining Type: 3D surface finishing (curved surface)
Machining Time: 12 hoursHardened SUS630 typically demands conservative engagement and stable tool holding, especially for long finishing programs where heat accumulation and edge wear can become critical.
V. Process Parameters (Fixed for This Case)
The following parameter set was used for the finishing operation:
Cutting speed: Vc = 188 m/min
Spindle speed: S = 10,000 rpm
Feed rate: F = 1,600 mm/min
Depth of cut (Ap): 0.03 mm
Width/step-over (Ae): 0.06 mm
Tool: MW-MS2R-12.0R624H*100L
Holder: Hydraulic Holder
Why These Values Make Sense for 50 HRC Finishing
For hardened materials, surface finishing success typically relies on:
- · Very small engagement (low Ap and Ae) to control heat and vibration
- · Stable clamping and low runout to keep the surface texture uniform
- · A cutting speed window that supports edge stability without overheating
In this case, Ap 0.03 mm and Ae 0.06 mm keep cutting forces controlled, which is especially important when the program runs continuously for 12 hours.
VI. Key Stability Practices for a 12-Hour 3D Finishing Cycle
Long-cycle hardened finishing introduces risks that do not always appear in short jobs. The following practices are commonly critical:
1. Runout control as a priority
Small finishing stepovers amplify the effect of tool runout. A Hydraulic Holder helps maintain a more consistent cutting behavior and surface appearance.
2. Smooth toolpaths and controlled acceleration
3D finishing toolpaths should avoid sudden direction changes that can introduce small vibration marks on hardened surfaces.
3. Thermal stability and process monitoring
Over long cycles, thermal drift and gradual wear can affect final quality. Stable machine behavior and a disciplined setup reduce these risks.
VII. Results Focus: Consistent Surface Texture on Hardened Material
The primary goal in this case is not maximum removal rate—it is stable, repeatable surface quality on a 50 HRC part over a long finishing cycle. The combination of our Milling Cutter and a Hydraulic Holder, paired with small finishing engagement, supports:
- · Uniform surface texture across complex blended areas
- · Reduced risk of chatter marks or abnormal streaking
- · A more predictable process window for repeated production
Wear width: 0.03mm
Wear width: 0.035mm
VIII. We Are a Factory: Custom Milling Cutter and Hydraulic Holder Solutions
This case also represents how we support customers beyond a single tool SKU.
As a factory, we can manufacture tools based on your real requirements. You can send us:
- · Material type and hardness (e.g., SUS630 at 50 HRC)
- · Surface type and geometry (3D finishing, cavity, grooves, etc.)
- · Machine conditions (spindle speed range, holder interface, coolant method)
- · Target results (surface finish level, cycle time, tool life)
We can then propose and produce a matched Milling Cutter and Hydraulic Holder solution designed for your specific machining goals.
If you are machining hardened materials and need stable long-cycle finishing performance, contact us. Provide your workpiece photo, material hardness, and machining targets—we will produce the Milling Cutter and Hydraulic Holder solution you need for reliable surface finishing and consistent production results.
Post time: Jan-18-2026
