The Ceratizit Fullmax universal solid-carbide reamer is now available in a short version. Offering even greater stability, the Fullmax short variant allows for higher cutting speeds, with the added advantage of long service life and a lower price.

With its reduced length, the Fullmax solid-carbide reamer offers numerous advantages. Firstly, the tool is very stable and characterised by low vibration, resulting in up to 10% higher cutting speeds in the main application areas of steel and cast iron. Secondly, feed rates can increase by 10-20%.

This combination delivers machining times up to 20% faster.

In addition, there are better reaming results in terms of surface finish and dimensional accuracy, reports Ceratizit.

Like the universal standard Fullmax reamers, the short versions are characterised by their specialised coating and cutting edge pitch, which help to reduce chatter marks and improve chip formation. In detail, the unequal division, with cutting edges facing each other in pairs, leads to reduced deviations in circularity and cylinder shapes. The increased angle differences reduce the tendency for the tool to oscillate and form chatter marks.

Thanks to the flute-shape opening angle adapted to the new pitch, there is sufficient space for optimised chip removal, even on long-chipping materials. The targeted coolant supply provides further assistance. Although the Fullmax short-version reamer is suitable for deployment on all CNC milling and turning centres, its reduced dimensions make it particularly attractive for use on sliding-head lathes.

The short series Fullmax is available from stock in H7 tolerance and 1/100 mm increments. Dimensions are individually configurable in the diameter range from 2.96 to 20.05 mm.

For further information
www.ceratizit.com

Walter has expanded its D4120 drilling line to introduce 2xD, 3xD, 4xD and 5xD dimensions, therefore superseding the B4000 Series Xtra.tec insert drills.

Regarded as a flexible all-rounder, the extended D4120 indexable insert solid drill line is available in a range of diameters that span from 13.5 to 59 mm. The product expansion now incorporates the D4120-02 2xD and D4120-03 3xD drills for creating holes from 13.5 to 41.3 mm diameter, as well as the D4120-04 and D4120-05 4xD and 5xD drills for holes from 17 to 59 mm diameter.

The drills feature outer and centre inserts that ensure precision balancing of the cutting forces to maximise productivity. To this end, the centre insert is slightly larger than the outer indexable inserts, which are equipped with a corner protection chamfer. As well as providing greater process reliability, this design plays a crucial part in increasing precision levels, stability and reducing drilling noise. Adding to process reliability is a hardened and polished drill body design that offers increased protection against friction in operation, and an improved coolant channel design that allows the flow of 25% more coolant than previous drills.

Walter is also now offering inserts with a wiper edge for high-quality surface finishes. The drill body features two through coolant channels and a measuring collar for easy drill identification, even when assembled. Polished flutes and a hardened surface further optimise chip evacuation and wear resistance.

The combination of the D4120 drill body and the four-edged indexable inserts offers users cost-efficiency advantages and high levels of flexibility thanks to a co-ordinated system.

For further information
www.walter-tools.com

Ceratizit has introduced its PCD MaxiMill SEC12 face-milling cutter to target the machining of crankcases, cylinder heads and other automotive-related components made from aluminium and non-ferrous metals, the interiors of which must remain chip-free. Key to the success of the MaxiMill SEC12 is the design of the insert seat and cutting-insert topology, supported by the coolant pressure, which together create a suction effect that at high speed clears virtually 100% of chips from the workpiece.

Anyone working in engine manufacture will be familiar with this problem: during the conventional face milling of crankcases and cylinder heads, chips fall into the water chambers and get stuck there to such an extent that complete removal by automated washing processes is difficult. Instead, the chips must be removed manually, which involves additional time and costs. And if chips remain, there may be a need to scrap an expensive component.

The new PCD MaxiMill SEC12 (Suction Effect Cutter with 12 mm insert size) eliminates this problem, saving time and cost. Thanks to cutting inserts with a ground-in chip-removal notch and their novel positioning in the body of the milling cutter, the tool develops a suction effect that clears chips away from the part. In addition, the working angle from the flat surface is approximately 30°, which means that hardly a single chip can enter the interior of the component. Coolant flow at the optimum pressure further enhances chip evacuation.

Ceratizit’s MaxiMill SEC12 offers numerous other advantages. One of the most important is its modular design (made entirely of standard components), which enables individual versions to be created for any requirement. The milling cutter consists of a milling adapter in HSK-A63, -A80 or -A100 design, which holds the base body of the face mill.

For further information
www.ceratizit.com

Guhring is extending its Diver series of end mills for the micro-machining sector. Coined by the company as the ‘smallest diver in the world’, the new RF100 Micro Diver end mills machine small components of any material.

Providing plunging and milling in a single tool, Guhring says that the RF100 Micro Diver permits very high cutting depths that until now, were beyond the realms of micro-precision cutting tools. Available in two variants, the 6808 and 6809, the RF100 Micro Diver features a symmetrical drilling face for stability when ramping and drilling, a new transition geometry to improve rigidity, and a novel flute form that further enhances rigidity and eliminates vibration.

The RF100 Micro Diver 6808 series is a three-flute solid-carbide end mill suitable for cutting materials up to 48 HRc at depths up to 2.5xD. With a 40° helix angle to evacuate chips from the work area when conducting high-speed machining, the 6808 series is available with a H5 4 or 6 mm shank diameter and a H8 cutting diameter from 0.79 to 3.175 mm (with a multitude of dimensional increments available).

For the machining of pockets and slots up to 5xD, manufacturers can select the longer 6809 series, which offers an overall tool length from 45 to 57.15 mm with a 5.00 to 15.87 mm cutting length.

From a tool life perspective, both end mills have an optimised geometry that adds strength and rigidity, while Guhring says that its new HIPIMS Durox coating enables end users to achieve a very high surface finish with optimal chip-removal rates.

For further information
www.guhring.co.uk

With the recent pandemic forcing more businesses to look at their costs, Floyd Automatic Tooling has given a UK launch to the MicroTurn eLine of boring tools from Ifanger. The MicroTurn eLine MTEE is an optimised universal boring tool that is 25% less expensive than Ifanger’s existing MTEC or MTEN tools.

Available as a right-handed boring tool in seven variants, the universal inserts are suitable for small-bore machining starting from 1.80 mm diameter. With the new eLine MTEE, the series incorporates a positive-cut 8° rake angle and a short neck length for rigidity and stability.

From a dimensional perspective, the MTEE line is available with a 4 or 6 mm diameter shank, and an overall length of 31 or 43 mm. Neck lengths range from 5 to 19.5 mm, while corner radii extend from 0.05 to 0.15 mm. MTEE-series inserts are currently available uncoated, which retains edge sharpness and precision when machining certain materials, and with a TiALN coating.

Complementing the MTEE line is the classic series of Ifanger boring inserts that incorporates the MTEC, MTEN, MTKE and MTKH boring and copying tools. For profiling applications, Ifanger has a diverse range of geometries and coatings to support manufacturers with all their threading, grooving, chamfering and axial plunging requirements.

Although the new MTEE line caters for the majority of small boring applications with the most commonly-used dimension ranges initially available, Floyd Automatic Tooling and Ifanger can customise this extensive range upon demand.

For further information
www.floydautomatic.co.uk