Any engineer knows the consequences of cutting tool vibration, which is why MSC Industrial Supply is making this effect a thing of the past with the new and exclusive MSC MillMax service.

For generations, machine operators have tentatively followed the prescribed cutting speeds and feeds based on manufacturer recommendations, having to later reduce cutting parameters and productivity rates based upon excessive tool vibration and deflection. This tool chatter can be caused by a seemingly endless number of factors that emanate – individually or collectively – from the machine spindle, tool holding configuration and cutting tool. Every machine tool and its respective tooling configuration operates at a unique frequency.

An often challenging puzzle to solve, engineers can only hope for a satisfactory result by relying upon experience, best practice and in some cases luck to attain the best possible outcome. Now, MSC surpasses this perceived ‘best possible outcome’ by applying a scientific approach. The new MSC MillMax service analyses and records frequencies and interprets the data to provide the customer with optimal machining parameters, replacing guesswork with exact scientific data that MSC Industrial says delivers unparalleled results.

MSC MillMax involves undertaking a simple ‘tap test’ that analyses and records the frequencies of the tool in a matter of minutes. Experts from MSC can interpret information from the system and provide the end user with a new set of optimised machining parameters.

Already proving successful in the USA, MSC MillMax is recording a 170% average improvement in material removal rates with a 40% decrease in cycle times.

For further information
www.mscdirect.co.uk

The latest solid-carbide cutter from Ceratizit features patent-pending geometry that delivers fibre compression across the entire length of MonsterMill FRP CR mills when producing parts from carbon fibre reinforced plastic (CFRP). Thanks to this maximum utilisation of the cutting edge, Ceratizit says that tooling costs and programming times reduce, while tool life increases.

When machining CFRPs, cutting tools must withstand high levels of abrasion and deliver optimum quality. In comparison with conventional routers featuring a fixed compression zone, the left- and right-hand helix on each cutting edge of the MonsterMill FRP CR form criss-cross pattern cuts that eliminate any pulling up or pushing down of the component when under cut.

Regular left and right-hand cuts on each cutting edge, and the accompanying fibre compression across the entire cutting length, result in the clean removal of fibres in all directions without damaging the component, reports Ceratizit, which greatly reduces delamination and projecting fibres. Also, depending on component thickness and the fixture, it is possible to use MonsterMill FRP CR multiple times as fibre compression is present across the entire cutting length, thus maximising the tool’s full flute length. This capability gives the customer the opportunity to lower costs.

Other benefits of MonsterMill FRP CR include reduced time and effort spent on programming for shaped components. When compared with a conventional router featuring a fixed compression zone, no zone on the component aligns with the MonsterMill FRP CR for the milling and profiling of shaped parts.

For further information
www.ceratizit.com

By optimising a roughing process when recessing 42CrMo4 steel (1.7225) hardened to 1000 N/mm2, German subcontractor Jörg Bamann CNC Dreh- und Frästeile in Geretsried has been able to save just under 100 minutes per component thanks to the use of DAH high-feed milling cutters manufactured by Paul Horn GmbH.

The subcontractor’s second-generation managing director Jörg Bamann has been using tools from this manufacturer in his production facility for 20 years, but it was only 10 years ago that the DAH high-feed face-milling system was launched. Due to low vibration tendency, the tools can reliably absorb high loads at the usual feed per tooth of fz = 1 mm, at cutting depths of up to 1.2 mm.

The large radius on the main cutting edge of the indexable inserts results in a soft cut, ensuring even distribution of the cutting forces and consequently extending tool life. On the inside, a smaller cutting edge radius makes for quick and easy ramping, while the wedge angle gives excellent cutter stability, reports the company.

It was a conversation with a Horn application engineer at EMO 2019 that led Bamann to swap from a toroidal milling cutter to Horn’s DAH high-feed system when machining a core part of a hydraulic rotator for excavator attachments.

With the former tool, which had five indexable inserts, it took over 100 minutes to rough the recess in the rotator parts, and it was able to machine 30 before the inserts needed indexing. In contrast, the time for machining the recess with the Horn DAH system is now just seven minutes per component – more than 14 times quicker than before – and the life of the triple-edged indexable inserts has increased three-fold to 90 components per edge.

For further information
www.phorn.co.uk

Widia is releasing a new MS geometry insert for the brand’s best-selling Top Drill Modular X (TDMX) drill. With the MS geometry expansion, the TDMX platform now offers three material-specific inserts, broadening the platform’s application capabilities to include inclined entry and exit, stacked plates and cross-hole drilling in stainless steel, super alloys, steel and cast iron materials.

In a recent customer test, the TDMX body, paired with the new MS geometry insert, achieved a 60% increase in tool life versus competing solutions while machining a 13-8 Hyper Chrome 110 KSI workpiece material at 3xD with a cutting speed of 75 m/min.

The MS geometry insert for the TDMX modular drill platform provides increased stability when drilling stainless steels and super alloys. Notably, the drill’s X-shaped pocket and tapered seat provide stability in challenging applications, while making it easy to change out the insert without disassembling the body from the holder. According to the company, these key design features reduce the unstable cutting conditions experienced with other drills commonly available on the market, while enabling higher penetration rates and reducing overall machine set-up times and costs.

Widia’s TDMX modular drill features a double-angle pocket seat design and a flanged shank that is said to provide outstanding flexibility and stability. It is possible to regrind all three inserts to extend tool life. TDMX is available in 1.5xD, 3xD, 5xD, 8xD and 12xD lengths, and diameter ranges from 16 to 40 mm.

For further information
www.widia.com

Walter has added lengths from 16 to 30xD to its X·treme Evo series of solid-carbide drills from the DC160 Advance range, thus facilitating deep-hole drilling applications. The DC160 Advance makes deep-hole drilling possible in a single operation without pecking, which is credit to Walter’s XD technology.

Complementing the existing 3, 5, 8 and 12xD offer, new arrivals include 16, 20, 25 and 30xD variants. The 16 and 20xD drills are available in diameters from 3 to 16 mm, whereas the longer 25 and 30xD variants come in diameters from 3 to 12 mm. The through-coolant drills are available with an overall length from 89 to 430 mm, depending upon the depth by diameter ratio of the selected drill.

Just like existing versions of the DC160 Advance, the latest deep-hole drills feature the new thinner web with 140° point angle and the fourth land in an advanced position. The thinner web ensures increased positional accuracy and reduces centre cutting forces, while the advanced-position fourth land optimises drill guidance. Furthermore, the new drills incorporate a pronounced chip gullet relief that creates a smooth and efficient cutting action upon initial entry. This softer cutting action reduces the required feed force, which subsequently eliminates deflection.

Grade selection ranges from the wear-resistant WJ30ET and WJ30EU to the tough K30F micro-grain substrate with TiSiAlCrN/AlTiN multi-layer coating. Furthermore, the polished flutes from 8xD optimise chip evacuation and reduce cutting forces.

Typical applications for the drills, which are available with or without through-coolant, include general engineering, as well as the mouldmaking, energy, automotive and aerospace industries.

For further information
www.walter-tools.com