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

With the new double-edged WT26 indexable inserts and the compatible tool-holder system, Walter says it offers a solution that can optimise the machining of small parts on Swiss-type sliding-head turning centres. According to the company, the dovetail shape of the insert clamp absorbs lateral forces to elevate stability, process reliability and accuracy. The clamp system and the large contact surface in the insert seat maximise rigidity, counteracting any vibration of the bar material.

Another special feature is the possibility of performing operations on both sides. This design concept is credit to a clamping screw that features a Torx screw drive on both the head side and threaded side, facilitating operation from the side of the counter-spindle on right and left-hand tools. Users can index the inserts quickly without removing the tool holder, reducing non-productive time.

The tangentially mounted WT26 indexable inserts are precision-ground and boast sharp cutting edges specifically for turning small precision parts. Furthermore, the periphery-ground chip-breaker geometries are available in DG8 and VG8 designations, which Walter says facilitates optimal machining results even at feed rates as low as 0.03 mm.

Walter’s WT26 indexable inserts come in seven different versions, covering all turning operations. This selection includes everything from basic recesses and external threads, to reverse turning with specially developed chip breakers.

The new WSM23X cutting tool material is suitable for machining steel, stainless steel and lead-free brass. In addition, the uncoated WN23 grade suits aluminium and non-ferrous metals. Operators can use the inserts in any WT26 tool holder, regardless of the system.

More information www.walter-tools.com

Kennametal is expanding its turning portfolio with the introduction of new inserts and cutting tools that significantly broaden the company’s capabilities in the small parts and medical machining space. The three new products – TopSwiss turning inserts, TopSwiss Micro Boring Solid (MBS) tooling and KCU25B turning inserts – are designed to improve output, enhance component quality, reduce errors, and help customers achieve accurate and clean results.

Kennametal’s new TopSwiss turning inserts are for Swiss-type small parts machining, delivering low-feed, high depth-of-cut applications in the medical sector, as well as industries like aerospace, defence, general engineering and transportation. The portfolio features four new carbide grades, one new cermet grade and seven new geometries.

Straight and curved cutting edges are available for stable cuts and smooth chip flow in low-feed, high-depth-of-cut applications. Polished finishing geometries offer increased welding resistance and improved surface finishing, while medium and finishing wiper geometries deliver increased feed rates and higher surface quality. Other geometries feature high chip breaker walls and large pockets for better chip evacuation.

New TopSwiss Micro Boring Solid (MBS) tooling allows for the machining of even smaller applications with greater versatility and flexibility. According to Kennametal, it offers sharp cutting edges, low cutting forces and superior chip evacuation.

Also new are KCU25B turning inserts for roughing and medium metal cutting at shops working with steel, stainless steel, cast iron and high-temperature alloys. Ideal for the most common turning, grooving and cut-off applications, KCU25B inserts also feature Kennametal’s proprietary KENGold PVD coating, delivering multiple layers of protection for better flank and chipping resistance.

More information www.kennametal.com

As part of its Bidemic family of patented cutting tool inserts, Tungaloy-NTK UK is introducing its JX1 grade that offers cutting speeds close to 500 m/min on aerospace alloys. Suitable for turning, internal turning, grooving and boring applications, the new grade provides durability with cutting speeds on hard materials that will take productivity to the next level.

Complementing the JX1 grade is the new JX3. Where the JX1 offers wear resistance for extended tool life, JX3 is for tough operations. Suitable for rough machining, profiling and semi-finishing, both the JX1 and JX3 can machine at parameters from 180 to 480 m/min, with a depth of cut up to 2.5 mm and a feed rate up to 0.27 mm/rev.

Also now available is the JP2 grade for finish turning. According to Tungaloy-NTK UK, the JP2 is capable of achieving cutting speeds 10 times higher than carbide equivalents. With machining in the realms of 520 m/min possible, the JP2 delivers surface finishes of Ra 0.6 µm with a feed rate of 0.15 mm/rev. It features multi-edges and a TiN coating in support of higher durability and efficiency.

Providing added flexibility for high-performance turning, Tungaloy-NTK UK can also offer its new BX815 CBN grade for high-speed finishing. Extending the application range of the patented JX and JP Bidemic grades, the BX815 is for both external and internal finish-turning in the speed range from 80 to 500 m/min, making it an all-rounder for manufacturers that demand smooth surface finishes on heat-resistant alloys.

Designed for machining superalloys, the BX815 incorporates alumina-based binders and zirconia grains that offer heat dissipation, oxidation and fracture resistance.

More information www.tungaloy.com/uk