Paul Horn GmbH is expanding its range of gear cutting products. Horn’s new tool system for milling bevel gear teeth allows the complete machining of bevel gears on universal turn-mill centres. The system was created in cooperation with machine manufacturer INDEX and means that users no longer need any special machines to manufacture gears of this kind. It also allows all functional surfaces to be produced together with the gear teeth in one clamping. This enables high component precision, short lead-times, a very cost-efficient process and short machining times as a result of controlled machining cycles.
With a universal turn-mill centre from INDEX, components with bevel gear teeth can be efficiently and flexibly manufactured, including in small quantities. This also makes the process attractive to small and medium-sized companies that would previously have bought in gears or had them manufactured externally.
For the process, Horn relies on its S276 and S279 double-edged indexable inserts, which are screwed on tangentially. This makes it possible to achieve a stable insert seat, which is particularly important during form milling. The tool does not have to be remeasured after the inserts have been turned around or changed because the inserts are precision-ground on the circumference.
The milling body can be equipped to allow for different numbers of teeth and outer diameters when cutting gears. The process of developing the complete system (cycle, tool and clamping) called for a great deal of expertise on the part of both the machine manufacturer and the tool manufacturer. To implement the process, various types of INDEX machine with a “bevel gear hobbing” cycle are required. Horn offers the milling cutter bodies with the HSK-T40 and HSK-T63 interfaces. The profiles of the inserts are module-dependent and precision-ground.
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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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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:
Applications
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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.
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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.
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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.
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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.
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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.
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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.”
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