FEATURE ON TOOLING

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

Innovation optimises titanium alloy machining

With its shell-type cutter,Mitsubishi Materials has adapted to the latest recognised approach for milling titanium alloys. To emphasise the strength, high power and large metal removal capability, the company has recently expanded its ASPX series with two integrated HSK single-piece shank types. The new types are an HSK-A100 and an HSK-A125, both with 80 mm cutting diameter bodies.

The HSK shank encompasses a central through-coolant channel that feeds internally to each insert pocket, thereby providing coolant directly to the insert face. This direct coolant approach makes it possible to maintain feeds rates and extend tool life, even under the most demanding of deep-side and slot-milling applications.

ASPX series cutters now have a new grade, MP9140, to add extra performance and reliability. MP9140 is made from an enhanced super-fine cemented carbide substrate for increased toughness that also retains hardness for longer tool life. Using the (Al-Ti)-N coating method ensures optimal resistance to wear and heat. According to Mitsubishi Materials, the combination of these properties provides excellent fracture resistance and a very low coefficient of friction, delivering the welding resistance necessary to machine modern titanium alloys successfully.

The cutting edge geometry features a high rake edge to ensure a smooth but strong cutting action.

ASPX series cuttersare able to utilise the positive effects of the modern roll-into cutting approach. The roll-into cutting strategy controls sharp increases in cutting loads and prevents sudden chipping of inserts. Also, when utilising a climb milling direction of cut, roll-into is effective at almost eliminating the usual vibrations associated with the conventional direct approach.

ASPX cutters are available in a shell type in sizes 50, 63 and 80 mm diameter.
For further information www.mmc-hardmetal.com

Technical collaboration delivers productivity gains

With over 50 years of experience machining components for the aerospace, defence, medical, electronic and automotive industries; utilising everything from two-axis lathes through to multi-pallet five-axis machining centres axis, Aylesbury-based CNF Precision Engineering could be expected to have all the expertise it needed. However, when it won a significant order to machine exhaust collector manifolds for a motorsport customer, it found itself in need of additional support.

The issue faced by CNF was the complexity of the components, which came in six variants, along with the material, 304 stainless steel.

“When we were faced with stainless steel that required extra-long tool overhangs, we knew we would need additional technical input,” says Mark Baron, CNF’sproduction manager.

Ceratizit provided a range of tooling on trial, with no commitment until successful completion of the process. Key to that success wasthe use of35 mm diameter (with 4xD flute length) KUB Pentron indexable insert drillsfor the main internal port machining, along with a selection of high-feed indexable insert milling cutters using button and square inserts, with finish milling completed using Ceratizit’s Silverline solid-carbide mills and Torus cutters.

The collaboration resulted in significant cycle time savings along with greatly improved tool life. For example, the indexable milling inserts are showing a 300% increase in tool life after testing a variety of carbide grades, eventually settling on Ceratizit’s grade for heat-resistant materials, CTCS245. A 20/30% gain in tool life was seen when switching to Silverline cutters for finish milling, when compared with an incumbent competitor cutter.

In terms of cycle time, the work undertaken with the Ceratizit Torus cutters proved to be productive, with 40-50% decrease in cycle time generated from the switch from a conventional ball-nose cutter to a Ceratizit Torus Monstermill cutter.Tool life also doubled.
For further information www.ceratizit.com

Allied Machine expands thread-mill portfolio

Allied Machine and Engineering, a manufacturer of hole-making and finishing cutters, has added new sizes to its AccuThread T3 thread-mill line. AccuThread T3 is now available in larger UN and ISO sizes up to 1”-8 and M24x3. Machine coding for the new sizes is included in Insta-Code, Allied Machine’s online thread-mill program generator.

Targeting high-production facilities, tool and die industries and high-temperature applications, the additional AccuThread T3 thread-mill sizes create a high-quality thread without the concern of breaking the tool in an expensive workpiece. Allied designed the tool to only machine three threads at a time, which reduces pressure and dramatically increases the chances of tool survival.

The AccuThread T3 is for machining hardened or hard-to-machine materials such as stainless steel, tool steel, and high-temperaturealloys in classifications P, S, M, H, K and N.

According to Allied the advantages of the thread-mill line include: improved tool life and a more precise thread form; the ability to cut harder materials and produce deeper threads than a standard thread mill; and improved cycle time and tool life.

Among notable features is left-hand cutting, which allows the tool to climb mill while it moves from top to bottom, creating a right-handed thread. Further features include the use of three teeth that cut minimal threads all at once and reduce side deflection, along with AM210 multi-layer PVD coating.

Among industries set to benefit are aerospace, agriculture, automotive, firearms, construction, marine, mining and renewables.
For further information www.alliedmachine.com