Casting light on first-stage aluminium machining

In order to boost the first stage roughing operation on newly cast aluminium parts for the automotive industry, Sandvik Coromant is introducing its M5Q90 tangential milling cutter.

Automotive – Milling – Aluminium – Machining example

Designed to complete ‘cubing’ (first machining of faces after casting) in a single operation without creating burrs, the new tool is fitted with PCD tangential inserts that provide a smooth and stable cutting action to lower power consumption and eliminate vibration. This concept ensures reliable performance, improved tool life, exceptional surface finish, high metal removal rate and an increased number of parts per insert.
“To enhance efficiency, our new M5Q90 tangential milling cutter features fully engineered cutter bodies matched with dedicated PCD insert geometries that feature a positive cutting angle to reduce cutting force and load on the machined component,” explains Emmanuel David, global automotive product manager.
M5Q90 cutter bodies are designed according to customer specifications and hence meet the requirements of high-productivity machining – the tool can operate in high-speed conditions in excess of 20,000 rpm. However, all cutter bodies offer the same design of tip seat, coolant channel, lead angle and rake angle. Inserts are always kept in stock.
Aluminium cylinder heads and engine blocks will be among the principal components to benefit, typically at automotive foundries or tier one/two suppliers. By way of example, the cubing operation on a cast cylinder head would involve machining the camshaft face, inlet/outlet face and combustion face. Typical cutting data using M5Q90 might include a speed of 2500 m/min and feed per teeth of 0.20 mm. Users also benefit from high-precision coolant channels that provide the option for either emulsion or MQL application.
For further information www.sandvik.coromant.com

End mill and slot drill ranges released

Expanding the series of solid-carbide end mills and slot drills defined by Sumitomo Electric Hardmetal as its “global standard”, the GSX Mill series is now available. The latest milling cutters have been developed based on a fine carbide substrate to increase toughness.

GSX Mill tools also have a high transverse rupture strength and provide high levels of shock resistance with enhanced orders of consistency and reliability, especially in wet cutting conditions.
The GSX Mill series, covering tools between 1 and 25 mm diameter, has a special flute design and large rake angle. The cutters come in many varieties, covering two, three and four-flute types, in four different lengths of flute. A novel combination of flute design and rake angle enables effective chip evacuation from the cutting zone, while the specific design of two cutting edges improves sharpness and extends the type of workpiece that can be machined.
Typical end mill and slot drill applications cover surface milling, drilling and grooving, with two types of cutting edge profiles. The sharper edged S-Type is suitable for removing inside corners when finish-cutting, while the strengthened edge C-Type, having a gashed land, creates higher resistance to fracture for both roughing and finishing cycles.
The GSX-SLT slot-type cutter is a multi-purpose tool developed for plunge drilling and slot milling, having a large rake angle for efficient chip removal. Also within the GSX Mill series is the GSXVL, which is an anti-vibration, square-type cutter for shoulder milling with an optimised irregular pitch and lead angle that improves resistance to chatter.
Finally, the Sumitomo GSXB Mill ball-type cutter has two flutes and a large 30° helix angle that reduces any resistance to cutting forces, so is suitable for milling hardened steel up to 60 HRc, titanium alloys and cast iron.
For further information www.sumitomotool.com

Westermans broadens ProArc distributorship

Westermans International is enhancing its services to customers in both the home and international markets with a sole UK and Ireland distributorship agreement for the ProArc range of welding, cutting and drilling systems.

Although a supplier of ProArc equipment into worldwide markets for some 25 years, this latest move is set to strengthen product availability and choice in the UK and Ireland, while also providing support where needed for the company’s European sales activity.
Key markets where the development will be of particular note include automotive exhaust, vacuum component and cryogenic vessel manufacturing, as well as water tank, aircraft component, flexible metal hose and sheet metal fabrication. Westermans will be stocking a broad range of ProArc products. Also, a number of units will be set-up for viewing and demonstration at the company’s Leicester premises.
For further information www.westermans.com

Extra CNC axes boost VMC productivity

Compound tables for converting a three-axis VMC into a four-axis or five-axis machine are becoming increasingly popular.

Such tables boost output by reducing the number of component set-ups, often enabling one-hit production, and minimising tolerance build-up for higher accuracy machining. Fixture costs are lower, handling is less and smaller batches can be produced economically, reducing cost per part.
Provided that a rigid, high quality table is purchased, the metal-cutting configuration will be just as robust and accurate as the rotary axes on true five-axis machines.
Kitagawa, which is represented in the UK by sole agent 1st Machine Tool Accessories, manufactures the world’s largest range of NC rotary tables, covering single- and multiple-spindle, tilting, and waterproof models. The tables can be configured with the motor on the right, left, back or top. Table diameters range from as small as 100 mm, including some with built-in 5C spindles, up to 500 mm.
Most models can be supplied with a number of options – including integral ports in the faceplate to enable hydraulic fixture operation – allowing workpieces to be secured automatically.

The most popular tables can be configured for use in conjunction with the Kitagawa Quinte controller. Using a simple M code, a table can be operated from any CNC system, providing the versatility to swap work between three-axis VMCs with different controls. Another option is to operate the Quinte controller through an RS232 connection, which allows the rotary table to be controlled via the machine CNC, eliminating the need for two separate programs.
Through 1st Machine Tool Accessories, Kitagawa offers various options to complement its rotary tables, such as manual, pneumatic or hydraulic tailstocks, tail spindles with built-in clamping system, trunnion assemblies, rotary joints, air/hydraulic intensifiers, and manual, pneumatic and hydraulic
chuck systems.
For further information www.1mta.com

Mazak achieves record sales in 2018

Yamazaki Mazak celebrated a record year for machine sales in 2018, due to strong performance across a number of key market sectors, including automotive, oil and gas, and medical.

“The resurgence of the oil and gas market was much-welcomed, and we saw great success with the sales of machines from the larger section of our portfolio, such as the Integrex e-H range of multi-tasking machine tools, as well as our MegaTurn vertical turning centres,” says Alan Mucklow, managing director UK and Ireland sales division.
“A particularly pleasing aspect of our 2018 sales performance was the volume of commodity machines, including the UK-made, entry-level QT Compact turning centre range, and the Quick Turn series,” he continues. “The company has invested heavily in improving its European Manufacturing Centre in Worcester in recent years, and it is especially rewarding to see that investment translate into shorter lead times and strong
sales for UK-built machines.”
For further information www.mazakeu.co.uk