Walter is extending its range of solid-carbide milling cutters for ISO N machining with the addition of two distinct roughing specialists, the MD265 Supreme and the MC268 Advance. The MD265 Supreme three-edged cutter with a diameter range from 16 to 25mm is available as coated or uncoated, standing out with its coolant channels in a star-shaped configuration, as well as robust cutting edges with RAPAX profile.

It was designed to achieve high productivity and process reliability required in sectors such as automotive. Whether uncoated with polished surfaces or coated with Walter’s new WJ30DD grade, it can optimise chip removal, reduce material build-up and extend tool life. This is of particular interest for manufacturers machining die-cast aluminium with the high silicon content.

Also new to the portfolio is the 6 to 25mm diameter range MC268 Advance. Incorporating a polished innovative profile that can be used universally, it is designed for long-chipping wrought aluminium alloys that are often found in the aerospace industry, for example. The coolant outlets of the three or four-edged milling cutter feature a radial arrangement for strategies such as dynamic milling. Furthermore, it reduces tooling costs as it is suitable for reconditioning.

Both solid-carbide milling cutters aim to reduce machining times in ISO N materials and increase metal removal rate. The V-shaped cutting edge, which is typical of both milling cutters was developed in-house at Walter, which says it is the only one of its kind on the market. Grooved cutting-edge profiles split the chips into short, easily controlled segments. This effect increases process reliability and allows users to work with reduced cutting forces.
For further information www.walter-tools.com

Actuating tools are the means of choice for creating turning geometries on machining centres. When it comes to machining stator bores on electric motors, tools with indexable inserts and fine boring tools were state-of-the-art until now. Mapal has developed a complex four-blade actuating tool to round off its solution portfolio for stator drilling.

With its solution, Mapal has come up with a highly productive machining process for the series production of stator housings used in electric motors. The solution offers productivity and precision as well as short cycle times with a process of three steps: pre-machining, semi-finishing and fine machining at machining diameters of more than 220 mm and with an HSK100 connection. A sophisticated actuating tool is part of the solution.

“With an actuating tool, the internal machining of the bore can be handled by a machining centre, which means turning is no longer necessary,” says Oliver Müller, customer service specialist at Mapal’s centre of competence for actuating tools. The entire machining process is thus executable with a single set-up. The only thing needed to use the actuating tool is a spindle with a drawbar – a so-called Uaxis in the machining centre.

“When it came to machining parts for electric cars, we were at our customers’ side with our tools from the very beginning,” says Müller.“Today, we help them to increase flexibility while machining the parts reliably and with short cycle times.” The actuating tool achieves more flexibility by ensuring both fast machining of varying contour trains in the bore and micron-level precision.
For further information www.mapal.com

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

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