skip to Main Content
Advantages Of Collaborative Development

Advantages of Collaborative Development

The larger the series of parts to be produced, the more important cycle times and tool costs are. And the properties of both the machine tool and the tool itself need to be optimally suited to each other—and to the chosen manufacturing process. This article discusses the benefits of having a collaborative development partnership between a machine manufacturer and a tool manufacturer. Article by MAPAL.

“We have a unique approach when we receive customer inquiries,” says Meinolf Wolke, Sales Team Leader at Elha-Maschinenbau Liemke KG  in Hövelhof. The special machine construction company places the workpiece and its machining at the centre of development and devises an optimal solution perfectly designed for the process sequence.

“In doing so, we take all the technical and economic requirements into account,” clarifies Wolke. Only then do those responsible decide whether an existing machining concept can be used for the process or whether an individual, application-specific construction is required. Wolke explains, “As well as providing the machine, we offer services that stretch from process development and the construction of fixtures all the way through to complete, ready-to-operate solutions with automation and production support.”

Special Tools for Low Total Costs

“The machining tasks are often as unique as the parts themselves – including in terms of the workpiece materials,” adds Alexander Wiesner, Technical Advisor at MAPAL. “Of course, a lot of machining work on complex parts can be achieved with standard tools. But that often comes with significant drawbacks in terms of cycle times, quality, and cost-effectiveness, particularly when large quantities are being produced.” In these cases, special tools that are precisely calibrated by MAPAL for the machining task in question are preferred.

“During the tool design phase, it’s essential to determine the necessary parameters for the machining process,” says Wiesner, “particularly in the case of challenging geometries.” In order to design the process in the best possible way, MAPAL often makes prototype tools. These are then used to carry out extensive tests with the part to be machined.

“That, in turn, helps the equipment manufacturers design the machine with the values identified during testing,” continues Wiesner. He says that MAPAL has had a long-standing partnership with ELHA in this area. The following three examples demonstrate the resulting benefits to customers:

Solid Drills for the Machining of Suspension Arms

“We were dissatisfied with the solution that we had been using for drilling from solid in aluminium when machining a suspension arm, which included creating a fitting,” remembers ELHA Project Leader Friedhelm Dresmann.

At the time, the company was using tools with brazed PCD cutting edges. In order to keep the machining time as low as possible, these drills were being used with very high feed rates. The disadvantages of this solution were the high drive power required and the insufficient durability of the PCD cutting edges on the solid drill step.

 

To continue reading this article, head on over to our Ebook!

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Ready For Direct Connection: igus Hybrid Cable For New Motor Generation

ANCA Updates Toolroom For Barrel Shape Ballnose Endmills

Achieving Consistent Quality

NUM Launches Digital Twin Technology For CNC Machine Tools

On The Safe Side When Drilling

A Drill for All Materials

Smart Manufacturing Market to Reach US$573B By 2027

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

A Drill For All Materials

A Drill for All Materials

It’s said that life is a marathon, not a sprint. For automotive manufacturers, longer lasting tooling solutions are integral to more profitable production—but, often, manufacturers see little reason to change their existing tool set-up. In this article, James Thorpe, global product manager at Sandvik Coromant, explains why the benefits of longer-lasting tools shouldn’t be underestimated, particularly for reducing costs-per-part or increasing overall output.

A Drill for All Materials

Unpredictable tool life is one of the biggest threats in mass automotive production, particularly as its operations are so highly-automated and use some of the world’s most advanced robotics and automation systems. Downtime is time-consuming, disrupts production and is also expensive, so it goes without saying that tool failures should be avoided at all costs. 

In some instances, manufacturers set the tool change interval to less than the maximum tool life. This approach is normally preferred because material variations in automotive components are minimal. It follows that the tool changes should be predictable, and safer, than trying to extend the tool life to manufacture a few more components. 

