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Stability Across A Broad Spectrum

Stability Across A Broad Spectrum

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.

 

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Significantly Better Surface Finishes Thanks To Vibration Damping

Cheto: SiC Deep-Hole Drilling & Milling Machine

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

 

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

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

Walter has expanded its Perform product range with the launch of the new MC232 Perform solid carbide milling cutters. The MC232 milling cutter features a corner radius and reduced neck, allowing the user to better approach individual component geometries. It also improves the tool life of the milling cutter, as the edge stability is increased. The reduced neck in turn makes the milling cutter more flexible, as the user can use it with an even wider variety of cutting depths.

Other features of the Perform line have been adopted: the high level of cost efficiency for small and medium batch sizes, or Walter’s own WJ30ED grade, which provides a high level of wear resistance. ISO P materials are the primary application of the MC232 Perform, with ISO M and ISO K as secondary applications. The new milling cutters are likely to be of particular interest to job shops and manufacturers with frequently changing orders or quantities.

The Walter range in the MC232 Perform family now includes solid carbide cutters with or without a reduced neck and with or without a corner radius in a total of 126 dimensions, of 2–20mm in diameter. The milling cutters can be used for all typical milling applications (lateral milling, full slotting, pocket milling, helical plunging, ramping) and are suitable for a variety of materials and milling strategies.

 

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Walter’s HU5 Geometry Enhances Capabilities Of Cutting Machines

Walter’s HU5 Geometry Enhances Capabilities Of Cutting Machines

Walter AG has launched new single-sided indexable inserts with HU5 geometry for ISO M and S materials, helping users produce more components using the same number of machines.

The HU5 has a larger contact surface to the tool holder, increasing the stability and allowing for greater cutting depths, feeds and a larger metal removal rate—specifically, in the practical test, this comes to 18.36l/h instead of 10.71l/h. In addition to the stable fit, the decisive factor behind this is the combination of the geometry and Walter Tiger·tec Silver cutting tool materials, which allows for increases in tool life of up to 75 per cent. The geometry itself has been specially developed for heavy roughing of stainless steels and high-temperature alloys. It is typically used for applications in the oil and gas industry, for instance, in large valves made from AISI 316 material, or in the aerospace industry with Inconel 718 or titanium materials.

The main cutting edge, which is protected by a negative chamfer, prevents fractures when machining hard edge zones and optimises the performance for hard scale, for example, of forged parts. Components with interrupted cuts and other demanding machining operations are equally feasible.

The curved cutting edge and a deep chip breaker groove produce low cutting forces with high feed rates, consequently reducing the machining temperature. The variable rake angle in the area of the corner radius allows for soft chip reforming and increases the tool life. Available in standard CNMM, DNMM and SNMM, Walter rounds off its vast product range in the areas ISO S and M with the HU5 geometry. Walter now offers a total of 12 geometries in six grades as well as tools with precision cooling and ceramic or CBN inserts.

 

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New Geometry And Special Post-Treatment Increase Tool Life Of Walter Thread Former

New Geometry And Special Post-Treatment Increase Tool Life of Walter Thread Former

Walter AG has expanded its range of threading tools with the release of the TC410 Advance HSS-E thread former with TiN coating and a new geometry, which can be used universally for blind and through-hole threads (metric, metric fine, UNC/UNF and G), all formable materials from the ISO material groups P, M and N as well as for ISO K and S as a secondary application.

The tool’s new geometry and special post-treatment help reduce the cutting time in the material—hence reducing friction and, consequently, the amount of heat generated, which in turn reduces wear and ultimately increases the edge life of the tool. Likewise, the post-treated, extremely smooth surface of the tool reduces the torque and increases the tool life as a result.

Walter’s TC410 Advance is available in two variants: without lubrication grooves or with lubrication grooves for deeper threads up to 3.5 × DN. The tool is suitable for users with medium to large batch sizes in particular, because it can produce more threads with the same tool.

 

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Grinding Symposium 2019 A Success

Grinding Symposium 2019 A Success

Over 1,500 international visitors—including customers, experts and industry representatives—experienced new metalworking technologies and current trends in the manufacturing industry at the Grinding Symposium 2019, a three-day trade event held by the United Grinding Group in Thun, Switzerland.

Packed with technology presentations and lectures, the Grinding Symposium also featured FutureLAB—which highlighted the future technologies in the metalworking and manufacturing industries.

“Our aim in presenting these future technologies is to create a dialogue with our customers and to discover more about their individual expectations and requirements,” explained Christoph Plüss, chief technology officer at United Grinding Group.

Through the 16 lectures at the symposium, attendees were able to discuss opportunities and challenges in the cooperation of human and machine, the potential of artificial intelligence (AI) and machine learning in the manufacturing industry, and practical production topics.

