Turning grade features advanced coating technology

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

Aluminium component milling at expert level

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 tool with four inserts for stator bores

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

Walter completes range of rough-turning inserts

With the new HU3, HU5 and HU7 geometries, Walter is completing its range of indexable turning inserts for heavy-duty roughing operations. The ‘H’ designation is for negative, single-sided and therefore highly stable inserts, standing for ‘Heavy (roughing)’, while the ‘U’ refers to universal use. Each of the three new geometries has specific features making them suitable for different applications.

The HU7 geometry for steel and cast-iron workpieces is the most stable turning indexable insert in Walter’s product range. It has a straight cutting edge while the negative protective edge chamfer ensures its suitability for use at high feed rates with depths of cut up to 17 mm. According to Walter, HU7 demonstrates excellent stability and is suitable for large-volume machining, even in difficult conditions, including the machining of forged parts or interrupted cutting operations.

Compared with HU7, HU5 geometry incorporates a curved cutting edge and an open chip-breaker groove design that provides a slightly softer cutting action to reduce cutting pressure and cutting forces. HU5 is therefore the first choice insert wherever heat generation and/or vibration occur. The grade is particularly suitable for the rough turning of high-temperature alloys and stainless steel.

The third insert design, the HU3 geometry with V-shaped chip formation optimises chip breaking even at small depths of cut and fluctuating material removal rates. This feature makes the HU3 suited to machining parts with a forged skin or varying surfaces. HU3 is primarily for use on steel materials with depths of cut from as low as 0.8mm, while maintaining chip control.

All three turning insert geometries are coated with the new Tiger•tec Gold grades, WPP10G, WPP20G and the WPP30G.
For further information www.walter-tools.com

Jones-Nuttall on right track with ITC

When Warrington-based Jones Nuttall undertook a review of the overall service and support from its supply chain partners, cutting tool vendors were under the microscope. This forensic review based on a multitude of factors opened the door to UK cutting tool manufacturer, Industrial Tooling Corporation (ITC).

Located in the northwest, Jones Nuttall is a subcontract manufacturer with more than 60 employees to help it supply more than 30,000 different components to over 250 clients every year. This client list includes recognised names such as London Underground, Network Rail, Linde Group, ScotRail and Bombardier.

The machine shop is very versatile with over 12 CNC Hurco milling machines and eight CNC lathes, including models from Mazak.Producing everything from 1-offs and small batches up to runs of over 1000 from a diverse range of materials, the company utilises solid carbide and indexable tools for turning, milling, drilling and threading. When the company was witnessing indifferent service from its regular vendors, the company turned to ITC.

ITC technical sales engineer Chris Fairbrother says: “To emphasise the quality and productivity of ITC tools, we first manufactured special form tools for hydraulic components used in the fluid control industry. With supply chain issues from its previous vendor on special tools, we demonstrated our expertise by understanding the requirements of Jones Nuttall, providing technical support and then manufacturing special tools on short lead times. The tools performed exceptionally well, laying a foundation of trust and confidence in the ITC brand.”

With the relationship blossoming, Jones Nuttall incrementally introduced more ITC solid-carbide end mills to its shop floor with impressive results.

“The performance of ITC solid-carbide end mills immediately reduced tooling costs by more than 20% at Jones Nuttall,” says Fairbrother by way of example.
For further information www.itc-ltd.co.uk