According to Walter GB, aerospace manufacturers that require special solid-carbide tooling for titanium workpieces will have to wait no longer than three weeks using the company’s newly introduced Xpress service.

An example of the cutter options available to aerospace component manufacturers is the Prototyp Ti38 Z6-10 solid-carbide milling cutter. Featuring a newly developed substrate and PVD coating, this cutter is able to operate at cutting speeds of up to 140 m/min. In addition, multi-tooth solutions with up to 10 teeth allow the feed to be increased by up to 50%, says Walter, in turn providing an increase in metal removal rates of up to 50% compared with conventional solutions.
In one case, tool life on a titanium aerospace window frame with a tensile strength of 1250 N/mm² has been raised by 154% when semi-finishing and finishing using a Prototyp Ti40 cutter. On the same component, using a Prototyp HDC Ti38L for finishing the outer contour, tool life was extended by 116%, while cutting speed increased by 25% and machining volume by 23%.
Also, the use of Walter’s CVD coating technology for its WSM45X indexable insert which, for instance, is used in the Walter Blaxx M3255 porcupine milling cutter, is seen as pivotal. Using this tooling combination, titanium structural components are typically machined using full slotting and climb milling at a cutting speed of 45 m/min and a feed of 0.12 mm. A further option is to increase the cutting speed to 65 m/min, achieving a predictable tool life of around 60 minutes.
Customers of the Xpress tool service can use the my.Walter software to design the tool online. This will be followed by an email quote for the purpose-made tool along with a 2D drawing and 3D model; all within an hour.
For further information www.walter-tools.com

CoroMill Plura routers unveiled by Sandvik Coromant are designed to offer optimised milling and slotting operations in composite materials such as CFRP and GFRP. According to the company, customers will benefit from the patented geometries featured on the new routers.

When milling and slotting composite materials, the CoroMill Plura routers are used primarily in full radial engagement and at full depth of cut. In some cases, finishing passes can also be deployed. Helix angles have been carefully designed for sharpness and cutting edge strength, helping to ensure longer tool life and high-quality surface, edge and slot finishes. The range comprises three cutters: the CoroMill Plura compression router, CoroMill Plura low-helix router, and CoroMill Plura serrated router.
The CoroMill Plura compression router, with its dual 40° helix, works best with special woven glass layers on both sides of CFRP components. As there is an overlap between compressed flutes, the router performs well in thin, flat materials by reducing material vibration.
Specifically designed for smooth and burr-free finishing passes in CFRP workpieces, the CoroMill Plura low-helix (5°) router features a high number of teeth and a coating that is designed to facilitate quick cutting and protection from heat. Right- and left-helix options allow flexibility in material with challenging support conditions, such as weak or compromised fixtures.
Finally, the CoroMill Plura serrated router, with its large flute form, is designed for very high material removal rates. The geometry also offers a dual cutting action to reduce delamination and vibration, ultimately providing a single-pass solution to minimise stress on composite parts.
All three CoroMill Plura routers can be used with or without coolant.
For further information www.sandvik.coromant.com

The new Eliminator series of end mills from Quickgrind is purpose-designed to increase metal removal rate (MRR) when performing five-axis machining operations. According to Quickgrind, the end mills incorporate a conical or tapered form that will deliver reductions in cycle time of up to 95%. This bold claim is substantiated by the ability of Eliminator to reduce tool-path distances while utilising the entire flute length to increase the step-down rate and subsequent MRR. Furthermore, the geometry of Eliminator reduces the potential for thermal deformation, dissipating heat from the cutting edges to extend tool life and improve surface finish.

From an application perspective, Eliminator tools are suited to semi-finish and finish-machining processes on a range of components, including aerospace turbine blades. The solid-carbide end mills are available uncoated or with Quickgrind’s Type D geometry, which features an MX coating for the machining of low- and medium-alloy steel, tool steel, cast iron and hardened steels. Alternatively, Type S end mills are XRed coated for the machining of high-temperature alloys such as Inconel, Hastelloy and titanium, as well as stainless steels.
Eliminator cutters can be used as a direct replacement for ball-nose and standard end mills. The tools are available as three- or four-flute cutters, which are offered in shank diameters of 6, 8, 10, 12 and 16 mm, which taper down to a ball nose diameter of 1, 2, 3 or 4 mm.
For further information www.quickgrind.com