The 13 technology presentations provided opportunities for attendees to experience the latest machines and solutions—from the Mägerle MFP 30, an innovation in machining aircraft engine blades, to the European premiere of the Studer S31 for machining very long workpieces; and from the extensive services offered by the United Grinding Group’s Customer Care department through to the production of ultra-hard tools using laser on an EWAG LASER LINE ULTRA.

The United Grinding Group is one of the world’s leading manufacturers of precision machines for grinding, eroding, laser cutting, measuring and combination machining. Its corporate brands include Mägerle, Blohm, Jung, Studer, Schaudt, Mikrosa, Walter and EWAG.

 

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Walter Celebrates 100 Years Of Innovation

Walter Celebrates 100 Years Of Innovation

Walter AG, a provider of machining tools for milling, turning, drilling and threading applications, celebrated the centenary of its foundation on May 14, 2019.

Guests included international customers and partners, as well as Klaus Tappeser, Chief Commissioner of the district of Tübingen; Joachim Walter, District Chief Executive of Tübingen; and Boris Palmer, Lord Mayor of the city of Tübingen.

“For 100 years now, Walter AG has been a synonym for high-calibre engineering with a strong commitment to innovation. The company is an extraordinary exponent and shining example for manufacturing precision tools, where it holds a leading role in Germany,” said Dr Nicole Hoffmeister-Kraut, Baden-Württemberg’s State Minister for Economy, Labour and Housing, during the foundation day celebration.

The celebration focused on the innovation, creativity and future potential of Walter. Prof Dr Peter Post, Member of the German Council of Science and Humanities as well as Head of Applied Research at Festo AG, spoke about the meaning of digitalisation and innovation for the German industry.

The event featured the grand opening of the new company museum.

Richard Harris, president of Walter, said, “Walter employees have not only further developed the numerous inventions of company founder Richard Walter, but also created new tools, coatings and production methods. Our new company museum is a testimony to the Walter spirit of innovation, and it will be an inspiration to new generations of Walter engineers and technicians. Today, we celebrate their inventiveness and creativity.”

 

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Shorter Cycle Times As A Central Objective

Shorter Cycle Times As A Central Objective

For the high requirements in the automotive sector in particular, Walter AG is introducing new boring tools with tangentially arranged indexable inserts. The usually high feeds for tangential systems are therefore transferred from the milling to the holemaking. In contrast to radial tools, tangential tools can work without good chip clearance.

Walter combines the extremely stable tool core that results from this with a separate indexable-insert geometry – and therefore not only improves the surface quality: A second clearance angle reduces the effective clearance angle, which is otherwise high for tangential tools, and reduces “chattering”. The square-shaped indexable insert can be installed at any angle. At 72° and 90°, a face chamfer (wiper) also works. This also guides the tool and keeps it quiet. Boring conditions of 4 × Dc can therefore be achieved. Even small diameters (from 24 mm) can be machined with three teeth (z3).

The objective of combining roughing and finishing in a single roughing/finishing machining process is achieved in many cases thanks to the tangential boring tools. Multiple steps and high feeds shorten the machining time here. Other arguments put forward by Walter in favour of the concept include high precision thanks to stability as well as the cost-effectiveness of the indexable inserts with 4 plus 4 cutting edges. A wide range of inserts make the special tools particularly advantageous for users who manufacture components made of cast iron, chrome-nickel materials or steel and aluminium, such as turbine or gearbox housings, gears, cylinder bores and steering knuckles. This is especially the case if they want large machining allowances of 2 to 7 mm.

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Richard Harris To Be The New President Of Walter AG

Richard Harris To Be The New President Of Walter AG

Richard Harris will become the new President of the Management Board on 4 February 2019. He follows Mirko Merlo, who has been President of Walter AG since 2012 and decided at the end of 2018 to leave the company at his own request.

Richard Harris brings with him to Tübingen many years of experience in tool production and in strategic supply management. The new Walter President has held various management positions for the parent company Sandvik since 2002. Most recently, Richard Harris led the Powder and Blanks Technology division within Sandvik Machining Solutions, which has been trading under the name SMS Supply since 2018. While there, he has made decisive advances in the strategic and operative development of supply management.

The 49-year-old from Britain said of his new position as President of Walter AG, “Walter has an outstanding reputation in the machining industry: The company is a pioneer for technology in many areas. The digitalisation strategy, started by Mirko Merlo, puts the company in an ideal position for the future. Together with the Walter Team, I want to further develop this successful business strategy so that we can continue to grow globally in a demanding and ever-changing market environment.”

Walter AG would like to thank Mirko Merlo for 35 years of very successful work for the company. In his time as President, he set Walter AG on a path of growth and profitability. “Walter has performed extremely well over the last six years. Now is the right time to enable change at the highest level of management and to lead the company strategically into the future,” Mirko Merlo explained with regards to his decision. “I wish Richard Harris great success in his future tasks and positive challenges.”

