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.
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.
ISCAR is upgrading the ISCARMILL F75 family of 75 deg indexable face milling cutters, which carry single-sided square inserts SP , by introducing new milling cutters that are intended for mounting the same inserts
The new cutters, designated as F75…-M, are available in a shell mill configuration and feature an advanced design for better productivity. In accordance with the new design, the inserts that are mounted in the cutters F75…-M are clamped with the use of a wedge system, providing high clamping reliability and high repeatability for positioning an insert active cutting edge. In addition, the wedge clamping principle enables quick and easy mounting of the inserts and their indexing.
The main features of the new cutters are as follows:
50 – 125 mm cutter diameter range
Shell mill design configuration
Clamping inserts by wedge for reliable, quick and easy securing of the inserts and their indexing
Coolant holes directed to each active cutting edge of the mounted inserts for effective coolant supply through the cutter body
Silver-grayish protective plating is applied to the cutter bodies, ensuring increased body tool life due to improved anti-scratch and abrasive-resistance properties and high anti-corrosion protection
Machining main engineering materials such as carbon and alloy steel, cast iron and stainless steel
Wide range of face milling operations
Broad range of usage in various industrial branches
With Accure·tec, Walter provides a damping system specially for turning and milling using tools with a long projection length. The vibration damping provided by the axially and radially flexibly positioned damper element is preset at the factory. The tools can therefore be used immediately without any time spent on adjustment.
Turning operations up to 10 x D can be manufactured with high process reliability and with very good surface finish quality using the A3000 boring bars. Examples include H7 engineering tolerances and the counterboring of generator shafts to Rz 6.3. The equally new QuadFit quick-change heads enable rapid tool changes and increase repeat accuracy (±2 µm). When milling, Accure·tec AC001 adaptors up to 5 x D can be used with cutting data up to three times higher than conventional tools.
Accure·tec AC001 adaptors are ideally suited to the Walter milling cutter range. This applies in particular to high-feed milling cutters, which have their main cutting force in the direction of the spindle. This means that the system is highly versatile: For example, for components with deep cavities in aircraft construction, as well as in mechanical engineering, the aerospace industry and the automotive industry. With turning applications, the focus is on the energy sector (e.g. valves for the oil industry) and/or on the aerospace industry (e.g. landing gear). Users benefit from good vibration damping and a system with low noise levels. Accure·tec promises longer tool life, productivity and process reliability and protects tools and machine spindles – despite higher cutting data. Walter offers Accure·tec AC001 (milling) and A3000 (turning) with all popular machine interfaces: Walter Capto, HSK/HSK-T, SK, MAS-BT and parallel shank.
Walter is introducing three new high-feed milling cutters: The Xtra·tec XT M5008 high-feed milling cutter for diameters of 16–66 mm (⅝–2½”), and the two MC025 Advance and MD025 Supreme solid carbide milling cutters for diameters of 1–25 mm (⅛–1″), with application ranges that perfectly complement one another.
The key characteristic for all three roughing tools is a shallow approach angle and easy-cutting geometries, which facilitate high feeds per tooth at low cutting depths. Together with the high number of teeth, this ensures high machining volumes, stability and process reliability. Furthermore, vibration tendency is reduced for long tools. The tools’ shallow approach angle reduces the radial load on the tools. This means that the MC025 Advance and MD025 Supreme solid carbide milling cutters are perfectly suited to machining thin-walled connecting elements, such as hinges and struts in aircraft construction.
The MD025 Supreme is the benchmark in the aerospace industry. This is due to, first, short machining times and its versatility for smaller ISO S components; and second, the short, stable peripheral cutting edge, reduced neck and compact design, which are very advantageous for milling deep cavities. All three milling cutters can be used in the ISO material groups P, M, K and S and satisfy high demands, for example in mould and die making.
The Xtra·tec XT M5008 high-feed milling cutter enables near-net roughing and combines stability with wear-resistant Tiger·tec cutting tool materials – for optimum cutting data and tool life, such as for milling deep pockets, grooves or freeform surfaces. The most striking feature of both solid carbide milling cutters fitted with a parallel shank or ConeFit exchangeable head is their end-face geometry, which is specially developed for high-feed milling.
Dr. Wolfgang Baumann of Mapal explains the benefits of their latest radial insert milling range.
