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

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

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

Recent years have shown the machining industry that sustainable cost containment holds the key to stability and survival, even in turbulent economic periods. At the same time, the industry needs faster ways to develop new technologies and tools that can respond to changing circumstances. Smart software is a key to making these developments responsive and effective. In certain situations, it can enable manufacturers to optimise machining and production processes by up to 40%, eliminating some of the repetitive manual processes.

Non-digitised processes force production personnel to look up product information manually, which wastes time and may not yield accurate results. For example, with the help of Seco Assistant smartphone app, production personnel can simply scan the product package or tool to reduce the time required for routine tasks on the shop floor. As a result, operatives can quickly receive relevant product information or calculate cutting data and compare insert geometries and grades from different suppliers.

Some 30-60% of tooling inventory is likely to be uncontrolled, floating around the shop floor or simply stacked by machines in excess quantities. Smart software, such as the Seco Inventory Management system, can help to tackle this issue in a more cost-effective and secure way. Apart from physical flexibility, its main benefit lies in monitoring tool and equipment usage, and increasing staff accountability. This way, the inventory management systems help to reduce wasted set-up time because of misplaced items and keep track of high-value tools and mission critical items.

According to Seco, smart software can eliminate the unnecessary inventory of materials and tooling for up to 20% lower inventory costs. With processes optimised for efficiency through technology that removes repetitive manual processes, labour productivity can rise up to 30% and machine downtime drop by up to 50%.
For further information www.secotools.com

Allied Machine and Engineering, a manufacturer of hole-making and finishing cutting tools, is launching a new series of Wohlhaupter fine-boring lay-down cartridges. The ES-Bore (Easy Set Bore) and inventory will be available from 16 October.

The new lay-down cartridges are easily mountable to the body of a custom tool, while the dimensions allow the cartridge to fit on existing bodies and replace current lay-down cartridges, in addition to providing 3ETECH+ functionality.

When used with standard Wohlhaupter components, the lay-down cartridges have a diameter range of 28 to 3200 mm. However, a maximum boring range is not definable for custom boring tools as the range is unlimited and application-dependant. Currently, the cartridges are available for two different insert sizes – the ISO form 101 and Wohlhaupter’s form 20 insert – providing suitability for all common materials.

For customers looking to build their own custom tool, the ES-Bore is available in analogue or digital versions for use with the new 3ETECH+ digital readout module. The 3ETECH+ provides enhancements such as improved visibility with a larger OLED display screen, improved diameter adjustment accuracy of 1 µm and a rechargeable battery via USB-C.

This new product introduction provides the possibility to design custom tools incorporating the ES-Bore lay-down cartridges, allowing customers to receive special tools within a shorter delivery time and at lower cost. Additionally, the release of the fine-boring cartridges gives users the opportunity to build their own special tool because the customer only needs an ES-Bore lay-down cartridge for mounting to the boring bar in manufacture.
For further information www.alliedmachine.com