According to Walter GB, aerospace manufacturers that require special solid-carbide tooling for titanium workpieces will have to wait no longer than three weeks using the company’s newly introduced Xpress service.

An example of the cutter options available to aerospace component manufacturers is the Prototyp Ti38 Z6-10 solid-carbide milling cutter. Featuring a newly developed substrate and PVD coating, this cutter is able to operate at cutting speeds of up to 140 m/min. In addition, multi-tooth solutions with up to 10 teeth allow the feed to be increased by up to 50%, says Walter, in turn providing an increase in metal removal rates of up to 50% compared with conventional solutions.
In one case, tool life on a titanium aerospace window frame with a tensile strength of 1250 N/mm² has been raised by 154% when semi-finishing and finishing using a Prototyp Ti40 cutter. On the same component, using a Prototyp HDC Ti38L for finishing the outer contour, tool life was extended by 116%, while cutting speed increased by 25% and machining volume by 23%.
Also, the use of Walter’s CVD coating technology for its WSM45X indexable insert which, for instance, is used in the Walter Blaxx M3255 porcupine milling cutter, is seen as pivotal. Using this tooling combination, titanium structural components are typically machined using full slotting and climb milling at a cutting speed of 45 m/min and a feed of 0.12 mm. A further option is to increase the cutting speed to 65 m/min, achieving a predictable tool life of around 60 minutes.
Customers of the Xpress tool service can use the my.Walter software to design the tool online. This will be followed by an email quote for the purpose-made tool along with a 2D drawing and 3D model; all within an hour.
For further information www.walter-tools.com

CoroMill Plura routers unveiled by Sandvik Coromant are designed to offer optimised milling and slotting operations in composite materials such as CFRP and GFRP. According to the company, customers will benefit from the patented geometries featured on the new routers.

When milling and slotting composite materials, the CoroMill Plura routers are used primarily in full radial engagement and at full depth of cut. In some cases, finishing passes can also be deployed. Helix angles have been carefully designed for sharpness and cutting edge strength, helping to ensure longer tool life and high-quality surface, edge and slot finishes. The range comprises three cutters: the CoroMill Plura compression router, CoroMill Plura low-helix router, and CoroMill Plura serrated router.
The CoroMill Plura compression router, with its dual 40° helix, works best with special woven glass layers on both sides of CFRP components. As there is an overlap between compressed flutes, the router performs well in thin, flat materials by reducing material vibration.
Specifically designed for smooth and burr-free finishing passes in CFRP workpieces, the CoroMill Plura low-helix (5°) router features a high number of teeth and a coating that is designed to facilitate quick cutting and protection from heat. Right- and left-helix options allow flexibility in material with challenging support conditions, such as weak or compromised fixtures.
Finally, the CoroMill Plura serrated router, with its large flute form, is designed for very high material removal rates. The geometry also offers a dual cutting action to reduce delamination and vibration, ultimately providing a single-pass solution to minimise stress on composite parts.
All three CoroMill Plura routers can be used with or without coolant.
For further information www.sandvik.coromant.com

The new Eliminator series of end mills from Quickgrind is purpose-designed to increase metal removal rate (MRR) when performing five-axis machining operations. According to Quickgrind, the end mills incorporate a conical or tapered form that will deliver reductions in cycle time of up to 95%. This bold claim is substantiated by the ability of Eliminator to reduce tool-path distances while utilising the entire flute length to increase the step-down rate and subsequent MRR. Furthermore, the geometry of Eliminator reduces the potential for thermal deformation, dissipating heat from the cutting edges to extend tool life and improve surface finish.

From an application perspective, Eliminator tools are suited to semi-finish and finish-machining processes on a range of components, including aerospace turbine blades. The solid-carbide end mills are available uncoated or with Quickgrind’s Type D geometry, which features an MX coating for the machining of low- and medium-alloy steel, tool steel, cast iron and hardened steels. Alternatively, Type S end mills are XRed coated for the machining of high-temperature alloys such as Inconel, Hastelloy and titanium, as well as stainless steels.
Eliminator cutters can be used as a direct replacement for ball-nose and standard end mills. The tools are available as three- or four-flute cutters, which are offered in shank diameters of 6, 8, 10, 12 and 16 mm, which taper down to a ball nose diameter of 1, 2, 3 or 4 mm.
For further information www.quickgrind.com

At the recent EMO exhibition in Hanover, Hainbuch introduced its latest mandrel system, the Maxxos T211. The segmented clamping bushing of the Maxxos T211 has an internal hexagon shape that fits on to the clamping pyramid to help maximise cutting performance.

Thanks to the hexagonal pyramid clamp, maximum torque transmission can be achieved. In comparison with the classic Mando T211 mandrel, the new addition to the Hainbuch line-up generates up to 155% more transmissible torque and up to 57% higher stiffness. This makes it possible to achieve higher machining parameters and consequently improve the yield of finished parts. Greater process reliability is facilitated by the spacious layout between the clamping bush and clamping pyramid. Even during the clamping process, this design prevents virtually any dirt or contaminants from getting on to the surfaces.
Overall, the Maxxos T211 mandrel has a clamping diameter range of 18 to 100 mm, while the clamping areas of each size are designed to overlap. The advantage of this configuration gives users the ability to choose from up to three mandrel sizes depending on the clamping diameter. With the Maxxos, the larger the mandrel, the greater its stability and rigidity. The aligned, segmented clamping bushings have a minimum concentricity of 0.01 mm and can even be supplied in a high-precision version.
For further information www.hainbuch.com

Mapal used the EMO exhibition in Hanover last month as the launch pad for its new c-COM cloud-based data platform, as well as a host of new cutting tool lines. Tooling launches included the CPR500/510 replaceable-head reamer. Incorporating optimised cooling that offers an economic advantage when machining castings, this new arrival can extend tool life as its solid-carbide replaceable heads feature a purpose-designed CVD coating.

Complementing the latest reaming line was a complete new programme of ISO indexable inserts for boring steel, stainless steel and heat-resistant cast steel. Depending on prevailing conditions, such as material, machine stability, coolant and clamping, customers can choose between PVD- and CVD-coated cutting materials.
Elsewhere on the stand, Mapal revealed an extension to its three-edge Tritan-Drill range, which was launched last year. At EMO, the introduction of a specially adapted version for steel means that this material can be machined more cost-effectively compared with drills featuring two cutting edges.
Mapal also extended its programme of solid-carbide milling cutters for roughing applications with the new five-edge OptiMill-Uni-Wave. This full-slot mill makes it possible to produce groove depths up to 2xD, thanks largely to a highly ductile carbide substrate with a wear-resistant coating and special edge preparation.
For face-milling operations, EMO saw the arrival of a new generation of milling tools for cutting depths up to 4 mm. With replaceable PCD milling cartridges, PowerMill-Blue is designed for machining aluminium in the automotive industry. Chip-guiding geometry has been optimised for the series, while the chip former is no longer integrated in the tool body but directly in the milling cassettes, ultimately resulting in better surface finishes.
For further information www.mapal.com