FEATURE ON TOOLING

CBN insert proves decisive at hydropower specialist

Gilbert Gilkes & Gordon (Gilkes), a specialist in the design and manufacture of hydropower turbines and pumps, is constantly looking at new, more exotic materials to help reduce wear and extend operating times.

Says Derek Thomas, Gilkes’ production engineering manager: “Most recently we utilised tungsten carbide coatings on the runner systems within our turbines. This development posed challenges to our in-house production team, who worked closely with our tooling supplier Ceratizit to achieve the desired result.”

The part in question was a 600 mm diameter F35 Super Duplex ring that was subject to abrasion from sediment. Ceratizit recommended a new CTBH 40U CBN grade insert, which was developed specifically for turning hardened materials, especially where intermittent cutting was an issue. Two inserts were ordered and delivered the next day and, with cutting data of 210 m/min surface speed and 0.12 mm/rev feed rate with a 0.25 mm depth of cut, it was put to the test.

“The result was superb, just one insert was needed to complete the machining operation and the surface finish generated was excellent,” says production engineer Justine Marshall. “The insert cut the tungsten-carbide coating like a dream.”

The suggestion of the CBN CTBH 40U insert is typical of the support offered to customers by Ceratizit UK & Ireland’s time-served technical sales engineers and applications engineering teams, who can call on over 100,000 products in the standard catalogue to solve specific problems. In the case of Gilkes, Ceratizit visits on a fortnightly basis to discuss any upcoming requirements and service the two Ceratizit tool-vending machines on site. One of these vendors is the latest TOM 840 unit capable of storing up to 840 individual items.
For further information www.ceratizit.com

Latest inventory management system unveiled

Tooling Intelligence has introduced its latest inventory management system, the SmartDrawer+. The new system has evolved from the established SmartDrawer, with its intuitive touchscreen control, safe and secure construction, and user-friendly dispensing. SmartDrawer+ meets the ever-expanding requirements of a broad range of sectors, with weight-based vending, in-compartment charging, ticket printing, enhanced security and customised lighting all available.

Richard Swaffield from Tooling Intelligence says: “The SmartDrawer system continues to be an extremely successful distribution point for engineers since its market introduction. We continually record customer feedback and work to evolve the SmartDrawer beyond industry expectations.”

Offering further enhancement to SupplyPro’s serialised and calibrated asset management features, SmartDrawer+ includes in-compartment charging, with power sockets built into the locked compartments that allow the controlled recharging of assets such as laptops, tablets, batteries, power tools and testing equipment. Furthermore, network-enabled pockets allow businesses to implement critical security updates or send important software and data to devices.

The new SmartDrawer+ offers an extra level of control with its reliable weight-based vending, which gives the customer 100% control over the movement of inventory in and out, while eliminating the need for users and administrators to spend time counting parts. Users simply take what they need and SmartDrawer+ reports the activity instantly, and with complete accuracy.

SmartDrawer+ is supported around the clock with proactive device monitoring, technical support and advice. Furthermore, SmartDrawer+ incorporates all of the latest Industry 4.0 technology that has been built into the user-friendly interface to make shop-floor utilisation a fail-proof operation.
For further information www.toolingintelligence.co.uk

Reliable and stable machining of steel parts

With the new MP6 geometry, Walter is rounding off its range for the medium machining of steel (secondary application: ISO M, K, S). The MP6 combines features for medium machining, such as a positive rake angle, with those of roughing inserts, such as a tough cutting edge. This makes the geometry a suitable link between the existing MP4 geometry for medium machining (with good chip-breaking on soft steels) and the RP4 geometry for roughing operations (with a tough cutting edge for high feeds).

Walter offers the MP6 geometry in CCMT, DCMT, TCMT and VBMT basic ISO shapes. A short primary chamfer on the cutting edge, which is characteristic of roughing inserts, ensures a high degree of stability, even in challenging conditions like when machining forged parts with interrupted cuts. The 18° rake angle, tough cutting edge and special chip-breaking geometry ensure chip control during medium machining.