Multi-material Drilling

For Sandvik Coromant’s specialists, the key to longer tool life is not limited to the amount of time a tool spends in use, but also the drill design itself. This approach led to the development of the CoroDrill 860 with enhanced -GM geometry, a new design solid carbide drill that’s optimized for a wide range of materials and applications, across all industry sectors. 

For the CoroDrill 860-GM, Sandvik Coromant applied its machine tooling and metal cutting expertise to develop a new grade, a unique fine-grained carbide substrate known as X1BM. The fine-grained carbide is imbued with increased hardness while maintaining toughness.

Furthermore, the drill is tip-coated with a multi-layer physical vapor deposition (PVD) thin film coating. This is key to improving the drill’s productivity and delivering a consistent tool life across a variety of materials. The result is a tool with excellent stability, machining security and improved tool life when machining cast iron, steel, stainless steel, hardened steels and non-ferrous metals.

Assessing Tool Life

A better way to assess tool life is by measuring the amount of material removed. To aid productivity, the CoroDrill 860-GM has an innovative, polished flute design that improves the evacuation of chips and yields greater hole quality. This also helps to reduce heat build-up in the tool, and further benefits are high core strength and reduced cutting forces while drilling.

The 860-GM forms part of Sandvik Coromant’s CoroDrill range of solid carbide drills. They are designed not only for optimized performance but also versatility, which means they can be deployed in a variety of applications and materials across multiple industries.

This includes use with the following material groups: ISO-P, the largest material group in metal cutting that ranges from unalloyed to high-alloyed material; ISO-M that includes difficult-to-cut stainless steels, austenitic steels and duplex steels; ISO-K grey, nodular and compacted graphite cast iron; ISO-H steels with a Rockwell hardness of between 45-65 HRc; and ISO-N for softer, non-ferrous materials such as aluminium, copper and brass. 

Advanced Geometry

As mentioned, the CoroDrill 860-GM has an enhanced design, but what exactly does this entail? Much of this relates to the design of the drill itself that includes an advanced optimized point and flute geometry, reinforced core and corner chamfers, edge preparation to remove cutting edge micro defects, and a double margin to enhance drilling stability. The drill’s point is also designed with refined clearance angles and improved surface quality. 

Overall, these design features stabilise the drill, reduce entry and exit burr and improve the hole tolerance, finish and straightness. The drill also gives stable wear progression and delivers excellent hole accuracy. 

To continue reading this article, head on over to our Ebook!

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Profound Machinery Benefits Of A Multi-disciplinary Design

Expertise In Grooving For Small Part Production

Global Aerospace Materials Market To Reach US$10.8 Billion By 2025

Walter Strengthens Tool Offering With Acquisition Of Melin Tool Company

Customising For Efficient And Consistent Performance

Long Tool Life In Series Production

Making the Industry More Sustainable with the Circular Economy

Accelerating the Journey to Series Production

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Kennametal Introduces Flat Bottom Geometry For KenTIP FS

Kennametal Introduces Flat Bottom Geometry For KenTIP FS

Kennametal has expanded its replaceable drill offering for KenTIP FS modular drill series with the new FEG insert for flat bottom hole applications. Applicable in steel, cast iron, and stainless steels, the FEG insert eliminates end milling operations and completes a task in a single operation, saving time and tooling costs.

Drilling flat-bottom holes is a challenge. So is drilling on inclined or curved surfaces, drilling into cross holes, drilling stacked plates, and drilling into cross holes, stacked plates and castings and other rough surfaces. Not anymore. Leveraging the success of its KenTIP FS modular drill, Kennametal has developed a unique insert geometry (FEG) that streamlines many of these types of applications and simplifies the drilling of counterbores and pilot holes as well.

“The FEG insert is so versatile, you can use it for nearly all your drilling applications”, says Georg Roth, Kennametal’s Global Product Manager of Holemaking for Modular Drilling Tools.

