A solution has been developed by Mapal for producing the small connecting pin bore on automotive connecting rods.

The newly developed tool is suitable for wet or MQL machining operations, on transfer lines or machining centres.
Within automotive engines, connecting rods are highly stressed components. To take account of downsizing trends and the reduction of CO2 emissions, connecting rods are also becoming increasingly lighter. Indeed, the combination of high-strength materials and modern production processes has seen modern connecting rods change shape and dimension.
During the machining of connecting rods, the small connecting pin bore is a particular challenge. Depending on the geometry, there are completely different drilling situations that cater for the connecting rod’s forms, flats and conical/spherical surfaces. Especially for this type of machining, Mapal has developed a modular tool concept for drilling from solid with indexable inserts. The introduction of radially integrated, sintered indexable inserts – each with four cutting edges – can now be applied to such operations.
Mapal has designed the indexable inserts and chip spaces to meet the special requirements of the different drilling applications. The insert materials and composition have also been adapted. Among other things, the newly developed CVD coating is applied to combine the previously opposing high ductility and high wear resistance parameters. As a result, there now exists the potential to machine at significantly higher cutting speeds than before.
The tool body of the range is made from an optimised material that produces significantly less vibration. Furthermore, a central coolant supply in the holder ensures the optimum provision of coolant directly to the cutting edges.
For further information www.mapal.com

The DTM lightweight milling system has been expanded by Horn to include two newly developed versions.

DTM.CX09 arbour milling cutters are designed as roughing tools for use in applications that involve high cutting depths and place fewer demands on surface quality, while the DTM.CX09.AL.F face mill for finishing adds an adjustable body to the existing product range. Axial run-out can be adjusted to the exact micron using a presetter.
Tool holders feature an aluminium body with a low mass, resulting in reduced energy consumption during acceleration and deceleration. As the weight is less than that of a steel cutter, faster spindle speed changes can be achieved. There is also less wear on the spindle at high speeds as the cutter body features a protective hard coating to prevent damage caused by chip impact.
Diameters between 40 and 125 mm are offered by the arbour milling cutter bodies, which feature from four to eight effective cutting edges. All body versions feature an internal coolant supply. The system is used for milling up to a maximum cutting speed of 5,000 m/min. Inserts are available from stock in several diamond materials and a variety of geometries, making it possible to obtain a cost-effective alternative to brazed face mills. Chip-breaker geometries reduce chip volume and increase process reliability.
The inserts are available with a PCD or CVD-D coating. PCD grade PD75 is described as a useful all-rounder for aluminium machining. Horn recommends substrate PD70 for alloys with a high silicon content. The substrate HD08 (CVD-D) is used for highly abrasive materials. CVD-D consists of 99.9% diamond to maximise wear resistance. All material versions are available in a range of different geometries to suit the application.
For further information www.phorn.co.uk