Grinder keeps pace with demanding schedule

A well-established Midwest-based manufacturer that cranks out millions of shafts each year, ranging from 38 to 203 mm in length, and up to 32 mm in diameter, has recently sourced a new centreless grinder from Total Grinding Solutions (TGS).

The machine was selected thanks to its ability to handle the company’s myriad of part sizes and diameters with minimal changeover time. Robustness was an equally important factor.
With hundreds of different component sizes to process, TGS incorporated two machine upgrades to ensure that parts were handled properly. First, a custom part-pusher assembly was placed alongside the load conveyor to ensure consistent part pick-up by the accompanying Fanuc robot. Second, an advanced vision monitoring system was attached above the load conveyor to check incoming parts for size and shape, and to eliminate any potential for misfeed. Since the initial order, the manufacturer has ordered two additional TGS machines with sophisticated automation systems.
For further information www.totalgrindingsolutions.com

Vibration-free boring system is plug and play

Kennametal has unveiled a boring system that boasts the most effective anti-chatter mechanism ever developed by the company.

In addition, the system offers an extensive range of indexable heads and shank sizes. However, according to Sam Eichelberger, product engineer for lathe systems engineering and part of the team that developed the internal dampening mechanism, “perhaps the most important thing to know about the new bar is that it’s plug and play. There is no need whatsoever for tuning or adjustments – you simply pull it out of the package, mount it in the turret, and get boring.”
The system includes a serrated bolt-on connection at the bar’s business end that clamps a variety of styles and sizes of indexable heads. Better yet, the heads feature a shorter length and lighter weight that provides greater stability. They are also coolant-fed, to direct a stream of high-pressure coolant where it is needed most.
Most important of all is the internal dampener. Says Eichelberger: “The bars are both vibration- and maintenance-free. Within the bar there is a mass that’s supported by a pair of elastic supports, inside of which sits dampening fluid. This mass vibrates at a predetermined frequency during machining, attenuating the natural frequency of the bar around it to suppress vibration. There are no wear components to worry about.”
According to Kennametal, the vibration-free system offers superior performance in boring applications up to 10xD, much deeper than solid carbide or heavy metal boring bars can manage. Internal and customer test results show surface finishes as good, or in most cases better, than competitor systems, with significantly more aggressive cutting parameters possible across the board. The portfolio starts at 25 mm and goes to 100 mm.
For further information www.kennametal.com

Milling cutter offers high versatility

The DoTripleMill from Tungaloy can use an octagon insert that offers 16 cutting edges which can take a depth of cut up to 3.4 mm However, if the depth of cut requirement is greater, then the same cutter body can accommodate an eight-edged square insert with depth-of-cut capability of 6 mm.

Tungaloy’s DoTripleMill is also capable of using an eight-edged round insert. There are many advantages to a round insert. Round inserts are the strongest of all cutting tool geometries and can handle several applications. Another feature of round inserts is that with a light depth of cut, chip thinning can be utilised to offer feed rates that rival high-feed cutters.
A big part of the performance advantage of DoTripleMill is found in the way the insert is secured into the pocket. The insert has a ground-in groove that circumnavigates the periphery of the insert, midway through the insert thickness. This groove acts to lock the insert into a mating protuberance in the pocket.
With conventional face-milling cutters, the neck of the screw is the only factor holding the insert down. Where the DoTripleMill uses the milling cutter pocket to wedge the insert into place, this method acts as a dovetail locking mechanism that fully secures the insert, prevents movement, accurately tracks the insert and reduces strain on the screw, which is a common issue with conventional milling cutters. This design configuration facilitates higher feed rates, improved repeatability, increased dependability and better surface finishes.
Inserts are available in both CVD and PVD coated grades. The CVD grades run at elevated spindle speed, while the PVD grades are used for sharper cutting edges. Diameters start at 50 mm and go to 160 mm.
For further information www.tungaloy.com

Small-part turning tools unveiled by NTK

NTK Cutting Tools is releasing its Stick Duo Splash cartridge insert line for the turning of small parts. Stick Duo Splash inserts direct high-pressure coolant at the cutting edge, helping to overcome the issues of poor swarf clearance when machining small parts that require internal turning and threading operations.

The Stick Duo Splash is available in two variants that offer either a single coolant outlet directed to the tip of the insert or, alternatively, a two-outlet holder which delivers cutting fluid to both the front and rear side of the tool insert. Stick Duo Splash inserts with two coolant outlets have been designed for evacuating chips during the processing of blind holes, while the single coolant outlet tool is suitable for the machining of through-holes and bores.
NTK’s Stick Duo Splash tool-holder cartridge has been developed for use with machine tools that have both standard and through-coolant delivery configurations. However, the flexibility of the Stick Duo Splash allows end users to attach the coolant hose to either a screw hole at the rear end of the cartridge, or via a connection point located at the front end. NTK has developed the Stick Duo Splash with two coolant inlet options to meet the various tooling configurations and set-ups of small turning centres and sliding-head machines with compact work envelopes.
Stick Duo Splash is available with a variety of cartridge dimensions that meet the specifications of all modern turning machines. Available diameters include 16, 19.05, 20, 22, 25 and 25.4 mm, with an overall length of 90, 110, 120 and 125 mm.
For further information www.ntkcuttingtools.co.uk

High-precision, high-volume face-milling solution

ElectroMill diamond and CBN electroplated grinding solutions from Engis are designed to replace expensive, complex, tungsten carbide or PCD milling cutters in the production of high-quality, flat milled surfaces in high-volume applications – even those with an interrupted cut or where multiple materials must be machined simultaneously.

Designed for use on a variety of machining centre types, in fact any system with high pressure coolant and 10,000+ rpm spindle, ElectroMill improves surface finish and flatness, while extending tool life and reducing cost per part, says the company.
ElectroMill solutions are offered either as an integral unit, providing increased rigidity and internal balance, or as a multi-part (shell) design, offering more flexible options and adaptability for legacy tool-holding situations. A number of standard taper options are also available.
The major benefits of the Engis ElectroMill include reduced numbers of operations, set-ups and inspections, along with high stock removal rates and low heat build-up (providing stress-free, cool cutting action). Engis says that ElectroMill extends tool life compared with conventional milling cutters because the diamond stays sharp with constant controlled micro-fracturing and no dressing cycles required. In addition, the ElectroMill solution is environmentally friendly, being usable with water-soluble or synthetic coolants.
The ElectroMill is aimed at sectors that include marine, automotive, aerospace and defence – and at a wide variety of components in ferrous, non-ferrous and exotic materials.
For further information www.engis.com