Recent years have shown the machining industry that sustainable cost containment holds the key to stability and survival, even in turbulent economic periods. At the same time, the industry needs faster ways to develop new technologies and tools that can respond to changing circumstances. Smart software is a key to making these developments responsive and effective. In certain situations, it can enable manufacturers to optimise machining and production processes by up to 40%, eliminating some of the repetitive manual processes.

Non-digitised processes force production personnel to look up product information manually, which wastes time and may not yield accurate results. For example, with the help of Seco Assistant smartphone app, production personnel can simply scan the product package or tool to reduce the time required for routine tasks on the shop floor. As a result, operatives can quickly receive relevant product information or calculate cutting data and compare insert geometries and grades from different suppliers.

Some 30-60% of tooling inventory is likely to be uncontrolled, floating around the shop floor or simply stacked by machines in excess quantities. Smart software, such as the Seco Inventory Management system, can help to tackle this issue in a more cost-effective and secure way. Apart from physical flexibility, its main benefit lies in monitoring tool and equipment usage, and increasing staff accountability. This way, the inventory management systems help to reduce wasted set-up time because of misplaced items and keep track of high-value tools and mission critical items.

According to Seco, smart software can eliminate the unnecessary inventory of materials and tooling for up to 20% lower inventory costs. With processes optimised for efficiency through technology that removes repetitive manual processes, labour productivity can rise up to 30% and machine downtime drop by up to 50%.
For further information www.secotools.com

Allied Machine and Engineering, a manufacturer of hole-making and finishing cutting tools, is launching a new series of Wohlhaupter fine-boring lay-down cartridges. The ES-Bore (Easy Set Bore) and inventory will be available from 16 October.

The new lay-down cartridges are easily mountable to the body of a custom tool, while the dimensions allow the cartridge to fit on existing bodies and replace current lay-down cartridges, in addition to providing 3ETECH+ functionality.

When used with standard Wohlhaupter components, the lay-down cartridges have a diameter range of 28 to 3200 mm. However, a maximum boring range is not definable for custom boring tools as the range is unlimited and application-dependant. Currently, the cartridges are available for two different insert sizes – the ISO form 101 and Wohlhaupter’s form 20 insert – providing suitability for all common materials.

For customers looking to build their own custom tool, the ES-Bore is available in analogue or digital versions for use with the new 3ETECH+ digital readout module. The 3ETECH+ provides enhancements such as improved visibility with a larger OLED display screen, improved diameter adjustment accuracy of 1 µm and a rechargeable battery via USB-C.

This new product introduction provides the possibility to design custom tools incorporating the ES-Bore lay-down cartridges, allowing customers to receive special tools within a shorter delivery time and at lower cost. Additionally, the release of the fine-boring cartridges gives users the opportunity to build their own special tool because the customer only needs an ES-Bore lay-down cartridge for mounting to the boring bar in manufacture.
For further information www.alliedmachine.com

For manufacturers that witness the scourge of stringy swarf when using small boring tools to machine materials such as unleaded brass or aluminium, Floyd Automatic Tooling is introducing the UK market to a new addition to the Ifanger MicroTurn internal boring system.

The new Ifanger MicroTurn is available in two different types: the MicroTurn MTEP for rough internal turning and boring; and the MicroTurn MTEF for finishing operations. Each of the designations comes in three product length ratios of 2xD, 3xD and 5xD that presents tools from 26 to 53 mm in length. Supplied with a through-coolant facility, the MicroTurn series is available with a 4 or 6 mm diameter solid-carbide shank that minimises vibration while enhancing strength, longevity, tool life and performance.

Ifanger’s MicroTurn MTEP for roughing is available in diameters from 2.5 to 6 mm diameter, enabling manufacturers to efficiently machine bores and intricate internal features from 2.5 mm diameter and upwards with high productivity levels. To achieve even greater results when machining non-ferrous alloys, Ifanger can offer the MicroTurn series with an optional diamond-like coating (DLC) that can ramp up productivity and tool life performance on a host of materials.

Complementing the MicroTurn MTEP for roughing is the MTEF for finish turning. The geometry of the MTEF presents high-quality surface finishes and performance when conducting turning operations on small bores. To maximise performance on the smallest and most detailed bores from 1 to 2.2 mm diameter, the MTEF has a sharp edge for high precision while tools from 2.5 to 6 mm incorporate a 0.05 mm corner radius to prolong tool life and reliability.
For further information www.floydautomatic.co.uk

Among the highlights on the stand of tooling expert Mapal at the EMO exhibition in Hanover last month were the deep drills of the company’s new MEGA-Deep-Drill-Steel product range. Designed for machining steel and cast iron, users can achieve depths up to 40xD.

The solid-carbide deep drills feature protection via a coating with HiPIMS technology in the cutting edge area, ensuring frictionless chip removal. The remaining length of the MEGA-Deep-Drill-Steel remains uncoated. Thanks to its geometry, Mapal says the new deep drills stand for long tool life and high productivity. Compared with its previous-generation tools, it is possible to can attain up to 50% higher feed rates.

Mapal also presented a series of new cylindrical shank reamers with brazed cutting edges. A special feature of the FixReam 700 reamers is their high usability, derived from an expansion system. It is possible to re-grind a tool twice before new cutting edges require brazing-in. After that, the tool can benefit from two more re-grinds before replacing the cutting edges again and performing yet two further re-grinds. Tool costs reduce by up to 15% in comparison with a tool that does not have an expansion function. Furthermore, thanks to new (patented) geometries, users achieve up to 30% better roundness and cylindrical form, as well as improved chip removal, compared with other cylindrical shank reamers.

Also taking the spotlight at EMO was Mapal’s new OptiMill-Alu-Wave for aerospace customers, a tool that can deliver material removal rates of up to 21 litres per minute when machining aluminium.
For further information www.mapal.com