Padiham-based Mini Sport Group has been supplying its customers with parts for the iconic classic Mini for over 50 years. Since 2005, group company Motorsport Advanced Developments (MAD) has been manufacturing many of these parts in-house.

In order to support recent increased machining demand and capacity, MAD turned to long-term tooling partner Ceratizit UK & Ireland, with which it has worked with from the outset of the business. Already a user of Ceratizit’s vending systems, in the form of two TOM60 vending machines, the challenge was to supply increased tool storage capacity without compromising floor space. The solution was the installation of the latest TOM840, which will replace the two existing units. TOM840 has a maximum capacity of 840 tools in compartments that are adjustable to take a wide variety of shapes and sizes.

The Ceratizit TOM vending system also provides users with detailed traceability, offering the ability to track the distribution of every tool, from time of vend, to which operator took it, while also monitoring costs. With its integrated SIM card communications, the machine automatically sends replenishment stock orders to the team of five dedicated vending support staff based at Ceratizit’s office in Sheffield. A Ceratizit tool service engineer then replenishes the stock and, once a month, the system raises an invoice. As the stock within the TOM840 is supplied on a consignment basis, only those tools vended are charged for.

A further advantage of the consignment stock is that the user can never be left with obsolete tools; whenever an update is released, the tools are replaced. This latest vending installation brings the total number of machines in the market to 435.

For further information
www.ceratizit.com

Now available from Horn is a new generation of milling cutters for machining at high feed rates. The DAH82 and DAH84 milling systems feature a precision-sintered indexable insert with eight cutting edges for cost-effective metal cutting. Despite its negative mounting position, the positive cutting geometry ensures good chip removal combined with a smooth, soft cut. Furthermore, the large radius of the insert’s main cutting edge ensures even distribution of the cutting forces, extending tool life.

Horn offers the inserts in the SA4B substrate, which is suitable for universal use on various materials. Maximum cutting depths are 1.0 mm for the DAH82 and 1.5 mm for the DAH84.
The DAH82 variant is available as an end mill and as a screw-in milling cutter in the following diameters: 20 mm (z = 2), 25 mm (z = 3), 32 mm (z = 4), 35 mm (z = 4) and 40 mm (z = 5), where z denotes the number of inserts. As an arbour milling cutter, it is available in diameters of 40 mm (z = 5), 42 mm (z = 5) and 50 mm (z = 6).

For diameters in excess of 50 mm, the larger DAH84 indexable insert is used. It can be supplied as an arbour milling cutter in the following standard diameters: 50 mm (z = 4), 52 mm (z = 4), 63 mm (z = 5), 66 mm (z = 5), 80 mm (z = 6), 85 mm (z = 6), 100 mm (z = 7) and 125 mm (z = 8). All tool bodies receive a special surface treatment of high strength and hardness, providing long-term protection against abrasive wear from chips.

For further information
www.phorn.co.uk

Seco Tools is offering a new family of versatile, highly productive solid-carbide end mills: the JSE510 series. Redesigned to offer more rigidity, chip control and tool life, the company says the new milling cutters achieve the lowest possible costs per metre of machined steel, stainless steel, cast iron, titanium and some aluminiums. The cutters provide high process reliability across a broad application range.

JSE510 cutters offer higher versatility in comparison with the previous version of this product range, not just for general engineering, contract manufacturers and job shops, but those specifically serving the aerospace, medical and automotive industries. Seco’s design for the JSE510 stands up to tough milling applications with a versatile carbide grade, advanced polished SIRA coatings and a strong, sharp cutting edge. To extend tool life further, the tools offer a vibration-damping variable pitch design and an optimised helix.

Seco’s JSE510 family includes 216 tools in four geometries, with two length variants in the three and four-flute version: normal (LV2) and long (LV3). The two-flute JSE512 handles the large chips produced in helical interpolation or peck drilling, keyways and slotting applications, while the three-flute JSE513 offers universal milling performance for ramping, full slotting and side milling. The four-flute JSE514 is for side milling and slotting, as well as dynamic milling. Finally, the ball-nose end-mill geometry of the JSB512 offers the versatility required for finishing operations.

“These cutters offer productivity in less stable machining conditions or when pushed hard to balance productivity and tool life costs,” says Rob Mulders, solid end mills global product manager. “This versatility makes the JSE510 series particularly useful when shops face increased tooling costs because of a greater variety of applications and materials.”

For further information
www.secotools.com

Dormer Pramet has expanded its offer for true 90° shoulder milling in various materials.

With improved cost per edge, the company’s new range of TNGX16 inserts and STN16 cutters feature larger double-sided inserts with six-cutting edges, providing greater depths of cut (up to 10 mm) and higher feed compared with its existing TNGX10 range.

By offering low cutting resistance, the assortment improves the connection between passes, creating high surface quality. This reduction in forces leads to smooth, quiet machining for additional process security.

Positive geometry and through-coolant offer improved chip evacuation across a range of materials, including steels, stainless steels, cast iron and non-ferrous metals.

Dormer Pramet’s TNGX16 assortment is available in radii from 0.4 to 1.6 mm and in a range of grades. Three geometries, F, M and FA, support the insert. F is the first choice for low to medium carbon content steel. A high positive geometry with narrow peripheral land makes F geometry suitable for light to medium machining.

M geometry is for machining carbon steel, stainless steel and cast iron. This positive geometry with medium T-land makes it suitable for light to medium machining.

For use on non-ferrous metals, FA is a high positive geometry with a sharp cutting edge. The polished insert face reduces adhesion to machined material.

Meanwhile, STN16 tool holders provide a higher number of teeth for greater productivity in comparison with the original assortment. The differential pitch offers smooth machining in diameters above 50 mm.

For further information
www.dormerpramet.com

The new MaxiMill 275 milling system from Ceratizit suits the rough machining of high-alloy stainless and refractory steels, materials often found in the manufacture of turbocharger housings and exhaust manifolds. Ceratizit’s MaxiMill 275 face milling system is suitable for processing flat surfaces on these components. The tool is robust in its construction and design, with a maximum number of indexable inserts for efficient machining. Inserts are ground all around to ensure a smooth milling action, high-quality surfaces, long tool life and high efficiency.

The face milling of turbocharger components presents huge challenges for cutting tools due to the demanding nature of the material – often refractory cast steel containing niobium. In addition, the features of turbocharger housings and exhaust manifolds frequently create insecure machining conditions, bringing a requirement for tool stability so that it cuts effectively and achieves the necessary quality.

“Our development team began the process by designing the cutter body to be extremely stable and have low vibration,” says Detlef Erdei, application manager automotive at Ceratizit. “We were then able to optimise the number of cutting edges based on the diameter.”

This work resulted in the largest MaxiMill 275 with 125 mm diameter featuring 18 teeth, while the smaller 63, 80 and 100 mm diameter variants have 7, 10 and 14 teeth respectively.

The Ceratizit development team paid particular attention to the accuracy of the insert seat, which keeps the indexable insert firmly and precisely in place using a wedge clamp.

Ceratizit’s indexable inserts have also been refined thanks to the use of a special cutting material for the highest thermo-mechanical demands. Furthermore, a positive geometry with a 20° rake angle enables the inserts to cut effectively and guarantee a smooth machining action.

For further information
www.ceratizit.com