Whether they’re producing turbochargers, steering knuckles, or cylinder blocks, customers can mill their cast and steel parts considerably more cost-effectively with Mapal’s radial insert milling range than with the previously available solutions. Since the product launch in 2018, there have been many measurable successes resulting from the use of the tools in the series.
Mapal first showcased a product range for milling with compressed radial indexable inserts at the AMB exhibition in Stuttgart in 2018. “This move was the natural next step towards our aim of being a comprehensive service provider for our customers,” explains Dr. Wolfgang Baumann, who is responsible for the product range of tools with ISO elements at MAPAL. “But our aim isn’t just to provide the customer with all their machining needs in terms of tools and chucks—we also want to offer them added value through our solutions.”
According to Baumann, their focus before this milling range was mainly on supporting customers with specific application needs, such as providing support for high levels of stock removal or unstable conditions. This machining was mostly carried out using ground tangential indexable inserts.
“We’re obviously not the first company to offer a radial milling range. We’ve simply plugged a gap in our portfolio,” explains Baumann. “Through our work with special applications, we’ve accumulated extensive in-depth knowledge that has been incorporated into the development of our compressed radial blades. They, therefore, offer considerable added value and, in particular, economic benefits for users. The success stories that we’ve gathered over the past year prove that our meticulous work is paying off for our customers today.”
In many applications, the cost per part (CPP) was considerably reduced. “In many cases, other tools were superseded once we had analysed the application and selected the optimal tool,” Baumann explains. “For some applications, our tools now machine significantly more parts until the blades have to be replaced. And in some other machining operations, the same machining times per part can be achieved with fewer blades. However, there are other cases where we can achieve considerably higher cutting data with more blades. We sometimes rely on indexable inserts with more cutting edges, thanks to which each individual indexable insert can be used for considerably longer.”
As an example, three machining operations on customer parts demonstrate the added value that the radial milling range offers:
1.Turbocharger machining: Face milling of the hot side made of stainless steel
Mapal’s face milling cutter with nine blades replaces the previously available face milling cutter with seven blades.
With the new solution, 50 percent more parts are milled in total; the cycle time is considerably reduced; and the costs per part are 44 percent lower than previously.
2. Steering knuckle machining: Shoulder milling/roughing of various connection points on a steering knuckle made of cast iron with spheroidal graphite—stock removal of between 2.5 and 4.5 mm.
Mapal’s shoulder milling cutter with six blades replaces the previously available shoulder milling cutter with seven blades. Despite its negative clearance angle, it achieves the same tool life as the previously used solution with positively aligned indexable inserts.
Although the new milling cutter machines have exactly the same number of parts as the previous one, the costs per part are reduced by more than half—by 58 percent!
3. Cylinder block: Shoulder milling/roughing of various surfaces on cylinder blocks made of cast iron with lamellar graphite—stock removal of between 2 and 4 mm.
Mapal’s eight-edged shoulder milling cutter replaces a shoulder milling cutter that also has eight edges.
The tool life of the new milling cutter is considerably longer than that of its predecessors under identical operating conditions—even with its negatively aligned indexable insert. And on top of that, the cost per part is also reduced by 58 percent.
To address the difficulties manufacturers face when performing disc milling operations in hard-to-machine materials, Seco Tools has announced a new line of products, the Seco 335.18 And 335.19 Cutters Enable Smooth, Problem-Free Disc Milling. Close-pitch insert pockets improve stability and productivity, while plug-and-play internal coolant system further ensures the highest tool life and superior chip control. These features, as well as a new corrosion-resistant cutter body and indexable inserts with four cutting edges, allow these disc mills to outperform high-speed steel alternatives, especially in tough materials like sticky stainless steel, titanium and superalloys.
Designed for slotting operations between 4-12 mm and cutting-off operations from 4-8 mm, the 335.18 and 335.19 cutters are available in metric diameters ranging from 32 mm to 125 mm. Inch diameters range from 1.25″ to 4″ with widths from 0.156″ to 0.50″. Inserts for these cutters are available with the full range of grades, edge geometries and corner radii (0.2-6.0 mm, 0.008″-0.236″). For the greatest flexibility and ease of use, as well as superior radial and axial reach, the 335.18 and 335.19 cutters utilise modular Combimaster connections.