Get to the point

Aside from one-step drilling of flat-bottom holes, the KenTIP FS-FEG excels at drilling through
cross-holes, inclined exits, and for use as a pilot drill in deep hole applications up to 12xD.

Conceptually, the FEG geometry design is simple. It features a 180 deg cutting edge, and a conical center point, which acts as a pilot to provide exceptional hole position and straightness. Corner chamfers serve to protect the cutting edges and reduce exits burrs. Four margin lands provide stability when breaking into interrupted cuts and cross-holes. And Kennametal’s KCP15A grade uses a nano-structured AlTiN coating and fine grain carbide substrate, providing both toughness and wear resistance when drilling steel, stainless steel, and cast iron. The diameter range covers 6.0 – 26.0 mm (0.236 – 1.024 in.) and drilling depth of up to 12xD is possible depending on the KenTIP FS modular drill body.

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Sandvik Coromant Launches Indexable Drill for 7xD Hole Depth

New High-Definition Feature Scanner For Automated Inspection

Tungaloy Eliminates Coolant Hose Connections with TungTurn-Jet

TTD-Tritan – Machining of heat exchangers taken to the next level

Expertise In Grooving For Small Part Production

Wider Range for Heavy-duty Cutting Needs

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

An All-rounder In Metal Cutting

An All-rounder In Metal Cutting

Here’s how a 5-axis universal machine revolutionised the production processes at Polar-Form Werkzeugbau GmbH. Article by GROB.

G550 5-Axis universal machining centre at POLAR-FORM Werkzeugbau GmbH.

Permanent bottlenecks in the milling area and high time and cost pressures in production have, over the years, convinced POLAR-FORM Werkzeugbau GmbH to purchase a 5-axis universal machining centre with automation. An internal technical committee with all decision-makers and machine operators determined what the new machine was capable of or, better still, what existing problems it had to solve. This included issues such as deep hole drilling, milling, high payload weight, large additional tool magazine, large working memory, enormous data volume, limited space, pronounced reliability, and perfect automation.

After intensive market research, three machines were finally selected. The final decision was made in favour of a 5-axis universal machine from GROB, which is equipped with a circular pallet storage system and additional tool magazine.

“We never had any doubts about our decision, but what this machine can really do only gradually became clear to us,” says Polar-Form Production Manager Dietmar Klötzle.

Optimal Configuration – Perfect Training

The detailed work began once it was certain that a machine from GROB would be purchased. Despite the limited space available, the GROB layouts and installation plans enabled the perfect location to be found quickly. 

The training of the employees took place on-site at POLAR-FORM. Even in the initial phase, the trainees practiced on a range of parts that are actually produced at POLAR-FORM.

“The idea behind this was to have the machine demonstrated on POLAR-FORM parts and not just on any sample parts,” says Klötzle. Since the programming of the machine was also carried out on-site using a CAM program, all the employees concerned could be called in and thus were trained from the very beginning. This way, all of the basic settings were quickly covered via testing and the horizontal spindle concept of the new GROB machine could be illustrated very clearly.

Machine programming was also very simple, since it was possible to load the programs much more elegantly than before via the programming station, and this no longer had to be done directly at the machine. “It soon became apparent just how well the CAM system communicates with the G550 and Heidenhain control system,” recalls Michael Gür, team leader for rough cutting at POLAR-FORM. Now the cycles can be transferred one-to-one to the G550—a procedure that was not possible with the previous machines.

To continue reading this article, head on over to our Ebook!

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Enabling More-accurate Measurement in the Micron Range

Profound Machinery Benefits Of A Multi-disciplinary Design

Sheet Metal Fabricator Cuts Inspection Time by 60%

Machine Shops in a Challenging World

Competence Days 2019: New technologies, New Solutions

FARO Launches Latest 3D Portable Gage CMM

Process Efficiency in Focus

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Grade Upgrade

Grade Upgrade

Has the development of new tool materials already reached its peak and is experiencing stagnation? Find out more from Andrei Petrilin and Marcel Elkouby, ISCAR.

