Diamond tools for hard materials

Horn is releasing an expanded range of CVD (chemical vapour deposition) diamond-tipped tooling for the cost-effective drilling and countersinking of sintered carbides and ceramics of hardness up to 3000 Hv. According the company, the tools enable short throughput times, high surface quality, low costs and more flexibility within the production process, as well as long tool life.

The DDHM tool system allows rigorous machining processes to take place on conventional milling and turning centres, eliminating the need to invest in expensive new machinery or resort to costly, time-consuming grinding and eroding processes. Due to their ability to machine carbide punches and dies efficiently, the cutters are particularly suitable for use in the tool- and die-making sector. However, they also offer production advantages in the medical, aerospace and automotive industries.

The CVD-D-tipped drills are suitable for producing holes in solid material to a maximum depth of 10xD. Each tool is of two-edged design and is available in diameters ranging from 2 to 10 mm. All versions feature internal channels for cooling with air. For chamfering and countersinking, Horn offers CVD-D end mills with diameters of 3 and 6 mm, and with flank angles of 15, 30 and 45°. The 3 mm version has five teeth, while the 6 mm variant has six.

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Faster drilling of aerospace parts

Kennametal has introduced the FBX drill for the flat-bottom drilling of structural aerospace parts. The patented FBX drill delivers high stability and up to 200% higher metal removal rates when machining high-temperature alloys and stainless steel, reports the company.

Quickly removing large amounts of material remains a challenge for aerospace structural components.

Traditionally, the first process step is to enter the material by using ramping techniques. This is a time-consuming process and low metal removal rates are the norm.
Says Georg Roth, product manager at Kennametal: “Our FBX drill dramatically speeds up the machining process by combining the advantages of a flat-bottom drill and a Z-axis plunge mill. The flat bottom design eliminates radial forces while four effective cutting edges provide increased feeds and speeds, leading to up to 200% higher metal removal rates than traditional ramping techniques and freeing up capacity for aerospace manufacturers.”

Once the drill has shaped the basic structure of the component, roughing and finishing with indexable and solid end mills are the next process steps.

Four effective cutting edges provide stability in challenging applications like chain-hole drilling, while large chip flutes ensure hassle-free chip evacuation. Supported by a series of exchangeable coolant nozzles to help eliminate heat build-up, the drill point is characterised by a centre insert with two effective cutting edges and chip splitters for maximum feed capabilities.
The drill bodies are available in diameters 60, 75 and 90 mm, and come in a long and short version (150 and 95 mm).

Design modularity means the drill connects to Kennametal’s bolt taper flange (BTF) mount adapters – available in various spindle connection types.

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Tapping tools optimise hole-making

Sandvik Coromant is upgrading its range of tools for steel tapping operations with two updates to its solid round tools range. The company says that its next-generation CoroTap T200 and T300 spiral tapping tools for ISO P materials deliver improved process security, longer tool life and a reduced cost per component.

CoroTap T200 and T300 are suitable for ISO P1 and P2 steel workpiece materials, and can therefore help improve the machining of parts such as crankshafts, steering knuckles and general engineering components like housings and flanges.

The CoroTap T200 has a spiral point, with the T300 featuring a spiral flute. While the spiral point of the T200 is suited to the machining of through holes – where chips are pushed forward – the T300 caters for blind holes, where there is no exit hole and chips must be pulled backwards. As part of the upgrade, both tools have a new surface treatment, as well as improved edge rounding for better finishing inside the machined hole. An enhanced flute form also aids better overall performance.

As a result of these upgrades, Sandvik Coromant reports that manufacturers will benefit from improved process security with an increased resistance to edge chipping, leading to fewer tool breakages and enhanced thread quality. In addition, the cutting-speed capability is higher than with previous versions of the tool, subsequently leading to an overall reduction in the cost per part.

Another major difference compared with previous versions of the CoroTap range is that customers can benefit from Sandvik Coromant’s ‘Tailor Made’ web assortment. This service gives customers the freedom to specify their own dimensions, without paying for a specialist tool.

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New tools for sliding-head lathes

Vargus UK has introduced the new ST-Cut line of cutting tools for small part machining. Developed specifically for the turning of small components on Swiss-type sliding-head turning machines, the ST-Cut line presents a solution for virtually every small part turning application.

The ST-Cut series features a novel insert replacement system that provides fast and easy changeovers of tips from both sides of the tool. This capability is particularly suitable for manufacturers running sliding-head turning centres where space is often limited inside the working envelope.

Furthermore, the clamping system demonstrates high repeatability and rigidity for manufacturers aiming to part-off a maximum diameter of 17 mm.

The ST-Cut series incorporates both left- and right-hand inserts with a cutting width from 0.5 to 2 mm, with a range of cutting depths, geometries and insert grades. Similarly, the square grooving/turn and round grooving line offers left- and right-hand variants with insert widths from 0.5 to 3 mm, while the round groove inserts provide a choice of radii from 0.2, 0.5, 0.75, 1, 1.25 and 1.5 mm. From a threading perspective, the left and right-hand inserts are available with a 55° and 60° profile option, offering a maximum insert width of up to 3.2 mm.

ST-Cut inserts are available in two grades, including the AlTiN PVD coated VPG grade for achieving medium to high cutting speeds on alloy steel, stainless and titanium alloys. The uncoated VS020 sub-micro grade is suitable for medium to low cutting speeds. This grade is uncoated to ensure a sharper cutting edge that is crucial for very small components where accuracy is paramount.

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New thread mills from Guhring

Guhring has expanded its hole-making and threading range with the arrival of the MTMH3-Z. An expansion of the Drifter series of thread mills, the new MTMH3-Z Drifter helical-drilling thread mill demonstrates high performance levels when processing materials up to 66 HRc.

Combining core drilling and threading in a single operation, the MTMH3-Z Drifter helical-drilling thread mill offers process reliability when wet- or dry-cutting all material types. With two oil grooves on the shaft to provide optimum cooling with cutting fluid or air, the range also has a left-hand cutting geometry that stabilises performance during climb milling. A fine-grained carbide composition characterised by its high hardness complements this geometry and makes the tool suitable for hard machining.

Guhring’s temperature-resistant TiSiN coating prolongs tool life and performance. Furthermore, the MTMH3-Z Drifter incorporates a special face geometry with hollow grinding that makes process-safe core-hole drilling and thread milling possible in almost all material types.

With a shank diameter from 3 to 12 mm and a neck relief from 5 to 40 mm, the new thread milling series is suitable for creating threads from M2 to M16 on a material range that includes all steels and stainless steel, cast and graphite iron, aluminium, and titanium alloys. Suitable for drilling and threading holes up to 2.5xD in a single operation, the MTMH3-Z Drifter can reduce set-ups, cycle times, tool inventory and costs.

CNC Guhro thread-mill software enables users to specify the thread data by selecting from all current thread standards and then inputting the material requiring machining. At this stage, the software provides the optimal parameters.

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