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Tools At The Touch Of A Button

Tools At The Touch Of A Button

Walter AG supports its customers with high-quality product data, which is available from tool data management systems and online libraries such as MachiningCloud. Article by Walter AG.

A focus on the needs of customers sets machining specialist Walter apart, including when it comes to providing digital product data. Konstantinos Bountolas, Product Data Solutions Manager at Walter, summarises the company’s data philosophy as follows: “Product data that is ready to use enables our users to find, choose and assemble tools more quickly when it comes to designing, planning, NC programming and purchasing, as well as on the shop floor.”

Walter’s strategy of focussing on its customers is also geared towards the customers’ procurement preferences. “We leave it to our customers to choose where they would like to access the product data for our tools. Everyone has their own preferred channels for obtaining this data. All that matters is making sure that we provide our data exactly where our customers are looking for it,” he explains. Walter mainly relies on the “channels” of MachiningCloud, the e-catalogue for TDM and Tools United.

Walter On MachiningCloud

Customers around the world can access more than 40,000 Walter tool elements on MachiningCloud. “MachiningCloud is perfect for us,” underlines Konstantinos Bountolas. “There, we present our tools in virtually the same way as in our catalogue. Thanks to Walter’s standardised product designations, the way in which the products are presented and the logos that customers are familiar with, users will find our products without fail on MachiningCloud.”

Walter E-Catalogue For TDM

MachiningCloud and the Walter e-catalogue for TDM have similar functions, such as product specification lists (cutting diameter, projection length, length of cutting edge, the direction of rotation, etc.), 2D drawings, 3D models, photos and descriptions. But the Walter e-catalogue for TDM goes into even greater detail. With an average of 20 parameters, it contains all the information that is required by a CAD/CAM system. The e-catalogue can also be linked to ERP software via TDM. Konstantinos Bountolas confirms: “It’s not good when customers have to manually re-measure missing properties, such as lengths and diameters and have to manually enter parameters. Customers want product data at the touch of a button.”

Tools United

More than 900,000 tool components from 36 different manufacturers, including Walter, are stored on the Tools United tool platform. The platform provides NC programmers, buyers, tool managers, project managers and design engineers with product data based on their requirements in standardised formats and common export interfaces for tool management systems and CAM systems.

Optimising Processes With Apps From Walter

Optimally prepared digital product data, which the company provides to its customers across different platforms, is just one part of the digital product range. Walter offers a whole host of apps for various applications in the machining process. These include apps for wear optimisation, for ascertaining the ideal indexable inserts, for calculating starting values and for configuring special tools.

Walter eLibrary

The Walter eLibrary app provides access to all printed catalogues and brochures in 17 languages. PDFs can be printed out as individual pages. The app is optimised for use on all devices.

Walter GPS

The Walter GPS machining navigation system is another way of finding the right tool without fail. It supplies tool and cutting data recommendations perfectly adapted to the machining task at hand, along with information on the machining strategy, cost-efficiency calculations and more. Konstantinos Bountolas is certain that “with Walter GPS, we definitely have one of the best applications for tool recommendations currently available on the market.”

Walter Machining Calculator

The Walter Machining Calculator supplies cutting data for milling, drilling and turning machining operations. For example, torque, drive power and machining volume, as well as the main operating time, main cutting force and chip thickness. In addition, a simple cost comparison of two tool solutions is possible with the integrated profitability calculator.

Wear Optimisation app

This helps increase the tool life by visualising forms of wear and illustrating the causes of wear.

Walter Insert Converter app

The Insert Converter specifies exactly which Walter indexable insert is compatible with the solution that is currently in use.

Feeds & Speeds app

Walter Feeds & Speeds calculates starting values and the cutting speed and feed for turning, drilling, threading and milling.

Walter Xpress

Walter Xpress configures special tools using an interactive online form and is available for around 10,000 defined variants.

Konstantinos Bountolas summarises: “We are convinced that high-quality data is the basis for optimising customers’ processes. With our digital solutions, we are paving the way towards Industry 4.0 for our customers.”

 

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Real-Time Data For Process Optimisation: Practical Software For Machining

Real-Time Data For Process Optimisation: Practical Software For Machining

Industry 4.0, Big Data, Internet of Things (IoT), digitalisation, networked production – these topics seem to be everywhere. So much so that the mere mention of the buzzword “Industry 4.0” causes uncertainty among many technicians in medium-sized companies. This is because they are unsure what “Industry 4.0” will actually mean for their own day-to-day work and their future-proof production strategy and production planning. By Florian Böpple, Digital Manufacturing Manager at Walter.

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