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 Italianon 16th September 2020 from 9 a.m. to 12 p.m.
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.
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.
Externally cooled Walter DB133 Supreme micro drills have become successfully established worldwide for machining precision parts. Walter is now presenting two new developments in micro drilling: the DB133 Supreme solid carbide micro drill with internal coolant in dimensions of 5, 8 and 12 × Dc, and the DB131 Supreme pilot micro drill, with a geometry and diameter tolerance perfectly tailored to the DB133 Supreme, in the dimensions of 2 × Dc.
Both drills cover the diameter range from 0.7 mm to 1.984 mm, while the pilot drill is also suitable for diameters from 0.5 mm. The combination of these two drills is not the only factor behind the positive effects. Thanks to a new flute design, the chips break so that they are shorter and are reliably evacuated. A special cutting edge preparation enables outstanding surface finish quality on the component and ensures a long tool life.
With these new products, Walter has further refined the adaptation of the L/D ratio to the required drilling depth. The result is a range of micro drills that ensures maximum stability when machining thanks to its broad scope and the optimised design. Walter offers both micro drills in the WJ30EL grade with micrograin carbide and full-length AlCrN coating, while the DB133 Supreme is also available in the WJ30ER grade with micrograin carbide and AlCrN point coating. The micro drills and can be used with emulsion or oil and are suitable for all ISO material groups. In addition to the watchmaking industry and medical technology, the premium manufacturer cites general mechanical engineering, mould and die making, and the energy and automotive industries as other specific areas of application.
Walter is providing new insert widths up to 19 mm to its standard product range. With the G2016-P groove turning holder and the UX grooving insert with GD2 geometry, Walter is launching a grooving system developed specifically for heavy-duty cutting. It is transferring the insert widths of 12 and 19 mm from the special to the standard product offering.
Special features of the system include tangentially mounted UX insert, while the toolholder and insert are additionally connected via a stable positioning groove. These design features make the system incredibly stable and prevent the insert being ‘twisted out’ of the seat during machining.
The GD2 geometry, which is also new, features a protective chamfer for a strong cutting edge, which transitions directly into a positive chip formation. As a result, it enables a very soft cutting action at the same time as good chip breaking—even with large cutting depths and feeds (f) from 0.2 to 0.6 mm.
With this system, Walter is expanding its insert widths in the standard range from the previous maximum of 10 to 19 mm now. As a result, in-stock inserts are now available from a quantity of one unit. The primary application is steel; but it is also possible to achieve good results in cast iron. The high degree of stability and process reliability of the grooving system is beneficial for the heavy-duty cutting needs in the energy and wind power sector in particular, for example, for machining generator and turbine shafts. The same applies to large shaft manufacturers, shipbuilding and mechanical engineering.
The combination with wear-resistant Walter Tiger·tec Silver MT-CVD grades additionally increases the tool life—and therefore, the cost-efficiency of the system.
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:
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.
The trend towards miniaturisation of even complex component geometries is driving the need for highly reliable grooving tools. Article by Walter AG.
Grooving processes play an important role, especially in mass production. The trend towards miniaturisation of even complex component geometries is one of the driving forces, especially in the field of parting off and grooving tools. For several years now, the Tübingen-based machining specialist Walter AG has successfully positioned itself here as a provider with excellent technological expertise.
Markus Stumm, product manager for grooving at Walter, states, “We have significantly expanded our portfolio in recent years. In 2020, we will further strengthen our activities in this field. With the Walter Cut DX18, we are launching a tool with innovative clamping that will set completely new standards.”
Conquering the Conservative Market with Innovative Solutions
Users are particularly conservative when grooving. Stumm explains, “In mass production, when the process is running reasonably well, manufacturers rarely change the tooling system. We have to offer a clear advantage in terms of productivity and cost-efficiency to get to the machine. Problems with process reliability with the existing tools, or when a machining strategy is changed, provide us with an opportunity.”
