Railway-focused cutting tools can often be complex due to the specific requirement needed to machine a certain component in an efficient and reliable manner. Therefore, across many applications, the majority of cutting tools for the railway industry are classed as specials. However, there are several tools available within Dormer Pramet’s standard assortment that are suitable for the production of various railway components.

The company’s Penta HD and Econ HN, for example, are milling tools from the Pramet indexable range for applications that include the machining of switches, base plates and wagon parts, such as frames, wheel axles and bogies.

When machining switches, one of the first operations is roughing the top and bottom sections of the rail. This requires a large diameter cutter, enabling the fewest number of passes possible. Both the Penta HD and Econ HN assortments have indexable cutters up to 315 mm diameter.

Dormer Pramet developed the Penta HD milling cutter specifically with switch machining in mind. Offering up to 10 mm depth of cut and a feed rate of 0.7 mm per tooth, the range enables high metal removal rates and productivity.

Another railway operation that can benefit from the use of standard tools is the machining of base plates – the connecting element which attaches the rail to the tie or sleeper. When machining the bottom part of base plates, for example, face milling cutters with diameters up to 160 mm are often used. The Pramet Econ HN assortment offers a 45° face milling cutter, which is available from 25-315 mm in diameter and includes HNGX 06 and HNGX 09 inserts.

For further information
www.dormerpramet.com

To better provide technical support in the COVID-19 era, Ceratizit has introduced its LiveTechPro app. The app offers immediate visual support to deliver technical assistance in the event of machining issues, or simply to help optimise processes. LiveTechPro features a live, bi-directional video and audio connection between the customer’s machine operator/production engineer and the technical support team from Ceratizit. The app offers a reliable service that users can activate within seconds to ensure production continues to run smoothly.

“Although our success has been built on the direct technical support that our engineers give on site – and we would always want to work this way as a first choice – we are operating in extraordinary times and ongoing support for customers remains our main priority,” says Tony Pennington, managing director, Ceratizit UK & Ireland. “The LiveTechPro app is the next best thing to a physical visit, allowing our team to provide that support remotely.”

The technology involved with LiveTechPro will enable detailed discussions to take place as if a Ceratizit engineer was on-site. Specific issues or elements of a component can be highlighted on screen, downloaded if necessary for detailed discussion, with responses and solutions being provided there and then in terms of technical advice.

LiveTechPro allows for multiple levels of operation via smartphone or tablet, with conventional video being the starting point. However, the app is also compatible with virtual reality technology to take support to the next level. LiveTechPro is available for iPhone and Android operating systems.

For further information
www.ceratizit.com

Kennametal has introduced a new line of PCD round tools for aluminium machining that the company says delivers up to 10 times higher productivity than carbide tooling. The company says that its new line of drills, reamers and end mills provides long tool life and high wear resistance, even in very abrasive aluminium alloys, and is available on very short lead times.

“Our new PCD round tools line enables customers to machine aluminium significantly faster, for greater productivity on the shop floor,” says Michael Hacker, product manager. “In drilling and reaming operations, these tools perform consistently at cutting speeds of up to 900 m/min. Milling operations can be performed at 6000 m/min, far higher than non-PCD tooling.”

With through-the-tool coolant capabilities and an MQL-ready interface, these PCD round tools are suitable for both rough and finish machining.

Extremely sharp cutting edges and low-friction rake surfaces eliminate concerns over built-up-edge. Low-friction machining also produces superior surfaces in finishing operations, such as reaming. Surface roughness of Ra 0.1-0.8 μm is achievable.

PCD grade KD21 / 2810 assures extended tool life and is particularly beneficial in the high-silicon content aluminium used to make automotive parts like engine blocks or cylinder heads.

Kennametal’s latest line of PCD end mills includes 6 to 50 mm diameter tools for cutting depths up to 50 mm. Centre-cutting, roughing and finishing geometries are available in various rake angles. The PCD drill offering encompasses 6 to 20 mm diameter tools in 0.5 mm increments for cutting depths of up to 5xD. Kennametal’s PCD reaming portfolio includes 6 to 20 mm diameter tools in 1 mm increments. Through- and blind-hole versions are available. For larger diameters up to 42 mm, Kennametal offers the PCD modular reaming system with KST coupling.

For further information
www.kennametal.com

Paul Horn GmbH is expanding its 220 cartridge system to cover virtually every grooving insert type in the company’s portfolio. It is possible to clamp all cartridges directly and quickly in universal holders – and the system’s T-shaped interface offers stability and a high level of precision during cartridge exchange.

All variants feature an interface between the holder and cartridge for an internal coolant supply. The jet emerges from the clamping finger and support to target coolant directly at the point of cutting. If required, users can close off the upper opening of the coolant supply with a screw.
Horn offers radial grooving cartridges for the following insert types: S100, S224, S229, S274, 34T, 312, S315, S316 and the S64T six-edged grooving insert. For axial grooving, the cartridges suit the S25, S224 and S229 systems.

The versatile system supports a large number of groove widths, groove depths and parting-off operations, as well as substrates and coatings tailored to the workpiece material. Users can select the holders according to the type of machine interface. Horn offers the holders in square or round shank, as well as TS, HSK and polygon interface versions.

According to Horn, the modularity of the tool systems plays a vital role in enabling the flexible and productive use of tools when turning small and medium batches of components. The aim is to reduce set-up times significantly during tool change, thereby making the lathe more efficient. Horn’s system is suitable for use on all types of turning machine, from single-spindle lathes to multi-spindle autos.

For further information
www.phorn.co.uk

Following the introduction of its newly developed IG3I substrate, Horn is optimising its DS solid-carbide end mills to enable productive, cost-effective machining of titanium and its alloys. By combining the novel carbide grade with a new coating, the tool specialist says it has been able to increase cutter life significantly.

Sharp micro-geometry on the cutting edges, positive rake angles, large clearance angles and polished flutes prevent strain hardening of the workpiece and built-up edges on the rake faces of the mill when machining titanium. In addition, variable helix angles and different tooth pitches ensure quiet, low-vibration milling.

Despite the sharp cutting edges, the new coating demonstrates high layer adhesion, ensuring good edge stability. Thanks to its high temperature resistance, the coating serves as a heat shield and reduces the amount of heat transferred to the carbide, which demonstrates homogeneous wear.

The effective length is two or three times the diameter. DS titanium milling cutters were developed based on tried-and-tested solid-carbide milling cutters in the DS system, which for years have been used to machine soft and hardened steels, chromium-nickel steels and super alloys, as well as copper, aluminium, plastics and fibre-reinforced plastics. The end mills are available in diameters from 2 to 20 mm as standard, with four or five flutes.

For further information www.phorn.co.uk