Mitsubishi is expanding its MC6100 range of inserts to include MC6135, a tough grade for

applications that range from continuous turning through to rough and interrupted cutting. This new grade will complement the existing range and provide end users with a choice to machine a vast array of steels and of different applications.

MC6135 utilises crystal-orientation control technology that enables thinner but

still impact-resistant coatings for improved chipping and wear resistance. Such features are optimal for use on the tough MC6135 grade. Additionally, the coating is 50% thinner compared with previous types.

In cutting trials of interrupted cutting on DIN 41CrMo4 material, Mitsubishi found the tool life of MC6135 to be 20% more than conventional grades.

Regarding the existing range, MC6115 is a CVD-coated turning grade for steel workpieces that is capable of high-speed machining with its high levels of cutting edge stability. MC6125 grade is versatile, enabling an easy first choice start point when choosing an insert for turning steels and thereby reducing inventory levels.

Both grades have CVD coatings that provide the double benefit of cutting edge stability

and long tool life for machining a wide range of steels, reports the company. MC6115 has the combination of a high hardness base material and new thick Al2O3 outer coating with

improved wear and peeling resistance at high temperatures, while MC6125 has the combination of a tough base material and the advantages of Al2O3 coating. It also has higher peeling resistance and cutting edge stability, achieved through the application of super Tough-Grip technology. This enhances adhesion between the Al2O3 and TiCN base coating layers.

More information www.mmc-carbide.com

Empower Your Aluminium Machining’ was the motto of Mapal’s presence at this year’s AMB trade fair in Stuttgart last month. Among the product innovations on show was a new patent-pending bayonet-type connection for replaceable-head milling systems. Users benefit from easy handling, a rigid connection and optimum cooling.

The functional principle is simple: users insert the replaceable head and rotate it by 90°

to lock it in place, which is significantly easier than with a threaded system. The bayonet system achieves high rigidity and good force distribution thanks to the large cylinder face connection.

Mapal also presented a new holder design with a ring of cooling channel bores for a higher cooling volume. The coolant is channelled directly to the cutting edges, increasing tool service life and machining quality. Notably, the greater rigidity of the milling heads improves form and position tolerances, while simultaneously enhancing process smoothness and tool life.

Another innovation in the spotlight helps to protect aeroplanes against lightning strikes, where all parts require connection in an electrically conductive manner. For this purpose, paint requires removal in the area of drill bores during assembly. Mapal can now offer a tool with a patented micro-stop cage for this so-called spot facing, which replaces conventional brushes. The tool also performs countersinking, chamfering and deburring.

The new Mapal spot-facing tool, a plug-and-play solution, rotates in a micro-stop cage and only protrudes as far as the material that requires removal. With its long service life, one tool can replace several hundred brushes and is therefore not only reliable, but also economical.

When used for deburring, the cutting edges are completely inside the cage, leaving 0.1 mm of the burr. The depth stop is also useful for countersinking or chamfering.

More information www.mapal.com

Rainford Precision is adding to its cutting tool portfolio with the arrival of the CEHS end-mill series from Union Tool that the company says reduces chatter and improves precision and surface finish. 

The new CEHS tungsten-carbide four-flute end mills are for manufacturers struggling to hit the ‘sweet spot’ with their high-end machining applications. Suitable for machining everything from carbon and alloy steels to pre-hardened steel, cast iron, copper, titanium and heat-resistant alloys, the CEHS series incorporates a 40° helix and a variable pitch design for both slot and standard milling. Furthermore, the new large-pocket design of the main flute enhances swarf evacuation and eliminates the re-cutting of chips to extend tool life and machining performance.

Union Tool’s CEHS series has a h4 shank diameter tolerance of +0/-0.004 mm. To enhance milling stability, the end mills feature a small relief surface that further promotes stability and prevents chatter, even when undertaking operations with long tool overhang and reduced machining stability.

A micro-grain carbide, UT coating technology and 16° tapered shank design enable the 6 mm diameter version to machine slots in unstable conditions with an increase in milling efficiency of 80% improvement when compared with conventional tools, reports Rainford Precision.

Capable of cutting at machining parameters of 5000 rpm and 900 mm/min feed with a feed per tooth of 0.045 mm at a depth of 6 mm, the CEHS range of end mills is available in diameters from 1 to 6 mm in 0.5 mm increments with additional diameters from 6 to 12 mm offered in 1 mm increments. Each diameter designation has three different lengths of cut from 1.5xD to 3xD.

More information www.rainfordprecision.com

Ceratizit says that its new ProACT-Mill UNImax solid-carbide milling cutter is not only powerful and universally applicable, but also environmentally friendly thanks to the resource-efficient manufacturing process of the upGRADE CT-GS20Y grade, part of a particularly sustainable carbide family which the company calls upGRADE.

“What’s special about upGRADE CT-GS20Y is the significantly smaller carbon footprint generated during production compared with carbides from conventional production,” explains Michael Wucher, global technical product manager. “We achieve this using 99% reprocessed cutting tools as the raw material.”

The test results of the new series underline its potential: Ceratizit says that ProACT-Mill milling cutters deliver up to 30% higher performance compared with other universal tools. The newly developed coating, which brings with it additional performance and tool life reserves, further contributes to this level of performance.

A variable helix pitch ensures extremely quiet running and optimum chip removal. The ProACT-Mill UNI has an HB shank for optimal force transmission, while the reinforced tool core ensures even force distribution throughout the milling process.

To ensure stability of the cutting edge, the mill features a radial clearance face. The face-finishing chamfer promises top surface quality with base machining, while cutting edges with an irregular pitch specifically suppress vibration. Ramping milling and helical milling are possible up to an angle of 30°.

The ProACT-Mill UNI with a cutting edge length of 3xDC is particularly suitable for series production and trochoidal machining. Chip breakers in a radial design deliver long tool life and break the chips to a length of 1xD, with even and consistent removal thanks to the special shape of the chip space.

When it comes to maximum material removal rates, the ProACT-Mill UNImax offers special geometry design for depths-of-cut of up to 2xDC.

More information www.ceratizit.com

Cutting tool manufacturer Horn has extended downwards in size its M475 grooving and cut-off milling system. A user could previously select a grooving width of either 5, 6 or 8 mm, but now smaller inserts with a cutting width of 3 or 4 mm are available. In the UK and Ireland, the tools are available via the German manufacturer’s subsidiary in Ringwood, Hampshire.

The M475 system employs precision-ground, indexable inserts with four cutting edges. Positive geometry and a round chip-breaker groove, together with the new RC4G carbide grade, deliver economical, productive machining performance, reports the company. High toughness and hardness enable the machining of steels at elevated cutting speeds. These attributes also serve to increase insert life significantly.

The cutter bodies are available from stock as side, shell and screw-in milling cutters – the two latter variants feature internal coolant supply.

Side milling cutters range in diameter from 80 to 200 mm and have cutting widths of 3, 4, 5, 6 or 8 mm. As shell mills, the tools are available in diameters from 63 to 200 mm and with identical grooving widths. The screw-in cutters are for a groove width of 5 mm and are available in diameters from 40 to 63 mm as standard. The effective number of teeth of depends on tool diameter and ranges from two to 13. Special surface treatment of the tool body offers protection against abrasion from chips.

More information www.phorn.co.uk