Cutting tools may not demand high investment in overall production process but it plays a vital role in productivity of the end product. Many people do not pay much attention in choosing right cutting tool and incur loss.

Things to consider before choosing the cutting tools

Cutting tools play an important role while defining a strategy for machining process. It becomes more important when all the new materials like Ni and Ti based alloys, composites and other difficult to cut materials are coming in. The right selection of cutting parameters, grades and geometries not only do the efficient machining, but also helps to maintain the geometrical tolerances of workpiece, improves productivity and maintains the cost per component ratio (See picture below). The selection of right cutting tools is based on the material to machine, power available on machine, fixture stability, machine dynamics which leads to the right selection of cutting tool material, grades, geometries, depth of cuts and the feeds.

Factors impact the productivity of the end product

The selection of right strategy to machine the component/operation is the key to success. Rather than going for the conventional way of machining, adopting the right strategies that suits the application can improves the material removal rates. The other important factor is to maintain the average chip thickness ratio which improves the productivity in multiples. This can be done by selecting the right cutting speeds and feeds depending on radial engagement of the tool. One more important aspect is the know-how training for the effective utilization of the cutting tools and machining process.

Current Scenario

We are living in a highly competitive world and to compete, everyone in the industry wants to update themselves. In fact, the customers are going for the high-end machine tools and to take the maximum output from that, they are using the cutting tools which can be highly productive, offers geometrical tolerances to avoid the rejection/rework rates, predictable, consistent and suits to the defined strategy. Several Indian customers are still hesitant to use the high-end products because of the fear for the mis-use of the product on the shopfloor and incidences like power failure which leads to the breakage of the tools. Also, at times shopfloor personals are not adequately trained in cutting tool technology to gain the maximum out-put from it.

India is ready to adopt high-end technologies

In recent years there is shift in thought process, now, Indian companies are tuned to adopt the new technologies to provide better quality product. With the introduction of latest machines tools and software, it becomes important to use the latest cutting tools, which the Indian companies are adopting to remain competitive and to produce the quality products. In fact, they are looking for the more productive ways to complete the process to lower down the cost per component. It is also our responsibility to update and demonstrate them regarding the latest innovations, techniques and strategies which help them to achieve their goal and to become a cutting tool partner in there machining process rather than being a mare tooling supplier.

About Author:

Rajesh Gupta, Dy General Manager – Technical Support, Seco Tools India (P) Ltd is having over two decades of hand-on working experience in metal working industry. He is with Seco Tools since last 15 years.

Image Courtesy: Seco Tools India (P) Ltd

The most important demands made by the mold and die making industry are stable component quality and surface quality as well as process reliability during production. Furthermore, the shorter product life cycles of the molds also require a permanent reduction of the reaction and processing times. The product launch time must be as short as possible.

LMT Kieninger is the competence center for mold and die making in the LMT Tools Group. In the past, the experts there have developed a complete and highly productive range of tools and are always searching for new, efficient solutions for users.

The innovations focus on cutting materials and cutting edge geometries in the macro and micro ranges as well as customized coatings from the in-house coating center, based on intensive knowledge sharing with users and the tool experts at LMT Fette. At the AMB trade fair, LMT will be underlining its leading position as a partner of the mold and die making industry.

New Nanomold Black coating – universal application range
High-performance coatings have a fundamental significance for difficult machining operations: The coating has the closest contact with the workpiece and is therefore primarily challenged by force and temperature influences. Coating systems thus have a substantial productivity potential. At the own coating center, experts repeatedly manage to create new coatings tailor-made for the respective application.

One innovative example is the new “Nanomold Black” coating, which will be presented for the first time at the AMB trade fair. It closes the application gap between the already established high-performance coatings “Nanomold Gold” and “Nanomold Red” (image 1). Whilst the gold coating is the first choice for roughing and semi-finishing materials in the lower hardness range and the red coating displays its true performance during the finishing of hardened materials up to 65 HRC, Nanomold Black covers a more universal application range. It is highly suitable for machining steel, cast steel and cast iron up to a hardness of 56 HRC.