Kennametal announced the latest addition to its best-selling HARVI line of high-performance solid end milling tools, the HARVI I TE four-flute solid carbide end mill. With a radical new design, the HARVI I TE delivers outstanding performance in a broad range of materials, including steel, stainless steel, high-temperature alloys and cast iron –with tool life to match. And thanks to significantly reduced cutting forces, this game-changing tool can be used on any machining center or mill-turn center in the shop.
“The HARVI I TE consistently outperformed competing four-flute end mills in both wet and dry machining tests on a variety of materials and applications, with unprecedented tool life in many cases,” said Bernd Fiedler, Manager, Solid End Milling.
“It performs exceptionally well on heavy roughing and finishing cuts alike – from deep cavities and full width slots to shoulder and dynamic milling.”
Kennametal engineers designed the HARVI I TE to address four key problems that plague more than 90 percent of all milling applications: chip evacuation, tool deflection, corner stability, and breakage due to radial cutting forces. The result is a tool that’s durable and versatile enough to tackle the lion’s share of milling applications.
Consider chip evacuation. The HARVI I TE has an innovative flute design that helps curl and break chips into manageable pieces, while a series of chip gashes within the flute lift those chips up and away from the workpiece. Both serve to promote coolant flow, eliminate chip re-cutting, and improve tool life. A twisted end face and unique gashing further promote chip evacuation but are also responsible for the HARVI I TE’s awesome ramping and plunging capabilities.
Tool deflection is reduced thanks to the tool’s parabolic core, as well as an eccentric, faceted relief along the entire flute length that significantly lowers cutting friction. This relief also increases edge strength, making the tool a versatile solution.
Together with a variable helix angle and asymmetric flutes it dampens vibration before it can negatively affect machining operations.
“The HARVI I TE improves process stability, surface quality and chip evacuation,” said Fiedler. “Most importantly, it maintains these benefits even at increased feeds, speeds, and depths of cut – delivering maximum metal removal, tool life and productivity.”
Producing threads in hardened steel is costly. This applies to blind hole machining in particular because reversing the tap during this process can cause torque peaks when the root of the chip is sheared off, resulting in fractures.
Walter is solving this problem with two new taps – offering its customers a full product range for producing threads in hardened steels with an additional thread milling cutter: The TC388 Supreme (50–58 HRC) or TC389 Supreme (55–65 HRC) and the TC685 Supreme (> 44 HRC). The TC388 and TC389 Supreme solid carbide taps boast special cutting geometries. These fully shear off the root of the chip when reversing; torque peaks are minimised. This prevents fractures, prolongs the tool life and increases process reliability. Lubrication with oil, which was often necessary until now, is no longer required. Instead, emulsion can be used, which optimises handling and saves additional machining time. Both taps are characterised by a short machining time.
The TC685 Supreme orbital drill thread milling cutter enables maximum process reliability and the highest possible tool life quantity. The core hole and thread (chamfer if required) are produced in a single operation, thereby saving tool spaces. The milling geometry on the face produces stabilising forces in the axial direction. This improves the stability when milling and reduces the deflection. Advantages for the user: Fewer radius corrections and reduced wear, with a high tool life quantity and minimal costs per thread. The 15° helix angle and internal coolant from M6 guarantee reliable chip evacuation. This allows even tougher steels and deep threads to be machined reliably. Common applications for all the tools mentioned include mould and die making, for example.
The optimum machine tool combined with the optimum tool results in a perfect combination. And that makes cost-effective processes and impressive machining results possible. Article contributed by MAPAL.
Figure 1: Dietmar Maichel (left), project manager 3D milling at MAPAL, and Steffen Nüssle, sales director export and head of applications engineering at Zimmermann, in front of the FZH horizontal machining center (HMC).
The optimum machine tool combined with the optimum tool results in a perfect combination. And that makes cost-effective processes and impressive machining results possible. One good example of this is the cooperation between machine manufacturer F. Zimmermann GmbH and MAPAL.
F. Zimmermann developed its first horizontal machining centre (HMC) especially for the machining of structural parts for the aerospace industry. The aluminium structural parts, such as wing parts and frame ribs, are generally milled from solid material—with up to 95 percent material removal.
Fault-free machining with respect to dimensional accuracy and surface finish is crucial here. And the component structure that becomes more and more delicate with increasing material removal represents an additional challenge.
In order to make the milling process as efficient as possible even in these areas, Zimmermann has developed the FZH machining centre that offers maximum rigidity and features a robust, water-cooled travelling column. Whereas conventional machine concepts suffer from lever-related deviations with increasing slide, the guide carriage distance of the FZH increases with increasing plunging depth into the material.
