Speeds close to 500 m/min on aerospace alloys

As part of its Bidemic family of patented cutting tool inserts, Tungaloy-NTK UK is introducing its JX1 grade that offers cutting speeds close to 500 m/min on aerospace alloys. Suitable for turning, internal turning, grooving and boring applications, the new grade provides durability with cutting speeds on hard materials that will take productivity to the next level.

Complementing the JX1 grade is the new JX3. Where the JX1 offers wear resistance for extended tool life, JX3 is for tough operations. Suitable for rough machining, profiling and semi-finishing, both the JX1 and JX3 can machine at parameters from 180 to 480 m/min, with a depth of cut up to 2.5 mm and a feed rate up to 0.27 mm/rev.

Also now available is the JP2 grade for finish turning. According to Tungaloy-NTK UK, the JP2 is capable of achieving cutting speeds 10 times higher than carbide equivalents. With machining in the realms of 520 m/min possible, the JP2 delivers surface finishes of Ra 0.6 µm with a feed rate of 0.15 mm/rev. It features multi-edges and a TiN coating in support of higher durability and efficiency.

Providing added flexibility for high-performance turning, Tungaloy-NTK UK can also offer its new BX815 CBN grade for high-speed finishing. Extending the application range of the patented JX and JP Bidemic grades, the BX815 is for both external and internal finish-turning in the speed range from 80 to 500 m/min, making it an all-rounder for manufacturers that demand smooth surface finishes on heat-resistant alloys.

Designed for machining superalloys, the BX815 incorporates alumina-based binders and zirconia grains that offer heat dissipation, oxidation and fracture resistance.

More information www.tungaloy.com/uk

Library provides instant cutting data suggestions

Seco has launched a web-based tool that provides customers with product-specific, instant cutting data recommendations based on their machine information. The Seco Machine Library simplifies the process of identifying, purchasing and optimising tools that are appropriate for specific machines.

“Machine Library is the latest addition to the Seco ‘My Pages’ portal that supports customers with a personalized digital experience at secotools.com,” says Seco product lead Simon Karlström. “Customers can quickly access detailed cutting data for a particular tool based on their specific machine characteristics, in addition to getting fast product information. Machine Library closes the loop with all the data an operator needs to get the machine cutting straight away.”

Customers can easily add, edit and delete machines, along with characteristics such as manufacturer, model, CNC, coolant, rpm, torque and power by simply logging in to their secure My Pages portal and navigating to ‘Machine Library’. Once the library is populated with machine information, customers simply add their machine in the cutting data tab on the product details page to obtain machine-specific cutting data recommendations. Additionally, users will be able to adjust machining parameters like cutting methods and number of passes to optimise their processes.

Configuring and saving their individual machines in Machine Library enables customers to integrate with future Seco digital products. Calculating cutting data based on their unique machine settings gives operators quicker and more accurate parameter recommendations to avoid costly trial and error. Machine-specific cutting data will help shops be more productive with increased throughput and decreased scrap.

Seco Machine Library recommends cutting data for any combination of machine and tool.

More information www.secotools.com

FCR end mills offer vibration-free machining

Now available in the UK from Industrial Tooling Corporation (ITC), Fullcut Mill FCR indexable end mills from Big Kaiser are said to deliver vibration-free machining. The new Big Kaiser system integrates its indexable inserts with the machine spindle via the BBT (Big-Plus BT taper) interface. FCR end mills are also available in HSK A-63 and BDV interfaces. Notably, the monoblock design helps to reduce vibration and chatter while improving system rigidity. As a result, manufacturers can achieve improved process reliability and consistency.

The Fullcut Mill FCR is an indexable insert tool that come in two variants: standard and long nose (both supplied with a BBT interface). Big Kaiser’s FCR is available in four diameters spanning 16 to 32 mm, with two or three insert seats. The long nose version is more cylindrical and thinner, resulting in a smaller interference contour for difficult-to-access work surfaces.

