FEATURE ON TOOLING

Exactaform Acquires Precision Tooling Specialist

Exactaform Cutting Tools has acquired the trade and assets of PJ Tooling, an established
name in the precision tooling industry. The move not only strengthens Exactaform’s
commitment to growth and expansion but also carries a sentimental value that dates back
to the company’s roots.

Exactaform founder John Inglis started his career at PJ Tooling. This experience laid the
foundation for his future in the tooling industry and was instrumental in the formation of
Exactaform. With this acquisition, his journey has come full circle, bringing PJ Tooling under
the Exactaform umbrella and creating new opportunities.
“PJ Tooling gave me my start in the industry, so it’s a great privilege to be able to bring the
business back into the fold and ensure its legacy continues,” says Inglis. “We’re excited to
bring our expertise and resources to PJ’s operations and support its customers with the
same high standards of service that we provide at Exactaform.”
PJ Tooling’s location in Warwick is just a short drive from Exactaform’s headquarters in
Coventry, making the transition smooth with operations now united under one roof at the
latter facility. By centralising operations, Exactaform can leverage its state-of-the-art
facilities and expert team to enhance further the company’s ability to deliver on complex
projects.
The acquisition of PJ Tooling presents exciting opportunities for Exactaform to strengthen its
position in the hydraulic component industry, among others. While the company already
has some experience in this sector, there is a considerable amount of crossover between
existing capabilities and the specific requirements of manufacturing bespoke cutting tools
for machining hydraulic components.
With PJ Tooling’s established reputation and Exactaform’s manufacturing processes, the
company is excited to expand its reach and deliver even greater value to customers who
require high-precision tools for hydraulic applications.
More information www.exactaform.com

Tool Management Engineered In Record Time

Mapal’s offer for the series production of the motor block required for a new Deutz 3.9-litre
diesel engine included almost 100 different tools, as well as tool holders and adapters.
Effective tool management was therefore a priority. However, in the capable hands of
Mapal, the Zafra, Spain facility of Deutz knew it could rely on the delivery of an optimised
solution.
Deutz’s new 3.9-litre diesel engine sees most use in agricultural and construction machines.
Series production is due to start in the coming year after the current prototype phase. Some
50,000 units per annum will require manufacturing.
“Our clients’ development periods for new parts are becoming shorter and shorter,” states
Thomas Spang, global head of tool management at Mapal.
For the engine block of the new 3.9-litre diesel engine, Mapal only had two weeks after the
design freeze to complete a final offer. When Deutz sent its request, the Tool Management
department in collaboration with the Technology Expert Team (TET) at Mapal in Aalen first
gave some initial thought to the production process.
“To be quick, we don’t concern ourselves with detail at this early stage, but instead pull
together reference tools and concepts from previously completed projects”, explains Harald
Traub, project engineer from TET, who is responsible for planning the entire process. “In this
way, we’re able to specify an approximate budget and the rough scope of the tool package
for the client.”
After initial planning, concrete tool design followed in the second week. Mapal’s offer for
the series production of the motor block included almost 100 different tools. Many of them
are custom tools that achieve short machining time and thus high economic efficiency.
To produce prototypes quickly, a few close-to-standard tools were also specified.
More information www.mapal.com

New connection for replaceable-head mills

Mapal has introduced a patent-pending bayonet-type connection for milling cutter systems with a replaceable head. Users benefit from easy handling with a rigid connection and optimal cooling. The tool manufacturer also saves carbide with the connection, conserving resources.

The functional principle of the new connection could not be easier: the replaceable head only has to be inserted and turned 90° to achieve locking. That is a lot easier than the previous system for replaceable-head milling cutters from Mapal or comparable systems where the replaceable head is threaded and has to be screwed-in several turns. 

Mapal’s new bayonet system achieves very high rigidity thanks to its large cylindrical face connection. While the force only acts on one side when tightening a thread due to its pitch, the Mapal system ensures a symmetrical insertion and good distribution of force.  

Together with the connection, Mapal is introducing a new tool-holder design. The tool holder has a ring of cooling channel bores, which enables a much higher volume of cooling than conventional internal cooling is able to provide. By channelling the coolant directly to the area of the cutting edges, the tool life is extended and machining quality improved. 

In addition, by eliminating the need for a central cooling channel bore, the milling head becomes much more stable. The tool holder is 10-15% more rigid than comparable systems, reports Mapal, resulting in higher achievable form and position tolerances, smoother processes and longer tool life.

 

The solid-carbide replaceable heads from Mapal offer high process reliability as inserts cannot become loose at high temperatures. If tool breakage does occur, the connection’s simple assembly ensures operators can resume the machining process quickly.

More information www.mapal.com

Optimal small-part turning on sliding-heads

With the new double-edged WT26 indexable inserts and the compatible tool-holder system, Walter says it offers a solution that can optimise the machining of small parts on Swiss-type sliding-head turning centres. According to the company, the dovetail shape of the insert clamp absorbs lateral forces to elevate stability, process reliability and accuracy. The clamp system and the large contact surface in the insert seat maximise rigidity, counteracting any vibration of the bar material.

Another special feature is the possibility of performing operations on both sides. This design concept is credit to a clamping screw that features a Torx screw drive on both the head side and threaded side, facilitating operation from the side of the counter-spindle on right and left-hand tools. Users can index the inserts quickly without removing the tool holder, reducing non-productive time.

The tangentially mounted WT26 indexable inserts are precision-ground and boast sharp cutting edges specifically for turning small precision parts. Furthermore, the periphery-ground chip-breaker geometries are available in DG8 and VG8 designations, which Walter says facilitates optimal machining results even at feed rates as low as 0.03 mm.

Walter’s WT26 indexable inserts come in seven different versions, covering all turning operations. This selection includes everything from basic recesses and external threads, to reverse turning with specially developed chip breakers.

The new WSM23X cutting tool material is suitable for machining steel, stainless steel and lead-free brass. In addition, the uncoated WN23 grade suits aluminium and non-ferrous metals. Operators can use the inserts in any WT26 tool holder, regardless of the system.

More information www.walter-tools.com

Kennametal adds new turning inserts and tools

Kennametal is expanding its turning portfolio with the introduction of new inserts and cutting tools that significantly broaden the company’s capabilities in the small parts and medical machining space. The three new products – TopSwiss turning inserts, TopSwiss Micro Boring Solid (MBS) tooling and KCU25B turning inserts – are designed to improve output, enhance component quality, reduce errors, and help customers achieve accurate and clean results.

Kennametal’s new TopSwiss turning inserts are for Swiss-type small parts machining, delivering low-feed, high depth-of-cut applications in the medical sector, as well as industries like aerospace, defence, general engineering and transportation. The portfolio features four new carbide grades, one new cermet grade and seven new geometries.

Straight and curved cutting edges are available for stable cuts and smooth chip flow in low-feed, high-depth-of-cut applications. Polished finishing geometries offer increased welding resistance and improved surface finishing, while medium and finishing wiper geometries deliver increased feed rates and higher surface quality. Other geometries feature high chip breaker walls and large pockets for better chip evacuation.

New TopSwiss Micro Boring Solid (MBS) tooling allows for the machining of even smaller applications with greater versatility and flexibility. According to Kennametal, it offers sharp cutting edges, low cutting forces and superior chip evacuation.

Also new are KCU25B turning inserts for roughing and medium metal cutting at shops working with steel, stainless steel, cast iron and high-temperature alloys. Ideal for the most common turning, grooving and cut-off applications, KCU25B inserts also feature Kennametal’s proprietary KENGold PVD coating, delivering multiple layers of protection for better flank and chipping resistance.

More information www.kennametal.com