Kennametal says that customers have been asking for a new carbide grade to machine titanium 6Al4V at higher cutting speeds instead of having to increase feed rates or depth of cuts, which can result in greater cutting forces on the workpiece, fixture and spindle. With this in mind, the company’s latest KCSM40 grade has a cobalt binder that provides thermal fatigue resistance without sacrificing toughness. In addition to the new material substrate, Kennametal´s proprietary AlTiN/TiN coating is said to enhance wear resistance at the cutting edge.

The target cutting speed for KCSM40 in Ti6Al4V was 53 m/min, while hitting in excess of 327 cu cm/min metal removal rate for 60 minutes. According to Kennametal, not only did KCSM40 achieve this but showed the capability to mill titanium at speeds up to 85 m/ min at a lower radial depth of cut.
Recent internal testing with the new Harvi Ultra helical milling platform achieved over 100 minutes of tool life running at 47 m/min with a 0.12 mm/t chip load. Radial depth of cut was 25 mm and axial depth of cut was 76 mm. Kennametal says that the edge condition on the KCSM40 grade still looked great.
The company is also witnessing many other good results. For instance, in one face-milling operation on a hardened steel wear plate, the number of passes was reduced from 234 to just 22.
For further information www.kennametal.com

According to Sumitomo Electric Hardmetal, key to the capability of the Sumi Dual Mill TSX series of higher efficiency, 90° shoulder mills is the combination of fine-carbide insert press/sintering technology with precision profile-grinding techniques. This enables the periphery ground inserts used with the new tangential cutter body design, which is available in standard, medium and fine-pitch versions, to generate high levels of surface finish.

The TSX series is based on the use of tangentially mounted carbide inserts offering a choice of chip-breakers: L for low-rigidity machine set-ups, G for general purpose operations and H where a stronger insert edge is required to support tasks such as rough, heavy interrupted and hard-steel milling, for example.
Sumitomo’s TSX shoulder mills comprise shell-type bodies between 40 and 160 mm diameter, and shank-type bodies between 16 and 160 mm diameter, to support operations such as face and shoulder milling, slot milling, and side and face-milling tasks. Two sizes of insert, each with four corners, are precision ground to accommodate 8 or 12 mm depths of cut.
A recent customer trial witnessed the milling of a workpiece made from 42CrMo4 alloy steel. Using a TSX shell cutter body combined with ACP200 grade inserts and G-type chipbreaker, the process (with coolant) was run at 270 m/min cutting speed, 0.05 mm/rev feed and 8 mm depth of cut. Not only did the Sumitomo set-up improve component wall quality, it increased the number of parts produced from 135 to 220.
For further information www.sumitomotool.com

Dormer Pramet has launched a new milling grade for general machining applications in a variety of common engineering materials, particularly steels. Suitable for both finishing and roughing, even in unfavourable cutting conditions, the M8330 grade is said to provide a reliable and versatile option when machining either with or without coolant, in steels and cast iron. The new grade is also suitable for stainless steel, super alloys and hardened steels.

The M8330 replaces the existing 8230 grade and features a nano-layered PVD coating which is designed to offer increased resistance to thermal cracks, improved toughness and greater impact strength.
Added to more than 90 different types of existing Pramet milling inserts, M8330 is also available in a completely new range of inserts for copy milling. RCMT10 inserts offer high metal removal rates, with up to 5 mm depth of cut and strong durability. Designed to allow a high feed per tooth, RCMT10 is available in three geometries to support operations in a range of materials: geometry F is for stainless steels, super alloys and low-carbon steels; geometry M for steels and stainless steels; and geometry R for cast iron and hardened materials.
To support this addition, Dormer Pramet has expanded its current line of SRC copy-milling cutters. The SRC10 is a series of small diameter cutters available in sizes from 25 to 66 mm, and in a variety of types, including end mills, modular and shell mills. A double-negative design is deployed to provide a stable cutting action, even during roughing, making it suitable for operations such as face milling, helical interpolation, ramping, progressive plunging and high-feed cutting.
For further information www.dormerpramet.com