Grade Upgrade

Fig 1: CBN grade IB20H insert for hard part turning.‎

Building a house begins with laying the foundation. The strength and the reliability of the whole house depends on how strong the foundation is. In cutting tool engineering, this foundation is a cutting material.

There are various types of cutting materials: cemented carbide, polycrystalline diamond, high speed steel, and ceramics, to name a few. Each type contains different grades. At various stages in metal cutting history, the introduction of each cutting material and its use has led to a significant change in the level of cutting speeds and, consequently, productivity. However, if the previous century, especially its second half, was marked by the rapid progress of tool materials, today we do not see any significant new solutions in this field. Does this mean that the development of new tool materials has already reached its peak and is experiencing stagnation?

Of course not. It is simply that the new developments are deep within the cutting material and are focused on its structure, and can be observed only with the help of scanning electron microscopy (SEM), X-ray diffraction (XRD), electron backscatter diffraction (EBCD), and other sophisticated methods. They cover a tremendously complicated world of coatings that is extremely diverse despite its very small thickness, measured only by microns. 

Cemented Carbide

Grade Upgrade

Fig 2: Parting tool carrying IC1010 grade insert‎.

The most commonly available cutting material today is cemented carbide (primarily coated), also known as ‘hard metal’, ‘tungsten carbide’ or simply, carbide. In terms of performance, it represents a reasonable balance between efficiency, tool life and cost. A combination of cemented carbide, coating, and post-coating treatment produces a carbide grade. Only one of these components—the cemented carbide—is an essential element in the grade. The others are optional.

Cemented carbide is a composite material comprising hard carbide particles that are cemented together by binding metal (mainly cobalt). Most cemented carbides used for producing cutting tools integrate wear-resistant coatings. There are also various treatment processes that are applied to already coated cemented carbide (for example, the rake surface of an indexable insert). New developments in cemented carbide, as a tool material, are concentrated in three directions: carbide production technologies, advanced coating methods, and innovative post-coating techniques. Considerable success has been achieved in each of these directions; this is reflected in the wealth of new products introduced to the market by leading cutting tool manufacturers.

Cutting tool customers might analyze the grades using parameters such as productivity, tool life, and performance. Indeed, the question of how a new product was created to meet customer requirements fades into the background as applicability and efficiency form the main measure of progress from the customer’s  point of view. 

Upgrading Carbide Grades

In upgrading carbide grades, ISCAR is very sensitive to a challenge faced by the metalworking industries. In this context, ISCAR’s tool material solutions—developed considering the trends of modern metalworking—can be quite indicative. Take, for example, difficult-to-cut materials such as titanium and heat-resistant steels and exotic superalloys. Recently, the share of their application in industry has increased significantly. Along with the aircraft industry, a traditional consumer of these materials, they may be increasingly found in power engineering, automotive, and oil and gas branches. The growing usage of the materials demands technological solutions, including machinery and cutting tools. The new tools require an appropriate foundation, made of advanced cutting tool materials,  to achieve the desired cutting geometry. And for the construction of this foundation, ISCAR offers its new effective ‘bricks’—upgraded carbide grades. 

 

To continue reading this article, head on over to our Ebook!

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Walter Launches Double-sided Indexable Inserts

Round Tool Concepts: Indexable, Solid or Both

Long Tool Life In Series Production

The Next Stage In The Evolution Of ISO Turning

c-Com Projects With MARPOSS And Oerlikon Balzers To Introduce Intelligent App For Tooling

