New parting-off tool for small components

Kyocera Corporation has developed a new parting-off solution, denoted KGZ, for small component machining. KGZ uses a new clamp structure with three proprietary mechanisms to lock the insert in place, suppress chatter and achieve stable machining. In addition, the constraint surface of the holder has a shape that distributes stress, improves durability and realises high-efficiency machining.

Within the insert grade’s line-up, a newly developed PVD-coated grade known as the PR 20 is also available for the KGZ. The new coating, MegaCoat 1 Nano EX, which is resistant to oxidation and abrasion, achieves high precision, long tool life and stable machining when parting-off steel, stainless steel and cast-iron workpieces.

Notably, the new KGZ design improves the holding force of the insert and the durability of the tool holder through three proprietary mechanisms: gap section, top clamp and stopper.

With the gap section, users can simply press down on the insert from directly above to firmly secure it in place. Generally, it is structurally difficult to fix the insert directly above with a parting-off tool. KGZ has a tapered slit with a slanted cut, so when tightening the fastening screw it applies a restraining force from directly above the insert, securing it in place.

The top clamp serves to pull the insert inward and increase the binding force. Designing the shape so that force is applied inward when clamping the insert suppresses the displacement of the insert in the front and rear directions.

Kyocera’s stopper disperses stress over a large area and improves the durability of the holder. According to the company, this design reduces the amount of stopper wear to about one-third of that of competitor products.

More information www.kyocera-unimerco.com

Hexalobe is a star for the medical industry

With star-shaped hexalobular bone screws (TORX) proving the design of choice in the medical industry, Floyd Automatic Tooling is introducing the UK market to CrazyDrill Hexalobe drills and CrazyMill Hexalobe end mills from Mikron Tool.

Medical screws for orthopaedic procedures are predominantly manufactured from titanium, stainless steel and cobalt-chrome. Machining these precision screws to impeccable surface finishes is a challenging task – that was until the arrival of the Mikron Hexalobe series. According to Floyd Automatic, machining hexalobe screws 50% faster with precision burr-free results is what makes this next-generation series the first choice for manufacturers in the medical sector.

These high-performance drills for generating pre-holes in TORX sockets are available in two variants: the pre-hole CrazyDrill Hexalobe TORX drill with a tip angle of 140°, and the CrazyDrill Hexalobe Flat drill with a tip angle of 180°. Both are available from 0.9 to 3.8 mm in diameter for producing T4 to T30 TORX sockets. Upon request, Floyd Automatic can provide the drills as a customised combination drill for streamlining operations. The CrazyDrill Hexalobe series combines two operations into one, as it simultaneously machines a flat pre-hole and a 120° chamfer.

The Mikron CrazyDrill Hexalobe from Floyd Automatic generates chamfer surface quality to a finish of Ra<0.3 µm while guaranteeing high profile accuracy and perpendicularity.

Completing the process is the CrazyMill Hexalobe micro end mill. Available from 0.2 to 1 mm diameter for T4 to T30 socket variants, the CrazyMill Hexalobe presents three- or four-flute variants with milling depths of 3.5xD and 5xD. The CrazyMill Hexalobe milling cutter demonstrates sufficient stiffness for machining with high feeds and stepover rates, while guaranteeing the necessary hex lobular profile accuracy.

More information www.floydautomatic.co.uk

Powering up productivity for EV manufacturer

As a machine tool builder that manufactures high-end four and five-axis machines for the global market, Heller UK has frequent involvement in turnkey projects for prestigious OEMs. On one of its more recent projects, the Redditch-based company enlisted the support of the cutting tool experts at Guhring.

There has been a wide spectrum of tools used on this project for a leading manufacturer of electric vehicles (EVs), including Guhring tool holders and tool vending technology. As part of the package of tool holders to accompany the cutting tools, the EV manufacturer has selected a vast range of standard heat-shrink, hydraulic and synchro-tapping chucks.

The cutting tools for the project included a huge range of standard products from Guhring’s portfolio of drills, taps and reamers. Although these accounted for a significant element of the system integration project, it was the bespoke PCD combination tools that demonstrated Guhring UK’s expertise as a one-stop solution provider and valued partner for turnkey projects.

With the PCD combination tools manufactured at Guhring UK’s Birmingham manufacturing facility and its main manufacturing plant in Germany, the bespoke tooling solutions were developed to achieve ‘one shot’ plunging. The bespoke tooling aimed to reduce cycle times and adhere to the high surface finishes required over the life of the tool.

“We delivered 22 four- and five-axis machines in this project, all built in the UK,” says Tad Forys, area sales manager at Heller Machine Tools UK. “Guhring has been with us for every step of the journey, clocking in tools and optimising speeds and feeds to make sure we have the most efficient process for the customer before delivery of the machines.”

More information www.guhring.co.uk

Mapal gains foothold at Kramer+Grebe

To stay competitive in mould and die making for the automotive industry, efficient production with a high degree of process reliability is vital for Krämer+Grebe of Biedenkopf-Wallau. Manufacturers such as Krämer+Grebe also judge cutting tool suppliers by their applications engineering. Mapal is earning trust in this respect with its reamers and high-feed milling cutters.

Machinery at Krämer+Grebe is all state of the art. The 16 machining centres are predominantly from DMG and Hermle. There is also a deep-hole drilling machine, two turning centre, three EDM machines and 3D printers. The company has 11,000 m²

of production space at its disposal, where the transition to electric mobility is well underway. Powertrain parts here include stator housings for the electric motor.

Co-operation between Mapal and Krämer+Grebe is reaching its five-year anniversary, a partnership which began with multi-bladed reamers. Mapal was the only manufacturer Krämer+Grebe could find that was able to produce these tools with the necessary quality and short lead times. Bores with H7 quality are needed to insert heating cartridges in low-pressure moulds.

Mapal’s application engineers left a lasting impression. They provided user training on site and helped commission the process on the machine. As part of process optimisation, Krämer+Grebe parted company with some of its former tool suppliers, of which there were many.

After such a good experience with the reamers, Krämer+Grebe began adopting Mapal’s high-feed milling cutters. The tools demonstrate long tool life and generate large chip volumes during roughing, thus reducing production times. The milling cutters are also extremely reliable to allow for multi-machine operation.

More information www.mapal.com

70 new jobs in Galway

Fastening solutions specialist PennEngineering is expanding its operations in Galway, a move that will create 70 new jobs over the next five years. The €14m expansion project, which involves the construction of a new building, includes a state-of-the-art technology and training centre, testing laboratories and a customer experience centre. The new jobs will span a variety of roles that include manufacturing, engineering, training and more.

PennEngineering’s expansion project has support from the Irish Government through IDA Ireland. Estimates suggest the work will be complete by January 2025.

More information www.pemnet.com/eu/