A new, high-feed milling system forfinishing non-ferrous metals and plastics is now available from Horn Cutting Tools. Designated DTM 1710, the tool system employs inserts with PCD cutting edges brazed onto cassettes that allow fine axial tuning to micron precision via adjusting screws on the tool carrier. The PCD substrate is laser-cut to achieve high surface quality during the finishing process. Axial run-out is set by Horn engineers before tool delivery.

Compared with other tools of this type on the market, Horn says its milling system offers a higher number of cutting edges for any given size. The tools are available in the diameters 50 mm (z = 10), 63 mm (z = 14), 80 mm (z = 18), 100 mm (z = 24) and 125 mm (z = 30), with z representing the number of inserts. All variants have internal coolant supply.

To achieve a high-quality machined finish on the workpiece and enable use at high speeds, the tool must be in balance with the tool holder, for which purpose balancing holes are available around the cutter body. Furthermore,the combination of machine design, guideways, spindle and work-holding system, as well as the milling tool, have a decisive influence on the result.

The aluminium alloy milling body is lightweight, minimising centrifugal force and hence prolonging spindle life. For long-term protection against abrasion from chips, the cutter body is surface treated.The Horn high-performance PCD cutting material comprises a mixture of different diamond grain sizes. As the proportion of diamond by volume increases, so does the effective hardness, toughness and cutting edge quality. For the DTM 1710 milling system, Horn offers two different PCD substrates to suit the workpiece material.
For further information www.phorn.co.uk

A new-generation turning grade is now available that its manufacturer Dormer Pramet says offers one of the highest levels of productivity and versatility available on the the market today. The company says that its T9415 is the most advanced MT-CVD coated turning grade it has launched in almost 10 years, bringing greater stability and performance in a variety of cutting conditions.

This fourth-generation Pramet grade covers a broad application range, replacing the previous T9310 and T9315. In addition, the new grade partly overlaps with the company’s T9325 grade, giving T9415 one of the widest range of applications in steel turning.

Featuring a 30% thicker coating than the previous generation, the Pramet T9415 improves tool durability by increasing resistance to wear and offers higher productivity by allowing for higher cutting speeds. Additionally, a new post-treatment process improves toughness and reliability of the cutting edge, especially in interrupted cuts and unstable conditions. The T9415 is also suitable for high cutting speeds.

Notably, grinding of the insert seating area improves stability and enhances heat transfer away from the cutting edge. This capability further helps to improve tool life, reducing the plastic wear on the cutting zones. Also, a gold TiN coating allows operators to detect wear along the flank of the inserts.

Using the latest technologies, Pramet T9415 inserts have optimised cutting-edge geometry that reduces cutting forces and enhances performance. Along with saving energy, the inserts themselves are manufactured using the latest production technologies, which supports a more sustainable and environmentally friendly offer.
For further information www.dormerpramet.com

Kennametal has introduced a higher performance turning grade with an advanced coating technology. KCP25C with KENGold is now the company’s first-choice offer for metal-cutting inserts with improved wear and higher metal removal rates in steelturning applications.

“Our high performance KCP25C grade inserts with KENGold coating technology sets a new standard for machinists working across a variety of steel turning applications,” saysvice president of global product management Scott Etling. “This gold standard turning insert delivers a one-two performance punch of higher metal removal rates and improved wear resistance, meaning our customers can machine longer and with greater productivity and efficiency than before. Additionally, the insert’s gold flank makes it easy to visually identify wear, maximise edge use and reduce waste.”

According to Kennametal, KCP25C is the company’s first-choice carbide grade for turning inserts in general purpose applications in a variety of steel materials and delivers consistent, repeatable performance. KENGold is a proprietary, multi-layer coating technology with enhanced pre- and post-coat processes that deliver an effective thermal barrier for greater resistance against crater wear, which is common in these types of machining applications.

KCP25C with KENGold is an example of how Kennametal’s global modernisation investments are enabling the company to innovate higher-performing products for customers. Kennametal uses next-generation CVD technology to produce the coating while advanced pressing and surface treatment technologies deliver tighter tolerance levels than ever before, resulting in a more consistent, reliable tool life.

Kennametal is releasing KCP25C with KENGold in the most common insert shapes and styles: C, D, S, T, V and W. Longer term, the company plans to expand on KCP25C with additional turning insert shapes and styles—all featuring the KENGold coating technology.
For further information www.kennametal.com

Walter is extending its range of solid-carbide milling cutters for ISO N machining with the addition of two distinct roughing specialists, the MD265 Supreme and the MC268 Advance. The MD265 Supreme three-edged cutter with a diameter range from 16 to 25mm is available as coated or uncoated, standing out with its coolant channels in a star-shaped configuration, as well as robust cutting edges with RAPAX profile.

It was designed to achieve high productivity and process reliability required in sectors such as automotive. Whether uncoated with polished surfaces or coated with Walter’s new WJ30DD grade, it can optimise chip removal, reduce material build-up and extend tool life. This is of particular interest for manufacturers machining die-cast aluminium with the high silicon content.

Also new to the portfolio is the 6 to 25mm diameter range MC268 Advance. Incorporating a polished innovative profile that can be used universally, it is designed for long-chipping wrought aluminium alloys that are often found in the aerospace industry, for example. The coolant outlets of the three or four-edged milling cutter feature a radial arrangement for strategies such as dynamic milling. Furthermore, it reduces tooling costs as it is suitable for reconditioning.

Both solid-carbide milling cutters aim to reduce machining times in ISO N materials and increase metal removal rate. The V-shaped cutting edge, which is typical of both milling cutters was developed in-house at Walter, which says it is the only one of its kind on the market. Grooved cutting-edge profiles split the chips into short, easily controlled segments. This effect increases process reliability and allows users to work with reduced cutting forces.
For further information www.walter-tools.com

Actuating tools are the means of choice for creating turning geometries on machining centres. When it comes to machining stator bores on electric motors, tools with indexable inserts and fine boring tools were state-of-the-art until now. Mapal has developed a complex four-blade actuating tool to round off its solution portfolio for stator drilling.

With its solution, Mapal has come up with a highly productive machining process for the series production of stator housings used in electric motors. The solution offers productivity and precision as well as short cycle times with a process of three steps: pre-machining, semi-finishing and fine machining at machining diameters of more than 220 mm and with an HSK100 connection. A sophisticated actuating tool is part of the solution.

“With an actuating tool, the internal machining of the bore can be handled by a machining centre, which means turning is no longer necessary,” says Oliver Müller, customer service specialist at Mapal’s centre of competence for actuating tools. The entire machining process is thus executable with a single set-up. The only thing needed to use the actuating tool is a spindle with a drawbar – a so-called Uaxis in the machining centre.

“When it came to machining parts for electric cars, we were at our customers’ side with our tools from the very beginning,” says Müller.“Today, we help them to increase flexibility while machining the parts reliably and with short cycle times.” The actuating tool achieves more flexibility by ensuring both fast machining of varying contour trains in the bore and micron-level precision.
For further information www.mapal.com