Nanomold Black is for the various versions of WPR- and WPB- indexable inserts available and also on two different types of carbide: For LCPK15M for semi-finishing and finishing as well as for LCPK25M for roughing and semi-finishing, for both wet and dry machining.

CopyMax 2 copy milling insert – quadruple tool life

The CopyMax product range is a particularly important milestone in goal-oriented tool development. It treads new paths in the production of indexable inserts. Thanks to the high-quality sintering (HQS) process, even more stable cutting edges are achieved using a high press pressure and a special shape. The first product in this series is the CopyMax2, which is the forerunner of this new generation.

The coating of the newly developed CopyMax2 indexable insert from LMT Kieninger is Nanomold Gold, which is already an indication of top performance in mold and die making (image 1). But it doesn’t stop there. The copy milling plate itself has an entirely new construction design. It has improved cutting and material properties as well as a fully functional second cutting edge (image 2). When the first cutting edge is worn, the insert can be turned over and re-used with the same long tool life.

The challenge for the engineering experts was to integrate the second cutting edge into the tool geometry in such a way that the user would be able to mount the indexable insert accurately, securely and easily in the tool holder. The solution includes the new conical shaft and a specially designed clamping screw. The tool is available as an end mill cutter or screw-on milling cutter in the diameters 16, 20 and 25 mm.

The tool is particularly beneficial for the roughing and semi-finishing of large molds as well for removing residual material and ensures maximum process reliability during the machining of large workpiece surfaces.

During milling of a wave section made from cold work tool steel 1.2379, the ball nose copy endmill has already exceeded the expectations of the developers. The cutting speed was 240 m/min, the cutting depth was 1.5 mm and the radial depth of the cut was 0.5 mm. In a direct comparison with an existing copy milling insert, the CopyMax2 insert achieved more than double the tool life: approximately 470 minutes compared to 220 minutes with the same wear (100 µm maximum). But there is also the second cutting edge, which resulted in a tool life which is over four times higher (image 3). A significant leap in efficiency.

HSCline SuperFinish4 – copy milling in top quality

 The requirements with regard to finishing in die and mold making are process reliability, good surface quality and an extended tool life at high cutting speeds. The new HSCline SuperFinish4 ball nose copy endmill from LMT Fette sets new standards in exactly these points (image 4). It has 4 cutting edges with a special S-cut. Compared with the already established
HSCline SuperFinish2 with 2 cutting edges, the processing time can thus be reduced even more whilst simultaneously increasing the tool life. This is particularly useful when machining larger components with a long production time.

Its high-precision cutting geometry with defined cutting edge preparation enables a productivity increase of up to 40%. The spiral angle of 30° and the carbide shaft reduce the tendency to vibrate. In addition, the high dimension accuracy enables a significant surface quality increase thanks to a narrow radius tolerance of +/- 5 µm. The tool can be used for the finishing of hardened steel up to 65 HRC and for the finishing and semi-finishing of high-strength steel.

The preferred area of application of the new HSCline SuperFinish4 lies in the mold and die making sector for creating free-form surfaces, for example, for injection molding and thermoforming tools as well as in general machining. A diameter range of 6-12 mm is available.

Tool technology outlook

With regard to tool technology, more powerful milling tools will be
required due to the increasing use of high strength, annealed or hardened materials. To this end, the development of special geometries, cutting materials and coatings is intensively promoted.

The required process reliability should already be simulated in advance. This requires excellent information and data quality. The “Industry 4.0” initiative of the German industry makes a future-oriented contribution to this. In this context, the additive “3D printing” manufacturing method should also be mentioned. With the appropriate digitally linked equipment, not only models, prototypes and auxiliary tools can be produced at short notice. In addition, there are also new design options with new or improved functions for tool technology. For example, bores “around the corner” enable a more effective coolant supply directly at the cutting edge.

LMT Tools has already implemented various modules for “Industry 4.0” and has also invested in “3D printing” technology.