Compared with solid-carbide end mills, the Fullcut Mill offers enhanced performance through its increased stability and lower running costs. This is credit to users only needing to swap out inserts and not an entire solid-carbide end mill. The advantage of the Fullcut Mill is its insert geometry, which consists of a dedicated single-diameter geometry with a sharp cutting edge for both high radial and axial rake angles. The result? A smooth cut that requires less cutting effort and therefore less spindle power, leaving the surface smooth and burr-free, even when performing a strong interrupted cut.

“The Fullcut Mill FCR is a versatile tool that’s able to handle multi-functional operations such as helical milling, peck-milling, grooving and shoulder milling,” says Giampaolo Roccatello, chief sales and marketing officer for Big Kaiser Europe.

More information www.itc-ltd.co.uk

New drills suit stainless steel and titanium

Guhring has developed a new addition to its hole-making range: the new RT100 InoxPro series of solid-carbide drills. Designed for the drilling of stainless steels and titanium alloys, the new RT100 InoxPro overcomes the challenges of tool wear with its combination of tough carbide grade, new geometry and dedicated coating technology.

According to Guhring, RT100 InoxPro gives manufacturers a 50% increase in feed rates and productivity, with a 60% improvement in tool life compared to conventional stainless steel drills. Furthermore, the geometry design of the RT100 InoxPro optimises swarf control and evacuation to ensure process reliability, even when drilling up to 7xD.

This performance level is achieved with an optimised sickle-shaped cutting edge that forms and evacuates swarf, a smooth Perrox coating which increases wear protection and polished flute surfaces that remove swarf from the cutting area at speed to prevent built-up edge. Available in 3xD, 5xD and 7xD lengths, the RT100 InoxPro comes with a 140° point angle and coolant channels to support swarf removal and extend tool life

Guhring’s RT100 InoxPro is available from 3 to 20 mm diameter in 0.1 mm increments, with all imperial dimensions supported. The 3xD series has an overall length of 62 to 131 mm and a flute length of 20 to 79 mm, depending on the chosen diameter. In contrast, the 7xD range of drills has an overall length from 70 to 244 mm with a cutting length from 30 to 190 mm.

Complementing the new RT100 InoxPro is the new InoxPro fluteless taps, which offer synced macro and micro geometry with an optimised lubricating flute geometry and polygon shape. Guhring says this ensures reliable fluteless tapping in stainless and other high-grade austenitic steels.

More information www.guhring.co.uk

Notable cycle time savings with Ceratizit tools

Lancashire-based subcontract manufacturing specialist Woodbrook Precision continually invests in the latest machine tools, supported by cutting tool solutions from Ceratizit UK. 

Indeed, Woodbrook’s managing director Stephen Hogg says that Ceratizit has been instrumental in enhancing the productivity of the company’s new machinery.

Stephen’s father founded the second-generation business more than 35 years ago.

Initially investing in three-axis Mazak VMCs with rotary tables and turning centres with live tooling, more recent acquisitions have included two 3.5-m bed Mazak VTC800/30SR five-axis machining centres and a five-axis Mazak CV5-500. As the business has shifted from machining steel and aluminium to stainless, super duplex, titanium, Inconel, carbon fibre and Hastelloy, Ceratizit UK has risen through the ranks to be the cutting tool partner of choice.

“Over 10 years ago, Ceratizit was one of many suppliers but, as I took control of the business, it became evident that Ceratizit had the best-performing tools and their service was far beyond anything else,” says Hogg, who can cite many successful examples.

“We recently implemented Ceratizit facing and parting-off tools, and it reduced the component cycle time on 400-off job from 1 minute 58 seconds to 1 minute 26 seconds. Furthermore, Dragonskin CircularLine DLC-coated solid-carbide end mills have cut cycle times on an aluminium part from 3 minutes to 1 minute 20 seconds, while more than doubling tool life.”

On another 100-off repeat order for stainless steel aerospace fixtures, the company needed to reduce its cycle times to maximise margins and reduce costs. Ceratizit introduced a high-feed indexable end mill, reducing our cycle times from 38 to 26 minutes per part, with a tool life improvement of more than 20%.

More information www.ceratizit.com