Walter specifies feeds from 0.1 to 0.4 mm/rev and depths of cut from 0.4 to 4 mm as the range for the machining parameters. To prevent vibration on thin-walled components, Walter has given the MP6 geometry an open chip-breaker groove, which reduces cutting pressure even when machining at a higher depth of cut. This feature also makes the MP6 suited to unstable components and components with long overhangs, such as during internal turning. Its straight cutting edge makes it suitable for use as a chamfer insert, regardless of the application.

In addition, the new Tiger·tec Gold grades have a positive impact on tool life. WPP10G, WPP20G and WPP30G are adapted to different operating conditions, leading to increased tool life and performance across a broad range of applications.
For further information www.walter-tools.com

Milling with added insert density and speed

Tungaloy has expanded its TungForce-Rec Series of square shoulder milling cutters to include size 12 inserts and associated tool bodies. The TungForce-Rec range is a high-density shoulder-milling cutter with a secure insert clamping system that boasts high process security. Incorporating all of the benefits of the existing size 06 V-bottom TungForce-Rec inserts, the new size 12 inserts offer an extended cutting edge length that is twice as long as the existing size 06 inserts. Suitable for shoulder milling, slotting, side milling, pocketing, ramping and trochoidal milling, the size 12 addition to the TungForce-Rec enables manufacturers to extend their machining parameters and material removal rates.

The TungForce-Rec size 12 tool body retains all of the characteristics of the smaller TungForce-Rec 06, including a particularly thick core diameter and heavily supported backing behind the insert. This thick core diameter delivers improved stability during machining, especially when cutting at elevated speeds, feeds and depths of cut. Likewise, increased support behind the insert permits the use of longer insert clamping screws. This design provides greater screw-thread engagement security that ensures tool reliability and longevity when using the TungForce-Rec at high metal removal rates. As a further point, this combination also reduces vibration and improves surface finishes and insert life when machining at increased cutting parameters.

Tungaloy’s new TungForce-Rec 12 boasts a 50% higher tooth density than competing shoulder milling cutters of the same size. For example, this gives a 16 mm diameter cutter three insert pockets, while a 50 mm diameter tool can accommodate 12 inserts. The development allows the new shoulder milling series to run at a higher feed rate than competitor products, reports Tungaloy.
For further information www.tungaloy.com

High-feed helical milling is 14 times faster

Carbide insert and cutting tool manufacturer Horn reports an application at Jörg Bamann Mechanische Werkstatt, a job shop in Geretsried, Germany, where a Horn DAH high-feed, indexable-insert milling cutter in a B-axis lathe is able to helically interpolate a circular groove into a round steel workpiece 14 times faster than a toroidal mill.

The 42CrMo4 (1.7225) alloy steel billet, quenched and tempered to 1000 N/mm², requires the rough machining of a 40 mm wide groove with a 240 mm outside diameter and a depth of just less than 90 mm. This component is a key part of a hydraulic rotator, used in construction and forestry for rotating attachments carried by excavators.

Seeking to optimise the groove machining process, owner Jörg Bamann approached Horn application engineer Korbinian Niedermeier, who recommended a high-feed milling solution. The subcontractor has been using Horn products for two decades.

Bamaan says: “Before switching to milling, we tried to produce the recess in the component by axial turning. We also tried a five-flute toroidal milling cutter with indexable inserts in the B-axis tool spindle. Neither were sufficiently successful.”

Niedermeier instead proposed a 40 mm diameter, high-feed DAH mill with five triple-edged inserts. At a cutting speed of 150 m/min, the tool is helically interpolated into the rotating workpiece with a continuous infeed depth of 1 mm and 0.8 mm feed per tooth. The new machining time for the recess is now just seven minutes per component, more than 14 times faster, while the life of the indexable inserts has increased threefold to 90 components per edge.

Bamann confirms: “Using the high-feed milling cutter has reduced the cycle time considerably and the load on the machine has also decreased, as cutting pressure and vibration are lower.”
For further information www.phorn.co.uk