In order to achieve maximum efficiency, Zimmermann employs its own patented M3ABC three-axis milling head in the machining centre, especially in the pocket corners of a workpiece. This milling head has to perform only very small swivel movements, allowing the feed rate to be kept constant and hence, the machining time to be significantly shortened.
At an open house in June 2017, Zimmermann demonstrated its machining centre with tools from competitors. These tools failed to meet the expectations, however, and were unable to exploit the performance of the machine.
“Why not test the performance of the MAPAL tools?” thought the project managers at Zimmermann, as MAPAL was presenting its milling cutters for high-volume machining at the event. A short time later, representatives of the two companies carried out extensive milling trials with different tools together.
Figure 2: MAPAL tools used at Zimmermann (from left to right): SPM-Rough ISO shoulder milling cutter with indexable inserts as roughing solution for diametre ranges above 25mm; SPM-Rough solid carbide milling cutter with wave profile as roughing solution for diametre ranges up to 25mm; OptiMill-SPM solid carbide milling cutter for multi-stepped semi-finishing of thin-walled structures; and SPM-Finish solid carbide milling cutter for finishing of deep pockets and delicate structures in a single pass.
The Milling Cutters
“Our goal was to choose the optimum tools from our portfolio for the machining operations on the Zimmermann machine,” explains Dietmar Maichel, project manager 3D milling at MAPAL. The tool manufacturer’s portfolio contains different milling cutters for the different tasks during the high-volume machining of aluminium structural parts. The tools are perfectly designed for use on such high-performance machines as the Zimmermann machine.
In particular, the SPM milling cutters, which are available in a solid carbide design and with PCD and ISO inserts, are being used today—a total of four tools, to be exact—at Zimmermann for the different demands of the roughing and finishing operations.
“The perfect combination of the machine, the three-axis milling head and the tools from MAPAL give the user a real performance boost,” says Steffen Nüssle, sales director export and head of applications engineering at Zimmermann, immediately after the first tests. “With the SPM-Rough ISO shoulder milling cutter, we achieved the best results that we have ever achieved with a tool with indexable inserts.”
The ISO tools with polished indexable inserts are the latest addition to the MAPAL SPM product range. The SPM-Rough with wave profile also surpassed the expectations for material removal with excellent smooth running.
“The complete machining of a 190x190x40 mm pocket is now effectively possible in less than a minute,” explains Nüssle.
The experts at F. Zimmermann are convinced by the MAPAL tools. “The use of the SPM milling cutters has given us a quantum leap forward in the aluminium machining. And it shows us what the perfect combination of tool and machine means in terms of performance,” says Nüssle. The tools are the first choice when it comes to machine acceptance tests or demonstrations for customers from the aerospace industry at Zimmermann.
The Zimmermann machines are suitable not only for the machining of metals. “Many of our customers manufacture parts of composite materials,” says Nüssle.
Zimmermann, therefore, also wants to mill trial parts of these materials using MAPAL tools.
“We are optimistic that with the MAPAL milling cutters for composite machining, we will also find a new secret weapon to exploit the performance of our machines even better,” says Nüssle. The corresponding plans are already in hand.
Walter AG is releasing the new TC620 Supreme thread milling cutter in diameters up to M20.
High cutting pressure and tool deflection are the greatest challenges when it comes to thread milling. This results in restricted cutting parameters, necessary cutting passes and short tool lives or even tool breakage. With the TC620 Supreme universal thread milling cutter, Walter is now transferring the functional principle of its T2711 indexable insert thread milling cutter to smaller diameters too. Tool wear is drastically reduced thanks to minimal cutting forces and the resulting high feeds per tooth. The multi-row concept not only reduces the machining time and wear, but also improves process reliability and handling – even when used with more demanding materials such as stainless steels or Inconel 718.
Reliable chip evacuation, thanks to internal coolant, and simple handling of the TC620 Supreme guarantee maximum process reliability. Radius corrections are seldom necessary, and when they are required, it is often only once competitor tools have already reached the end of their tool life. Walter is launching the TC620 Supreme for thread depths of 2 and 2.5 × DN in the dimension range from M4 to M20 as well as UNC 8 to UNC ¾ – and is therefore seamlessly linking to the Walter T2711 indexable insert thread milling cutter.