FEATURE ON TOOLING

Floyd showcases latest product lines

The distinctive orange stand of Floyd Automatic Tooling was back at the MACH exhibition last week with yet more tooling innovations and accessories, including the Masa Microconic sub-spindle collets. Microconic consists of a cartridge and precision collet. Importantly, no machine adaptations are required: the collet fits inside the cartridge and is adjusted before being fitted directly into the existing collet sleeve.

With a concentricity level of between 3 to 5 µm, Microconic is suitable for sliding-head lathe marques that include Tornos, Citizen and Star. The system is currently available for F20 and F25 style collets, with F37 versions in development. A 5C version can also be offered.
For components to be permanently marked, Floyd Automatic also introduced the latest Hommel+Keller brand of Zeus marking systems at the show. Zeus marking tools from Hommel+Keller GmbH can be integrated into a production process on all standard turning and machining centres, meaning the end of manual re-tooling on separate machines.
Also making a debut at MACH was the enhanced FLO-Tool Triple back-working holders and the Schwanog Form tool programme for users of turning centres and sliding-head lathes. Furthermore, Floyd introduced a full range of milling tools and the Nutex slotting tools from Alesa of Switzerland.
For users of tool and cutter grinders like Anca, Walter, Schneeburger, Studer, Strausak and Vollmer, exhibition visitors were able to see the latest range of Schaublin work-holding solutions. Innovations for these machines included the SRS runout adjustment system and the recently launched cartridge system with interchangeable adaptors.
For further information www.floydautomatic.co.uk

Y-axis parting aids stability

Sandvik Coromant has unveiled a new blade for its CoroCut QD parting-off system, which in combination with new process methodology, improves the tool’s stability by realigning the resultant cutting force. Among the benefits said to be available are improved productivity, enhanced surface quality and reduced noise levels.

In conventional parting-off tool configurations, the capability of feed motion in the XZ plane is an inherent limitation. When performing parting operations, the resultant vector of cutting forces is inevitably directed sharply across the tool’s cross-section, leading to high loads and potential deformation.
As a remedy for the situation, Sandvik Coromant has developed a solution that takes advantage of capability in modern turning centres and multi-task machines to feed the tool in the Y direction. In the new concept, the top face of the insert is placed parallel to the end of the blade, as if rotating the insert seat 90° anti-clockwise. The new blade cuts its way into the workpiece with its front end, which roughly aligns the resultant vector of cutting forces with the longitudinal axis of the blade. FEM analysis confirms that this process eliminates the critical stresses typical to conventional blades and increases blade stiffness by six times compared with standard designs. With enhanced stiffness, customers can increase feed rates or use a longer overhang without losing stability.
The new CoroCut QD blades come in widths of 3 and 4 mm. Standard length versions (in both 3 and 4 mm widths) are offered for parting up to 120 mm diameter, as well as an extra-long 4 mm wide blade for parting up to 180 mm diameter.
For further information www.sandvik.coromant.com

Drills offer 140% more life

A re-engineered drill range from Seco Tools is said to increase tool life by 140%. The company’s Perfomax indexable-insert drills feature a new flute design with special anti-friction surfaces and laser-hardened fronts (60 HRc) that provide added strength, stability and accuracy.

Furthermore, the flutes have larger helixes, centre chip areas and smoother chip-flute exits, while an engineered wave pattern helps minimise contact between chips and flute surfaces. The new design also features a larger radius at the bottom of the drills’ insert pockets for extra rigidity.
Ultimately, Perfomax drills generate shorter chips that can be evacuated quickly and thereby reduce the risk of chip jamming’ which, if left unchecked, can damage the workpiece and have a negative impact on process security.
Seco’s DS2050 and DS4050 insert grades, which are recommended for use with the new Perfomax drills, are suited to drilling heat-resistant materials like titanium and titanium alloys. These grades, with their recently developed free-cutting MP and MC geometries, help increase productivity and extend insert life, says the company.
Perfomax drill bodies are available in a range of diameters from 15 to 59 mm, and in length to diameter ratios of 2xD, 3xD, 4xD and 5xD. Compatibility is offered with most spindle interfaces.
For further information www.secotools.com

Milling inserts come in seven grades

AMXT inserts with a choice of seven substrate grades and three chip-breaker geometries have been developed by Sumitomo Electric Hardmetal to meet specific demands where lower powered machines or less stable application conditions are encountered. Each insert has a high rake featuring a curved wave form to the cutting edge. With greater insert width, this design creates a more stable seating to support the cutting action.

The seven grades: ACP100, 200 and 300; ACK200 and 300; and ACM 200 and 300, can cut to depths of up to 5 mm. ACP100 has the latest Sumitomo ‘FF’ CVD coating, giving wear and thermal resistance in the high-speed and light cutting of steel. Sumitomo’s ACP200 uses the company’s ‘Super ZX’ PVD coating on a carbide substrate, which is said to enable milling 1.5 times faster than conventional inserts. ACP300 also has Super ZX coating and is designed for use under more arduous roughing applications.
ACK200 grade with its ‘Super FF’ CVD coating is for use in general machining tasks (including interrupted cuts) involving grey and ductile cast irons. ACK300, which is coated with Super ZX, provides a solution able to generate even greater levels of productivity.
Sumitomo’s ACM200 is coated with Super FF to provide high orders of wear resistance when machining PH stainless steels, while ACM300 is first choice (with its Super ZX coating) when balanced wear and fracture resistance is required.
The AXMT inserts can be paired with Sumitomo’s new WEX Type 1000 cutter bodies for 90º shoulder-milling applications. In fact, pocketing, helical boring, slotting, shoulder milling and ramping cycles can be carried out with the same tool, says the company.
For further information www.sumitomotool.com

Latest grade suits heat-resistant alloys

The AH8000 insert series, which has been developed as part of the TungTurn line from Tungaloy, is said to demonstrate high performance levels when machining heat-resistant alloys. Extended tool life is credited to the composition of the grade, which incorporates newly developed substrates, a multi-layered nano AlTiN coating with a high Al content and Tungaloy’s proprietary PremiumTec surface technology.

Tungaloy says that these characteristics result in an insert grade that is at least 20% harder than alternate grades. In addition, the bonding of the substrate prevents notch wear and further extends performance parameters when machining heat-resistant alloys. Under test conditions on a variety of Inconel, titanium and other aerospace alloys, Tungaloy reports that the AH8000 more than quadrupled tool life while reducing machining times.
Included in the AH8000 series is the AH8005 grade for continuous machining at higher spindle speeds, and the AH8015 grade, which is said to be extremely hard and durable for interrupted cutting applications. As well as the two grade options, Tungaloy has developed its HRM chip-breaker for finish to medium cutting, and the HRF breaker for finish-turning operations. Adding to these negative insert chip breakers, Tungaloy has also launched a positive insert line with PSF, PSS and PS chip breakers.
The AH8000 series includes a 35, 55 and 80° rhombic insert, a square, triangular and trigon insert (90, 60 and 80°), and a round insert range.
For further information www.tungaloy.com/uk