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Walter AG Presents New Grades For ISO K And ISO H Materials

Walter AG Presents New Grades For ISO K And ISO H Materials

With the WBK20 and WBK30 CBN grades, Walter is launching two new indexable inserts for turning ISO H and ISO K materials: WBK20 (grain size diameter 3.0 μm) for finishing cast iron; WBK30 (grain size diameter 10.0 μm) for high metal removal rates in ISO H and when finishing with a heavily interrupted cut. Both CBN grades are made from a substrate with a high CBN content and are also suitable for roughing and finishing sintered steel.

The WBK20 indexable inserts are “tipped”. The “CBN tip” is applied to the corners of the insert with high tensile strength by means of vacuum soldering. The WBK30 grade is made from a solid CBN substrate and allows for higher cutting speeds and therefore a higher productivity in cast iron than indexable inserts made from carbide.

In addition to the high-precision manufacturing, a strong microgeometry on the cutting edge also contributes to the high quality, productivity and process reliability of the turning insert. This microgeometry is always matched to the respective application. Walter offers the new WBK20 and WBK30 CBN grades in all of the most popular ISO sizes and radii and thereby completes its extensive CBN turning range. These grades are particularly beneficial for users from the automotive industry, general mechanical engineering and the energy industry.

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Copy Milling Cutter Brings Benefits Of Single-sided Round Inserts To Double-sided Models

Copy Milling Cutter Brings Benefits of Single-sided Round Inserts to Double-sided Models

When machining components made of materials with difficult cutting properties, such as turbine blades, drive parts or engine parts for the energy or aircraft and aerospace industries, round insert milling cutters are often the first choice. Until now, single-sided indexable inserts have primarily been used for this purpose. With the indexable insert size RNMX1005M0 for small depths of cut, Walter AG is bringing an extension for the M2471 copy milling cutter to the market – the first to feature a double-sided round insert with eight useable cutting edges.

The system for milling cutters with diameters of 25 mm or more with ScrewFit, parallel shank or bore adaption is suitable for machining steel, stainless steels and materials with difficult cutting properties. Indexing using the flank face of the indexable insert ensures simple, safe handling.

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The M2471 copy milling cutter brings all the benefits of single-sided round inserts to double-sided round inserts, particularly in terms of their positive cutting behaviour. To ensure that this does not negatively affect process reliability, the insert and body are designed so that their overall stability is guaranteed during use of all eight cutting edges.

The technical features, as well as the eight useable cutting edges, reduce cutting material costs by up to 20 percent. Walter offers the new indexable insert in geometries ‘G57 – The universal one’ and ‘K67 – The easy-cutting one’ for medium and good application conditions, respectively. The copy milling cutter is also available in Tiger·tec Silver PVD grades WSM35S and WSP45S.

 

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Tungaloy DuoJust-Cut’s New JXPS Insert Boosts Productivity In Parting Operations

Tungaloy DuoJust-Cut’s New JXPS Insert Boosts Productivity In Parting Operations

Tungaloy is expanding DuoJust-Cut line of indexable parting tools to include JXPS inserts that features a pressed-in 3D chipbreaker for reliable chip control in during parting operations on Swiss-type lathes.

DuoJust-Cut features innovative insert clamping ensuring tool rigidity and stability in various parting operations. In addition to existing JXPG insert with a ground in chipbreaker on the rake face, the new JXPS insert incorporates a 3D chipbreaker pressed in to its “dual-rake” cutting edge which is designed to promote optimal chip control and evacuation without compromising surface integrity.

Four different types of DuoJust-Cut inserts fit in the same pocket of the tool holder, allowing an optimal insert cutting depth to be selected for a given application. An optional parting holder is also available when machining close to the sub-spindle is required.

