Major progress in external reaming of turned parts

The mass production of precise turned workpieces on multi-spindle automated lathes is subject to its own rules. In a hotly contested market, it is necessary to take every tiny opportunity for cost reduction, as Oberrindal-based WE Schultz, a customer of cutting tool specialist Mapal, can testify.

“As a true mass producer of comparably simple parts, we have to be able to compete in terms of price and quality with competitors from Asia here in Switzerland,” says Alexander Jaksch, deputy head of the turning shop.

A key lever in this ideology is the support of external partners such as cutting tool suppliers.
“Ultimately, the tools for a machine tool are as important as the tyres on a car,” states Jaksch.

The potential available here has been demonstrated to decision-makers at WE Schultz by a custom tool developed and subsequently optimised by Mapal.

“This project was about a part that seemed rather simple on the surface, a sleeve turned from solid with a diameter of almost 15 mm and a length of 10 mm,” says Emil Hugentobler, machine fitter at the Oberrindal plant. However, there are two crucial sticking points: a narrow diameter tolerance of 14.7 mm +12/-2 µm, and exceptionally low surface roughness of only Rz = 6 µm.

“In this situation we became aware of Mapal’s external reamers, particularly a custom tool for external reaming,” recalls Alexander Hildt,head of manufacturing. This external reamer is equipped with three guide pads and an adjustable indexable insert. The key advantage of the solution is that the outer dimensions of the workpiece are represented by the inner dimensions of the tool. Therefore, machine-related influencing factors such as increased play in the machine kinematics or the bearing of the spindle or chuckbecome practically irrelevant.
For further information www.mapal.com

New grades facilitate high feeds on tough metals

Horn has introduced two carbide grades for inserts used in its DAH82 and DAH84 high-feed milling systems, enabling their use for a wider range of materials. The expansion gives customers the ability to choose grades best adapted to their applications.

The new SC6A grade is suitable for machining materials in the ISO M group (stainless steels), as well as ISO S materials (superalloys) as a secondary application. The new IG6B grade is for machining ISO P materials (steels), while it is also suitable as a multi-purpose grade for other material categories, as is the pre-existing SA4B substrate.

With eight usable cutting edges, the sintered inserts offer a competitive price per cutting edge and hence economical machining. The positive geometry ensures a soft, quiet cut as well as good chip flow. Notably, the large radius of the insert’s main cutting edge also promotes a soft cut and,alongside an even distribution of cutting forces, ensuring long tool life.

In terms of machining parameters, the maximum cutting depth is 1 mm (DAH82) and 1.5 mm (DAH84). The DAH82 variant is available as an end mill and as a screw-in milling cutter in the following diameters: 20 (z = 2), 25 (z = 3), 32 (z = 4), 35 (z = 4) and 40 mm (z = 5), where z denotes the number of inserts. As a shell mill, it is available in diameters of 40 (z = 5), 42 (z = 5) and 50 mm (z = 6).

For diameters of 50 mm and more, the larger DAH84 system is first choice. The variants are available only as shell mills in the following diameters: 50 (z = 4), 52 (z = 4), 63 (z = 5), 66 (z = 5), 80 (z = 6), 85 (z = 6), 100 (z = 7) and 125 mm (z = 8).
For further information www.phorn.co.uk

MTC offers lifeline to Britishvolt employees

The Coventry-based Manufacturing Technology Centre is providing a lifeline to redundant employees of the collapsed battery manufacturer Britishvolt. In total, the MTC is offering Britishvolt workers with the opportunity to fill more than 50 engineering, manufacturing and supporting roles at its Ansty Park headquarters. The roles available include engineers of all levels, as well as project managers and trainers.

MTC chief people officer, Vicki Sanderson, says the MTC was keen to support the UK manufacturing community: “The UK has long suffered from a shortage of people with the right engineering and associated skills to take the country’s manufacturing industry into the future, so it’s important that these skills are not lost to other sectors.”
For further information www.the-mtc.org

Sustainability in DNA at GFMS

Machine tool manufacturerGF Machining Solutions aims to become a sustainability leader and, to achieve this ambition, has created three inter-connected pillars within its new business strategy.These pillars cover:product sustainability;climate andresource planning; and looking after the wellbeing of its employees. The first pillar requires constant innovation to ensure products and services have sustainable lifecycles, whilethe second pillar translates into decoupling resource consumption from growth. The third pillarhas a focus on creating diverse, engaging and safe workplaces.
For further information www.gfms.com

Innovative tooling at heart of partnership

MSC Industrial Supply Co UK (MSC) and Walter Tools have entered a new supplier partnership focused on ensuring machine shops receive high-precision tooling and value-added service.

“Walter Tools’ focus on innovation and new product development matches closely with MSC’s values of providing products and services of the highest possible standard,” explains James Howarth, head of category management at MSC. “Many industries, from automotive and energy all the way to aerospace, require high-quality suppliers with whom they can work closely; who understand their needs and can recommend the right tools for the job. Walter Tools’ focus on helping customers streamline their processes resonated with MSC and is a key reason behind the forming of this partnership.”
For further information www.mscdirect.co.uk