Kennametal has introduced its next-generation 3D-printed stator bore tool for the machining of aluminium engine housings for electric vehicles. This latest version of the tool features a newly designed arm structure, a larger centre tube made of carbon fibre and a further weight reduction of greater than 20% over the original design. The complex tool is capable of machining three large diameters in just one operation, saving set-up time and machining time for automotive component manufacturers, while delivering high accuracy and surface qualities.

The newly redesigned tool recently won MM MaschinenMarkt’s Best of Industry Award in the Production and Manufacturing category based on votes by readers and industry experts.

“As our automotive customers expand their offerings of hybrid and electric vehicles, we continue to respond to their need for lighter weight tooling solutions,” says Ingo Grillenberger, product manager at Kennametal. “By leveraging advanced manufacturing techniques like 3D printing, we’ve reduced weight a further 20% over the first-generation tool, while improving chip control and increasing tool rigidity – innovations that help our customers machine faster and more efficiently.”

Machining three diameters in one operation, the stator bore tool ensures the alignment and concentricity of the machined surfaces, while reducing cycle time significantly. The lightweight 3D printed combination tool enables a faster tool change and spin-up even on less powerful machines. According to Kennametal, the surface specifications and component tolerances are achieved without constraints.

Hassle-free chip removal arrives by means of aerofoil-shaped arms with through-coolant to ensure precise and powerful coolant supply to the cutting edges and guide pads. This capability would be difficult or impossible to produce economically with traditional manufacturing, but 3D printing enables Kennametal to realise even complex internal features.

For further information
www.kennametal.com

Tungaloy has extended its Tung-Tri indexable square shoulder milling system with the new size 04 insert. The 04 size has a 3.5 mm cutting edge length that makes this new arrival compatible with tool body diameters as small as 8 mm. With the 04 inserts available for tool bodies from 8 to 25 mm diameter, the extremely small Tung-Tri 04 insert has a 4 mm inscribed circle, yet it delivers the same benefits of light cutting and long tool life that existing Tung-Tri inserts have been providing for manufacturers. This capability enables the Tung-Tri 04 to generate up to double the tooth density when compared with alternate tools, and subsequently increase feed rates. The compact configuration enables a 16 mm diameter Tung-Tri 04 cutter to offer four inserts per cutter, whereas the 25 mm diameter cutter can facilitate six teeth. This insert density is common throughout the Tung-Tri series, ensuring that all tool body diameters and insert designations can offer maximum productivity levels and feed rates for end users.

Complementing the new compact size 04 inserts are tool bodies for size 06, 10 and 15 inserts. The 06 inserts are suitable for 12 to 50 mm diameter tool bodies, with 25 to 100 mm bodies for the size 10 inserts and 40 to 160 mm diameter bodies for the size 15 inserts.

The new Tung-Tri series uses three-edged inserts developed specifically to deliver precision, productivity and cost efficiency for shoulder milling applications. According to Vargus, this allows users to choose an optimal tool set-up according to the given part sizes and the required material removal volume.

For further information
www.tungaloy.com

Rainford Precision is introducing two new brands to the UK: 6C Tools AG and BSQ Tech GmbH.

Unlike many other products on the market, micro-tools from 6C Tools are manufactured by laser ablation, a process that is particularly gentle for material removal compared with grinding or spark erosion. This method of manufacture avoids damage and significantly increases the wear resistance of 6C Tools, creating a potential 5-10 times tool life increase.

The 6C product catalogue covers several drilling, milling and threading tools, as well as tailored tools manufactured from PCD and PCBN. Designed specifically for machining challenging materials such as tungsten carbide and zirconium, the standard 6C portfolio introduces PCD drills, PCD end mills, PCD chamfer tools, PCD ball-nose mills and ball-nosed polishing tools, as well as a range of PCD thread mills.

The ability to machine such difficult materials with impressive tool life and productivity characteristics makes the 6C range suitable for manufacturers in the medical, electronics and jewellery industries, to name but a few.

For engineers looking to improve their productivity when machining aluminium, aluminium alloys, copper, brass, plastics, PEEK and all other non-ferrous metals, Rainford can now offer the SwissCeraMill series from BSQ Tech, which the company says can increase tool life from 5 to 25 times and improve productivity by 400% compared with conventional carbide cutting tools.

Manufactured from high-tech ceramic zirconium oxide with a micro-grain structure, SwissCeraMill end mills are available in square-end, corner-radius and ball-nose designations, along with special-purpose tools to suit the diverse needs of industry.

For further information
www.rainfordprecision.com