ISCAR is expanding the MULTI-MASTER interchangeable milling heads line with new engraving tool heads and new centering drill diameters.

MM EPG
ISCAR is expanding the point angle variety of the single-flute MULTI-MASTER engraving tool heads with four new 60o and 90° point angles featuring flat crests (the current tools feature radius crests). Similar to the current engraving heads, the new tools feature T05 MULTI-MASTER threaded connection.

MM ECS
ISCAR is expanding the small diameter range of the interchangeable MULTI-MASTER centering drill heads (according to DIN 332 standard) by adding 1.0; 1.6 and 2.0 diameters.

Birla Precision is showcasing tooling solutions at IESS

India’s one of the most known tooling company, Birla Precision Technologies is all set to prove its mettle again. The leading Indian cutting tools manufacturer is showcasing their latest HSS Reamers, End Mills, HSS threading Taps, HSS end mills, end mill adopters, hydraulic chucks, shrink fit adaptors blades at the ongoing exhibition Indian Engineering Sourcing Show 2015 (IESS), Mumbai. The exhibition that was inaugurated today (November 24th, 2015) at the Bombay Exhibition Centre, Goregaon will go on till 26^th November.

What’s on display at BPTL ’s stall:- 

HSS Reamers

Available in a wide range of diameters to suit specific reaming operations to provide perfect accuracy and optimum surface finish.
Type : Parallel Hand Reamers, Long Fluted Machine Reamers, Chucking Reamers with Parallel Shank or Taper Shank, Bridge Reamers, Taper Pin Reamers, Socket Reamers, Machine Jig Reamers, Centre Reamers, Shell Reamers, Taper Shank Extra Long Machine Reamers etc.
Size Range : 3.00mm – 76.20mm : 1/8” – 3”
Material : HSS M2
Note : Reamers can also be supplied as per specific Customers needs as follows: • Non standard and special as per Customers drawing • Intermediate diameters • In different grades of HSS like M35, M42 etc. • Various surface coating like TiN, TiAIN etc

HSS Threading Taps

Available in a wide range of sizes, types and combinations.

RANGE : Type: Hand and Short Machine Taps, Long Shank Machine Taps, Nut Taps, Pipe Taps, BSW, BSF,UNC, UNF,NPSF,NPS,NPT,NPTF,NGT and Special Taps.

Size Range:– 3mm – 100mm : 1/8”-4” Material: HSS-M2Note:- Taps can be supplied as per Customer needs on request as follows:- • Serial or Non-serial • Individual Pieces or in Sets • Different types like Straight, Spiral Flute, Spiral point & Fluteless(Roll) • In different grades of HSS like M35, M42 etc. • Various surface coating like TiN, TiAIN ,TICN etc. • Special Taps as per Customer’s Drawing.

Hydraulic chucks

• Dynamically Balanced Collet Chucks supplied in G-6.3 & G-2.5 on request.

As a leader in the milling and drilling tools, turning tools, and wear and impact resistant tools, Japanese company Dijet paraded its variety of products at the IMTEX 2015, in Bangalore.

One of its flagship products called SKS Extreme grabbed multitudes of attention from customers and visitors at the exhibition. This tool is designed for high feed machining, and also acts as a next-generation high feed machining cutter

The SKS Extreme has economical double-side insert with 6 corners. Its insert thickness is measured at 7.5mm, which means it has improved strength by 1.5 times compared to conventional tool.

It exhibits its excellence in ramping and helical interpolation, and makes way for high and efficient pocket milling. The adopting of new PVD coated grade ‘JC7560’ provides improved fracture toughness and achieves longer tool life.

This tool finds its application in a variety of industries including dye and mold industry, general engineering, auto and power generation industry.

Kennametal intensifies its cooperation with local university to support technical education of students.

Kennametal Inc. recently announced that it received a ‘Running Snail Race Car’ from students of the Ostbayerische Technische Hochschule (OTH) Amberg-Weiden as a gift. This race car had been designed and manufactured by OTH’s Formula Student Team.

