Tungaloy’s DoFeed milling solutions have proven successful for almost a decade and, to build upon this reputation, the company has launched its AddDoFeed series. Developed for high-feed milling on small parts, the new line exceeds the cost efficiencies and productivity benefits of DoFeed solutions.

Suitable for manufacturers in the mould and die, automotive, oil and gas, and general engineering sectors, Tungaloy says this milling family is certain to improve productivity for end users. Although solid-carbide end mills have long been applied to small parts, it is unproductive to use such tools when requiring considerable stock removal in slotting or pocketing applications. This is because the low bending stiffness prevents the tool body from sustaining the heavy radial force generated when feed is increased to improve cycle times.

The new AddDoFeed uses small size 02 inserts with a 4 mm inscribed circle and offers close-pitch cutter bodies that boast high insert-to-diameter density for a small diameter indexable cutter. Tungaloy offers the AddDoFeed small diameter high-feed milling cutter series in diameters of 8, 10, 12, 16, 20 and 25 mm, which allows the 16 mm diameter tool body to carry four inserts, with five inserts on the 20 mm diameter tool and seven inserts on the 25 mm version. This insert density enables users to ramp up feed rates and increase productivity. The tool bodies are available with a rigid short-shank tool body or a long neck shank for difficult to reach surfaces, along with a modular-head system that is coupled with a tapered carbide shank for increased rigidity.
For further information www.tungaloy.com

Gühring has expanded its grooving and parting-off to include a new grade with a blade width of 3 mm for parting-off stainless steel materials. The System 222 expansion adds to the company’s existing indexable inserts for steel materials. With two cutting edges and a length of 22 mm, the new indexable insert is suited to parting off all common bar diameters.
The enhanced series also offers an extensive range of clamping holders with and without an internal coolant facility.

Many production facilities are seeing an increase in demand for stainless steel in particular, notably in sectors that include medical, automotive and general mechanical engineering. With this rise in demand – and following the successful launch of its 3 mm indexable insert for steel machining – Gühring has therefore developed the new indexable insert for stainless steel materials. In series production, this insert is suitable for parting-off operations on turning centres with a bar-feed system. As parting-off is frequently the last application in a machining cycle, process reliability is critical. If the tool breaks, the finished component could be subject to damage at its point of highest value (after significant machining time). For this reason, it is important to use an insert with application-optimised geometry, material composition and coating.

In one customer machining example, a feed-rate increase from 0.06 to 0.08 mm resulted in a reduction in machining time using the same cutting speed. With a series run of 15,000 components, the customer made a time saving of more than five hours. Despite the higher feed rate, the Gühring solution created 40% more parts per insert edge with a 25% productivity gain.
For further information www.guhring.co.uk

To provide manufacturers with versatility and high value, Seco has launched its X-Head quick-change replaceable milling head system. With the new solution, users can quickly and easily change between various solid-carbide milling geometries and types to optimise milling operations while reducing manufacturing costs and tooling inventories.

The milling heads mount to a variety of available shank lengths for even greater versatility, with short and long-reach capability for a variety of overhang lengths. Head changes only require a simple turn of a wrench, eliminating the need to remove the holder from the machine to change the cutter. Users also eliminate the need to reset tool lengths thanks to a secure and reliable connection that provides exchange accuracies within 50 µm.

According to Gary Meyers, Seco’s product manager for solid milling, shops must often purchase many different end mills and holders to machine different features on a workpiece, adding higher project costs.

“The Seco X-Head quick-change replaceable milling head system adapts to various machining needs with a range of geometries and types but without additional holders,” he says.

With 194 types of available cutting heads, users can choose between different cutters for multiple operations, as well as between specific high-performance, versatile high-performance and universal-type geometries. Seco also offers metric and inch products for heads and shanks.
For further information www.secotools.com

To highlight the numerous solutions it offers for milling freeform surfaces, German tooling manufacturer Horn points to a recent application involving the machining of a plastic injection mould for mass producing the lens for a headlamp. The large number of surfaces, shoulders and radii required the use of many different tools.

The customer used high-feed milling cutters with indexable inserts from Horn’s DAH 8 system to rough the mould, subsequently employing different variants of solid-carbide end mills from the Horn DS tool system for finishing. In addition to various diameters of ball-nose end mills, the customer also used circle segment end mills. The advantage of the latter, in contrast to ball or torus milling cutters, is that fewer passes were required to achieve a given freeform surface quality, reducing cycle time.

In the medical sector, a customer produced a complex titanium implant using a five-axis machining centre with Horn DS titanium milling cutters. The shape of the implant comprised numerous freeform surfaces, had about 20 different radii and contained many fillets arranged at different angles. A milling cutter of 10 mm diameter and with a corner radius of 0.2 mm and another of 6 mm diameter with a 0.5 mm corner radius completed the roughing. For finishing, the customer used a 1 mm diameter end mill.

DS cutters of 10, 6, 4, 2 and 0.6 mm diameter performed other operations on the implant, along with a 2 mm diameter ball-nose end mill and a DCG solid-carbide, coated thread mill with three cutting edges. In a single pass, the tool mills an M3.5 x 0.5 through-hole thread, which is 8 mm deep and inclined at 35°. Milling two tapered recesses proved to be highly challenging. The 43° taper is about 2 mm and must end in a geometrically perfect apex, but the customer met these requirements using a Horn micro-milling cutter for both roughing and finishing passes.
For further information www.phorn.co.uk