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

Widia Novo – the digital process planning system – has been enhanced with newly designed elements to enrich content and continue streamlining machine shop processes.

Availability in the UK is via Industrial Tooling Corporation (ITC). Among many capabilities, Widia Novo technology can supply a quick turnaround quote on modified standards of solid drills. Recently added to the Novo platform is the quoting of modified drill sizes, and an improved search engine and channel connections.
“Novo can supply a quick turnaround [in minutes] quote on solid drills modified against the standard option,” says Katie Richardson, Novo director of program management. “We’re continually adding new internal support systems that make finding the right tool even easier. Just tell us what you’re looking for and Novo can quote it, with expected delivery – fast.
“The search engine is always being fine-tuned for improvements,” she adds. “We took the ranking function of ‘Novo Advise’ and applied it to our product search so that the system can now rank the hundreds of turning inserts that fit your tool holder by performance and value. Machine shops can quickly choose the most effective tooling package based on performance, availability, price or whatever parameters they choose.”
Tens of thousands of tools are combined on Novo with 90 years of process knowledge into a cloud-enabled digital knowledge stream that interfaces with CAM packages, pre-setters and a growing number of technology providers. Responding to user questions, Novo defines machining sequences, selects and ranks the best tools, builds tool assemblies, downloads CAD models for simulations and process planning, and obtains application parameters that include speed/feed recommendations and inventory availability – all in minutes.
Recommendations for tooling can be further optimised for a customer’s specific machines and conditions.
For further information www.itc-ltd.co.uk

Rigibore says that an engine manufacturer has gained total control over its boring processes thanks to the introduction of the company’s automated boring tool compensation system, Zenith.

The system was selected for its ability to make compensations automatically from measurement data to an accuracy of 1 µm on diameter. Maintaining much closer machining tolerances on crankshaft bearing journals not only enhances the quality of the finished component, but has a direct impact on engine efficiency and emissions.
The concept was to produce line boring bars with five semi-finish cartridges set 0.1 mm below nominal, thus allowing five ActiveEdge finish cartridges to machine all journals in a single pass. ActiveEdge line bars were automatically compensated to nominal from data provided by offline gauging that was transferred to the machine control as part of the Zenith closed-loop system.
Before installing ActiveEdge tools, the customer carried out verification checks to confirm that each cartridge could be adjusted independently in increments of 0.001 mm on diameter. With this ability confirmed, an extended live cutting trial was instigated. The trial took place on a twin-spindle machining centre, with each spindle machining 946 crankshaft bores over a 24-hour period, so 1892 in total. In this time, not a single bore was out of tolerance thanks to ActiveEdge’s intervention. The finished bores had a mean diameter of 52.965 mm with a tolerance of ±0.015 mm. During the test period, bore sizes were maintained within a variance of just 2 µm.
Prior to installing the tooling, the process of ensuring nominal size before the production run took 45 minutes on average. In contrast, Zenith allows automatic, individual cutting edge compensations to be made with the tool located anywhere in the machine, completing the setting process after an insert change within a matter of minutes.
For further information www.rigibore.com