A versatile new range of milling cutters and inserts form an important part of Dormer Pramet’s first product launch of 2017. Expanding the company’s range of milling cutters, the development adds an adaptable option to support a wide range of insert shapes and operations from roughing to finishing.
The SOD05 cutter, developed under the Pramet brand, reduces tool changeover time and inventory costs with its universal pocket, which is capable of carrying octagonal, round and square inserts. It means that the cutter, available in diameters from 32-125 mm, can perform face milling, shoulder milling, slotting, plunging and ramping in steel, stainless steel, cast iron and non-ferrous materials.
To support the new cutter, Dormer Pramet has added to its range of octagonal (OD), round (RD) and square (SD) inserts. The OD insert has eight cutting edges and low cutting forces, promoting an economical option for face milling, while the RD inserts are suitable for high-feed roughing, shallow profiling and ramping. SD inserts have four cutting edges and offer a 90° option for square-shoulder milling, providing depths of cut up to 10 mm.
All insert types have the same radial and axial positions of edges – allowing for easier CNC programming and manual operations.
Meanwhile, Dormer Pramet has announced a new range of small diameter cutters (12-40 mm) for turn-milling operations, which have a high number of teeth to improve productivity.
For further information
www.dormerpramet.com

SandvikCoromant has unveiled a new turning concept that is said to offer improved machining flexibility and the potential for significant productivity gains. Unlike conventional turning operations – which have remained largely unchanged for decades – PrimeTurning allows machine shops to complete longitudinal (forward and back), facing and profiling operations with a single tool. The methodology is based on the tool entering the component at the chuck and removing material as it travels towards the end of the component. This allows for the application of a small entering angle, higher lead angle and the possibility of machining with higher cutting parameters. Furthermore, conventional turning (from part-end to chuck) can be performed using the same tools.
SandvikCoromant believes that some applications could see productivity increases in excess of 50% through the deployment of PrimeTurning rather than conventional techniques. Some of these improvements are due to the small entering angle and higher lead angle, which create thinner, wider chips that spread the load and heat away from the nose radius. The result is said to be increased cutting data and extended tool life.
PrimeTurning is initially supported by the introduction of two dedicated CoroTurn Prime turning tools and the PrimeTurning code generator, which supplies optimised programming codes and techniques. CoroTurn Prime inserts have three edges/corners; one for longitudinal turning, one for facing and one for profiling, thus delivering efficient edge utilisation and longer tool life.
For further information
www.sandvik.coromant.com

Mapal has released its HPR400 reaming tool to simplify the fine machining of bores with large diameters in a defined tolerance range. According to the company, tool quantity can therefore be reduced, as can the subsequent logistics and even tool-setting efforts.
The fine machining of large, tight-tolerance bores traditionally leads machine shops to deploy multi-edged reaming tools as these are both fast and less sensitive to interrupted cuts. However, the reconditioning of reamers with fixed inserts is a complex process.
Instead, by incorporating high-accuracy insert seats on the HPR400, customers can replace inserts instantly using a torque wrench. Incorrect insert mounting is eliminated, as only one mounting position is possible and the inserts can be fitted in any pocket. As a result, no setting is required and there is no need to send tools away for time-consuming or expensive reconditioning.
Available from 50 to 315 mm diameter, the HPR400 is offered with either a HSK or Mapal’s own module adaptor. It can be applied to almost any workpiece material as inserts are available in a variety of grades and geometries.
For machining cast iron, Mapal has developed the wear-resistant HC419 insert grade with a CVD coating for use with the HPR400 reaming tool. One automotive customer is using the tool to machine the main bore in a differential housing made from GJS400 cast iron. With a tool diameter of 150 mm using eight inserts, the HPR400 is obtaining a tolerance level of IT7. These results arrive using a cutting speed of 160 m/min with a feed of 1.6 mm to achieve an average surface finish of 1.35 Ra.
For further information
www.mapal.com

Horn has launched a new range of solid carbide milling cutters designed specifically for machining titanium alloys such as Ti6Al4V. The programme comprises cutters with diameters from 2 to 20 mm, available in four- and five-flute geometries with a cutting edge length of 2xD and 3xD.
The newly-developed TSTK grade is specifically intended for machining titanium, widely used in the aerospace and medical industries. As well as offering good tribology properties and high temperature resistance, the material transmits minimal heat into the substrate and acts as a kind of thermal shield.
Further important characteristics of the newly-designed solid carbide end mills are alternative helix angles and pitches to ensure a softer, gentler cut, therefore eliminating vibration and chatter. As titanium’s low thermal conductivity makes it difficult to remove heat from the point of cutting, a copious supply of coolant directly to the cutting edge is essential, advises Horn.
For further information
www.phorn.co.uk

Before, during and after graduating from the University of Falmouth with a degree in sustainable 3D design, David Forsyth always had a keen eye for turning the most creative of designs and concepts into a reality. The entrepreneur spent time designing and building surfboards, campervan conversions, trophies and much more.
Prior to setting up Newquay-based Digital Fabrications, Forsyth spent time teaching students how to use 3D milling machines; a period that also educated him in the value of acquiring cutting tools from Industrial Tooling Corporation (ITC). “We used cutting tools from ITC at the university and always had excellent technical support, so when Digital Fabrications started with its first AXYZ routing machine, ITC was the natural choice for cutters.”
Among recent projects is the creation of two 7 m high, 1.8 m wide sycamore leaf sculptures for ‘The Address Downtown Dubai’ hotel in Dubai. ‘The Address Downtown Dubai’ hotel faces the iconic BurjKhalifa, the world’s tallest building.
Layers of the sculptures were machined on the AXYZ routing machine. This workhorse was cutting high-density foam for over 12-15 hours a day, for almost six weeks. The company employed an ITC Brit Cut 20 mm four-flute AlTiN-coated square-end milling cutter for rough-machining the complete profile of the 7 m model. The scale of the sculpture required the long-series Brit Cut 204 tool to use its full 75 mm flute length.
Once the rough-machining process was complete, Digital Fabrications then finish-machined the profile of the sycamore-leaf sculpture with a 20 mm diameter Brit Cut 204 series ball-nose end mill.
To put the tool life of both cutters into perspective; one 7 m sycamore leaf required three weeks of machining at 15 hours a day. This equates to over 220 hours of machining, something that was completed with just one square-end roughing tool and one ball-nose finishing cutter.
For further information
www.itc-ltd.co.uk