  • At a Glance
    • JXPS insert with a pressed-in 3D chipbreaker
    • Innovative insert clamping to ensure machining reliability
    • Optimal insert cutting depths can be selected for given operations ensuring process security
    • Holder option is available for machining close to the sub-spindle
    • Total of 8 inserts to be introduced

 

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Cutting Tools That Cut Out Vibrations

Cutting Tools That Cut Out Vibrations

How to say no to vibrations in machining? Find out more in this article by Andrei Petrilin, Technical Manager at ISCAR.

Figure 2: The FINISHRED series of solid carbide endmills features chip-splitting geometry coupled with variable pitch flutes.

Vibrations in machining are generally an unavoidable part of the metal cutting process. They have a forced or self-excited nature and always accompany a cutting action. Machining vibrations are referred to as “chatter,” highlighting their specific nature, which inheres in every processing where chips are formed. Even if cutting is considered as stable, it does not mean that vibrations do not take place. In this case, the vibrations simply remain on a level that provides the required machining results, and is considered as a “no vibration” operation.

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In fact, vibrations in cutting are a damaging factor that reduces performance. Manufacturers make every effort to diminish vibration and, ideally, bring them to a level that does not affect machining results. Chatter is a subject of serious research that has already provided manufacturers with ways to model vibrations in machining which, despite their complexity, can be very effective in finding a way to reduce chatter. However, this modelling takes time and requires various input data, including sometimes additional measurements. In most cases, when manufacturers face vibrations during machining, they only have a few tools at their disposal for a real-time response to decrease the chatter. The most common practice is to vary cutting speed and feed, which usually leads to productivity reduction. Therefore, any effective method of diminishing vibrations that does not adversely affect machining operation productivity will be attractive to manufacturers.

Vibration reduction in machining requires consideration of a manufacturing unit as a system comprising the following interrelated elements: a machine, a workpiece, a work-holding device, and a cutting tool. While the influence of each element on total vibration reduction is different, improving a vibration characteristic of one element may have a significant impact on the system’s overall dynamic behaviour. Most efforts to protect against vibrations focus on developing more rigid machines with intelligent sensors and computer control, and advanced vibration-dampening tooling. Can a cutting tool, the smallest – and probably the simplest – system component, dramatically change the vibration strength of a manufacturing unit? Even though producers might not have great hopes for the role of cutting tools in decreasing chatter, in certain cases a correctly selected tool can simply stop vibration without any adverse effect on productivity.

Cutting Geometry

Figure 3: The SUMOCHAM-IQ family of HCP exchangeable carbide heads.

The right tool geometry makes cutting action smooth and stable. The geometry strongly influences cutting force fluctuations, chip evacuation and other factors, which are connected directly with vibration modes. ISCAR’s tool design engineers believe that the cutting geometry can considerably strengthen vibration dampening of a tool and have developed interesting solutions accordingly.

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ISCAR’s various indexable inserts, exchangeable heads, and solid carbide tools feature chip-splitting cutting edges. Such an edge may be serrated or have chip-splitting grooves. The chip splitting action causes a wide chip to be divided into small segments, resulting in better dynamic behaviour of a tool during machining, and vibration is stabilised. In rough machining, extended flute milling cutters remove a large material stock and work in heavy conditions. Significant cutting forces acting cyclically generate vibration problems. When using chip-splitting indexable inserts, it is possible to tackle these difficulties. Mills with round inserts, a real workhorse in machining cavities and pockets, particularly in die and mold making, are often operated at high overhang that affects rigidity and vibration resistance of a tool. Problems with cutting stability occur when the overhang already exceeds 3 tool diameters. Applying serrated round inserts with a chip-splitting effect redresses this situation and substantially improves robustness (Figure 1).

A skilfully defined tooth pitch is an effective way of taking the dynamic behaviour of a cutting tool to the next level. ISCAR’s CHATTERFREE family of solid carbide endmills (SCEM) was designed on the basis of a pitch control method. The family features a variable angle pitch in combination with a different helix angle. This concept ensures chatter free milling in a broad range of applications.