The parameters, according to which the decision for a parting off process and the corresponding tools is made, are machine run times, tool life and process reliability. Typical problem areas, especially for machining operations in which you are grooving deeper into the workpiece, are the stable fixing of the indexable inserts, chip breaking, and cooling. Users who want to play it safe therefore reduce the cutting data below the recommended values. Who wants to risk stopping the production process due to chip jams, a vibrating tool or even if a cutting edge breaks?
This is exactly where the Walter grooving experts come in: With its portfolio of grooving tools, Walter already covers a wide range of grooving applications. Walter Cut DX18 is a double-edged system for grooving and parting off especially on Swiss type auto lathes or multi-spindle machines.
Walter Cut DX18 – Maximum Stability and Convenient Changeover
The Walter DX18 system is suitable for parting diameters of up to 35 mm. With the innovative, patent-pending positive engagement system, Walter’s developers are addressing the fundamental problems of narrowly dimensioned parting off tools: the stability and handling of the cutting insert.
In conventional screw clamping, the cutting forces act in such a way that the existing clamping forces are not sufficient—with negative effects on machining quality and process reliability. In contrast, the new Walter Cut DX18 cutting insert geometry locks the insert securely via positive engagement.
Another innovation is the SmartLock system, which considerably simplifies insert changeover. With conventional screw-clamped systems, the machine operator has to remove the entire tool for this purpose—and this, in cramped and not always user-friendly “oily” machine conditions. With the Walter SmartLock system, the clamping screw is located on the side of the tool: simply insert the screwdriver, unscrew and change the indexable insert. Thanks to the positive engagement, the new cutting insert adjusts correctly, even with very narrow insert widths.
The potential of the system was successfully proven in a tool life test on a Swiss type auto lathe. An outer diameter of 12 mm was parted off from 1.4057 material. The cutting edge width used was 2 mm. Stumm comments, “With the new double-edged Walter Cut DX system, we were able to more than double the tool life compared to the single-edged competitor—with maximum process reliability and productivity. The customer particularly liked the fact that they no longer had to remove the tool for changing the insert.”
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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.
Michael Schmid of WALTER EWAG discusses the Thailand market, opportunities and challenges, and trends shaping the metalworking industry in the region. Article by Stephen Las Marias.
WALTER EWAG Asia Pacific Pte Ltd, part of the United Grinding Group headquartered in Bern, Switzerland, specialises in tool grinding, laser machining, eroding, measurement, and software. Its machines are used in fields such as the watch industry, the dental, electrical, automotive and aviation industries, as well as in the manufacture of precision micro-components.
WALTER EWAG is a system and solutions provider for complete tool machining. It offers an extensive product range for manufacturing and re-grinding of rotation symmetrical tools and inserts made of tungsten carbide, HSS , PCD PCBN or any other super hard materials like MCD , CWD and even natural diamonds.
At the recent METALEX 2019 event in Thailand, Asia Pacific Metalworking Equipment News sat down with Michael Schmid, managing director of WALTER EWAG in Singapore, to discuss the Thailand market, opportunities and challenges, and trends shaping the metalworking industry in the region.
WHAT ARE YOUR ACTIVITIES IN THAILAND?
Michael Schmid (MS): We have been doing business in Thailand for more than 20 years now. In fact, we installed our first CNC machines here in Thailand in 1996.
Currently, we have a training and demo centre in the country, where we do test cuts and demonstrations for customers. Our customer care, service engineers, and applications specialists, are all based here.
WHAT OPPORTUNITIES ARE YOU SEEING IN THAILAND, AND WHICH INDUSTRIES ARE DRIVING GROWTH?
MS: With our substantial product portfolio and the specialised team of technicians, we can actually cater to all needs in terms of tool making and resharpening required in the industrial environment—which Thailand has, such as the automotive, aerospace, semiconductor, and all kinds of metalworking industry.
WHAT ARE TOP CHALLENGES OF YOUR CUSTOMERS?