Seco Tools: Prevent Delamination In Hybrid Stacked Material Machining

Schunk Releases Robot Deburring Tool

Doosan Machine Tools Partners With TITANS Of CNC

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

New Dimensions In Deep-Hole Drilling With Walter

New Dimensions In Deep-Hole Drilling With Walter

With the X·treme Evo solid carbide drills from the DC160 Advance range of drills, Walter is forging a link to the “next generation of drilling”. By introducing lengths of 16 to 30 × D, the tool manufacturer its expanding its range to now include deep-hole drilling. As the successor to the Alpha 4XD drills which have been established on the market for a long time now, the DC160 Advance, like its predecessor, makes deep-hole drilling possible in a single operation without pecking – and therefore boasts the advantages of XD Technology. The coating and geometry have been optimised. Just like the existing versions of the DC160 Advance, the deep-hole drills also feature the innovative new thinner web with 140 deg point angle and the fourth land in an advanced position. The former ensures increased positioning accuracy and reduced cutting forces in the centre, while the latter optimises the guidance of the drill.

The grades of the drills (WJ30ET and WJ30EU) are another new addition. These comprise the K30F fine-grained substrate and a TiSiAlCrN/AlTiN multi-layer coating (as a point or complete coating). The layer structure makes the drills both tough and wear-resistant and plays a crucial part in the process reliability and performance of the DC160 Advance drills. Polished flutes from 8 × Dc also optimise chip evacuation. Typical application areas of the drills, which are available with or without (internal) cooling, include general mechanical engineering, mould and die making, and the energy and automotive industries. Walter offers intermediate sizes and special dimensions via its Xpress service with faster delivery times.

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Walter Expands Perform Product Range With New Milling Cutters With Corner Radius

Walter: Machining Titanium Quickly And Safely In Aerospace

Expertise In Grooving For Small Part Production

Hexagon Intros Modular Metrology Fixtures to Online Shop

Crash Course In Milling: Drilling, Tapping, and Boring

Hexagon Expands AICON SmartScan Range

Sandvik And Renishaw Collaborate To Qualify New AM Materials

 

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

On The Safe Side When Drilling

On The Safe Side When Drilling

Walter Tools is completing its D4120 product range. With dimensions of 2, 3, 4 and 5 × D, the Tübingen-based company offers a wide range spanning diameters from 13.5 to 59 mm. Specially developed outer and centre inserts ensure precise balancing of the cutting forces. To this end, centre inserts slightly larger than the outer indexable inserts were selected and equipped with a corner protection chamfer. Besides greater process reliability, this plays a crucial part in increased precision and minimal drilling noise. Walter offers a version with wiper edge for high surface finish quality. The drilling body features two coolant-through channels and a measuring collar (Dc) for easy drill identification, even when assembled. Polished flutes and a hardened surface optimise chip evacuation and wear resistance.

The combination of D4120 and four-edged indexable inserts offers users cost-efficiency advantages and the greatest possible flexibility thanks to a coordinated system. This is of interest to users, both in the case of difficult machining operations, such as cross holes, chain drilling and inclined inlets and exits, and because these drills can be used in ISO materials P, K, M, N and S. Users in general mechanical engineering, mould and die making, and the energy and automotive industries could therefore benefit from outstanding precision in the hole diameter, a high degree of process reliability and cost-efficiency. Alongside the standard dimensions, Walter also offers the D4120 in special dimensions via Walter Xpress with faster delivery times.

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Reliable, Cost Effective Serial Production Of Turbochargers

Hexagon Intros Modular Metrology Fixtures to Online Shop

Walter Ewag: Laser Line Precision

Multisensor Measurement: Into A New Era

Seco Tools: Prevent Delamination In Hybrid Stacked Material Machining

Hypertherm Implements Strategies to Enhance Preventive Maintenance Program In Asia

Benefits Of Improved Multisensor Measurement

Automation And Digitalisation Pave The Way Forward For Smart Metal Industries

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Reducing Cost-Per-Part Of Your Tools

Reducing Cost-Per-Part of Your Tools

Drilling and threading work with round tools influences approximately 15 to 50 percent of the total costs per part in the automotive industry—therefore being able to reduce costs here remains a key factor for success. Article by Walter AG.