The FINISHRED series of solid carbide endmills features chip-splitting geometry coupled with variable pitch flutes (Figure 2) that provide surface finish when machined according to rough machining data.

The principles of vibration-proof cutting geometry, which demonstrated their effectiveness in solid carbide endmills , have been applied to the design of exchangeable multi-flute milling heads made from cemented carbides in the MULTI-MASTER family.

Chatter-Free Drilling

Figure 4: ISCAR’s ISOTURN WHISPERLINE family of anti-vibration cylindrical bars.

Chatter in drilling leads to poor surface finish and accuracy problems. In ISCAR’s SUMOCHAM family of assembled drills with exchangeable carbide heads, the double margin design of QCP/ICP-2M heads substantially increases tool dynamic stability. 

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If vibration occurs when a drill enters material, it may cause serious damage and even breakage of the drill. The SUMOCHAM-IQ family of HCP exchangeable carbide heads (Figure 3), intended for mounting in the bodies of standard SUMOCHAM tools, can ensure reliable self-centring capabilities. The key is an unusual concave profile for the head cutting edge reminiscent of a pagoda shape. This original cutting geometry enables high-quality drilling holes of depths of up to twelve hole diameters, directly into solid material without pre-drilling a pilot hole.

The “magic pagoda” features another ISCAR innovation: the LOGIQ3CHAM family of latest-generation drills carrying exchangeable carbide heads with 3 teeth to ensure higher productivity. The steel drill bodies have 3 helical flute that weaken the body structure when compared with a 2-flute assembled drill of the same diameter. In order to improve the dynamic rigidity, the flute helix angle is variable. This design principle in combination with the pagoda-shaped cutting edge provides a durable chatter-proof solution for stable high-efficiency drilling.

Tool Body Material

An assembled cutting tool comprises a body with mounted cutting elements such as indexable inserts or exchangeable heads. Choosing the right body material presents an additional option for forming a chatter-free tool structure. Most tool bodies are made from high-quality tool steel grades, for which the material stress-strain behavior is similar. However, in some cases tool design engineers have identified successful material alternatives to improve vibration strength.

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The MULTI-MASTER, an ISCAR family of rotating tools with exchangeable heads, provides a range of tool bodies, referred to as shanks, produced from steel, tungsten carbide or heavy metal. A steel shank is the most versatile. Tungsten carbide with its substantial Young’s modulus provides an extremely rigid design, so carbide shanks are used mainly when milling at high overhang and machining internal circumferential grooves. Heavy metal, an alloy containing around 90 percent tungsten, is characterised by its vibration-absorbing properties, and heavy metal shanks are most advantageous for light to medium cutting operations in unstable conditions.

Anti-vibration Tools for Deep Turning

A typical tool for internal turning or boring operations comprises a boring bar with a mounted insert or a cartridge carrying an insert. The bar is the main factor in the dynamic behaviour of a tool. Stiffness of a bar is the function of the bar overhang to diameter ratio, and large ratios may be a reason of tool deflection and vibrations, affecting dimensional accuracy and surface finish during machining.

ISCAR has developed three types of boring bar to cover a wide range of boring applications: two integral (from steel and solid carbide) and one assembled, having a vibration dampening system inside.

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The steel bars enable stable machining with the overhang up to four diameters. Exceeding this value can induce vibrations due to steel’s elasticity characteristics. Changing the bar material from steel to a more rigid solid carbide ensures efficient vibration-free boring with the overhang of up to seven diameters. However, further increasing the boring depth is also limited by the material stress-strain behaviour. In order to clear this overhang barrier, ISCAR developed the ISOTURN WHISPERLINE family of anti-vibration cylindrical bars. The bars carry interchangeable boring heads for indexable inserts of different geometries and have inner coolant supply capability. The main element of the bar design is a built-in vibration-dampening mechanism to provide “live” vibration damping during machining. This enables effective boring with the overhang from seven to 14 diameters (Figure 4).

