New aerospace turning grade

For the finish-turning of HRSA materials, NTK Cutting Tools has introduced its JP0 Bidemics range of inserts. Suitable for machining HRSA materials at speeds up to 480 m/min, the JP0 is the latest addition to the NTK range of Bidemics, a material that the company says can greatly improve productivity for aerospace manufacturers which are regularly cutting challenging materials.

Capable of machining at cutting speeds up to 15 times faster than carbide and CBN alternatives, the NTK JP0 demonstrates high wear resistance and consistency. The new JP0 insert grade is suitable for running at cutting speeds from 180 to 500 m/min, with a feed rate of 0.05 to 0.2 mm/rev, and a depth of cut from 0.1 to 0.7 mm.

Currently, NTK has introduced the new high-performance finish turning grade in three different designations: the CNGA, DNGA and VNGA geometries. The 4.76 mm thick CNGA and DNGA inserts are available with a 0.4, 0.8 or 1.2 mm corner radius, and an IC of 12.7 mm. NTK’s VNGA insert designation is available with a 0.4 or 0.8 mm corner radius, and a 9.525 mm IC. The company says that all three designations demonstrate outstanding quality with the 0.04 mm honed edge preparation.

NTK recommends that when turning HRSAs and other extremely challenging material types, manufacturers should utilise button inserts from the Bidemics, Whisker and SiAlON series for heavy-duty roughing, followed by the NTK SiAlON range for semi-finish passes and the new JP0 for finishing with a constant depth of cut.

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Mills suit various machine conditions

Widia is releasing the M1600 face mill for roughing to semi-finishing operations in steel, stainless steel, cast iron and nodular iron materials. With 16 cutting edges and a novel insert design, the M1600 performs in various machining conditions, including low-power machines, unstable set ups, long overhangs, weak machines or weak fixtures.

The precision-ground insert with a positive geometry enables low cutting forces and low power consumption, resulting in higher tool life and low cost per edge. Widia’s M1600 has one universal insert geometry in three versatile grades: WP35CM, WK15CM and WU20PM.

The WP35CM grade targets all types of steels, while the WK15CM grade is for cast-iron materials and performs best in dry applications, but can also be used wet. The universal WU20PM grade is for the machining of steel, stainless steel and high-temperature alloys in both dry and wet applications.

Notably, the ‘smart’ insert design features a seating surface below the cutting edge that promotes smooth chip flow and reduces cutting forces on the tool. The insert also has a curved cutting edge and is axially positive, resulting in reduced power consumption. These key design features, coupled with 16 cutting edges, make M1600 an economical face milling option.

M1600 face mills are available in six metric diameter ranges between 50 and 160 mm. Inch diameters will follow shortly. Orders for the M1600 bodies and inserts, as well as other Widia tooling, can be placed through Widia’s authorised distribution partners.

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New drills deepen productivity gains

The productivity of deep-hole drilling has taken a step forward with the arrival of a four-flute series of gun drills from Guhring. VB 80 deep-hole drills (with a solid-carbide head) and the VB 100 solid-carbide series are productivity partners for cast-iron drilling.

These straight flute deep-hole drills are robust with a geometry that ensures the drill core is more than 50% of the overall diameter. Guhring has also developed geometry that consists of two core cutting edges supported by four outer flutes that are axially displaced to split the chips and improve centring and precision, while reducing cutting forces. As a result, the bottom of the hole will be two-stepped as the drill has a 141° angle on the primary cutting edge, followed by a 145° angle on the outer cutting edges. Four cooling channels further improve chip clearance, allowing high-pressure coolant to each of the four cutting edges – prolonging tool life by preventing swarf re-cutting and creating an efficient chip removal sequence.

VB 80 and VB 100 deep-hole drills also consist of four round margins with a 90° division that further enhances precision, concentricity and surface finishes down to IT6. With the abrasive wear divided through four flutes as opposed to two, as in most ranges, the VB 80 and VB 100 improve tool life and performance significantly. In fact, the drills have reduced cycle times by more than 30% during field tests, while extending tool life, hole quality and overall performance far beyond the realms of two-flute gun drill variants.

At present, both the VB 80 and VB 100 series are available in diameters from 13.5 to 28 mm diameter, with flute lengths up to 500 mm.

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Motorsport firm gains from tool vending

Padiham-based Mini Sport Group has been supplying its customers with parts for the iconic classic Mini for over 50 years. Since 2005, group company Motorsport Advanced Developments (MAD) has been manufacturing many of these parts in-house.

In order to support recent increased machining demand and capacity, MAD turned to long-term tooling partner Ceratizit UK & Ireland, with which it has worked with from the outset of the business. Already a user of Ceratizit’s vending systems, in the form of two TOM60 vending machines, the challenge was to supply increased tool storage capacity without compromising floor space. The solution was the installation of the latest TOM840, which will replace the two existing units. TOM840 has a maximum capacity of 840 tools in compartments that are adjustable to take a wide variety of shapes and sizes.

The Ceratizit TOM vending system also provides users with detailed traceability, offering the ability to track the distribution of every tool, from time of vend, to which operator took it, while also monitoring costs. With its integrated SIM card communications, the machine automatically sends replenishment stock orders to the team of five dedicated vending support staff based at Ceratizit’s office in Sheffield. A Ceratizit tool service engineer then replenishes the stock and, once a month, the system raises an invoice. As the stock within the TOM840 is supplied on a consignment basis, only those tools vended are charged for.

A further advantage of the consignment stock is that the user can never be left with obsolete tools; whenever an update is released, the tools are replaced. This latest vending installation brings the total number of machines in the market to 435.

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New high-feed milling cutters

Now available from Horn is a new generation of milling cutters for machining at high feed rates. The DAH82 and DAH84 milling systems feature a precision-sintered indexable insert with eight cutting edges for cost-effective metal cutting. Despite its negative mounting position, the positive cutting geometry ensures good chip removal combined with a smooth, soft cut. Furthermore, the large radius of the insert’s main cutting edge ensures even distribution of the cutting forces, extending tool life.

Horn offers the inserts in the SA4B substrate, which is suitable for universal use on various materials. Maximum cutting depths are 1.0 mm for the DAH82 and 1.5 mm for the DAH84.
The DAH82 variant is available as an end mill and as a screw-in milling cutter in the following diameters: 20 mm (z = 2), 25 mm (z = 3), 32 mm (z = 4), 35 mm (z = 4) and 40 mm (z = 5), where z denotes the number of inserts. As an arbour milling cutter, it is available in diameters of 40 mm (z = 5), 42 mm (z = 5) and 50 mm (z = 6).

For diameters in excess of 50 mm, the larger DAH84 indexable insert is used. It can be supplied as an arbour milling cutter in the following standard diameters: 50 mm (z = 4), 52 mm (z = 4), 63 mm (z = 5), 66 mm (z = 5), 80 mm (z = 6), 85 mm (z = 6), 100 mm (z = 7) and 125 mm (z = 8). All tool bodies receive a special surface treatment of high strength and hardness, providing long-term protection against abrasive wear from chips.

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