Kennametal has introduced its next-generation 3D-printed stator bore tool for the machining of aluminium engine housings for electric vehicles. This latest version of the tool features a newly designed arm structure, a larger centre tube made of carbon fibre and a further weight reduction of greater than 20% over the original design. The complex tool is capable of machining three large diameters in just one operation, saving set-up time and machining time for automotive component manufacturers, while delivering high accuracy and surface qualities.

The newly redesigned tool recently won MM MaschinenMarkt’s Best of Industry Award in the Production and Manufacturing category based on votes by readers and industry experts.

“As our automotive customers expand their offerings of hybrid and electric vehicles, we continue to respond to their need for lighter weight tooling solutions,” says Ingo Grillenberger, product manager at Kennametal. “By leveraging advanced manufacturing techniques like 3D printing, we’ve reduced weight a further 20% over the first-generation tool, while improving chip control and increasing tool rigidity – innovations that help our customers machine faster and more efficiently.”

Machining three diameters in one operation, the stator bore tool ensures the alignment and concentricity of the machined surfaces, while reducing cycle time significantly. The lightweight 3D printed combination tool enables a faster tool change and spin-up even on less powerful machines. According to Kennametal, the surface specifications and component tolerances are achieved without constraints.

Hassle-free chip removal arrives by means of aerofoil-shaped arms with through-coolant to ensure precise and powerful coolant supply to the cutting edges and guide pads. This capability would be difficult or impossible to produce economically with traditional manufacturing, but 3D printing enables Kennametal to realise even complex internal features.

For further information
www.kennametal.com

Tungaloy has extended its Tung-Tri indexable square shoulder milling system with the new size 04 insert. The 04 size has a 3.5 mm cutting edge length that makes this new arrival compatible with tool body diameters as small as 8 mm. With the 04 inserts available for tool bodies from 8 to 25 mm diameter, the extremely small Tung-Tri 04 insert has a 4 mm inscribed circle, yet it delivers the same benefits of light cutting and long tool life that existing Tung-Tri inserts have been providing for manufacturers. This capability enables the Tung-Tri 04 to generate up to double the tooth density when compared with alternate tools, and subsequently increase feed rates. The compact configuration enables a 16 mm diameter Tung-Tri 04 cutter to offer four inserts per cutter, whereas the 25 mm diameter cutter can facilitate six teeth. This insert density is common throughout the Tung-Tri series, ensuring that all tool body diameters and insert designations can offer maximum productivity levels and feed rates for end users.

Complementing the new compact size 04 inserts are tool bodies for size 06, 10 and 15 inserts. The 06 inserts are suitable for 12 to 50 mm diameter tool bodies, with 25 to 100 mm bodies for the size 10 inserts and 40 to 160 mm diameter bodies for the size 15 inserts.

The new Tung-Tri series uses three-edged inserts developed specifically to deliver precision, productivity and cost efficiency for shoulder milling applications. According to Vargus, this allows users to choose an optimal tool set-up according to the given part sizes and the required material removal volume.

For further information
www.tungaloy.com

Rainford Precision is introducing two new brands to the UK: 6C Tools AG and BSQ Tech GmbH.

Unlike many other products on the market, micro-tools from 6C Tools are manufactured by laser ablation, a process that is particularly gentle for material removal compared with grinding or spark erosion. This method of manufacture avoids damage and significantly increases the wear resistance of 6C Tools, creating a potential 5-10 times tool life increase.

The 6C product catalogue covers several drilling, milling and threading tools, as well as tailored tools manufactured from PCD and PCBN. Designed specifically for machining challenging materials such as tungsten carbide and zirconium, the standard 6C portfolio introduces PCD drills, PCD end mills, PCD chamfer tools, PCD ball-nose mills and ball-nosed polishing tools, as well as a range of PCD thread mills.

The ability to machine such difficult materials with impressive tool life and productivity characteristics makes the 6C range suitable for manufacturers in the medical, electronics and jewellery industries, to name but a few.

For engineers looking to improve their productivity when machining aluminium, aluminium alloys, copper, brass, plastics, PEEK and all other non-ferrous metals, Rainford can now offer the SwissCeraMill series from BSQ Tech, which the company says can increase tool life from 5 to 25 times and improve productivity by 400% compared with conventional carbide cutting tools.

Manufactured from high-tech ceramic zirconium oxide with a micro-grain structure, SwissCeraMill end mills are available in square-end, corner-radius and ball-nose designations, along with special-purpose tools to suit the diverse needs of industry.

For further information
www.rainfordprecision.com

Vargus Tooling has launched its new series of MACH Supersonic Threading products, which incorporates a complete range of thread turning tools and thread milling products.

The patent-pending turning range features a comprehensive range of MACH TT external inserts and corresponding MACH TT tool holders. MACH TT external turning inserts cater for the complete threading spectrum. Each of the respective thread geometries incorporates an improved rake featuring a reinforced geometry which creates a strong insert design with a high resistance that permits cutting at higher speeds while simultaneously reducing the number of passes required, says Vargus.

Adding to this geometry is the new Vargus VK8 insert grade that combines an AlTiN and TiN PVD coating to give durability and performance on materials that range from steel and stainless, cast iron and non-ferrous materials, through to heat-resistant alloys and hardened steels.

Complementing the thread turning range is the new MACH TM thread milling range. Like the thread turning range, the MACH TM thread milling line is available in a complete range of thread geometries to cater for the demands of any machine shop. The solid-carbide thread mills incorporate an improved edge design with a reinforced geometry to allow cutting under high loads. In addition, a large core diameter increases the stability and strength of the MACH TM series to enable higher speed and feed rates.

Further enhancing the ability to cut at high feed rates is a design feature that includes a fourth flute to improve cutting performance and evacuate the swarf at speed. Assisting this tool design in removing chips from the work zone is a through-coolant facility that flushes swarf from the cutting edge.

For further information
www.vargusuk.co.uk

With the support of Ceratizit UK & Ireland, Techni has dramatically cut the time to market for its compressor mount kits used in van-based refrigeration and compressed air applications.

Typically, Techni machines the kit’s compressor brackets from SG iron castings, as normal batch sizes make this the most cost-effective method. However, driven by a significant increase in home deliveries due to the Covid pandemic, customers have demanded faster turnaround, and volumes in much lower numbers but more diverse configurations.

“In order to compete we needed to review our production methods to reduce lead times by as much as possible, and billet machining was the logical step,” explains Ali Kerr Techni’s manufacturing engineer who worked on the project.

To help with the work holding, tooling and methodology, Techni turned to preferred tooling supplier Ceratizit UK & Ireland.

With the billet gripped, up to 90% of the machining, both roughing and finishing, is carried out using a WNT CircularLine end mill featuring Ceratizit’s extremely wear resistant Dragonskin DLC (Diamond Like Carbon) coating. In the case of Techni, these 4 mm diameter five-flute cutters run at a conservative 450 m/min surface speed and 0.2 mm/tooth feed, with a 10-20% step over.

“The help we’ve received from Ceratizit on this project has been invaluable,” says Kerr. “We can now deliver finished machined parts to customers within a week if required, compared to four months for a new cast product. This gives us a valuable competitive edge with new customers. In future, with batch quantities up to 300, billet machining will offer a significant advantage, and we already have more parts lined up for billet machining.”

For further information
www.ceratizit.com