Walter Tools is raising its profile for the machining of lightweight components with the
arrival of its new FMT competence brand. The machining solutions provider is bringing
together its global presence and the technical expertise of lightweight machining specialist
FMT (Frezite Metal Tooling).
In the overall share of processed materials in the manufacturing industry, the proportion of
lightweight materials such as aluminium alloys continues to grow significantly. Machining
specialist Walter has therefore been consistently expanding this area of its portfolio for a
number of years.
The new Walter FMT competence brand showcases the importance of lightweight
machining for Walter to its global customer base and wider industry. It stands for the added
value that Walter says it offers customers through various services from consulting and
planning to implementation and maintenance, and for a trusting partnership that goes far
beyond tools.
As vice president of Walter Lightweight Business Unit, Pedro Pacheco will be responsible for
the new competence brand. He served as the first managing director of FMT from 2006 to
2017 and took over the role again in 2019.
“My focus will be on bringing together the expertise and working methods of FMT and
Walter’s PCD division in the optimal way,” says Pacheco. “We want to increase our reach in
the market significantly and contribute to Walter’s strategic growth targets. I want to create
the right structures and processes to provide current and potential customers with an
attractive offering that enables them to achieve their own economic goals.”

More information www.walter-tools.com

Kyocera Corporation has developed a new parting-off solution, denoted KGZ, for small component machining. KGZ uses a new clamp structure with three proprietary mechanisms to lock the insert in place, suppress chatter and achieve stable machining. In addition, the constraint surface of the holder has a shape that distributes stress, improves durability and realises high-efficiency machining.

Within the insert grade’s line-up, a newly developed PVD-coated grade known as the PR 20 is also available for the KGZ. The new coating, MegaCoat 1 Nano EX, which is resistant to oxidation and abrasion, achieves high precision, long tool life and stable machining when parting-off steel, stainless steel and cast-iron workpieces.

Notably, the new KGZ design improves the holding force of the insert and the durability of the tool holder through three proprietary mechanisms: gap section, top clamp and stopper.

With the gap section, users can simply press down on the insert from directly above to firmly secure it in place. Generally, it is structurally difficult to fix the insert directly above with a parting-off tool. KGZ has a tapered slit with a slanted cut, so when tightening the fastening screw it applies a restraining force from directly above the insert, securing it in place.

The top clamp serves to pull the insert inward and increase the binding force. Designing the shape so that force is applied inward when clamping the insert suppresses the displacement of the insert in the front and rear directions.

Kyocera’s stopper disperses stress over a large area and improves the durability of the holder. According to the company, this design reduces the amount of stopper wear to about one-third of that of competitor products.

More information www.kyocera-unimerco.com

With star-shaped hexalobular bone screws (TORX) proving the design of choice in the medical industry, Floyd Automatic Tooling is introducing the UK market to CrazyDrill Hexalobe drills and CrazyMill Hexalobe end mills from Mikron Tool.

Medical screws for orthopaedic procedures are predominantly manufactured from titanium, stainless steel and cobalt-chrome. Machining these precision screws to impeccable surface finishes is a challenging task – that was until the arrival of the Mikron Hexalobe series. According to Floyd Automatic, machining hexalobe screws 50% faster with precision burr-free results is what makes this next-generation series the first choice for manufacturers in the medical sector.

These high-performance drills for generating pre-holes in TORX sockets are available in two variants: the pre-hole CrazyDrill Hexalobe TORX drill with a tip angle of 140°, and the CrazyDrill Hexalobe Flat drill with a tip angle of 180°. Both are available from 0.9 to 3.8 mm in diameter for producing T4 to T30 TORX sockets. Upon request, Floyd Automatic can provide the drills as a customised combination drill for streamlining operations. The CrazyDrill Hexalobe series combines two operations into one, as it simultaneously machines a flat pre-hole and a 120° chamfer.

The Mikron CrazyDrill Hexalobe from Floyd Automatic generates chamfer surface quality to a finish of Ra<0.3 µm while guaranteeing high profile accuracy and perpendicularity.

Completing the process is the CrazyMill Hexalobe micro end mill. Available from 0.2 to 1 mm diameter for T4 to T30 socket variants, the CrazyMill Hexalobe presents three- or four-flute variants with milling depths of 3.5xD and 5xD. The CrazyMill Hexalobe milling cutter demonstrates sufficient stiffness for machining with high feeds and stepover rates, while guaranteeing the necessary hex lobular profile accuracy.

More information www.floydautomatic.co.uk