“We are in close cooperation with the OTH for many years,” says Dr Dirk Kammermeier, Director Engineered Solutions EMEA, Kennametal. “And this fiscal year we intensified our technology collaboration and increased our sponsorship of the ‘Running Snail Racing Team’ with the help of the Kennametal Foundation. The race car is a symbol of our close partnership,” Kammermeier points out.

The Kennametal Foundation globally supports technical education projects in all regions where Kennametal has a subsidiary or facility. In this way Kennametal positions itself as the ‘Employer of Choice’ and pro-actively manages the skills shortage and talent gap.

Some facts about the cooperation with the OTH:

• Sponsoring of the Formula Student Team Project ‘Running Snail Racing Cars’ (www.running-snail.de)
• A lecture room, including Kennametal branding, is named after Kennametal
• Lectures of Kennametal experts are held at the OTH
• Tooling seminars are held by Kennametal experts
• Positioning of Kennametal as an indispensable partner for young students and junior employees as ‘Employer of Choice’
• Extended technology collaboration with talented young people in joint technical projects
• Build an international platform for internships and student exchanges
• Bridge building to emerging markets

Kennametal received the race car on November 27 and it is displayed now in Kennametal’s Technology Center at Fuerth/Bavaria. Matthias Pasler, Director Human Resources EMEA at Kennametal, was very delighted and appreciated this generous gift of the OTH Amberg-Weiden. “We are proud that Kennametal is able to contribute to the technical education of OTH’s students.” he said.

Further Kammermeier added, “The students learn within the Formula Student Team how to design and build a competitive race car. Their creativity is stimulated, teamwork gets pushed and their resilience as well as ability to work under pressure is fostered. They train their soft skills such as organizational talent, negotiating skills and leadership qualities, characteristics and skills that are requested by the industry. And they have a better balance of practical training and theoretical studies. The ideas and know-how of all team members shape this project and are turned into reality with this race car…dreams come true: designing and building a complete vehicle that is competitive in car racing.”

The race car will tour the German plants of Kennametal in the next couple of months to publicize and popularize Kennametal’s cooperation and technology collaboration with the OTH.

Seco’s new Thread Chaser inserts provide the speed, reliability and accuracy needed to meet the demanding requirements of the oil and gas industry and other segments that rely on special purpose threads such as API thread types to ensure superior hydraulic sealing in modern oil and gas components. Seco Tools also offers threading products that are produced under license from leading brands within the oil and gas industry.

The versatile Thread Chaser tool features inserts for both push and pull threading of I.D. features using multi-tooth patterns for fast single- or two-pass threading. The system’s multi-tooth inserts have precise thread patterns that quickly and reliably generate high-accuracy, consistently perfect thread pitches for industry-specific parts and pipe materials in a wide range of hardnesses.

Thread Chaser inserts increase productivity by generating the thread teeth, facing and taper at the same pitch as the thread type. The tools use a special substrate material and feature through-coolant holes and chip formers to direct high-pressure (up to 210 bar) coolant precisely to the cutting edges to optimise chip formation/evacuation and extend insert life. Inserts are available in push or pull and push/pull sets of one, two or three to accommodate various thread machine types.

Tuesday 25 November marked the start for Sandvik Coromant’s largest joint knowledge sharing event ever in Asia Pacific. About 200 visitors took part in activities and dialogue about the latest in metal cutting technology, at nine centers across the region. “Asia Pacific has a lot of manufacturing industry working with component solutions. We wanted to create a unique meeting place for professionals to discuss the latest technologies and at the same time meet peers and share know-how and expertise”, said Ee Sian Lee, President Market Area Asia Pacific.

Sandvik Coromant Center
The event was also an opportunity to celebrate the fact that the company recently opened a new state of the art center at its headquarters in Sandviken, Sweden. The new center is one of the largest of its kind in the world, committed to manufacturing, productivity, applications and research for the metal cutting industry.

With the new main center in place digital interaction and knowledge sharing between global networks of Sandvik Coromant Centers will increase further, as well as interaction with education institutes, customers and partners.