A vibration-dampening unit is used also in ISCAR deep grooving and parting tools. The unit is in a tool blade under the insert pocket. Each blade is pre-calibrated by ISCAR for optimal performance for a wide range of overhangs, but end-users can complete fine tuning calibration themselves if needed.

Cutting tool manufacturers have a limited choice of means in the abatement of machining vibrations, with only tool cutting geometry, tool body material, and maybe a cutting tool with built-in vibration-damping device at their disposition. Considerable skill and ingenuity are required to make a chatter-free tool with these limited resources. It is feasible, however, and ISCAR’s solutions highlighted in the above examples affirm the possibilities.

 

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Limitless Shoulder Grooving

Limitless Shoulder Grooving

Walter is launching a new system specially designed for grooving along a shoulder with the G3051-P groove turning holder and the new MX22-2L/R indexable inserts.

An insert installation position inclined by 3 deg and new grooving inserts with a level design on the component side (as left and right versions) enable deep grooving along a shoulder – with no end-face axial contact thanks to the grooving insert. The groove turning holder in new shank sizes of 12 to 25 mm is designed with Walter precision cooling. The precision-ground, four-edged indexable inserts are available with new GD8 and VG8 geometries. The VG8 geometry has been specifically developed for finishing operations behind a collar.

Thanks to reduced space requirements, enormous savings on material are possible in mass production compared to conventional V-style turning inserts. The G3051-P grooving system can be used on CNC lathes and multi-spindle machines, as well as automatic lathes. It allows for cutting depths of up to 5 mm and insert widths from 1.5 to 3 mm. This is why it is particularly suited to series production of smaller components, such as camshafts in the automotive industry, but also for precision parts in the medical technology industry.

 

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Walter Launches Double-sided Indexable Inserts

Walter Launches Double-sided Indexable Inserts

Walter Tools is introducing a new Walter Launches Double-sided Indexable Inserts for turning machining operations under the designation MU5. The insert can be used universally both for steel forged parts in automotive series production, such as drivetrain or gearbox components, and for components made from stainless materials.

In forged parts, the Walter MU5 geometry minimises crater wear, and thereby enables reliable, fully automated series production. For users with changing materials and small quantities, the Walter MU5 is appealing due to its universal use for steel and stainless materials. The combination of improved chip breaking with a longer tool life will also be equally beneficial for both target groups. These characteristics of the MU5 inserts are due to the positive macro-geometry.

An open chip breaker groove (long tool life and soft cutting characteristics), a V-shaped chip breaker (improved chip breaking) and a curved cutting edge (high surface finish quality). For copy turning, the MU5 geometry does not just improve chip breaking for longitudinal turning and facing, but also for inclines or radii that would otherwise be critical.

During the numerous field tests, the MU5 has also already proven that it significantly lowers tool costs, particularly when combined with the wear-resistant Tiger·tec Silver grades. The machining parameters of the insert are f: 0.15–0.6 mm; ap: 0.5–4 mm, which applies to 60 percent of all applications. In order to offer customers the best possible solution for their applications, the new MU5 insert is available in all common basic shapes.

 

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Tungaloy Expands HP Geometry Line Of T-CBN Inserts

Tungaloy Expands HP Geometry Line of T-CBN Inserts

Tungaloy is expanding its -HP geometry line of T-CBN inserts to ensure effective chip control in finish turning of hardened steel parts. The -Tungaloy Expands HP Geometry Line of T-CBN Inserts provides reliable chip control in finish cutting conditions at cutting depths of 0.2 mm (.0079″) or smaller, minimising part quality damages caused by poor chip control.

Around 22 additional -HP geometry T-CBN inserts are now available, which further increases the chipbreaker application range in hard turning.

The new chip former ensures good chip breakage and smooth chip control. The free cutting geometry eliminates bar deflection and vibration during machining, and the built-in wiper ensures better surface quality and chip control.

