Mapal says that its new NeoMill-Alu-QBig indexable insert milling cutter stands for top performance in the high-volume milling of aluminium. The tool manufacturer thus offers an economical solution for use on high-performance machines, such as those found primarily in the aerospace industry.

With its NeoMill-Alu-QBig solid-carbide roughing cutter for aluminium, Mapal says that machine shops can achieve a material removal rate of more than 18 l/min on high-performance machine tools. At the same time, it is of course also possible to use the high-volume milling cutter on less powerful machines. The tool manufacturer is thus taking into account the fact that aircraft parts often see manufacture on machines with spindle outputs between 40 and 80 kW, for which there was previously no suitable milling cutter in the company’s portfolio.

In order to maximise the material removal rate, Mapal designed the new aluminium volume milling cutter for use at spindle speeds of up to 35,000 rpm (with a diameter of 50 mm). For a tight fit, despite high centrifugal forces, screws with high tensile strength hold the indexable inserts firmly in the prismatic seat. In addition, countersinks on the indexable insert ensure weight savings. The tool body features a fine balancing system. Four threaded bores enable precise adjustment in order to protect the machine spindle at high speeds and achieve the smoothest possible surface finishes.

In addition, Mapal placed focus on low cutting forces and highly precise indexable inserts. High chip volumes with very high achievable surface finishes of Ra 0.8 µm and Rz 4.0 µm for rough and fine machining are thus achievable with the tool.

More information www.mapal.com

Seco Nanojet solid-carbide reamers enhance chip control with an innovative through-coolant outlet for optimal chip evacuation. This design eliminates costly scrapped parts, jamming and edge damage to increase safety, part quality and tool life.
 

Critical reaming operations require stable, secure, predictable tools. On blind and through-bores, Seco Nanojet solid-carbide Reamers extend the performance of the company’s Nanofix products with through-coolant outlets that stop chip jamming and enhance application stability. Seco says that the proprietary design of these new tools delivers a powerful, precise stream of lubrication directly to the cut zone for optimal chip evacuation and tool life. Along with production stability, shops can rely on Seco Nanojet to maintain cutting speed and part quality, reports the company.

This versatile range of multi-flute reamers comes in eight grades and more than 10 geometries, along with custom sizes and tolerances. The tools work with any precision toolholder. They hold tolerances from 10-15 µm and produce surface finishes from Ra 0.2 µm to Ra 1.2 µm. Seco inspects each Nanojet solid-carbide reamer and documents its measured diameter for consistent performance.

Many industries, including general engineering, automotive and aerospace rely on secure, reliable reaming to avoid costly scrap. According to Jean-Bernard Hantin, product manager at Seco, manufacturers realise that poorly manufactured or incorrectly specified reamers can jeopardise high-value parts. “Nanojet solid-carbide reamers provide cost-efficient performance with much needed quality and stability,” he says.

Seco Nanojet solid-carbide reamers are available in stock and custom diameters down to 1.461 mm. Through the online Seco MyDesign tool configurator, machine shops can obtain custom tools with the stability, reliability and availability of commodity products.

More information www.secotools.com

When machining heat-resistant materials, such as titanium and other super alloys, two factors play an especially crucial role in controlling temperature and minimising downtime: high-quality tools and a targeted coolant supply. The new additively manufactured MaxiMill-211-DC indexable insert milling system from Ceratizit showcases how proper nozzle positioning can prove a true differentiator.

“If the machining of titanium and superalloys is to take place in a financially viable manner, professionals often have to deviate from the proven ‘roadmap’ and be open to trying new strategies,” says Robert Frei, product manager at Ceratizit. “It’s for such stubborn instances that we developed our 3D-printed indexable insert milling system, the MaxiMill-211-DC.”

Optimised coolant is essential for achieving top-quality results, especially when machining titanium and other heat-resistant materials. Ceratizit says it is here where the patented shoulder mill shines, thanks to precision coolant placement on the milling indexable insert flanks.

“Additive manufacturing processes are no longer mere nice-to-haves, they are essential to achieving results that would be impossible with conventional strategies,” explains Frei.

Ceratizit’s team of engineers sought to optimise the flank cooling process. The objective was to funnel the maximum amount of coolant directly on the flank, which sounds straightforward enough. However, pulling it off required a very complex construction process, which was only made possible by additive manufacturing. In doing so, Ceratizit is able to guarantee full coverage wetting of the coolant on the indexable insert cutting surface. 

Despite the complexity of the numerous coolant holes present inside the tool body, the MaxiMill-211-DC is compatible with standard adapters with through-coolant supply, without requiring any standard coolant on the chip breaker.

More information www.ceratizit.com