Not only does the Walter Technology Centre present opportunities for visualisations and simulations, it also allows developers to test new solutions on the machine.

The cost per part (cpp) is the gauge by which process efficiency is measured in the automotive industry. The machining tool represents a not inconsequential cost factor in this regard. This is particularly true of solid carbide tools (round tools), which are primarily used for holemaking, milling and threading.

Estimates calculated by tool specialists Walter AG indicate that these tools already make up around half of the machining applications in the automotive industry today. Depending on the characteristics of the component, drilling and threading work with round tools influences approximately 15 to 50 percent of the total costs per part. Being able to reduce costs once again here remains a key factor for success.

Up to Speed with Automotive Industry Trends

The Walter TC 430 thread former produces tear-resistant threads under the application of dynamic force.

The transition from combustion engines to electric motors or other alternative drives, which is gaining momentum as a result of tighter environmental regulations, touches every area of the automotive industry—right up to every last detail in the production processes. Walter has been on hand to actively accompany the sector through these changes from the very start: The company presents car manufacturers and suppliers around the world with a comprehensive portfolio of tools and services, which is constantly expanding through the addition of innovative new solutions. This means the automotive experts at Walter are always up to speed with the ever-growing number of new materials. What’s more, existing tool solutions for established processes are also optimised, usually to meet customer-specific requirements, or alternative solutions are devised on the basis of new technologies.

Lightweight materials now represent a significant portion of automotive production. For instance, the proportion of engine blocks made from aluminium today is already around 70 percent—in an area of industry that until only recently still favoured traditional materials such as grey cast iron and steel. Aluminium alloys have already become the default materials for transmission cases or oil pump housings, both for chassis elements and in structural components. And with the growing trend for electric drives, we will see more and more of these alloys in use.

Seeing the Bigger Picture to Reduce Costs

Complicated machining tasks, including those involving these new materials, or sophisticated part geometries with a lot of cavities increase the complexity of the machining process and, in turn, put extreme pressure on costs. This is where the Walter machining experts come in.

“As a manufacturer of premium products with 100 years of experience, we already offer highly effective and optimum solutions for a diverse range of applications from our standard range, which comprises more than 25,000 products in the solid carbide segment alone. Walter’s expertise, or ‘Engineering Kompetenz’, however, extends far beyond the individual machining tool. We focus on the overall machining strategy and the customer’s machining process. If our experts are involved in the development of production and tool management processes from an early stage, customers will often experience efficiency gains that are felt via more than just the machining tool,” explains Gerardo Campitiello, Component Manager Transportation at Walter. “Requirements, such as making unmanned production processes safe, ensuring reproducible process reliability and quality across a company’s production sites, or making tools available at all times, can only be met by taking a holistic approach. Whether selecting the right tools from the Walter standard range or developing a special tool to meet process-specific specifications, it takes careful consideration of the full picture.”

A Quick Path to an Instantly Productive Special Tool

In the automotive industry, processes that may seem time-consuming on paper are actually completed in very tight time frames in practice. It is with this in mind that Walter establishes its own processes and structures: For instance, tools from the standard range are with the customer within 24 hours of ordering. The Walter Xpress special tool service ordinarily delivers tools, which are developed and manufactured to customer specifications, within two to four weeks. This is based on an automated 3D process, which can be adapted to suit the project in question. A dedicated in-house department (Business Applications Development) constantly monitors market trends to improve existing application solutions and develop brand new approaches. This team of engineers takes on the role of Component Managers, responsible for individual components such as engine blocks, housings, e-axle drives, turbine casings, or crankshafts. They are among the first to know about the market trends and technological advances, which is reflected in their product development work.

The new Walter solutions can be tested in true-to-life situations at the Technology Center in Tübingen, Germany: the test run on the machine incorporates the very latest visualisation and simulation technologies.

