FEATURE ON TOOLING

Walter adds M5250 to Xtra·tec XT series

Walter has extended its range of Xtra·tec XT milling cutters to cover diameters 50, 63 and 80 mm with the addition of the M5250 helical mill. The company says that its latest generation of indexable-insert milling cutters is characterised by high performance paired with process reliability.

These capabilities are credit to features like a reinforced insert pocket and insert seat. Moreover, each individual tooth on the M5250 has separate cooling. Walter uses proven, double-edged BC 1605 system inserts on the face of the M5250, and allows users to choose between various corner radii, cutting tool materials and geometries.

The G51 geometry (“the quiet one”) is for applications likely to incur vibration, or for tools with long projection lengths. In contrast, G55W cutting inserts with Walter WaveCut geometry are suitable for titanium components with high volume removal requirements, such as those found in the aerospace industry. Walter uses milling cutter-specific SC 1105 cutting inserts with four cutting edges as peripheral inserts.

In addition to steel, cast iron and materials with difficult cutting properties, the helical milling cutter is also suitable for use on aluminium and other non-ferrous metals. Unlike other fully effective helical milling cutters, Xtra·tec XT milling cutters can also be used for full slotting alongside shoulder milling, pocket milling and ramping.

As well as flexibility and process reliability (thanks to the operational smoothness of the cutter), Walter says the high machining volume results from the effective design of the mill and reduced process costs. These lower costs stem from the two or four useable cutting edges per indexable insert, along with new wear-resistant Tiger·tec cutting tool materials.

More information www.walter-tools.com

Allied Machine grows T-A Pro drilling line

Allied Machine and Engineering, a manufacturer of hole-making and finish-cutting tools, has expanded it T-A Pro replaceable-insert drilling line into the Y series. With a diameter range of (9.5-11.09 mm), T-A Pro Y series is available in stub to 15xD and ISO-specific carbide grades P, K, and N, as well as high-speed steel substrate X. 

Adding the Y series to the diameter offering of the T-A Pro line, which has a complete range of (9.5-47.8 mm), gives machine shops using high-speed steel twist drills and conventional style tools the opportunity to upgrade to a better system.

Additionally, for those using solid-carbide tooling, the Y series offers exchangeable tips, eliminating the need for regrinding, while also providing the ability to target specific materials and applications with an ISO-specific geometry selection on a single holder body. Ultimately, T-A Pro Y series benefits smaller scale part runs in various industries because of its favourable cost per hole. 

Like the T-A Pro Z series, the Y series is available in A and B body diameters. Offered in both imperial and metric as well as flat and cylindrical shanks for all length options, the Y series serves as an upgrade to manufacturing processes while also allowing machinists to increase throughput in their machining applications.  

John Weniger, product manager, says: “The T-A Pro line has established itself in the market as a go-to drilling solution that over-delivers on performance, reliability and consistency. The expansion of the T-A Pro drilling line into the Y series allows users to experience the benefits of the T-A Pro line at smaller diameters.” 

More information www.alliedmachine.com

Exactaform Acquires Precision Tooling Specialist

Exactaform Cutting Tools has acquired the trade and assets of PJ Tooling, an established
name in the precision tooling industry. The move not only strengthens Exactaform’s
commitment to growth and expansion but also carries a sentimental value that dates back
to the company’s roots.

Exactaform founder John Inglis started his career at PJ Tooling. This experience laid the
foundation for his future in the tooling industry and was instrumental in the formation of
Exactaform. With this acquisition, his journey has come full circle, bringing PJ Tooling under
the Exactaform umbrella and creating new opportunities.
“PJ Tooling gave me my start in the industry, so it’s a great privilege to be able to bring the
business back into the fold and ensure its legacy continues,” says Inglis. “We’re excited to
bring our expertise and resources to PJ’s operations and support its customers with the
same high standards of service that we provide at Exactaform.”
PJ Tooling’s location in Warwick is just a short drive from Exactaform’s headquarters in
Coventry, making the transition smooth with operations now united under one roof at the
latter facility. By centralising operations, Exactaform can leverage its state-of-the-art
facilities and expert team to enhance further the company’s ability to deliver on complex
projects.
The acquisition of PJ Tooling presents exciting opportunities for Exactaform to strengthen its
position in the hydraulic component industry, among others. While the company already
has some experience in this sector, there is a considerable amount of crossover between
existing capabilities and the specific requirements of manufacturing bespoke cutting tools
for machining hydraulic components.
With PJ Tooling’s established reputation and Exactaform’s manufacturing processes, the
company is excited to expand its reach and deliver even greater value to customers who
require high-precision tools for hydraulic applications.
More information www.exactaform.com

Tool Management Engineered In Record Time

Mapal’s offer for the series production of the motor block required for a new Deutz 3.9-litre
diesel engine included almost 100 different tools, as well as tool holders and adapters.
Effective tool management was therefore a priority. However, in the capable hands of
Mapal, the Zafra, Spain facility of Deutz knew it could rely on the delivery of an optimised
solution.
Deutz’s new 3.9-litre diesel engine sees most use in agricultural and construction machines.
Series production is due to start in the coming year after the current prototype phase. Some
50,000 units per annum will require manufacturing.
“Our clients’ development periods for new parts are becoming shorter and shorter,” states
Thomas Spang, global head of tool management at Mapal.
For the engine block of the new 3.9-litre diesel engine, Mapal only had two weeks after the
design freeze to complete a final offer. When Deutz sent its request, the Tool Management
department in collaboration with the Technology Expert Team (TET) at Mapal in Aalen first
gave some initial thought to the production process.
“To be quick, we don’t concern ourselves with detail at this early stage, but instead pull
together reference tools and concepts from previously completed projects”, explains Harald
Traub, project engineer from TET, who is responsible for planning the entire process. “In this
way, we’re able to specify an approximate budget and the rough scope of the tool package
for the client.”
After initial planning, concrete tool design followed in the second week. Mapal’s offer for
the series production of the motor block included almost 100 different tools. Many of them
are custom tools that achieve short machining time and thus high economic efficiency.
To produce prototypes quickly, a few close-to-standard tools were also specified.
More information www.mapal.com

New connection for replaceable-head mills

Mapal has introduced a patent-pending bayonet-type connection for milling cutter systems with a replaceable head. Users benefit from easy handling with a rigid connection and optimal cooling. The tool manufacturer also saves carbide with the connection, conserving resources.

The functional principle of the new connection could not be easier: the replaceable head only has to be inserted and turned 90° to achieve locking. That is a lot easier than the previous system for replaceable-head milling cutters from Mapal or comparable systems where the replaceable head is threaded and has to be screwed-in several turns. 

Mapal’s new bayonet system achieves very high rigidity thanks to its large cylindrical face connection. While the force only acts on one side when tightening a thread due to its pitch, the Mapal system ensures a symmetrical insertion and good distribution of force.  

Together with the connection, Mapal is introducing a new tool-holder design. The tool holder has a ring of cooling channel bores, which enables a much higher volume of cooling than conventional internal cooling is able to provide. By channelling the coolant directly to the area of the cutting edges, the tool life is extended and machining quality improved. 

In addition, by eliminating the need for a central cooling channel bore, the milling head becomes much more stable. The tool holder is 10-15% more rigid than comparable systems, reports Mapal, resulting in higher achievable form and position tolerances, smoother processes and longer tool life.

 

The solid-carbide replaceable heads from Mapal offer high process reliability as inserts cannot become loose at high temperatures. If tool breakage does occur, the connection’s simple assembly ensures operators can resume the machining process quickly.

More information www.mapal.com