Working closely with companies like Rolls-Royce, Collins Aerospace, Safran, Bombardier, ITP Aero, Marshall and Incora, Romford-based Xcel Aerospace is a subcontract manufacturer with an aerospace pedigree that few in the supply chain can match.

As part of its drive to ensure cost-effective manufacturing, the company recently invited tooling manufacturer Guhring to review the machining process on an aerospace valve component. The problem for Xcel was the cost efficiency of its existing Woodruff-type cutters when machining the cast aluminium component, which features 9% silicon content.
Only capable of completing 10 components before tool replacement, the abrasive aluminium was creating productivity, cost and surface finish issues for this aerospace expert.
“We explained to Xcel that Guhring has a new method of manufacturing PCD tools by printing them on a MarkForged Metal X 3D-printing machine,” says Guhring’s regional sales manager Dewar McKinlay. “We made a three-flute tool that was similar to the current tool but with brazed PCD tips. Despite the PCD tips lasting considerably longer on the abrasive high-silicon aluminium than the previous tool, we wanted to go further.”
The new design increased the number of cutting edges from three to five, allowing Xcel to increase the feed rate, while extending tool life.
“The previous solid-carbide tool was worn and required a changeover after 10 parts, but we have machined more than 180 parts with the new 3D-printed PCD Woodruff cutter and it is still performing well,” says McKinlay.
“Putting five cutting edges on a 21.7 mm diameter Woodruff tool with a solid-carbide body would create significant manufacturing challenges,” he adds. “The main benefit of printed tools is that we can produce multiple designs very quickly.”
For further information www.guhring.co.uk

The new Accure·tec vibration damping technology from tooling expert Walter GB ensures vibration-free and low-noise cutting in difficult-to-machine turning and milling applications using long – up to 10xD – tools.

These applications include the milling of components with deep cavities, as widely found throughout all sectors, and turning in the energy industry (oil industry valves, for instance), as well as aerospace landing gear.
Pre-set by Walter and delivered ready for use, the axially and radially positioned damping element allows turning operations up to 10xD with high process reliability and surface finish using, for example, A3000 boring bars.
Examples include H7 engineering tolerances and the counterboring of generator shafts to finishes of Rz 6.3. Moreover, the also new QuadFit quick-change heads enable rapid tool change to repeat accuracies of ±2 µm.
When milling, Accure·tec AC001 adaptors of up to 5xD can be applied with cutting data up to three times higher than with conventional tools, says Walter. The adaptors are particularly suited to Walter’s high-feed milling cutters, which exhibit their main cutting forces in the axial direction of the spindle.
Also promising longer tool life and higher productivity rates, Accure·tec AC001 (milling) and A3000 (turning) are supplied with all popular interfaces, including Walter Capto, HSK/HSK-T, SK, MAS-BT and parallel shank.
For further information www.walter-tools.com

Mapal has expanded its milling portfolio with the OptiMill SPM family of tools for processing aluminium and steel, which is available in two formats, the ‘Rough’ and ‘Finish’ series.

Optimised infeed machining depths, as well as the highest feeds during roughing, are possible with the OptiMill-SPM-Rough, reports Mapal. The reason for this performance is the novel knurled roughing geometry that ensures the power consumption during machining is significantly lower in comparison to tools with a straight cutting edge. Furthermore, heat introduction into the part is minimal due to the plunging characteristics of the tool.
The three-flute OptiMill-SPM-Rough is available with diameters of 12, 16, 20 and 25 mm, with corner radii of 2, 3 and 4 mm, to prolong tool life and prevent edge chipping during heavy-duty cutting. With a short flute length of 1.5xD and polished flutes, the OptiMill-SPM Rough has been designed for high material removal rates with vibration and cutting forces minimised due to the smooth cutting action of the tool.
For finishing contours and pocket walls, even at large depths in a single pass, Mapal has revealed the OptiMill-SPM-Finish. Mapal says this new end mill prevents swarf wrapping, even when operating in corners with enormous tool contact and high machining loads. Optimally designed cutting-edge geometry ensures there is no vibration during machining. The chip flutes are polished and, as a consequence, chip removal is optimal. Like the OptiMill-SPM-Rough, the new OptiMill-SPM-Finish is available in diameters from 12 to 25 mm, with imperial variants available upon request. The uncoated four-flute end mill is offered with corner radii from 2 to 4 mm and is first choice for aluminium machining.
In addition, Mapal is announcing the OptiMill-Uni-Wave as an extra-long version for roughing even in deep cavities. Availability is in diameters from 6 to 20 mm.
For further information www.mapal.com

Social media is currently ‘alight’ with UK engineers doing the country proud in meeting the ‘Ventilator Challenge UK’ demand to support the battle against COVID-19. Likewise, the supply chain is flying the flag for UK manufacturing with its response to keeping this critical infrastructure in motion.

Guhring UK, which is part of this supply chain, has stepped up to the plate with the critical supply of cutting tools. As a UK manufacturer with a factory floor space of over 60,000 sq ft, Guhring UK is holding in excess of £5m of standard cutting tool stock items. This stock is being directed to F1, aerospace and medical OEMs involved in the ‘Ventilator Challenge UK’, as well as the subcontract supply chain. In fact, with the impact of the pandemic on imports and the wider supply chain, Guhring UK is even delivering its products to recognised cutting-tool manufacturers and competitors that cannot meet the urgent demands of their customers.
Despite Guhring UK holding a plentiful stock of thousands of standard cutting-tool items for next-day delivery, it is the UK manufacture and coating of special tools that are really “saving the bacon” for pockets of the supply chain at such a critical time. One particular customer, Bellurgan Precision Engineering Ltd, based in Ireland, urgently required a three-step special drill for the production of ventilator components. Guhring stepped up to the mark by delivering within 48 hours.
Within that timeframe, Guhring UK had liaised with Bellurgan, designed and created a tool drawing that was subsequently approved, and then the race was on. The Guhring UK team immediately manufactured 16 identical cutters at its Birmingham headquarters and coated all tools in-house with its Signum coating technology before delivery to Bellurgan.
For further information www.guhring.co.uk

Sandvik Coromant has launched online application training to share knowledge and best practices for metal-cutting operations.

The eight-part programme has been released online and is accessible via the Sandvik Coromant website. Embarking on the programme, customers will develop theoretical and application-based knowledge in turning, milling, drilling and threading for both indexable and solid-carbide tools.
Communicated through pre-recorded presentations, the online training courses will provide customers with insights into the best practice strategies for machining. The programme includes specialist topic areas such as solid-carbide tools for drilling, milling and tapping, which is led by expert, Ben Lodge, solid round tools product specialist for north Europe at Sandvik Coromant. During the sessions, customers will learn the fundamentals for successful metal cutting, including the importance of process control and developing the correct machine set up.
A module on indexable drilling is led by Mikael Carlsson, indexable drilling and boring specialist for north Europe. Here, learners will develop an understanding of the vital process considerations for drilling deep holes and how to optimise chip formation for different drills and workpiece materials. A separate module on indexable milling is hosted by Barry Cahoon, indexable milling specialist for north Europe.
Lee Kendall, turning product specialist for north Europe, delivers modules on parting and grooving, thread turning and general turning, where learners can expect to develop new knowledge of different insert geometries and grades.
Each training module is approximately 30-minutes in length. As pre-recorded courses, the modules can be viewed at any time, allowing customers to complete the programme at their own pace.
For further information www.sandvik.coromant.com