A place for interaction
Almost 30 centers around the world offer a unique meeting place for customers, industry representatives, students, journalists, partners and company staff. The centers are for everyone who is interested in productivity gains, innovation and the future for global manufacturing within the metal cutting industry. At the event in Asia Pacific some of the participating centers were invited to interact with the event hosts in Singapore via a live broadcast feed.

“Our customers and partners are competent leaders in their own fields. We want to provide a meeting place for dialogue, knowledge exchange and collaboration. The Knowledge Event is a good arena for this.

Did you know that Sandvik Coromant started its first knowledge facility in Germany in 1971? More than 40 years later we provide the largest metal cutting knowledge program in the world both online and offline,” Ee Sian Lee.

Automotive in focus
In India, the Automotive Transmission knowledge sharing event took place in Sandvik Coromant Productivity Center at Pune. Numerous visitors from leading Automotive OEM’s like Tata Motors, Mahindra, Bajaj Auto, Bharat Forge, John Deere, Cummins, Carraro etc. attended the event.

Sharad Kulkarni, AVP Market Area Asia Pacific – Automotive, shared the technology and trends in Automotive industry globally & in Asia Pacific and also the developments expected in Automotive Transmission by year 2026. He also talked about several challenges faced by Automotive manufacturers and presented the ensemble of Sandvik Coromant’s highly advanced tooling solutions available today to tackle the same, keeping in mind the competitiveness & productivity needs in this industry.

TaeguTec’s QuadRush line, known for high accuracy and surface quality, is now available for external threading applications.

With this expansion into threading applications, TaeguTec is providing end-users the highest productivity and economical tools already employed by end-users in parting and grooving applications.

Furthermore, the QuadRush insert’s unique, multi-corner four cutting edges has been expanded to 60 degrees and 55 degrees partial profiles.

The new line includes the latest GoldRush coating – TT9080 grade – for maximum protection against tool wear and better surface roughness during operations on titanium, high temperature and titanium alloys, stainless, non- and low-alloy steels and cast iron.

The QuadRush insert’s unique chip former enables machining in multiple applications providing excellent chip control, outstanding performance and repeatability.

The addition of the threading line from the Asian metalworking giant’s highly popular QuadRush brand expands the family beyond grooving, parting, lateral turning and chamfer machining.

A further benefit of the new addition to the four corner family of tools is that all QuadRush threading inserts are compatible with QuadRush standard cartridges and holders.

Continuously developing new ways for its metalworking customers to maximise productivity and profitability, Seco recently released a new version of its workpiece material classification system (SMG) classification system that makes it even easier to understand the complicated interactions between cutting tools and workpiece materials during milling, turning and holemaking operations.

With the improved SMG v2, Seco provides new data as well as simplifies the way in which it organises the content so that more customers use the classification system as a basis for maximised metalcutting operations and productivity gains.

Seco expanded the new version of SMG to present the latest information on today’s advanced tool materials such as PCBN, PCD and ceramics. The company also widened its range of workpiece material classifications for steels, cast irons, non-ferrous materials, super alloys, titanium, plastics, composites and more.

The colour-coordinated groups within the classification system indicate the ISO category for each material type, while a comprehensive cross-reference list indicates where a material may appear in different SMG groups based on how it is processed, e.g., annealed, quenched and tempered for through hardening. Furthermore, each SMG category includes details on a reference material that the user can refer to in order to determine if the cutting data should be adapted for their specific application.

In terms of how of Seco organises the comprehensive data in SMG v2, the company makes identifying the most appropriate cutting tools and cutting parameters for a particular workpiece material quick and simple by presenting all relevant data in a concise, logical manner.

The company categorises workpiece materials by type, capabilities and characteristics, rather than relative levels of machinability. A simplified cutting-data chart format now runs common across all Seco product catalogues. Plus, a new data display format makes charts applicable to all tool types and includes cutting tool recommendations.

Seco applies the information featured in SMG v2 consistently across all of its support materials. For more information on the latest SMG classification system, please contact a local Seco representative.