Kennametal has introduced its HiPACS drilling and countersinking system for aerospace fastener holes. Designed to drill and chamfer holes in one operation, the high-precision tool meets the aerospace industry’s stringent accuracy requirements, while delivering long tool life when machining composite, titanium and aluminium aircraft skins.

“Most fastener hole tools used today are complex made-to-order tools with long lead-times,” says Georg Roth, product manager at Kennametal. “HiPACS uses standard, off-the-shelf components for quick delivery and low cost per hole, by allowing the drill and chamfer insert to be indexed independently from one another. What’s more, it’s the
only indexable drilling and countersinking system on the market that can hold the aerospace industry’s required fastener hole chamfer tolerances in just one operation.”

Designed to be clamped in a standard hydraulic chuck, the HiPACS modular system consists of three components that are fast and easy to assemble: a reducer sleeve with a built-in high-precision pocket seat which, in conjunction with a standard hydraulic chuck, provides ultra-secure clamping and a runout of no more than 3 µm to increase tool life and hole quality; a PCD countersinking insert that eliminates the need for expensive custom solution step drills, thus reducing manufacturing costs while meeting the industry’s accuracy requirements; and two series of solid-carbide drills – both diamond-coated and PCD-tipped – covering all material combinations found in a typical aerospace assembly. In addition, the straight shanked tools allow for length adjustments in increments of 10 mm.

It is possible to utilise the new HiPACS drilling and countersinking system on all machines typically used for aerospace applications. In less stable conditions, such as robot end effectors, the diamond-coated carbide drills offer long tool life and high hole quality.

For further information
www.kennametal.com

Dormer Pramet has launched a new generation of solid-carbide five-flute end mills, specifically for dynamic milling in general machining and mould and die applications. The company’s S7 assortment covers a wide range of operations in a variety of steels, cast irons and difficult-to-machine materials, including stainless steels and super alloys.

These latest additions – S770HB, S771HB, S772HB and S773HB – offer up to 25% more feed rate potential compared with four-flute cutters. All feature a positive rake angle for smooth cutting action and to reduce the risk of work-hardening. An AlCrN coating provides thermal stability, reduced friction, high wear resistance and prolonged durability.

The S771HB and S773HB cutters are suitable for narrow pocketing, trochoidal slotting and profiling applications. These end mills include a chip divider to break swarf into manageable smaller pieces, helping to reduce spindle load and increase metal removal rates. This capability provides a 50% larger width of cut in comparison to tools without a chip divider.

Dormer Pramet’s S770HB and S772HB are more suitable for profiling, trochoidal slotting, and semi-finishing applications, offering maximum productivity due to optimal metal removal rate and reduced machining time.

Meanwhile, Dormer Pramet has added three multi-application high-performance cutters to its S7 range for use on both CNC and conventional machine tools. The new additions – S722HB, S765HB and S768 – support most common operations, such as slotting, plunging, contour milling, ramping and copy milling in various materials.

Finally, the company has added a new solid-carbide cutter to enhance its assortment of end mills for hardened steel above 49 HRc. The S561 is specifically for high-performance milling in a variety of applications, including mould and die machining.

For further information
www.dormerpramet.com

Tooling manufacturer Paul Horn is expanding the range of products it supplies to manufacturers of equipment for machining pipes and sleeves used in oil and gas production, as well as to end users. The cost-effective OCTG (oil country tubular goods) machining solutions for use in API- and GOST-compliant – as well as premium joint applications – focus on ease of use. According to Horn, standard and customer-specific tools deliver a productive edge over other tools in the areas of handling, service life and cost per threaded connection.

The tool systems are available with standard machine interfaces including VDI, polygonal shank and round shank holders, and as solutions that are flange-mounted on turrets. They are adapted to suit the production process, from manual loading through to full automation. Both the screw clamp and ground geometries of Horn’s S117 and 315 systems, together with carefully matched tool holders, enable effective chip management.

There are no expensive parts such as chip breakers or shims to install, allowing customers to make savings when procuring tools. The two systems use substrates and coatings for the inserts that are tailored to the machining conditions, resulting in significant improvements in both cutting performance and tool life. Accurate interchangeability provided by the precision insert seats reduces the number of tool adjustments needed after changing inserts.

During thread cutting in API- and GOST-compliant applications, the S117’s numerous teeth enable the number of cuts to be minimised. The 315 system has three usable cutting edges, leading to cost optimisation. Horn says it is a good choice for premium joints that permit no more than one to three teeth per cutting edge.

For further information
www.phorn.co.uk

As Seco’s patented insert coating technology Duratomic enters its second decade, the company has released three new grades specifically for stainless steel turning. Among other things, the new TM grades offer customers used-edge detection technology, resulting in increased productivity.

More than a decade ago, Seco R&D specialists realised that it was possible to harness nanoscience and develop highly sophisticated coatings with thermal and chemical resistance properties that could be extremely strong and durable – at an atomically thin level. The result of their work was a patented insert coating technology that brought a combination of wear resistance and edge toughness to maximise insert grades in the prevention of cracks and breakage. Seco called it Duratomic.

“There are different ways to manipulate the various parts of the coating, and different translations of upper, bottom and centre layers for various usages. Knowing when and how to do it is what I would call the essence of Duratomic,” explains Mikael Lindholm, product manager – general ISO turning.

Today Duratomic has gone from strength to strength and is present in turning, drilling and milling applications.

“Seco Tools has always been expected to provide exceptional grade performance,” says Lindholm. “We recently released our Duratomic MP2501 and MP1501 milling grades, as well as three new grades within turning – TM1501, TM2501 and TM3501 — which are specifically for stainless steel turning.”

All these new Duratomic grades feature the company’s most recent generation of the technologies, with the possibility of access to chrome used-edge detection. The Duratomic TM turning grades improve productivity in a range of materials, from easy, often austenitic stainless steel to demanding high-alloy super-duplex stainless steels.

For further information
www.secotools.com

Walter has launched its MD377 Supreme and MC377 Advance solid-carbide milling cutters for the machining of titanium. Developed as high-end tools for the aerospace, motorsport and medical industries, the new arrivals are universal cutters for roughing, semi-finishing and finishing operations.

Incorporating a corner radius and central through-coolant supply, the new MD377 Supreme utilises Walter’s proven HPC Ti40 titanium geometry and new WTZ coating that makes it suitable for full slotting up to 1xD, ramping, shoulder milling and plunging. Also, the MD377 Supreme is suitable for dynamic milling processes.

The MD377 Supreme allows for tight tolerance machining and stands out thanks to its high metal removal rate. This high material removal rate is a credit to optimised cutting geometry and five cutting edges that can improve productivity levels and reduce vibration due to its differential pitch design.

Walter’s MD377 Supreme is available with a range of corner radii in diameters of 6, 8, 10, 12, 16, 20 and 25 mm, with a flute length of 13 mm on the 6 mm diameter tool ranging up to 45 mm on the 25 mm tool.

In contrast, the MC377 Advance is a four-flute titanium end mill that is also suitable for ISO P and M material designations. This diversity is credit to a tough AlCrN coating that works with Walter’s WK40EA substrate that makes the MC377 suitable for steel, stainless steel and titanium alloys.

The new MC377 Advance end mill without corner radii is available in diameters of 2, 3, 4, 5, 6, 8, 10 and 12 mm, while the MC377 Advance with corner radii comes with a 2, 3, 4, 5, 6, 8, 10, 12, 16, 20 and 25 mm diameter.

For further information
www.walter-tools.com