Kyocera Corporation has developed a new parting-off solution, denoted KGZ, for small component machining. KGZ uses a new clamp structure with three proprietary mechanisms to lock the insert in place, suppress chatter and achieve stable machining. In addition, the constraint surface of the holder has a shape that distributes stress, improves durability and realises high-efficiency machining.

Within the insert grade’s line-up, a newly developed PVD-coated grade known as the PR 20 is also available for the KGZ. The new coating, MegaCoat 1 Nano EX, which is resistant to oxidation and abrasion, achieves high precision, long tool life and stable machining when parting-off steel, stainless steel and cast-iron workpieces.

Notably, the new KGZ design improves the holding force of the insert and the durability of the tool holder through three proprietary mechanisms: gap section, top clamp and stopper.

With the gap section, users can simply press down on the insert from directly above to firmly secure it in place. Generally, it is structurally difficult to fix the insert directly above with a parting-off tool. KGZ has a tapered slit with a slanted cut, so when tightening the fastening screw it applies a restraining force from directly above the insert, securing it in place.

The top clamp serves to pull the insert inward and increase the binding force. Designing the shape so that force is applied inward when clamping the insert suppresses the displacement of the insert in the front and rear directions.

Kyocera’s stopper disperses stress over a large area and improves the durability of the holder. According to the company, this design reduces the amount of stopper wear to about one-third of that of competitor products.

More information www.kyocera-unimerco.com

With star-shaped hexalobular bone screws (TORX) proving the design of choice in the medical industry, Floyd Automatic Tooling is introducing the UK market to CrazyDrill Hexalobe drills and CrazyMill Hexalobe end mills from Mikron Tool.

Medical screws for orthopaedic procedures are predominantly manufactured from titanium, stainless steel and cobalt-chrome. Machining these precision screws to impeccable surface finishes is a challenging task – that was until the arrival of the Mikron Hexalobe series. According to Floyd Automatic, machining hexalobe screws 50% faster with precision burr-free results is what makes this next-generation series the first choice for manufacturers in the medical sector.

These high-performance drills for generating pre-holes in TORX sockets are available in two variants: the pre-hole CrazyDrill Hexalobe TORX drill with a tip angle of 140°, and the CrazyDrill Hexalobe Flat drill with a tip angle of 180°. Both are available from 0.9 to 3.8 mm in diameter for producing T4 to T30 TORX sockets. Upon request, Floyd Automatic can provide the drills as a customised combination drill for streamlining operations. The CrazyDrill Hexalobe series combines two operations into one, as it simultaneously machines a flat pre-hole and a 120° chamfer.

The Mikron CrazyDrill Hexalobe from Floyd Automatic generates chamfer surface quality to a finish of Ra<0.3 µm while guaranteeing high profile accuracy and perpendicularity.

Completing the process is the CrazyMill Hexalobe micro end mill. Available from 0.2 to 1 mm diameter for T4 to T30 socket variants, the CrazyMill Hexalobe presents three- or four-flute variants with milling depths of 3.5xD and 5xD. The CrazyMill Hexalobe milling cutter demonstrates sufficient stiffness for machining with high feeds and stepover rates, while guaranteeing the necessary hex lobular profile accuracy.

More information www.floydautomatic.co.uk

Paul Horn, the solid-carbide tooling, carbide insert and tool-holder manufacturer has supplied more than 200,000 special tooling solutions over the years and currently offers 25,000 standard products, including five that were introduced to the UK market at the recent MACH 2024 exhibition in Birmingham, UK.

For instance, an addition to the Horn Supermini boring, grooving and chamfering system was announced, namely a variant with a precision-ground rake face for producing ultra-fine bores. The ground cutting edge is free from notches at a magnification of x200 and the tool is suitable for machining components with an inside diameter from just 0.3 mm. Sharp insert geometry ensures process reliability, even with very small infeed and cutting feed rates. The special coating is suitable for stainless steels, non-ferrous metals and other metals.

Notably, the Supermini Type 105 system insert requires only one tool holder for well over 1000 insert variants, which applies equally to left-hand and right-hand versions. Carbide inserts are available coated or uncoated in various grades for a variety of applications, including hard machining up to 66 HRc. The patented, droplet-shape cross section has a vibration-damping effect and delivers high repeatability during insert exchange. Internal coolant supply to the insert increases tool life, enhances cutting performance and improves chip removal. Horn offers the tools with face clamping elements that allow easy changing of the insert without removing the holder from the machine.

Horn has also developed a new solid-carbide milling cutter range for machining stainless steels used widely in the watchmaking and other precision engineering industries. Due to their geometry and efficient chip breaking, the mills are also suitable for machining numerous other materials.

More information www.phorn.co.uk