This means Walter customers in all areas of the automotive industry benefit from the in-depth technical expertise of an innovative service provider who is active the world over and is also involved in the relevant fundamental research. The company makes major investments in its own R&D projects, and in the development of its own production capabilities in areas that competitors often contract out to third parties—such as being one of the few providers on the market to have its own coating system.

 

 Greater Pull-out Strength Under More Dynamic Forces: The Walter Thread Former

When forming threads in ISO P materials, the process reliability primarily depends on how susceptible the thread former is to breaking. With its TC430, Walter provides a model that stands out  for its durability. The extremely long tool life of the TC430 thread former, which is suitable for blind-hole and through-hole threads, is the result of a new substrate, the geometry with more  polygons, and an innovative new kind of pre-treatment and post-treatment. The result is that, despite having more polygons, the TC430 Supreme reduces the torque by around 30 percent. This  means that the thread former is also well suited for use in machines with a low power consumption.

Walter is planning to launch another carbide thread former for ISO P materials in early 2020. The new tool has already proven its exceptional properties in ongoing field tests. Designed for blank holes and through holes of up to maximum 3.5xDN, it demonstrates twice the tool life of comparable formers, and enables the reduction of power consumption on the spindle by more than 30 percent.

 

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Addressing Dirt And Oil In Deep-Hole Drilling And Milling

Addressing Dirt and Oil in Deep-Hole Drilling and Milling

The continuous dirt accumulation poses the biggest challenge for the deep-hole drilling and milling machine. This article looks at how the energy supply for such machines can be maintained reliably under extreme environmental conditions. Article by igus.

The AX-TLF series from Auerbach Maschinenfabrik GmbH combines conventional milling techniques with modern deep-hole drilling systems in one machine.

In machines combining milling and drilling functions, extremely high demands are made on the energy supply system for the main spindle. Dust, dirt and drilling fluid account for maximum loads from the outside. From the inside, heavy hydraulic hoses, in particular, affect the stability. Most of the time, the manufacturer relies on the very thick plastic energy tube for supply so that the performance data of the universal machine remains correct in the long run. This also protects and routes all cables and hoses.

“The continuous dirt accumulation poses the biggest challenge for the deep-hole drilling and milling machine,” says Thomas Gemeinhardt, managing director of the Auerbach Maschinenfabrik GmbH in Ellefeld. “In addition, the performance data of the machine tools increase, but the availability of interior space remains the same. To supply energy to the main spindle reliably, Auerbach uses the new energy tube ‘RX’ in its multi-function ‘AX-TLF’ type, which combines the milling and deep-hole drilling systems in one machine.” According to Gemeinhardt, it is 100 percent tight and ensures safe cable protection even in continuous use.

Milling and Deep-hole Drilling Systems in One

Manufacturing machine tools for over 60 years, Auerbach Maschinenfabrik manufactures not just the traditional milling machines, but also multi-functional machines.

Gemeinhardt comments, “Our customers want multi-functional machines. As a result, our specialty today is the combination of conventional milling techniques with modern deep-hole drilling systems in one machine.”

The ‘AX-TLF’ type series not only saves on purchase costs. The necessary set-up times can be reduced because the complete machining is possible with only one clamping. Depending on the design, the machines work on workpieces with drill diameters from 6mm to 65mm—in special cases up to 100 mm—whereby in one move, drill depths of up to 2.1mm, and in special cases up to 3mm, are possible. “We feel well-equipped for the future,” says Gemeinhardt.

Quality is top priority at the company. “With our high-quality machines, we want to constantly maintain our position as a special supplier in the market,” says Gemeinhardt. “For this, we have our own development department to implement specific customer requirements. We place value on the traditional German engineering quality. This also applies to the selection of suppliers.”

