Kyocera Corporation is introducing new CVD coating materials, CA115P and CA125P, for turning insert grades used in automotive and industrial steel machining. The new coating technologies achieve a high level of wear and fracture resistance, resulting in a long tool life. In addition, Kyocera is launching a PMG chip breaker, which covers a range of machining applications, along with the new insert grades.

The new CA115P and CA125P insert grades – the main grades for external and internal turning for steel machining – have a newly developed coating and carbide substrate. According to Kyocera, the coating achieves the industry’s highest level of uniformity in alumina crystal orientation through the company’s proprietary crystal-forming technology during the CVD process, which helps to ensure outstanding wear resistance.

By combining this ultra-uniform alumina layer with a proprietary TiCN layer and new carbide substrate offering greater high-temperature strength, the insert grades achieve higher wear resistance and fracture resistance, as well as long tool life and stable machining. In addition, the PMG chip breaker supports various machining conditions, from medium machining to roughing, making it possible to consolidate tools and deliver productivity improvements.

CA125P grades support a wide range of machining conditions, from continuous to heavy interrupted machining, and are highly versatile main grades. CA115P grades are for high-efficiency machining in continuous to light-interrupted machining, contributing to productivity improvement through long tool life and stable machining.

Kyocera’s new PMG chip breaker achieves smooth chip evacuation in medium roughing. In addition, the low-cutting-force design of the cutting edge suppresses crater wear on the rake face, which enables lasting chip evacuation.
For further information www.kyocera.co.uk

Groove, cut-off and gear milling are just three processes that the circular interpolation milling system from Horn now performs even more productively following the introduction of a range of tools with nine cutting edges. The system can be used from an inside diameter of 8 mm for the precise boring of grooves down to 0.25 mm wide, or for milling splines. Standard tools and special variants are available.

Smaller diameter circular interpolation mills from Horn were previously available with exchangeable heads having a maximum of six teeth. Three extra cutting edges offer higher material removal rates, raising productivity by shortening cycles and, at the same time, extending tool life. In addition, the cutters run more quietly and with less vibration compared with tools having fewer teeth. Consequently, the dimensional accuracy and surface finish of components see improvements.

Horn stocks the nine-edged milling systems M911, M913 and M928 in widths from 1.5 to 3 mm. Maximum milling depths are 3.5, 4.5 and 6.5 mm respectively. The cutter heads are available with different coatings to suit the material in cut. Due to its mass, the solid-carbide tool shank ensures vibration damping during milling. Horn designed all variants of the shank for internal coolant supply.
For further information www.phorn.co.uk

Business has been growing so quickly for Italian medical implant manufacturer Permedica that it can barely keep up with demand. However, a new strategy for its CNC department, in partnership with Seco Tools, has started to make a notable increase to its productivity.

“One of our machines could not operate at night due to the programming and the kinds of tools we were using,” explains Permedica sales manager Federico Perego. “The material was overheating, which was stopping the machine and meant that it couldn’t be programmed to operate automatically during the night.”

He continues: “Seco were always very direct in relation to the issue and in proposing a better solution. They didn’t make a promise they couldn’t keep, and they didn’t just try to sell us tools. Instead, they helped us to solve what was an important issue.”

One of the Seco Tools Italy team working with Permedica, manufacturing transformation manager Matteo Foglietta, says: “We were able to address swarf issues that were a big problem for the night shift. So Permedica has gained not only more productivity in terms of a shorter cycle time, but also an increase in machine capacity during the unmanned nightshift. This is also thanks to the global competence from our innovation hub that we can bring to the customer side through local and technical expertise here in Italy.”

Perego estimates that this initial success has helped to increase Permedica’s productivity by more than 40%. Now further initiatives, including the installation of tool vending machines to help with warehouse management, are underway.

“So far, we’re very satisfied,” says Perego. “There are still headaches to solve, but I hope we can continue with this great start and achieve important things together because there is a lot of complexity in our business, and we need many resources to support this. Permedica is reacting to the help being provided by Seco by placing more orders for tools, so it’s a win-win relationship.”
For further information www.secotools.com

With the FW4 and MW4 wiper geometries, Walter is introducing two turning indexable insert geometries. The new FW4 and MW4 combine the ‘wiper effect’ with new chip-breaker geometries and wear-resistant Walter Tiger•tec Gold grades. Walter’s curved wiper edge sweeps over the machined surface again, making it possible to either double the feed rate and increase productivity by 100%, or significantly improve the surface quality while maintaining the same feed rate.

With these new geometries, Walter is now transferring this effect from the existing FW5 and MW5 double-sided cutting inserts to indexable inserts with a positive basic shape. The result is the FW4 geometry with a narrow chip breaker for finishing operations and the MW4 geometry with an open chip-breaker groove and longer wiper cutting edge radius for medium machining.

Both geometries are for universal application in ISO materials P, M and K, as well as for secondary applications in ISO S materials. The FW4 and MW4 geometries make it possible to achieve improved surface quality, productivity and process reliability thanks to the wiper edge with its curved design. This curved wiper design also helps when the machine is not aligned 100%, for example after a crash or with slightly offset turrets.

As a further advantage, the new chip breakers increase the chip-breaking range with higher feed rates, resulting in less machine downtime caused by ‘birds nesting’. Higher feed rates reduce machining times and therefore contact times, increasing tool life and reducing the number of tool changes. The combination of double the productivity and/or surface quality is particularly appealing for series manufacturers.
For further information www.walter-tools.com