FEATURE ON TOOLING

Taps help thruster firm move in right direction

When a large new vessel is put to sea, it is usually equipped with a tunnel thruster that acts as a side propeller system to enhance manoeuvrability at berth and in open waters.

Tunnel thrusters, sometimes called bow thrusters, provide captains with increased control and can help to quickly turn a ship around.
Brunvoll AS is a global manufacturer of seaworthy motion systems with headquarters in Molde, Norway. The company has supplied more than 8000 complete side propeller systems mounted on more than 5000 different cruise ships, supply boats and navy vessels.
Machining of the side propellers, which are manufactured from nickel-aluminium bronze alloy, is conducted by the company mostly unmanned and at night. This demands a highly accurate and dependable machining process and cutting tools. Here, the versatility of Dormer’s Red Shark tap allows it to be used at different torque levels, such as when threading the propeller at the attachment to the rotor. To ensure optimal productivity and safety, the unmanned machines are slowed to a cutting speed of 25 m/min (the ideal cutting speed in the nickel-aluminium bronze is 35 m/min). However, in tests, Brunvoll ran the Red Shark up to 50 m/min – exactly double the required rate.
The Red Shark is one of several material-specific taps available from Dormer Pramet. Each tap features a colour ring on the tool shank denoting material suitability, promoting quick and easy tool selection. Dormer Pramet is set to add more tools to its assortment of Shark Line taps. This includes a range of yellow-ring taps for structural, carbon and low-alloy steels, and blue ring for stainless steels.
For further information www.dormerpramet.com

Latest shoulder mills eliminate finishing

The newly developed VSM490 series of Widia indexable-insert shoulder mills available from ITC is said to eliminate finishing operations and improve productivity when machining a wide variety of materials. In addition, the VSM490 double-sided 90° inserts offer four cutting edges to reduce costs.

This latest addition to the Widia Victory Shoulder Mill (VSM) range includes a complete line of insert grades that support the machining of cast iron, stainless steel, steel, titanium, aluminium and a host of aluminium alloys. The cutter’s versatility is facilitated by a positive geometry and the availability of both 10 and 15 mm inserts, along with an extensive selection of tool holders.
A total of four insert geometries are offered, including ALP geometry for low-power machine tools cutting non-ferrous materials, and ML geometry for stainless steel and light machining on a variety of other materials. For more robust applications, MM geometry incorporates features designed to bring greater strength to machining operations, while the heavy-duty MH grade is first choice for high-performance roughing on cast iron, chiefly credit to edge-protecting geometry and additional margins.
The VSM490 gives customers a full slotting solution with 100% radial engagement, shoulder milling with step-down capabilities that provide low or high engagement, as well as low or high radial engagement. Furthermore, the VSM490 can be applied to contour milling, Z-axis plunge milling, trochoidal slot milling and HPC face milling.
For further information www.itc-ltd.co.uk

Grinders give tooling firm elite position

A trio of Walter Helitronic Power multi-axis tool grinders, plus a Walter Helicheck tool-measuring machine, are enabling Elite Tooling to consistently supply special purpose tooling for customers in the aerospace, medical and Formula One sectors.
The machines have been installed over the past decade or so, following the company’s establishment in 1995 initially as a distributor for Tivoly tools before the Rotherham-based firm progressively moved into tool production and regrinding, which today account for 80 and 20% of output respectively.

According to production manager Lee Burkill, it is the machines’ Tool Studio software and Eco Loaders, as well as their solid construction that leads to consistently reliable operation, which has stood the company in good stead and in 2017 led to investment in its latest Helitronic Power with Eco Loader (supplied by Walter Ewag UK).
Walter’s Eco Loaders are available in versions able to accommodate 165 tools. The Eco Loader is mounted on the machine’s work table and the loading/unloading gripper is integrated into the grinding head.
“Specialising in mainly carbide bespoke tooling of all types – including profile and multi-step cutters usually machined in quantities of one- to 10-off to micron tolerances – as well as the production of Tivoly’s standard tools [for drilling milling, boring, tapping and threading] in batches of, say, 100, we regularly use the Eco Loaders for unmanned operation, especially for overnight production,” says Burkill. “This ability to maximise production times, coupled with the functionality of Tool Studio for quick and easy programming, and simulation of tool designs, contributes to our ability to produce high-class tools in the turnaround times that our customers demand.”
For further information www.walter-machines.com

High-feed mills suit aerospace materials

To enhance milling performance on ISO S materials, Sandvik Coromant is introducing a new series of end mills. CoroMill Plura HFS (High-Feed Side milling) cutters are intended for use on workpieces made from titanium and nickel-based alloys, bringing benefits to both aerospace engine and frame applications.

Sandvik Coromant’s CoroMill Plura HFS range comprises two end-mill families for titanium alloys, and one for nickel alloys. As chip evacuation and heat are specific challenges when machining titanium, the company has developed a solid version for normal chip evacuation conditions, and another featuring internal coolant and a new cooling booster (patent pending) for swarf and temperature control.
The end mills for titanium are available in GC1745 grade, which is based on a fine-grained (sub-micron) cemented-carbide substrate. A new multi-layer coating that contains silicon is said to provide good wear resistance and low thermal conductivity. The geometry of the cutters is based on a six-flute concept with no centre cut and uneven tooth pitch. Additionally, the core dimension has been optimised for higher stiffness in titanium alloys, while the corner radius, rake angle and relief are all designed specifically for machining ISO S materials.
For nickel alloys, grade GC1710 is deployed, which features a wear-resistant, fine-grained substrate designed to withstand high working loads when machining hard, highly adhesive, work-hardened materials such as aged Inconel 718. Here, a new coating produced with HIPIMS (high power impulse magnetron sputtering) technology offers adhesion-reducing properties to avoid the formation of BUE (built-up edge) and increase tool life.
For further information www.sandvik.coromant.com

Shoulder mills for challenging materials

Designed to boost productivity when milling challenging materials, Industrial Tooling Corporation (ITC) has launched the new VSM17 line of shoulder-milling tools from Widia into the UK market.

The 90° shoulder milling platform offers aggressive ramping angles of up to 8.8° with guided internal coolant supply; features that combine to help elevate material removal rates and chip clearance. The steel VSM17 tool bodies are available with screw-on, Weldon and cylindrical end mills from 25 to 40 mm diameter (with regular and long shanks), shell mills from 40 to 160 mm, and the M4000 cartridge milling system in diameters from 125 to 315 mm. The various tool bodies incorporate an optimised chip gash that is designed to optimise stability, chip removal and cutting efficiency.
This latest addition to the Widia 90° VSM series is suitable for everything from light, precision machining to medium roughing. The tool’s two-edged 16 mm inserts incorporate an embedded wiper facet for high surface finishes, an additional margin on the clearance face that strengthens the cutting edge and a positive rake design which generates a soft cutting action.
The inserts are offered in a range of grades for machining cast iron, steel, stainless steel, aluminium and a variety of additional materials. Each insert grade is offered with the option of the ALP, ML, MM and MH insert geometries. ALP is a peripheral ground geometry for the rough to finish machining of aluminium alloys, whereas ML is designated for light to finish cutting on stainless steel and titanium. MM and MH are general and heavy-duty cutting grades for a multitude of material types.
For further information www.itc-ltd.co.uk