Efficient machining of titanium parts

Following the introduction of its newly developed IG3I substrate, Horn is optimising its DS solid-carbide end mills to enable productive, cost-effective machining of titanium and its alloys. By combining the novel carbide grade with a new coating, the tool specialist says it has been able to increase cutter life significantly.

Sharp micro-geometry on the cutting edges, positive rake angles, large clearance angles and polished flutes prevent strain hardening of the workpiece and built-up edges on the rake faces of the mill when machining titanium. In addition, variable helix angles and different tooth pitches ensure quiet, low-vibration milling.

Despite the sharp cutting edges, the new coating demonstrates high layer adhesion, ensuring good edge stability. Thanks to its high temperature resistance, the coating serves as a heat shield and reduces the amount of heat transferred to the carbide, which demonstrates homogeneous wear.

The effective length is two or three times the diameter. DS titanium milling cutters were developed based on tried-and-tested solid-carbide milling cutters in the DS system, which for years have been used to machine soft and hardened steels, chromium-nickel steels and super alloys, as well as copper, aluminium, plastics and fibre-reinforced plastics. The end mills are available in diameters from 2 to 20 mm as standard, with four or five flutes.

For further information www.phorn.co.uk

Kyocera introduces finishing tool

The new MFF milling cutter augments the industrial tooling range offered by Kyocera in the field of finish-machining processes. Suitable for use on steel, stainless steel and cast iron workpieces, the cutter is available now.

A combination of semi-finishing and finishing inserts contributes to the efficiency provided by the MFF cutter. Years of know-how in developing and manufacturing tools has resulted in an innovative pressing method that yields robust inserts. The cutter’s wiper inserts are said to be especially suited to very high feed rates and the generation of outstanding surface qualities.

According to Kyocera, the strength of the MFF milling cutter come into its own on large components, such as construction parts made of construction steel, carbon steel or cast iron (grey and ductile iron). The robust cutter can even be used for hardened steel (up to 60 HRc) and stainless steel.
Typical problems such as vibration or scratches are avoided, principally through a combination of a sharp edge and patented Kyocera cermet technology dedicated for use as a substrate for inserts.

A new design of milling body allows the plates to be changed reliably, while time is saved thanks to the pre-set cartridge height of the MFF milling cutter; it is no longer necessary to readjust after changing a plate. The resulting precisely adjustable cutting-edge height improves handling and facilitates more reliable processes.

For further information www.kyocera.co.uk

Mapal introduces additive manufacturing

In general terms, if the weight of PCD cutting tools is reduced, then significantly higher cutting data can be achieved. To realise the benefits of lightweight cutting tools, Mapal is now utilising additive manufacturing processes.

An example of how Mapal uses the advantages of 3D printing is realised in the company’s new bell tools with brazed PCD inserts, which are frequently used in the hydraulic and automotive sectors. The company has optimised the existing, conventionally manufactured bell tool by integrating selective laser melting (SLM) into its manufacturing processes. This move allows the inside of the cutting tool to be modified. So, instead of utilising tools with a heavy solid-material design, the new tools have been specially designed with a honeycomb structure. As a consequence, the tools are at least 30% lighter, while tool life is increased by upwards of 40% credit to the enhanced vibration damping characteristics of additively manufactured designs.

Customers using Mapal’s additively manufactured tools are said to be witnessing productivity improvements in the region of 50%. Additionally, Mapal experts are using the 3D-printing technology to optimise cooling channels, ensuring that cutting fluid is delivered to the work zone via the most efficient route.

The new bell tool is a hybrid design that can be specified by end users to meet their exact machining requirements. Using SLM, the new tool geometry is printed on a precision tool body with an HSK-63 connection. The additively manufactured tool body is subsequently machined to provide the platform for the PCD inserts to be brazed into place and then cut to shape using a laser.

For further information www.mapal.com

Manufacturing capacity doubled

British luxury watch manufacturer Bremont made the most of a strategic partnership between Sandvik Coromant and DMG Mori as it introduced a turnkey manufacturing cell to double capacity at its factory in Henley-on-Thames.

High demand and the launch of six new watch designs meant that Bremont’s production capacity had to be increased, leading the company to purchase a DMG Mori NTX 1000 turn-mill machine equipped with tool packages from Sandvik Coromant.

DMG Mori’s NTX 1000 is equipped with a magazine for 38 Coromant Capto tools, with the option of expanding the capacity up to 76. The machine is suitable for turning and high-speed milling in five axes, simultaneously.

Frederick Shortt (application technician at DMG Mori) and his development team created and simulated the NC programs with Vericut software.
“Together with Sandvik Coromant we optimised all of the programs in such a way that as few tools as possible are required,” he says. In other words, Bremont only bought the tools it really needed. As this all took place before installation, Bremont was able to start producing from day one.

“This joint optimisation meant that any teething problems were reduced to a minimum and the investment quickly paid-off for Bremont,” adds James Rhys-Davies, strategic relations director, northern Europe at Sandvik Coromant.

Malcolm Kent, production manager at Bremont, says: “We produce very complex parts with tolerances of 3 to 5 µm, where quality and precision are of paramount importance. Thanks to the NTX 1000 in combination with Sandvik Coromant tools, the processes are absolutely trouble-free.”

For further information www.sandvik.coromant.com

Walter boosts drilling and turning

Tooling expert Walter GB has announced additions to two product ranges that will generate benefits in deep-hole drilling and turning. The company’s solid-carbide X-treme Evo drill now extends to capacities of 16-30xD and offers deep-hole drilling without the need for pecking, while new CBN insert grades for machining ISO K and H materials complete the company’s CBN turning range.

Part of the DC160 Advance range of drills – the successor to Walter’s Alpha 4xD drills – the new drills have optimised coating and geometry. Also featured is a thinner web with 140° point angle, while the fourth land is in an ‘advanced position’. The former ensures increased positioning accuracy and reduced centralised cutting forces; the latter optimises drill guidance. Furthermore, polished flutes optimise chip evacuation.

The drill grades (WJ30ET and WJ30EU) are also new. These grades comprise the K30F fine-grained substrate and a TiSiAlCrN/AlTiN multi-layer coating (as a point or as a complete coating). The layer structure makes the drills both tough and wear-resistant, as well as playing a crucial role in process reliability and performance. Walter offers the drills in intermediate sizes and in special dimensions, on request, via its fast-delivery Xpress service.

For turning, the new CBN indexable insert grades for ISO H and ISO K materials are WBK20 for finishing cast iron and WBK30 for high metal-removal rates in hardened steels (and for finishing with a heavily interrupted cut). Both grades are also suitable for roughing and finishing sintered steel. Walter offers the new grades in all of the most popular ISO sizes and radii.

For further information www.walter-tools.com