Industrial Tooling Corporation (ITC) is further enhancing its portfolio of bore machining products with the expansion of the Big Kaiser EWN monoblock range. The ability to improve productivity and performance arrives thanks to the introduction of Big Kaiser’s Smart Damper technology, which reduces chatter and, subsequently, cycle times.

The EWN Monoblock fine boring heads now include the new CK1 and CK2 products for the machining of diameters from 20 to 36mm and 25 to 47mm, respectively. The full EWN monoblock family of products ranges from the smallest CK1 to the largest CK7,today supporting fine boring from 20mm to over 200mm in diameter.

The Smart Damper mechanism helps to absorb vibration, essentially eliminating chatter and thereby achieving higher levels of precision with superior surface finishes. Thanks to its inherently stiffer design, ITC says the Monoblock boring head ensures high precision even when machining long bores.

EWN Monoblock CK1 and CK2 heads do not have an interface, enabling users to achieve significantly tighter tolerances. A major advantage of Big Kaiser’s Smart Damper technology is that it eliminates the need to reduce cutting speedsin order to manage vibration. This categorically increases metal removal rates and raises productivity levels.

 
Giampaolo Roccatello, chief sales andmarketing officer for Europe at Big Kaiser, says: “These new boring heads are ideal for achieving deep, chatter-free boring in challenging materials. Together with our EWB and EWB-UP ranges, the EWN boring heads represent some of the most advanced and sophisticated tools available on the market.”

For further information www.itc-ltd.co.uk

Mapal has carefully examined critical components of the fluid power industry and their potential for complete machining. An example is axial piston pumps and motors, a central component of which is the cylinder block, made either of steel (C45 or 42CrMoS4) or spheroidal cast iron (EN-GJS-500-7 or EN-GJL-400-15. Mapal experts have developed a solution that reduces the machining time for a customer’s cylinder blockby 19%.

“One customer was struggling with high costs for manufacturing cylinder blocks,” says Tobias Stolz, component manager for general machining at Mapal. “A great deal of effort was required to ensure the defined surfaces, which had to be between Rz = 27 and 37 µm, as well as the high quality of liners with tolerances for roundness, straightness and parallel alignment of 3 µm.”

The customer today machines the pressure and suction kidney with the Mapal OptiMill-Uni-Pocket solid-carbide milling cutter as part of a new process. This tool supports the boring operation by way of inclined plunging. The machining of these inlets and outlets therefore does not require any other tools.

A step drill with Tritan-Drill geometry offers similar benefits when pre-machining the piston bores, dispensing with the requirement for a spot face. Furthermore, thanks to sharp cutting edges, the bottom of the bore no longer requires deburring. The multi-stage Mapal fine-boring tool ensures optimal quality before pressing in the brass bush. It is not only very precise during machining but also particularly economical thanks to the HX insert’s six cutting edges. These three tools alone reduce machining time by 19% compared with the previous method.

“We offer our customers economical processing solutions to their machining challenges for all functionally relevant parts in the fluid power industry,” summarisesStolz.

For further information www.mapal.com

Walter is launching its patent-pending Tiger·tec Gold WSM33G grade: the company’s first PVD grade to accommodate the high loads that occur during grooving operations. The cutting tool material combines third-generation TiAlN with TiSiN to form a multi-layer coating with exceptional hardness and increased toughness, reports Walter.

A special post-treatment reduces friction and ensures a smooth surface, thereby optimising chip removal and process reliability. Furthermore, the gold top layer makes it easier for users to detect wear. Walter uses the new PVD coating on single-edged SX cutting inserts with positive engagement and a self-clamping system. It is also applicable to indexable inserts from the double-edged DX18 system, where a second prism ensures stability in the insert seat.

For manufacturers, the fact that this grade is usable with both systems delivers maximum versatility as it caters for all insert widths from 1.0 to 10mm. Another advantage of the Tiger·tec Gold WSM33G grade is its adaptability, even under challenging conditions. Walter says the universal grade is suitable for 75% of all applications, including grooving and parting-off, groove and copy turning,and slot milling.

The system can undertake these operations on a range of materials, including steel (ISO P30), stainless steel (ISO M30) and materials with difficult cutting properties (ISO S30). Offering universal application, long tool life and high resistance of the multi-layer coating against plastic deformation and flank face wear, Walter says that its WSM33G grooving inserts are a productive and reliable choice.

For further information www.walter-tools.com

Cutting tool specialist Walter has expanded its WL copy-turning system with the introduction of WL17 indexable inserts for Swiss-type automatic lathes and small diameter machining. Used on the W1011-S-P external turning toolholder, which is also a new arrival (along with W1210/W1211 boring bars), they bring the benefits of the existing WL25 inserts to smaller dimensions.

The W1011-S-P toolholder has a square shank that is available in the most common shank sizes of 12 x 12 mm and 16 x 16mm. They are for use on automatic lathes and multi-spindle turning centres. Walter says it is the only manufacturer to offer a turning system for automatic lathes with positive engagement and three-edge turning inserts.

As with the WL25 turning inserts and toolholders, the smaller indexable inserts facilitate equally high cost efficiencies, thanks to the three cutting edges, high stability and 50% improved indexing accuracy in comparison with ISO inserts. The targeted Walter precision cooling on the rake and flank faces also increases tool edge life.

When it comes to internal turning, the inner diameter (Dmin) of the workpiece is often a limiting factor. ISO turning inserts, such as the VBMT11, only have two cutting edges and are applicable at a 93° approach angle from a Dmin of 22mm. By contrast, the new Walter boring bars W1210 and W1211 with WL17 inserts are suitable for internal turning from Dmin 18 mm, while also sportingone more cutting edge.

Furthermore, the operator can use the indexable inserts for both forward and reverse turning. Just like all WL inserts, WL17 inserts can be used in a neutral, right-hand and left-hand configuration, and feature the latest cutting tool coatings, such as Tiger•tec Gold.
For further information www.walter-tools.com