FEATURE ON TOOLING

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

Drills boost productivity and tool life

The new range of Feedmax-P solid-carbide drills from Seco Tools is said to provide component manufacturers with up to 35% more productivity and improved tool life when machining steel and cast iron.

Featuring new geometry and a TiAIN coating, the range delivers improved chip management and control, says Seco. The end result being that manufacturers can drill holes faster (productivity) and use fewer drills (economy). Feedmax-P drills have strong, straight cutting edges with strategically located coolant holes. Moreover, narrow land margins help to minimise the effect of heat generation, while an improved flute design protects the drill point and delivers improved chip evacuation.
With a new TiAIN coating, which is said to deliver improved tool life when machining high heat-generating applications, combined with strong point geometry, cutting speeds of up to 190 m/min can be achieved when machining SMG P5 structural steel without causing excessive tool wear.
Feedmax-P drills are available in diameters ranging from 2 to 20 mm, and in length-to-diameter ratios of 3xD, 5xD and 7xD. Internal coolant supply is available as standard, while customised options, such as intermediate sizes, and chamfer and step-drill versions, can be supplied on request.
For further information www.secotools.com