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At High Speed From Component To Tooling

At High Speed From Component To Tooling

With “Walter Innotime”, Walter is introducing the world’s first digital design wizard for accelerating the consulting and ordering process.

Engineers in Walter Engineering are working with a new digital wizard: Walter Innotime. This web application links existing Walter systems to the Engineering Kompetenz of Walter employees. Based on a 3D model of the component drag-and-drop uploaded to the Walter website by the customer, Walter Innotime analyses which cutting operations are required and suggests to the engineer dealing with the enquiry (in future versions, directly to the customer) the appropriate machining tools with cutting data and prices from the Walter portfolio. This digital search at component level is currently unique in the market.

The engineer checks the proposal and optimises it, if necessary, according to the customer’s needs. As a result, the design process for complex enquiries is fast-tracked considerably – and the customer receives the most economical tailored tooling solution and a valid quote in the shortest time. Walter field service employees and engineers benefit from the preliminary work done by the system: in the physical design and the development of the optimum machining strategy for the customer component. “For our engineers and technical distributors, but primarily for our customers, Walter Innotime represents a milestone.

We deliberate intensively over the component and can deal with enquiries so much faster – for our customers, that’s something directly tangible,” explains Dr. Michael Hepp, Vice President Digital Business at Walter. “By combining the Engineering Kompetenz of our employees with the virtual intelligence of our software systems, we can assist our customers in quickly and easily finding, purchasing and employing the most economical tooling solution for them. In future, our customers will have to do nothing more than upload their 3D component – quick and easy.”

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Digital Customer Event: Experience Walter.live

Digital Customer Event: Experience Walter.live

Walter is inviting customers and others interested in the company to a digital event about “Seeing opportunities in solutions” on 15th and 16th September 2020. Participants can experience Walter.live: The tool manufacturer will present innovative solutions and precision tools for particular challenges in the machining of metals.

Richard Harris, President of Walter, says: “The most important trade fairs aren’t happening this year. For our customer, our partners and for us, these are important industry meeting places – not only to present new products, but also in terms of personal contact and exchange. That is why we decided to host a virtual trade fair experience in 2020: At Walter.live, we are not just presenting our new products and services on our own platform, but also paying a visit to the Walter Technology Center via live stream and offering live sessions with our Walter experts – in a way that is solution-oriented, compact, live and digital.”

During the online event, the machining specialist will present an innovation in digitalisation, which will make it particularly easy for customers to choose the right tools for their individual machining processes. Walter offers concrete solutions enabling customers to speed up planning processes, design tool-management processes to be more efficient and save costs. Participants will also be able to see new precision tools, for example for grooving and milling, live in action. In addition, the company will present solutions for analysing, monitoring and improving machining processes.

Customers and others interested can go to https://www.walterlive.com to sign up for the German Walter.live customer event on 15th September 2020 from 9 a.m. to 12 p.m. or register for individual topics. The event will be held in English and Italian on 16th September 2020 from 9 a.m. to 12 p.m.

View the Event Agenda here!

 

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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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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.

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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.

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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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Long Tool Life In Series Production

Long Tool Life In Series Production

Walter TC470 Supreme thread former with HiPIMS coating. With the TC470 Supreme, Walter is introducing a thread former especially for the requirements of series manufacturers – longer tool life, higher productivity and better process reliability.

Its geometry has more forming edges than comparable thread formers. The HiPIMS coating and the new type of tool pre- and post-treatment reduce edge wear and increase tool edge life. This enables higher machining parameters and increases productivity. The very smooth yet hard HiPIMS coating significantly reduces the torque. This, in turn, has a positive impact on the surface quality.

The TC470 Supreme has been developed for machining steel materials (ISO P). In practice, it has also produced similarly good results in aluminium (ISO N). A long tool life, high machining parameters and very good process reliability make the thread former appealing to mass producers such as those in the automotive industry. Users can choose from a large product range. Walter is offering the TC470 Supreme in four variants: With or without lubrication grooves and/or internal coolant, as well as with radial or axial coolant outlet, optimised for long and short threads. Dimension range (metric) M3–M10 or (metric fine) M10 × 1–M16 × 1.5 and for thread depths up to 3.5 × DN.

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Walter To Hold Online Tech Talks

Walter To Hold Online Tech Talks

While face-to-face meetings are temporary challenging, Walter is offering virtual training sessions to make sure you’re ready to go when things ramp back up.

Our Walter specialists will give you a tour of different tools and techniques being used in the industry today. We’ll also give some insight into what the company is working on to stay ahead of the competition.

Here are the dates and subjects for Walter Online Tech Talks:

Click here to register now!

 

Improve your productivity and lower your cost:

Productive processes reduce unit costs and increase productivity in production facilities in the long term

In order to make this a reality, you need qualified employees who know how to fully utilise the potential of modern cutting tools as efficiently as possible in their work. Knowledge of tools and their applications is key to successfully achieving increases in productivity whilst reducing costs. We will help you to overcome these challenges with qualified technical training for your employees.

Highly-qualified staff will help to lower your costs

If you want to use high-calibre tools efficiently and would like to guarantee reliable processes, you have to have excellent specialist knowledge at your disposal. Only with sound knowledge of machining, processes and strategies will your employees develop long-term expertise, which will give your company a competitive advantage.

Small application with a big impact

On average, tool costs in a modern production environment account for around four to six percent of the total production costs.
However, tools have an effect on the majority of production costs and therefore offer the greatest potential for optimisation.

 

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Walter: Vibration-Free Machining In Difficult Conditions

Walter: Vibration-Free Machining In Difficult Conditions

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.

 

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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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