Guaranteed injection moulding tolerances

A specialist in the manufacture of custom prototypes and low-volume production parts is helping to make life easier for design engineers by guaranteeing specific dimensional tolerances for each type of plastic injection moulding resin.

After extensive testing at its Telford facility, Protolabs is offering customers a machining tolerance of ±0.08 mm with a resin tolerance of between 0.002 and 0.010 mm/mm, depending on the material. The tolerance guarantee applies to all 50 of its stocked resins, although the company can advise on the accuracy of the other 1500 that are available to customers across the world.
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Milling cutter range expanded

The milling assortment for mould and die, as well as general machining applications, has been expanded by Dormer Pramet with several introductions.

Included in the expanded offer is the newly developed double-sided SNGX11 insert for high-feed milling with up to 1.7 mm depth of cut. A strong main cutting edge ensures high levels of durability and process security, especially when machining corners inside a pocket. With eight cutting edges, the square-shaped SNGX11 also represents an economical solution.
Designed for copy milling, helical interpolation, ramping, progressive plunging and face milling, the SNGX11 is available in two geometries. M is for machining steel, but also hardened steel and cast iron, while MM provides a smoother cut and is more suitable for stainless steel, soft steel and super alloys.
Dormer Pramet’s range is supplemented by the latest SSN11 cutter, which is available in diameters from 32 to 125 mm, with intermediate sizes for mould and die applications. All cutters feature a special through-coolant design to further improve process security, as well as a high overhang to support deep milling up to 10xD.
The company has also added to its ADMX07 milling programme with a newly introduced F geometry for finishing and semi-finishing applications. F geometry sits alongside the existing M, FA and HF geometries, and targets the light machining of stainless steel and low-carbon steels.
Aimed at vibration-sensitive machining, the chip breaker features a highly positive geometry with narrow peripheral land. This design reduces chatter and enables a smooth cutting action without burrs on the machined wall. Significantly, it also supports lower cutting forces, which not only reduce energy consumption, but prevent work hardening.
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High-feed mill range extended

The TungForce-Feed line of indexable, small diameter, high-feed milling cutters has been expanded by Tungaloy to include R2 inserts that feature a corner radius of 2 mm.

Available in diameters of 8, 10, 12 and 16 mm, the TungForce-Feed line is pitched as an economic profiling solution for the mould and die industry when compared with conventional solid end mills and indexable tools of similar size.
During the creation of a CAM program for the high-feed machining of complex 3D profiles in typical mould-making applications, it is common to use a theoretical corner radius for programming the insert radius. However, this method leaves excessive stock on the workpiece after machining, adding processes.
Looking to generate the ideal platform for subsequent finishing processes, many job shops are using solid-carbide square-end mills with large radii during roughing. The latest R2 insert requires no programming for the theoretical corner radius, as its 2 mm corner radius leaves no uncut material on the machined surface. This concept ensures that the TungForce-Feed series makes a good replacement for costly solid-carbide end mills.
Featuring an insert design that is 10% thicker than competitor products, the TungForce-Feed line is built to perform at higher machining parameters by withstanding fracture forces. The insert design incorporates a positive inclination angle for smooth chip evacuation which further reduces cutting forces by controlling chip formation, especially when shoulder and slot machining.
Designed for face and shoulder milling, as well as helical interpolation and ramping, the close insert pitch makes the TungForce-Feed line a good option for all milling applications. The series has been designed with a small entry angle for chatter stability that improves efficiency and tool life, even when machining in long-reach areas, says Tungaloy.
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Multi-function tools from Horn

Horn’s Supermini precision tooling system has been enhanced by the introduction of a variant with newly developed HP geometry, allowing higher infeed rates and other cutting parameters. The geometry also enables multi-functional use on a lathe across a range of operations, including drilling, boring, face turning and skimming.

In terms of capability, holes from 3 to 7 mm in diameter may be drilled into solid material using Supermini HP tools without a chip breaker. While the performance data cannot compete with normal drills, the system is a practical solution if the number of cutter locations in a machine is limited. With the single-edged version, various hole diameters can be produced using a single tool.
Horn’s Supermini HP offers the option of immediately boring an inner contour after drilling without having to change the tool. An accurate 90° shoulder can be achieved at the base of the hole, while the wiper geometry produces excellent surface quality, even at high feed rates, says Horn.
Tools can also be provided with a chip breaker, which are recommended for turning applications. Here, the slightly twisted flute helps to remove chips efficiently from the machining zone, while the EG35 coating allows machining of both standard and stainless steels.
As well as HP geometry, Horn has developed a tool holder for the Supermini type 105, whereby clamping is achieved using a tensioning wedge on the face rather than on the circumference, as was previously the case. The tool is held in place with more force, which in turn makes the entire system more rigid. Furthermore, the design results in a higher level of repeatability when changing the tool and permits more compact construction.
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