INTERNATIONAL NEWS

Reducing consumables spend:is it worth it?

Although it is understandable that consumable cost is often a target for savings, does the result justify the effort?With modern grinding machines costing anything up to £1m, the productivity or OEEof machinery and manpower can deliver multiple times the total consumable cost. Assuming the cost for a machine, labour and overhead is £150 an hour, how does this compare with consumable cost per hour? In recent tests using the latest generation of Viper wheels, Tyrolit was able to decrease cycle time by as much as 30%.
Considering consumable unit costs at approximately £25 each (Viper wheel) and machine platform at £150 per hour, a 30% time saving reduction is equal to £45, outweighing the cost of the consumable in just one hour.

Tyrolit says that its Toolscope modular assistance system is a revolutionary retrofit for any machine tool digitalisation project. The system creates measurable added value for customers through increased process transparency featuring numerous process options, such as OEE, collision detection, condition monitoring and more. This capability provides a window into machining practice and process, subsequently allowing customers to achieve consistent process quality by reducing scrap, downtime and cost.

As Tyrolit celebrates 25 years of partnership in the development of Viper grinding wheels, the introduction of a third generation is a complete game changer, reports he company. Tyrolit UK’s latest offering, the Viper Ultra Ceramic Hybrid wheel, uses its own ceramic blend but retains Tyrolit’s bond technology from its predecessors. Having only been on the market for 18 months, the results, its performance and the feedback from customers have been outstanding, reports Tyrolit.
For further information www.tyrolit.co.uk

Consistent gloss finishes in high quality

The field of surface finishing is characterized by demands for higher quality with increasing need for process consistency, traceability and resource efficiency. Frequently, this requires new finishing methods. With the DryLyte system, Rösler offers a system for electro-polishing metal components that require a perfect finish.

Contrary to traditional electro-chemical polishing, DryLyte is a dry process that utilises solid particles containing electrolytes. As a result, there is no need for acid baths or other process liquids. According to Rösler, the benefits of this technology include excellent surface finish, high geometrical consistency of workpieces, lower CO2 footprint and reduced costs for waste disposal. Furthermore, there is no more costly and complex treatment of used process liquids, while the finished workpieces emerge from the system perfectly clean.

The fully automatic DryLyte system simplifies and helps to standardise different surface finishing tasks such as deburring, surface smoothing, surface grinding, high-gloss polishing and even the post processing of 3D-printed components. Depending on the initial surface conditions und the specified finishing quality, it is possible to use dry electro-polishing as a stand-alone process or in combination with known mass finishing, shot blasting or other pre-grinding methods.

DryLyte technology applies the principle of electro-chemical material removal from the surface of components. However, the technology does not use liquid electrolytes but a multitude of polymer pellets in different sizes containing electrolyte media adaptedprecisely to the respective finishing task. In contrast with traditional electro-polishing systems, no hazardous vapours form that require energy-intensive exhaust systems and special protective gear for the operator. In addition, since electrolyte medium absorbs the material removed from the workpiece surface, no dust or metal particles escape into the environment, as happens with manual grinding and polishing operations.
For further information www.rosler.com

Improved turning of small stainless steel parts

To improve performance when machining small parts, Mitsubishi Materials is adding a new insert grade to its range of precision turning inserts. Suitable for sliding-head turning centres and intricate machining, the new MS7025 grade is now the company’s insert of choice for small stainless steel workpieces.

The multi-layer nano coating combines a high lubrication layer that boosts welding resistance, with a high hardness layer that suppresses wear progression. The damage caused typically by contact with the workpiece also sees a significant reduction, thus increasing tool life.

Mitsubishi’s high lubrication layer suppresses built-up edge caused by chip welding that tends to occur in low feed and low cutting speed machining. The company performed a comparison test between MS7025 and a conventional grade to assess dimensional changes during the low feed and low cutting speed machining of stainless steel components (SUS440C, DIN1.4125). Results showed a large improvement in dimensional accuracy after machining many parts, thereby reducing the number of insert changes. Another important benefit was the generation of consistently high quality surface finish

The MS7025 grade features a minus corner radius tolerance to ensure precision corner geometry on workpieces. The minus tolerance is available with designations 02M and 04M, which have a precision minus corner radii between 0.15-0.20 and 0.35-0.40 mm respectively. The series is available with two chip breakers: the FS-P for micro through to low depths of cut; and the LS-P for medium to high depths of cut. These chip breakers feature geometries suited to each type; both having a mirror finish polished surface for efficient chip evacuation. They also have high-quality cutting edges that maintain dimensional accuracy and reduce burrs, reports Mitsubishi.
For further information www.mhuk-carbide.co.uk

Horn launches boring bar with adjustable damping

German cutting tool and insert manufacturer Paul Horn unveiled new products and range expansions at the EMO 2023 trade fair in Hanover last month. Among the highlights was a boring bar with adjustable damping, which visitors could see carrying a grooving insert.

A long overhang can cause a turning tool to oscillate when boring internal geometries. In addition to causing chatter marks on the surface of the machined component, vibrations can lead to a significant reduction in tool life. For unfavourable length-to-diameter ratios, even damped boring bars may vibrate under certain conditions.

To address this problem, Horn has developed a boring bar that can be set to match the oscillation amplitude during machining. Precise adjustment enables vibration-free turning, resulting in better surface quality and a significant increase in insert life.

The damping element, a carbide rod supported in O-rings, is adjustable from the outside by turning a screw to fine-tune the pre-tension of the rings. This capability allows users to set the boring bar accurately to minimise any vibration predicted to occur during a machining cycle.

As standard, Horn offers the boring bars from stock in length-to-diameter ratios of 5:1 and 8:1. Higher ratios are available as special tools. In the case of grooving, Horn can provide the S224 double-edged system. The manufacturer’s BK 224 cassette system ensures a stable interface between the boring bar and grooving insert. To increase process reliability further, the tools have an internal coolant supply.

Markus Horn says: “As a precision tool manufacturer, we not only have to master our own products but the entire machining process, right down to the material being cut.”
For further information www.phorn.co.uk

Walter DC166 Supreme has new web thinner

In the field of aluminium machining, operators often look for more specialist tools as their requirements are typically very specific. Now, with the new DC166 Supreme, Walter is demonstrating just how special a standard drill can be.

This solid-carbide drill with internal coolant is for machining aluminium and other ISO N materials, which is why it boasts certain distinctive features. All the key surfaces on the drill – such as flutes, lands or clearance angles – are polished, reducing friction and preventing adhesion when machining the highly adhesive material. The effect is greater tool life and process reliability.

According to Walter, the patent-pending thinner web of the DC166 Supreme is like nothing else on the market. It prevents built-up edge, improves chip removal and enhances the supply of cooling lubricant.

The company says that its design facilitates high cutting speeds in conjunction with drilling quality, especially in terms of hole roundness and surface quality. Walter’s DC166 Supreme is suitable for use with emulsion, oil or minimum quantity lubrication (MQL), at depths up to 5xD with a diameter of 3 to 12 mm.

By having the Walter DC166 Supreme available as standard, Walter can quickly show the drill’s performance in action to potential users. At the same time, the company offers the drill as a special tool (up to 30xD in diameters from 3 to 20 mm) via the Walter Xpress Service. This service provides a shorter delivery time of two weeks maximum. The DC166 Supreme is of interest for all areas of application involving ISO N materials, especially the automotive sector and aircraft manufacturing.
For further information www.walter-tools.com