FEATURE ON TOOLING

New standard in drilling

Mapal says it has set a new standard in drilling with its Tritan-Drill range (featuring three cutting edges) which is being gradually expanded. For instance, a new universal version, made from HSS, has been specifically developed to maximise cost effectiveness in small-series production.

Thanks to the shape of its main cutting edge, the Tritan-Drill-HSS is robust, even in difficult drilling situations, says the company. Stable cutting edge corners mean that damage to the edge geometry is reduced, which allows for both greatly improved results and smooth machining. The coating of the Tritan-Drill-HSS is optimised for universal machining. As a result, the drill can be used for different materials while maintaining a long tool life, reports Mapal.
According to the company, the Tritan-Drill-HSS can achieve feeds up to 50% higher than twin-edged HSS drills, while at the same time has a tool life that is up to four times longer. Due to the special point geometry of the Tritan-Drill-HSS, piloting and centre-punching are not necessary. The tool can also be used on hand drills, with the pronounced drill tip preventing it from slipping over the chisel edge (in contrast to drills with two cutting edges).
Mapal’s Tritan Drill-HSS is available in a diameter range from 8 to 40 mm.
For further information www.mapal.com

Alitech races to success with ITC

As a subcontract machine shop, Alitech Precision is a company that is rapidly evolving, a fact credit to its aggressive investment programme, enthusiasm and love for all things motorsport. Since its inception little over three years ago, the Silverstone-based company has purchased three Haas machining centres, Open Mind CAM software, a Spinner five-axis machining centre and cutting tools from Industrial Tooling Corporation (ITC).

A recent example of the partnership between Alitech and ITC could be seen when it came to the profile machining of deep port pockets. Here, it was ITC that stepped up to the challenge with its lollipop cutters. The majority of projects undertaken by Alitech involve the complex, simultaneous five-axis machining of parts such as billet inlet manifolds, valve seats, inlet port heads, billet turbo manifolds and much more. Reaching deep into ports is a complex challenge for the machine tool kinematics, the CAM software, the cutting tools and tool holding. At the sharp edge are ITC 4101 lollipop end mills that permit Alitech to reach surfaces around corners and deep inside manifold ports.
Commenting upon the daily challenges at Alitech, managing director Darren Cudd says: “We recently machined a billet turbo manifold for a motorsport customer that required two 40 mm diameter oval shaped port holes with a curved machining depth beyond 200 mm. We used an 8 mm diameter ITC lollipop cutter necked to 5 mm that was protruding 70 mm from a slim 80 mm heat-shrink tool holder extension with a 75 mm long back-end configuration. The rigidity and geometry of the ITC lollipop tools ensure we attain an exceptional surface finish while machining at extremely productive speed and feed parameters.”
For further information www.itc-ltd.co.uk

Thread turning with over- and under-coolant

The CoroThread 266 thread-turning tool from Sandvik Coromant is now available with precision over- and under-coolant to improve process security and maximise efficiency. While over-coolant improves chip formation for more secure machining, under-coolant controls temperature for long and predictable tool life, says the company. Precision coolant also has positive effects on surface finish, further supporting the generation of high-quality threads.

“Process security and stability is paramount in thread-turning operations to ensure the machining of right-first-time threads, every time,” explains Hampus Olsson, product manager thread turning at Sandvik Coromant. “Along with precision coolant, this is why CoroThread 266 features the proprietary iLock interface between the holder and insert, which prevents cutting forces from causing micro-movements of the insert in the tip seat. In addition, for applications where long overhangs are unavoidable, the use of dedicated damped Silent Tools adaptors provide a proven way to reduce vibration and maintain precision.”
Suitable for external and internal thread turning, a standard assortment of insert thread profiles with dedicated grades and geometries is available for all materials. A bespoke offer can also be provided for an extended thread profile assortment.
Quick-change tool holders with precision coolant include Coromant Capto C3, C4, C5 and C6 (for use with 16 mm inserts), as well as QS shanks in 20 x 20 and 25 x 25 mm sizes (with 16 and 22 mm inserts). For internal thread turning, a minimum hole diameter of 20 mm is required.
For further information www.sandvik.coromant.com

Deep cavities within reach

Kennametal says it has solved the age-old problem of tool stability when drilling in deep cavities past tall shoulders or bulky fixtures. The company has developed a hydraulic chuck extension that meets these challenges, while increasing flexibility and reducing costs.

“We asked our customers how they drill holes in deep cavities and complex pockets,” explains Michael Schuffenhauer, senior global product manager tooling systems at Kennametal. “We wanted to know if they had problems with reaching past clamps and fixtures, how they were dealing with these issues, and the effectiveness of their existing solutions. Then we set out to develop a better one.”
Kennametal’s line of hydraulic chuck (HC) extensions offers a number of key features that include: runout to within 3 µm at 2.5xD; balanced to G2.5 at 25,000 rpm; and a slim design that allows, for example, a 12 mm drill to be clamped in a 20 mm chuck body. Furthermore, various reducer sleeves are available for both metric and imperial sizes, helping to maximise flexibility.
The design, in fact, is simple: just set any h6 tool shank inside the HC extension and turn the clamping screw on the end of the unit until seated. This causes a hydraulic piston within the unit to move forward, compressing the locating sleeve, and gripping the tool.
“Our HC Extensions are for customers that need the flexibility of a modular system but want to avoid the expense and limitations of a custom solution, as well as the constraints that come with traditional tool holders,” says Schuffenhauer.
For further information www.kennametal.com

Zimmermann opts for Mapal

For demonstrations and machine acceptance tests, machine tool manufacturer Zimmermann says it equips the company’s latest horizontal machining centre with milling cutters from Mapal.

Zimmermann developed its first horizontal machining centre specially for the machining of structural parts used by the aerospace industry. Aluminium structural parts, such as wing parts and frame ribs, are generally milled from solid material – with up to 95% material removal. Fault-free machining with respect to dimensional accuracy and surface finish is crucial. Moreover, the component structure becomes more and more delicate with increasing material removal, representing an additional challenge.
In order to achieve maximum efficiency, Zimmermann employs its own patented M3ABC three-axis milling head in the machining centre. Particularly in the pocket corners of a workpiece, the milling head has to perform only very small swivel movements – allowing the feed rate to be kept more or less constant and hence the machining time to be significantly shortened.
“The perfect combination – the machine, the three-axis milling head and tools from Mapal – give the user a real performance boost,” says Steffen Nüssle, sales director export and head of applications engineering at Zimmermann. “With the SPM-Rough ISO shoulder milling cutter, we achieved the best results that we have ever witnessed using a tool featuring indexable inserts.”
The ISO tools with polished indexable inserts are the latest addition to the Mapal SPM product range. SPM-Rough with wave profile also surpassed the expectations for material removal with excellent smooth running.
“Complete machining of a 190 x 190 x 40 mm pocket is now effectively possible in less than a minute,” explains Nüssle.
For further information www.mapal.com