Horn has introduced two high-performance coatings, IG6 and SG3, for the carbide inserts it manufactures for turning applications. Despite being less than 0.005 mm thick, such coatings can extend service life by a factor of 10 or more compared with uncoated inserts.

IG6 is a copper-coloured, aluminium-titanium-silicon nitride (AlTiSiN) coating for machining steels in groups P and M with Horn’s S224 and S229 grooving systems. In conjunction with the adapted carbide substrate, the coating allows faster material removal rates and significantly extended service life. Standard inserts are available from stock, while for special designs, Horn Greenline orders can be delivered within five working days of the customer signing off on the drawing.

Horn’s SG3 coating is for machining titanium alloys and superalloys, as well as for hard turning and hard grooving applications, and can withstand temperatures of up to 1100°C. Now that the advantages of the tool coating have been proven on selected Horn tool systems, the 105 Supermini grooving and boring system products are available from stock.

Over the past 15 years, Horn has developed a high level of expertise in the coating of precision tools, starting with five employees and one coating system and growing to over 50 employees working across 14 coating systems. Engineers are constantly researching and developing new and existing coatings with the aim of delivering ever higher performance. Horn continually invests in new, modern technologies. In 2015, CemeCon delivered to Horn the first of three HiPIMS (high power impulse magnetron sputtering) systems, which was the first in the world. The technology enables the formation of coatings that are very dense and compact, as well as extremely hard and tough.

For further information
www.phorn.co.uk

The machining of challenging materials is now simpler thanks to the expansion of the Union Tool range of CZS cutting tools. Available in the UK from Rainford Precision, the series of solid-carbide end mills from Union now covers new diameters. The range is currently available with a time-limited 50% discount (until end of January).

Union CZS end mills incorporate a geometry design that combines with a micro-grain carbide substrate and a tough UT coating to provide manufacturers with high performance levels. CZS end mills are suitable for machining everything from carbon, alloy and pre-hardened steels to 55 HRc, as well as aluminium, titanium, heat resistant alloys, copper and cast iron, making the CZS a high performing all-rounder on most types of engineering materials.

The new CZS end mills have a 40° high-helix angle for swarf evacuation that combines with a variable pitch helix which reduces harmonic effects and vibration when undertaking high-speed milling tasks. With a flat land as part of the patented tip geometry, the CZS series is suitable for drilling, milling, side milling, slotting, pocketing and trochoidal cutting operations, reducing the requirement for multiple cutting tools and excessive inventory. Furthermore, the edge geometry and high-quality carbide grade make the CZS suitable for vertical milling with high resistance to edge chipping, while the low-friction coating enhances chip evacuation and improves wear resistance.

The four-flute square end tools cover new diameter ranges that make the series available from 1 to 6 mm diameter in 0.1 mm increments, and 6 to 12 mm in 0.5mm increments. Rainford reports that 13, 16 and 20 mm diameter end mills are also available.

For further information
www.rainfordprecision.com

Kennametal has released its FIX8 heavy-duty turning system, delivering maximum metal removal rates in steel, stainless steel and cast iron. With eight cutting edges per insert, the FIX8 turning system increases productivity of any heavy-duty turning operation, providing low cost per edge while reducing cutting forces by up to 15%.

“From medium depths-of-cut to roughing in steels, cast iron and challenging materials like stainless steel, FIX8 handles it all,” says Matthew Fuerst, product manager at Kennametal. “Even extreme feed rates of up to 1.4 mm and depths-of-cut up to 12 mm are possible.”

The tangential design of the FIX8 insert features a rigid clamping system that pulls the insert securely into the pocket seat, offering high stability that enables the insert to withstand large cutting forces and vibrations for optimal performance. Importantly, the insert is also supported by a replaceable carbide shim, protecting the pocket against deformation and damage.

Kennametal says that the FIX8 tool holder features precision 3D coolant technology, supplying sufficient cutting fluid precisely where needed. Three coolant nozzles are directed to the rake face, controlling temperature, chip evacuation and supporting chip formation. Coolant exit holes in two different locations are directed toward the flank of the insert, controlling heat in the cutting zone and prolonging tool life.

FIX8 provides chip control for any heavy-duty turning application while increasing tool life, says the company. The insert design reduces cutting forces and power consumption, making it suitable for any low-power lathe.

For further information
www.kennametal.com

For the finish-turning of HRSA materials, NTK Cutting Tools has introduced its JP0 Bidemics range of inserts. Suitable for machining HRSA materials at speeds up to 480 m/min, the JP0 is the latest addition to the NTK range of Bidemics, a material that the company says can greatly improve productivity for aerospace manufacturers which are regularly cutting challenging materials.

Capable of machining at cutting speeds up to 15 times faster than carbide and CBN alternatives, the NTK JP0 demonstrates high wear resistance and consistency. The new JP0 insert grade is suitable for running at cutting speeds from 180 to 500 m/min, with a feed rate of 0.05 to 0.2 mm/rev, and a depth of cut from 0.1 to 0.7 mm.

Currently, NTK has introduced the new high-performance finish turning grade in three different designations: the CNGA, DNGA and VNGA geometries. The 4.76 mm thick CNGA and DNGA inserts are available with a 0.4, 0.8 or 1.2 mm corner radius, and an IC of 12.7 mm. NTK’s VNGA insert designation is available with a 0.4 or 0.8 mm corner radius, and a 9.525 mm IC. The company says that all three designations demonstrate outstanding quality with the 0.04 mm honed edge preparation.

NTK recommends that when turning HRSAs and other extremely challenging material types, manufacturers should utilise button inserts from the Bidemics, Whisker and SiAlON series for heavy-duty roughing, followed by the NTK SiAlON range for semi-finish passes and the new JP0 for finishing with a constant depth of cut.

For further information
www.ntkcuttingtools.co.uk

Widia is releasing the M1600 face mill for roughing to semi-finishing operations in steel, stainless steel, cast iron and nodular iron materials. With 16 cutting edges and a novel insert design, the M1600 performs in various machining conditions, including low-power machines, unstable set ups, long overhangs, weak machines or weak fixtures.

The precision-ground insert with a positive geometry enables low cutting forces and low power consumption, resulting in higher tool life and low cost per edge. Widia’s M1600 has one universal insert geometry in three versatile grades: WP35CM, WK15CM and WU20PM.

The WP35CM grade targets all types of steels, while the WK15CM grade is for cast-iron materials and performs best in dry applications, but can also be used wet. The universal WU20PM grade is for the machining of steel, stainless steel and high-temperature alloys in both dry and wet applications.

Notably, the ‘smart’ insert design features a seating surface below the cutting edge that promotes smooth chip flow and reduces cutting forces on the tool. The insert also has a curved cutting edge and is axially positive, resulting in reduced power consumption. These key design features, coupled with 16 cutting edges, make M1600 an economical face milling option.

M1600 face mills are available in six metric diameter ranges between 50 and 160 mm. Inch diameters will follow shortly. Orders for the M1600 bodies and inserts, as well as other Widia tooling, can be placed through Widia’s authorised distribution partners.

For further information
www.widia.com