MS: Some of the challenges are finding skilled people and developing know-how in cutting tool technology. But also, major challenges include productivity and quality, and being innovative in tool design.
HOW ARE YOU HELPING CUSTOMERS ADDRESS THESE ISSUES?
MS: Our aim is to help customers, educate them, and train them, through our software and machine design. There are a lot of possibilities to be creative. We help them become more creative in utilising our machines.
WHAT MAKES YOUR PRODUCTS UNIQUE IN THE MARKET?
MS: If you look, for example, at our Helitronic Series, these machines are extremely powerful and have very unique and efficient kinematics, which provides an ultimate stability and accuracy. All that, together with our in-house developed Tool Studio software, open all kind of possibilities in terms of flexibility, dynamics and performance for our customers in today’s modern tool manufacturing world.
Last but not least our tool grinding know how of over 50 years has of course influenced our todays products in unique way as well.
WHAT TRENDS ARE SHAPING THE METALWORKING INDUSTRY RIGHT NOW?
MS: One of the big topics is Industry 4.0. In this show, VDW is having a presentation about umati, a standardised interface linking machines. Besides that, of course, automation is always an issue. Lights-out production, smart manufacturing—these are something we hear every day from our customers, and a lot of companies are now working towards this. Apart from that, there are also new, innovative tool geometries, machines, tools, software—there’s a lot of possibility to change.
Of course, there are also new materials coming—lighter materials for e-mobility, for example. There industry is changing a lot—and I think that’s the interesting part in our business.
WHAT IS YOUR OUTLOOK FOR THIS YEAR?
MS: I don’t want to be pessimistic, but I also can’t be too optimistic, because when I talk to people here at the show, and the customers throughout the year, we saw some declines here and there. But some industries are still doing well.
It will be an interesting time to come in the next six to 12 months, because of all the changes happening. Maybe, we’ll have more time to think about new things for the industry. Considering this, I would not say it will be bad; I would say let us be all optimistic and look forward to a promising, interesting time.
Like I said, in the last years, we’ve been very busy. Maybe, now we have a little bit of time to think about how to do things differently, how to increase our efficiency; I think it should be a target for everybody because, if there is a crisis coming, and we get out of it, we should be fresh, more efficient, and more powerful.
For some time the market has been demanding that machine tools must be “more flexible”, “universal” and “automated”. The equally important requirements of “more specialised” and “more cost-effective” often cannot be reconciled with these demands. However, this is exactly what WALTER has achieved with the latest extension of their grinding machine portfolio, the HELITRONIC RAPTOR. WALTER offers the right machine solution for the grinding of tools for every customer application.
Flexible and cost-effective:
The HELITRONIC RAPTOR is a flexible and universal tool grinding machine especially designed for the grinding and re-sharpening of rotationally symmetrical tools for the metal and wood industry.
The specialised equipment of the HELITRONIC RAPTOR:
“Specialised” means in this case: optimising the important equipment options so that the HELITRONIC RAPTOR is targeted at the re-sharpening sector of rotationally symmetrical tools, in which one usually
– does not require a large variety of automation
– does not require automatic tool support systems
– does not require an automatic change of grinding wheels
– but still requires a high degree of flexibility in the working area for large and diverse types of tools.
For this reason, the HELITRONIC RAPTOR – unlike other machines from WALTER – is not configured for options such as wheel changer, robot loader or hydraulic tool support systems.
Tools with a maximum diameter of 320 mm and a maximum length of 280 mm including end face operation can be ground with the HELITRONIC RAPTOR. For automatic loading of up to 500 tools, an optional top loader, integrated in the working area, is available.
Further equipment features are:
– Low vibration, solid grey cast iron, gantry type construction
– 11,5 KW spindle motor
– Grinding software HELITRONIC TOOL STUDIO
– Top loader (option)
– Glass scales (option)
– Torque drive for the A axis (option)
– Probe for measuring the grinding wheels (option)