A total of 22 inserts, available in BXM10 for continuous cut and BXA20 for interrupted cut, are to be added.

 

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Cutting Tool Inserts To See Ballooning Sales

Cutting Tool Inserts To See Ballooning Sales

The global cutting tool inserts market is likely to account for about US$ 18.1 Billion by the end of the assessment year 2019, and is estimated to expand at a CAGR of about 7.0 percent during the forecast period of 2019-2029, according to a report by Persistence Market Research. Among the type of material, the carbides segment is anticipated to grow at a noteworthy rate, owing to their cost effectiveness and durability, thereby contributing to the relatively high growth rate of the carbides segment over the forecast period.

Key applications of cutting tool inserts such as threading, milling & shearing, parting and grooving, and drilling & boring, are expected to drive the cutting tool inserts market growth at a significant rate. The stainless-steel segment is estimated to retain its market share over the forecast period. According to the report, the demand for cutting tool inserts is expected to be driven primarily by the rise of automotive industry, oil & gas sector, construction industry, urbanisation, and the increasing demand from other end use industries. Furthermore, massive demand from automotive original equipment manufacturers (OEMs), automotive refinishing service companies, construction companies, general industrial manufacturers & maintenance service providers, marine service companies, manufacturers of cans, coils, and wood & transport industries will contribute to the demand for cutting tool equipment, which, in turn, will augment the demand for cutting tool inserts.

Europe’s Increasing Investments In Asian Markets Fueling Market Growth

European investments in Asia are motivated by the need to reduce costs, to exploit benefits of the local supply chains and to be close to an untapped customer base which enables them to better understand user needs and better serve their customers. European machine tool builders’ investment strategies abroad vary from strategic alliances to joint ventures, from the acquisition of foreign companies to opening production facilities in third countries. Increasing investments of global car manufacturers in emerging countries, for instance, India, China and Brazil, along with large publicly funded energy and infrastructure projects in these countries, make them attractive enough for European investments from machine tool builders.

APAC and Europe to be the Top Revenue Pockets

Geographically, APAC and European markets are picking up pace in the global cutting tool inserts market, owing to expansion of industrial infrastructure and an upsurge in the automotive and oil & gas industry over the years. Europe being an automotive hub has a lot of scope for transportation industry including railways. Most of the metal used in this industry is machined using the cutting tool inserts thus accounting for better sales of the same. The transportation segment is anticipated to soar the cutting tool inserts market in Europe. The demand for cutting tool inserts is majorly driven by its applications in various sectors such as aerospace, automotive, marine, medical, woodworking, die & mould, driven by growth in global GDP. Moreover, stable economic growth in developing countries such as India, Brazil, China, and ASEAN countries, and rising urbanisation and expenditure in these regions, acts as the major growth factors that are propelling the growth of the cutting tool inserts market.

Furthermore, the APAC region is also expected to remain the most attractive region in terms of market attractiveness by market share index, on account of the largest volumes of cutting tool inserts consumptions expected by the region, over the forecast period, mainly driven by China. A high growth rate due to considerable industrial activity in the region is expected to contribute to the rising demand. Europe is expected to hold a significant market share in terms of both value and volume after APAC region, owing to growing automotive and other end use industries and infrastructural developments in the region.

Vendor Insights – Key Companies Focus on Global Footprint Expansion

The global cutting tool inserts market highlights some of the key market participants operating in the global cutting tool inserts market, such as Kennametal Inc., Sumitomo Electric Carbide Inc., Sandvik AB, Knight Carbide Inc., Compagnie de Saint-Gobain, Total Carbide Ltd., Asahi Diamond Industrial Co. Ltd., Knight Carbide Inc., Tomei Diamond Co. Ltd., KYOCERA Corporation, Mitsubishi Materials Corporation, SHOWA DENKO K.K., YG-1 Co. Ltd., Element Six, ISCAR LTD., NGK Spark Plugs Co. Ltd. (NTK Cutting Tools), among others.

 

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