FEATURE ON TOOLING

End mill offers increased MRR

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

Hainbuch introduces strong Maxxos T211 mandrel

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

Cutting tool innovations from Mapal

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

Modular drill offers best of both world

Kennametal engineers say they have taken the strength and versatility of the KSEM modular drill system and combined it with the ease of use and low feed forces of its smaller companion drill, KenTIP. The resulting fusion of these advanced holemaking technologies is the KenTIP FS, a 6 to 26 mm, 1.5 to 12xD modular drill that is said to be simple to use and tough enough to compete with solid carbide drills across a range of materials. The tool has a full solid carbide front, enabling it to withstand more heat and abuse than competing modular drill technologies.

The drill’s flutes are highly polished after final machining, a process that Kennametal has found greatly improves chip evacuation and reduces washout near the tip. And instead of the two coolant holes found in most modular drill designs, the KenTIP FS has four – two at the tip and two in the chip gullet directly behind the head. This multi-coolant approach provides greater coolant volume to prevent chip packing while simultaneously drawing heat away from the cutting zone, prolonging tool life and improving hole quality.
Inserts with HPL and HPC point styles have through-tool coolant channels to provide better lubrication in this area to overcome the issue. In steel though, it´s better to concentrate coolant to the rake and take the heat from the contact zone between chip and rake surface. As a result, Kennametal has eliminated the front coolant holes in its HPG geometry inserts to raise insert tool life and improve chip breakage. In addition, this avoids built-up edge and makes the insert more rigid, which allows higher penetration rates in steel applications.
For further information www.kennametal.com

Marking line improves aerospace traceability

Floyd Automatic Tooling says that it now offers the latest Hommel + Keller brand of Zeus marking systems.
A manufacturer of aerospace industry connectors has recently chosen marking technology from Hommel + Keller as a means of clearly identifying components. The connectors vary in terms of diameter and material. For example, parts identical in design are made from nickel with a diameter of 3.33 mm and from brass with a much smaller diameter of 1.52 mm. To optimise production and further reduce set-up times, the aerospace manufacturer was also looking for an alternative to marking with the production number.

The solution was the Zeus spring return marking method. Explaining the situation, Hommel + Keller International technical sales engineer, José Cruz, says: “The customer was already using our tools for marking. However, the revolving method that depends on diameter was being employed. That meant there was a separate marking roll for each connector diameter and the customer often had to swap tools with production changes. Since the workpieces have very small diameters, the marking rolls also had an unfavourable ratio of 6:1 to ensure precise marking in multiple rotations. This increased the amount of set-ups required, particularly in the case of small and medium-sized production volumes. With our spring return system, we were able to offer the customer an even more cost-effective method of machining. Now, different connectors need only one roll for marking.”
In contrast to the revolving method, the spring return method ensures the embossing process takes place over just one partial rotation of the marking roll. This permits processing at high speeds.
For further information www.floydautomatic.co.uk