FEATURE ON TOOLING

Horn unveils CBN cutting tools

Horn has expanded its product portfolio to include tools tipped with CBN for machining difficult materials such as superalloys and hardened steels. Ultra-hard CBN material is capable of smooth machining even during interrupted cutting when hard turning and grooving. By extending its existing standard ranges of Supermini 105, Mini 11P, 229 and 315 systems, Horn is able to deliver the CBN tools quickly from stock.

The Supermini system is available in left- and right-hand versions with different corner radii. Notably, the CBN-tipped variants are for internal machining from a diameter of 2 mm. Different lengths of solid-carbide body are available. Tools in the Mini family feature internal diameters from 6.8 mm and are available in left- and right-hand versions. The single-edged tool type 315 is for external grooving from a width of 0.5 mm. In the cutting insert system 229, the higher performance substrate CB 35 replaces the previous CBN substrate CB 50. Inserts are available with two different corner radii and cutting widths from 3 to 6 mm.

CBN is the second-hardest material after diamond. Tools made from CBN wear much more slowly than other cutting materials when used appropriately. It is consequently possible to achieve higher dimensional and profile accuracy, even when machining hard materials such as steel up to 70 HRc.

There are no different grades of CBN. Differentiation between tools is down to the CBN volume fraction, the fillers, grain size and the ceramic/metallic binder phase (cobalt/nickel), which results in different CBN substrates. Hard machining usually takes place without coolant, as these cutting materials have high heat resistance and the elevated temperature within the chip formation zone has a positive effect.
For further information www.phorn.co.uk

End mills ease hard-part micro-machining

Kyocera has launched of its 2KMB solid-carbide ball-nose end mill for high-hardness material processing and micro-machining. Used in the fine machining of precision parts and metallic moulds, this new solid-carbide round tool product is now available globally from Kyocera.

2KMB is the second product launch in Kyocera’s K-series solid-carbide line, which combines new coating technology with a proprietary shape for the effective micro-machining of various high-hardness materials such as alloy tool steel, stainless steel and high-speed steel (HSS).

Kyocera’s new wear-resistant coating, MegaCoat Hard Ex, features a special two-layer structure to ensure stable processing with high toughness and chipping resistance. The wear resistance and chipping resistance both contribute to higher quality and longer tool life. According to Kyocera, the coating facilitates long tool-life processing due to its superior oxidation resistance and wear resistance. Notably, the coating supports quenched hardened steel processing from tempered steel up to 70 HRc.

The newly developed S-shaped cutting edge with high levels of sharpness deliver a high-quality surface finish on the component and maintain wear resistance. Here, a wide core thickness increases tool rigidity, which prevents collapse and ensures stable processing. As another stand-out feature, point cutting (strong back taper) reduces collapse and prevents chattering, while the novel cutting edge shape gradually changes rake angle and clearance angle, compatible with high blade edge strength and low resistance.
For further information www.kyocera.co.uk

PCD line for high-speed milling

Tungaloy has introduced its TungRec DX110 series of PCD insert grades for high performance when machining aluminium alloy components. The Tungaloy TungRec milling range has been an established performer with its innovative tool bodies and insert geometries, but now this line is set to take aluminium machining to a new level with the new DX110 PCD insert grade.

Developed for the finish-machining of ISO N materials, the DX110 grade incorporates an ultrafine micro-grain structure that the company says provides outstanding surface finishes and component quality while also demonstrating exceptional cutting edge integrity. This ability to maintain edge sharpness over a prolonged period ensures that end users benefit from long tool life and extended periods of unmanned running, with the economic benefit of reduced insert consumption.

DX110 is first PCD solution incorporated into the TungRec line, offering existing TungRec users the facility to enhance aluminium machining capabilities with existing tool bodies. At present, the PCD inserts are available for TungRec 11 size tool holders, offering the facility for improving small diameter milling tools where vibration and excessive tool overhang are commonplace. Furthermore, the insert geometry and composition reduce cutting forces to generate a smooth cutting action that rapidly removes chips from the work area, while further reducing vibration and improving surface finishes.

Suitable for the machining of aluminium components in the aerospace, automotive and general subcontract sectors, the DX110 insert grade and TungRec tool holders for insert size 11 provide manufacturers with an indexable cutting tool solution from as small as 12 mm diameter. With tool diameter bodies extending up to 100 mm diameter, this new arrival to the TungRec range complements the existing TungSpeed-Mill PCD series, where the smallest diameter tool body is 50 mm.
For further information www.tungaloy.com

Turning tools switch up flexibility

Floyd Automatic Tooling has introduced the new Switch-Line series of interchangeable turning tools from Applitec. Developed to deliver fast, easy tool changeovers with precision, repeatability and consistency, the Switch-Line series is for use with standard tool platens on turning centres.

Applitec has created the new line in response to customers that require quick and easy insert and tool changeovers with accuracy and reliability, which derives from a new ‘face and taper’ location system that not only improves positioning and accuracy, but also stability and cutting performance. Furthermore, the design characteristics see the Switch-Line provide ease of use and affordability, reports Floyd Automatic.

The interchangeable heads are available for all Applitec insert lines, including the Top-Line, Turn-Line and ISO-Line. With the Top-Line catering for parting, grooving and intricate form machining applications, and the Turn-Line and ISO-Line meeting the diverse turning requirements of any machine shop, Floyd Automatic says that the new Switch-Line is now the product of choice for manufacturers looking to improve productivity and performance with the added benefit of reducing machine downtime and tool changeovers. With a comprehensive range of insert dimensions, geometries and coatings to suit all material and application types, the new Switch-Line will benefit any users of sliding-head turning centres.

To improve handling and tool changeovers, Applitec has developed the system with a single-screw release system that demonstrates ease of changeover. The programme also incorporates a range of cylindrical tool holders with interchangeable ER collet holders and HSK designations for quick tool changes, further expanding the flexibility of the series. In addition, the Switch-Line series allows for through-tool coolant and high-pressure coolant facility via the Applitec Jet-line or HEB Mini Plug system.
For further information www.floydautomatic.co.uk

Simplifying gripper configuration and integration

The task of configuring bespoke vacuum gripper systems that will meet the specific requirements of individual applications has never been easier thanks to the comprehensive digital configuration services now available from Schmalz. This range of digital services helps end users, machine builders and system integrators to achieve quick configuration of products such as Schmalz SLG lightweight gripping systems for individual applications. Tools such as filters, configurators, ordering aids and apps simplify the process – regardless of the stage of the project, whether it’s product design, procurement or operation.

A simple and highly intuitive six-stage process guides users through steps such as: selecting the workpiece; defining the application; selecting the type, number, size and positions of vacuum cups; and finally choosing a vacuum generator and robot mounting flange. The proposed SLG lightweight gripper then generates automatically and is shown in 3D on the basis of users input and responses to this series of intuitive choices.

At the end of the process, a summary of all of the information used to specify the gripper is available for download, together with valuable information for the end user or machine builder covering gripper dimensions, weights, air flow and gripping force.

Additional digital services available from Schmalz make it possible to simulate your handling process with a digital twin of the products selected, and test the function of the system long before it is actually built. For example, it is even possible to obtain information about the behaviour of a suction pad in its operational state. There are also a series of software and function modules that help integrate Schmalz products even more quickly into the end user’s process and control system.
For further information www.schmalz.com