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

The new MFF milling cutter augments the industrial tooling range offered by Kyocera in the field of finish-machining processes. Suitable for use on steel, stainless steel and cast iron workpieces, the cutter is available now.

A combination of semi-finishing and finishing inserts contributes to the efficiency provided by the MFF cutter. Years of know-how in developing and manufacturing tools has resulted in an innovative pressing method that yields robust inserts. The cutter’s wiper inserts are said to be especially suited to very high feed rates and the generation of outstanding surface qualities.

According to Kyocera, the strength of the MFF milling cutter come into its own on large components, such as construction parts made of construction steel, carbon steel or cast iron (grey and ductile iron). The robust cutter can even be used for hardened steel (up to 60 HRc) and stainless steel.
Typical problems such as vibration or scratches are avoided, principally through a combination of a sharp edge and patented Kyocera cermet technology dedicated for use as a substrate for inserts.

A new design of milling body allows the plates to be changed reliably, while time is saved thanks to the pre-set cartridge height of the MFF milling cutter; it is no longer necessary to readjust after changing a plate. The resulting precisely adjustable cutting-edge height improves handling and facilitates more reliable processes.

For further information www.kyocera.co.uk

In general terms, if the weight of PCD cutting tools is reduced, then significantly higher cutting data can be achieved. To realise the benefits of lightweight cutting tools, Mapal is now utilising additive manufacturing processes.

An example of how Mapal uses the advantages of 3D printing is realised in the company’s new bell tools with brazed PCD inserts, which are frequently used in the hydraulic and automotive sectors. The company has optimised the existing, conventionally manufactured bell tool by integrating selective laser melting (SLM) into its manufacturing processes. This move allows the inside of the cutting tool to be modified. So, instead of utilising tools with a heavy solid-material design, the new tools have been specially designed with a honeycomb structure. As a consequence, the tools are at least 30% lighter, while tool life is increased by upwards of 40% credit to the enhanced vibration damping characteristics of additively manufactured designs.

Customers using Mapal’s additively manufactured tools are said to be witnessing productivity improvements in the region of 50%. Additionally, Mapal experts are using the 3D-printing technology to optimise cooling channels, ensuring that cutting fluid is delivered to the work zone via the most efficient route.

The new bell tool is a hybrid design that can be specified by end users to meet their exact machining requirements. Using SLM, the new tool geometry is printed on a precision tool body with an HSK-63 connection. The additively manufactured tool body is subsequently machined to provide the platform for the PCD inserts to be brazed into place and then cut to shape using a laser.

For further information www.mapal.com