Tooling specialist Walter GB says companies of every size can cash in on the benefits of high-dynamic milling, namely higher process reliability and faster, more cost-effective cutting by using higher speeds and feeds, as well as reduced ‘free travel’ of the milling cutter and longer tool life.

Indeed, compared with high-performance cutting (HPC), the advantages of high-dynamic cutting (HDC) can be realised when milling components of every size and in all materials, says the company.
The main differences between conventional HPC and HDC are in the movement of the cutter and the forces generated. During HPC milling, the tool takes relatively small depths of cut, while during HDC milling, the machine and its CADCAM functionality adapt the paths so that the tool delineates during machining to the shape of the workpiece and takes greater depths of cut.
Tool engagement angle is usually very large during HPC milling, so the process forces are accordingly high, which not only creates significant tool wear but places undue stress on the machine spindle. The tool engagement angle for HDC is normally small, so the forces which impact the tool and machine are much lower.
Higher cutting parameters, less free travel and increased process stability result in a much higher metal removal rate for HDC milling.The cornerstones of HDC are the tool, machine, CADCAM system and the workpiece – and the strategy is successful only when all four are in synchronisation.
For further information www.walter-tools.com

Dormer Pramet’s range of ProLog vending systems has been extended through the addition of three machines – SaveRing, SaveBin and SaveRent – giving even greater choice to suit individual customer requirements.

It is a known fact that tool inventory and management can be a costly and time-consuming process for any manufacturer. Having greater control over cutting-tool stock, availability, use and re-ordering, offers significant support and accountability.
When using ProLog vending systems, in addition to the standard check-in/check-out features, reports are available to provide detailed analysis of performance. Furthermore, users can automatically ‘age’ and lock-down tools based on specific criteria, set-up alert notifications when a tool has reached a defined setting, and access a full audit history by asset and user.
Dormer Pramet’s SupplyBay and SmartDrawer are its most popular vending devices. Enhancing its offer in this technology area, Dormer Pramet has launched three additional machines: SaveRing, SaveBin and SaveRent. All of these systems help companies to move away from peg-board or open-access methods.
SaveRing is a versatile vending machine which stores and distributes up to 540 unique items. The machine has four key functions to distribute, rent, return (for regrinding) or reserve products for up to 30 days. SaveRent is a locker-type tool renting and monitoring system that allows the storing, distribution and return of frequently used tools and items. Each transaction is saved and recorded when users access an item. With SaveBin employees return used or contaminated items, with the unit taking a photo of the product and logging the transaction to the employee. The system automatically produces an alert if waste levels reach a pre-defined number.
For further information www.dormerpramet.com

Introduced by Tungaloy is the company’s new TungForceFeed small diameter high-feed milling cutter. With a tool diameter range from 8 to 16 mm, the TungForceFeed caters for a diameter range smaller than the existing DoFeed series.

Aimed at the mould and die industry, and general machining applications, the TungForceFeed is available with both a high-feed insert and an R2 insert line that can be applied to machining a diverse range of materials, from alloy steel, stainless and hardened steels, through to cast iron, titanium alloys and heat resistant alloys such as Inconel and Hastelloy.
Tungaloy’s high-feed insert is suitable for general high-feed milling applications and subcontract machine shops, while the R2 insert designation is designed for full profiling and semi-roughing to semi-finishing processes. R2 inserts have a free-cutting geometry that eliminates chatter and improves surface finishes, along with a built-in wiper that reduces burr formation. Applying the latest PremiumTec coatings, the inserts are offered in Tungaloy’s AH3225 and AH8015 grades. The AH3225 incorporates a multi-layer nano coating that is said to optimise cutting-edge integrity and increase wear, fracture and oxidation resistance. AH8015 has a hard coating layer that improves performance on difficult to machine materials, reports Tungaloy.
Especially prominent in high-feed machining applications is the design of the toolholder, which is suitable for shoulder milling, slotting, ramping, plunging and helical feed drilling. The toolholder pockets are designed with a positive inclination that works in synergy with the thick corner inserts. Supporting this feature, the toolholders have a robust M2 screw that reduces screw neck shearing, which can be commonplace during high cutting force applications.
For further information www.tungaloy.com/uk

A solution has been developed by Mapal for producing the small connecting pin bore on automotive connecting rods.

The newly developed tool is suitable for wet or MQL machining operations, on transfer lines or machining centres.
Within automotive engines, connecting rods are highly stressed components. To take account of downsizing trends and the reduction of CO2 emissions, connecting rods are also becoming increasingly lighter. Indeed, the combination of high-strength materials and modern production processes has seen modern connecting rods change shape and dimension.
During the machining of connecting rods, the small connecting pin bore is a particular challenge. Depending on the geometry, there are completely different drilling situations that cater for the connecting rod’s forms, flats and conical/spherical surfaces. Especially for this type of machining, Mapal has developed a modular tool concept for drilling from solid with indexable inserts. The introduction of radially integrated, sintered indexable inserts – each with four cutting edges – can now be applied to such operations.
Mapal has designed the indexable inserts and chip spaces to meet the special requirements of the different drilling applications. The insert materials and composition have also been adapted. Among other things, the newly developed CVD coating is applied to combine the previously opposing high ductility and high wear resistance parameters. As a result, there now exists the potential to machine at significantly higher cutting speeds than before.
The tool body of the range is made from an optimised material that produces significantly less vibration. Furthermore, a central coolant supply in the holder ensures the optimum provision of coolant directly to the cutting edges.
For further information www.mapal.com

The DTM lightweight milling system has been expanded by Horn to include two newly developed versions.

DTM.CX09 arbour milling cutters are designed as roughing tools for use in applications that involve high cutting depths and place fewer demands on surface quality, while the DTM.CX09.AL.F face mill for finishing adds an adjustable body to the existing product range. Axial run-out can be adjusted to the exact micron using a presetter.
Tool holders feature an aluminium body with a low mass, resulting in reduced energy consumption during acceleration and deceleration. As the weight is less than that of a steel cutter, faster spindle speed changes can be achieved. There is also less wear on the spindle at high speeds as the cutter body features a protective hard coating to prevent damage caused by chip impact.
Diameters between 40 and 125 mm are offered by the arbour milling cutter bodies, which feature from four to eight effective cutting edges. All body versions feature an internal coolant supply. The system is used for milling up to a maximum cutting speed of 5,000 m/min. Inserts are available from stock in several diamond materials and a variety of geometries, making it possible to obtain a cost-effective alternative to brazed face mills. Chip-breaker geometries reduce chip volume and increase process reliability.
The inserts are available with a PCD or CVD-D coating. PCD grade PD75 is described as a useful all-rounder for aluminium machining. Horn recommends substrate PD70 for alloys with a high silicon content. The substrate HD08 (CVD-D) is used for highly abrasive materials. CVD-D consists of 99.9% diamond to maximise wear resistance. All material versions are available in a range of different geometries to suit the application.
For further information www.phorn.co.uk