Mirror-finish milling

Horn has expanded its DTM face-milling system to include inserts for the mirror-finish machining of non-ferrous metals and plastics. DTS inserts, which are tipped with monocrystalline diamond (MCD), are said to generate virtually perfect surface finishes with flatness of less than 1 µm.

The new DTS inserts are tailored to the DTM face-milling system and achieve high levels of efficiency and cost-effectiveness in conjunction with pre-machining inserts. Either polycrystalline diamond (PCD) or chemical vapour deposition diamond (CVD-D) is used for pre-machining, depending on the material being processed. All tools for mirror-finish machining are generally designed with single cutting edges, while the remaining insert seats contain roughing or balancing inserts.
The MCD-tipped cutting edge is set to an axial projection of 0.02 mm. Due to the structural design, the PCD-tipped inserts always pre-cut radially. As a result, it is virtually impossible for the MCD insert to be overloaded or damaged. The insert seats of the DTM milling body can be adjusted in the axial direction via an adjusting screw. Every 10° of rotation moves the insert seat by 0.01 mm, which means that the axial run-out of the individual cutting edges can be adjusted with micrometre precision.
An internal coolant supply ensures targeted cooling of the contact zone and efficient chip removal, while the low mass of the aluminium body protects the spindle and reduces energy consumption compared with steel bodies. Horn offers a fine-balancing option for the body to achieve high cutting speeds of up to 5000 m/min and ensure quiet running.
For further information www.phorn.co.uk

CrazyMill plunges into productivity gains

Mikron Tool has expanded its CrazyMill Cool P&S plunge-milling cutter programme with the inclusion of new dimensions to achieve even deeper machining cycles.

Now available in the UK from Floyd Automatic, the latest CrazyMill Cool P&S is characterised by the ability to plunge (drill) vertically into the material, mill slots or pockets into solid material in small spaces, and conclude milling operations with finishing cycles.
Although the milling depth in the short version (2.5xD) was based on the machining of keyways, the extended range has been developed to mill the deepest possible slots and pockets with a single tool, reaching more distant machining areas of a workpiece with one cutter. The new version of the solid-carbide plunge mill is based on the same technology as the short version, transferred directly to the new line. Now, it is possible to plunge perpendicularly into the material and reach the maximum milling depth of 5xD.
Good chip removal plays an important role at this depth. There is a higher risk that chips remain in the milling zone, are broken-up and subsequently damage both the milling cutter and the milled surface. The special cutting-edge geometry of CrazyMill Cool P&S and its extended chip area provide a remedy, ensuring lateral chip removal during plunging and tool stability during deep milling.
Alberto Gotti, head of the technology and customer project centre at Mikron Tool, says: “Customers can work with this tool at high speeds and feeds, and an axial infeed of 0.5xD, achieving extremely high chip-removal rates. For the user, this means up to five times shorter machining processes and significantly longer tool life compared with other milling cutters on the market.”
The CrazyMill Cool P&S is available in diameters from 1 to 8 mm, and for a maximum milling depth of up to 5xD.
For further information www.floydautomatic.co.uk

Additive tool cuts costs for Xcel Aerospace

Working closely with companies like Rolls-Royce, Collins Aerospace, Safran, Bombardier, ITP Aero, Marshall and Incora, Romford-based Xcel Aerospace is a subcontract manufacturer with an aerospace pedigree that few in the supply chain can match.

As part of its drive to ensure cost-effective manufacturing, the company recently invited tooling manufacturer Guhring to review the machining process on an aerospace valve component. The problem for Xcel was the cost efficiency of its existing Woodruff-type cutters when machining the cast aluminium component, which features 9% silicon content.
Only capable of completing 10 components before tool replacement, the abrasive aluminium was creating productivity, cost and surface finish issues for this aerospace expert.
“We explained to Xcel that Guhring has a new method of manufacturing PCD tools by printing them on a MarkForged Metal X 3D-printing machine,” says Guhring’s regional sales manager Dewar McKinlay. “We made a three-flute tool that was similar to the current tool but with brazed PCD tips. Despite the PCD tips lasting considerably longer on the abrasive high-silicon aluminium than the previous tool, we wanted to go further.”
The new design increased the number of cutting edges from three to five, allowing Xcel to increase the feed rate, while extending tool life.
“The previous solid-carbide tool was worn and required a changeover after 10 parts, but we have machined more than 180 parts with the new 3D-printed PCD Woodruff cutter and it is still performing well,” says McKinlay.
“Putting five cutting edges on a 21.7 mm diameter Woodruff tool with a solid-carbide body would create significant manufacturing challenges,” he adds. “The main benefit of printed tools is that we can produce multiple designs very quickly.”
For further information www.guhring.co.uk

Low-cost, high-performance turning inserts

As the manufacturing sector begins its recovery from the downturn attributed to COVID-19, Ceratizit has stepped up to provide a helpful hand in controlling tooling costs.

The introduction of its Standard Line of ISO turning inserts is said to provide customers with significant cost benefits, while retaining quality and performance.
In order to achieve these cost savings for customers, Ceratizit has streamlined the Standard Line into just three grades, with a reduced number of seven insert shapes. These shapes include the popular CNMG, DNMG, CCMT and DCMT styles, in a range of insert sizes, giving over 100 inserts from which to select. As highlighted by the insert designations, both positive and negative inserts are available, with a choice of two chip-breaker styles to suit specific machining applications.
Standard Line inserts are manufactured to the company’s exacting standards at Ceratizit’s Reutte, Austria facility, and by limiting the range to the most popular styles and sizes, volume manufacturing is helping to drive down costs.
“The Standard Line of turning inserts will benefit many customers, particularly those in the subcontract sector, where batch sizes may be low and frequently changed, and where business is price-focused,” explains Tony Pennington, managing director of Ceratizit UK & Ireland. “For example, savings when compared with mainstream competitors can be as high as 75% per insert, giving customers the competitive edge they are looking for in these challenging times.”
Standard Line turning inserts are available ex-stock with the same delivery promise as with all of Ceratizit’s products; if ordered by 18:30, delivery is guaranteed the next morning before noon.
For further information www.ceratizit.com

£6.85m funding for NAMRC facility

The Nuclear AMRC’s proposal to establish a new advanced manufacturing research centre in Derby has secured government funding.

Supported by Derby City Council and the D2N2 Local Enterprise Partnership, the proposal has been awarded £6.85m by the Ministry of Housing, Communities & Local Government. Local partners will also invest in the proposed £20m project to create a new permanent home on Derby’s Infinity Park for Nuclear AMRC Midlands, creating 70 jobs and helping to reboot the local economy after the coronavirus crisis.
For further information www.namrc.co.uk