The AX-TLF type series consists of five basic machines, which serve as a platform for numerous variation options. This modularity pays off. In addition to the traditional mold-making and tooling, the combination machines are used in, among other things, the aviation and aerospace industry, general mechanical engineering, solar industry, apparatus engineering, and the oil and gas industry. This wide-ranging spectrum of applications brings more than the most varied machining demands. Even the choice of materials is wide, ranging from soft graphite through aluminum, and standard steels up to high-strength stainless steels and titanium alloys.

Thick, taut hydraulic hoses that are as hard as an iron bar increase the pressure within the energy tube.

Addressing Continuous Dirt Accumulation

“Our machines are versatile,” says Gemeinhardt. In general, they can handle all types of materials. The requirements for a machine vary, such as the components used. And in this instance, dirt accumulation plays a major role. Graphite, for example, is machined dry and is extremely abrasive and lubricating. If it is not exhausted, the entire environment would be black in the shortest time. When it comes to deep-hole drilling, where a lot of drilling oil is used, this creeps in everywhere and is extremely aggressive.

One option is the minimum quantity lubrication. It only works with customers who machine a defined material. Here, lubricated air cooled at high pressure is used for deep-hole drilling. Due to the atomized oil, the particles fly through the work area before they settle everywhere.

While supplying energy to the main spindle, the plastic energy tube lies always in the immediate chip area. This means that hot chips remain partially on the tube, and it is exposed to continuous dirt accumulation and drilling oil. In the process, the machines, depending on orders, work in three shifts for seven days a week. In addition to the extreme environmental conditions, there is a particularly small bending radius of 100mm. And taut hydraulic hoses that are as hard as an iron bar increase the pressure within the energy supply system.

The rounded design of the energy supply system simply makes the chips bounce off. In addition, the pin/hole connection elements and the stop dogs are covered, so that no chips can stick there.

Enter the RX Energy Tube

“Due to increased milling capacity, we sought an even more robust solution for the energy supply for a customer as part of a retrofit with new built-in pressure hoses,” recalls Gemeinhardt. Since that time, only the RX energy tubes in the size 40 are used in the combination machine for milling and drilling.

The RX e-tube enclosed cable carriers from igus offer extreme protection against chips and dirt.

“Our universal machine tool needs to assert itself in a tough competition. Improvements are in the details,” says Gemeinhardt. “Accordingly, we are constantly improving the performance data of our machines. We are currently developing, for example, a water-cooled spindle. Here, the machine is equipped simultaneously with sealing air, which means we must lay two more cables.” Therefore, here, the new large RX size with an inner height of 73mm should be used to ensure energy supply.

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Iscar Expands Modular Exchangeable Drilling Heads Lineup For Large Diameter Deep Drilling

Iscar Expands Modular Exchangeable Drilling Heads Lineup For Large Diameter Deep Drilling

Iscar has expanded its large diameter drilling options with the new MODUDRILL line, which features two different types of exchangeable heads: one for 33-36mm drilling and the other for 37-40mm drilling.

The MD-BODY modular body measures 400mm, is produced from high-strength steel for durability, and features a small core with central coolant hole for efficient chip evacuation. Its new patented connection withstands high torque, and its high flute helix with polished surface provides a smooth and easy chip evacuation for chips of all sizes

Carrying HFP-IQ CHAMIQDRILL solid carbide head, the MD-DFN modular head from Iscar features a robust structure with concave cutting edge design to enable drilling at high feed rates and provide IT8-IT9 hole tolerance. Its unique pocket design enables many drilling head indexes. Its special axial stopper prevents the drilling head from being extracted during retraction, while its large radial head stoppers provide high resistance to cutting forces, enabling very high cutting conditions.

The MD-DR-DH modular head carries standard SOMX indexable inserts with four cutting edges, providing an economical solution for low- to medium-feed machining.

 

FOLLOW US ON: LinkedIn, Facebook, Twitter

READ MORE IN OUR LATEST ISSUE

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

 

 

  • 1
  • 2
Back To Top