Perfect to Machine Miniature Products made from Difficult-to-cut Materials

TaeguTec has introduced a new addition, the T-Burst high pressure coolant holder for Swiss turning applications.

The T-Burst holder for Swiss turning applications, as with the current T-Burst holder, applies high pressure coolant from dual holes directly between the metal chip and the insert’s rake face; a feature that optimizes control, extends tool life as well as increases productivity through higher cutting speeds and feed rates.

It is capable of handling coolant pressure up to 140 bar maximum and is designed to machine miniature products generally found in the automotive, medical and aerospace sectors. The new T-Burst holder is ideally suited for machining difficult-to-cut materials such as stainless steel, titanium, Inconel and other heat resistant alloys.

For added convenience, a simple coupling (one-touch exchange) system has been introduced. The hose connecting the machine to the holder can be easily and quickly attached or detached for replacement.

The coupling system’s hoses are available in two lengths: 200 millimeter and 300 mm depending on the machine’s specifications.

During product testing, be it on medical parts or parts for the automotive sector, the new T-Burst for Swiss turning applications increased tool life by a minimum of 100 percent over the competition.

In one test on a mission core workpiece made from steel magnetic iron, the new addition to the T-Burst line increased tool life by 300 percent over the competition.

In other tests on different materials such as steel magnetic iron and chrome cobalt molybden steel, the new T-Burst raised the bar by increasing tool life by 100 percent.

Perfect to Machine Miniature Products made from Difficult-to-cut Materials.

TaeguTec has introduced a new addition, the T-Burst high pressure coolant holder for Swiss turning applications.

The T-Burst holder for Swiss turning applications, as with the current T-Burst holder, applies high pressure coolant from dual holes directly between the metal chip and the insert’s rake face; a feature that optimizes control, extends tool life as well as increases productivity through higher cutting speeds and feed rates.

It is capable of handling coolant pressure up to 140 bar maximum and is designed to machine miniature products generally found in the automotive, medical and aerospace sectors. The new T-Burst holder is ideally suited for machining difficult-to-cut materials such as stainless steel, titanium, Inconel and other heat resistant alloys.

For added convenience, a simple coupling (one-touch exchange) system has been introduced. The hose connecting the machine to the holder can be easily and quickly attached or detached for replacement.

The coupling system’s hoses are available in two lengths: 200 millimeter and 300 mm depending on the machine’s specifications.

During product testing, be it on medical parts or parts for the automotive sector, the new T-Burst for Swiss turning applications increased tool life by a minimum of 100 percent over the competition.

In one test on a mission core workpiece made from steel magnetic iron, the new addition to the T-Burst line increased tool life by 300 percent over the competition.

In other tests on different materials such as steel magnetic iron and chrome cobalt molybden steel, the new T-Burst raised the bar by increasing tool life by 100 percent.

The automotive industry in India is one of the largest in the world and plays an important role in the country’s economy by significantly contributing to the manufacturing GDP.

According to the Society of Indian Automotive Manufacturers, the Indian automotive sector today is a $74 billion industry and by 2026, the industry is expected to achieve a turnover of $300 billion.

Therefore the growth in the automotive industry is very closely watched by all the nation’s stakeholders in order to assure that this rise continues with few hiccups.

To assist in the automotive sector’s growth, TaeguTec recently held a customer seminar for almost 50 executives, decision makers and managers in some of the country’s leading automotive productive parts companies.

For two days, guests attended seminars covering the newest, technologically advanced cutting tools that increase productivity and cut cost, spoke to product managers about ways to improve their manufacturing output and witnessed firsthand real-world product demonstrations on the materials they currently use and will use in the near future.

“Drilling demo was exciting, on an inclined surface is a challenge and we found some good recommendations to examine for our future,” said a purchasing manager for an Indian auto parts manufacturer.

“Since we are a medium size company that competes with the larger ones, we need tools that cut cost and increase productivity. We have large volumes of machining and what we saw here are definitely worth pursuing,” he added.

For holemaking applications, TaeguTec offers some of the finest tools in the business such as the TopDrill, SpadeRush, TwinRush and the hugely successful total package, the DrillRush.

During the product demonstrations, several different DrillRush products where showcased on a rainbow of materials such as the flat bottom drill, the long drill, a pre-thread drill, a small diameter DrillRush and chamfering rings that attach to DrillRush products.

“As an auto parts manufacturer, we make a lot parts, engine parts, chassis, some parts that go into transmissions; including steal forging and cast iron machining. So we use a range of tools for milling, drilling and so on. For us, the first tool we used from TaeguTec was a milling cutter, this was one of the best we ever tried and we have never looked back,” said an executive from a large Indian auto parts producer.

On display were a slew of milling products that have garnered the reputation from some of the largest manufacturers in the world.

Some of the products that brought on the most curious at the forefront were the ChaseFeed SBMT, the Chase2Feed BLMP, ChaseHepta 7EMT, Mill2Rush 6NKU and 3PKT, Chase2Mill 4NKT and the HardMill and ApexMill with the Typhoon attachment.

“The 2PKT and 4PKT are good ideas, also some positive inserts that were shown are good to examine too. There was also the interesting turning line that machines very thin materials,” said one of the top brass at another Indian auto parts producer.

During the demonstration for turning products, the Asian metalworking giant displayed the machining prowess of the new Life+ TT7015 and TT7005 cast iron grades on the BlackRush line.

Also, on demonstration on many different materials were the RhinoRush which has changed the face of turning due to its small but strong stature, the T-Turn and TurnRush lines, the ever popular and economical QuadRush line, the T-Clamp and the incredible force from the T-Burst high pressure coolant tool.

Concerning tools to machine miniature components, one auto parts manufacturer explained that there are not many cutting tool providers that offer not only a wide selection of tools, but also tools that consistently outperform the rest.

“With TaeguTec, we have a wide selection of miniature tools that have increased our production output,” said a parts manufacturer that concentrates on miniature components. “For our needs, I found that the TopMini and TopMicro for threading and face grooving are unmatched but I was also curious to get more information about the TopCap for future reference.”

With all this information supplied to TaeguTec’s visitors, other guests were interested in tool management services like the CTMS and MATRIX.

The MATRIX tool management storage unit comes in two sizes, the MAXI and MINI. It is fully scalable and modular in order to offer the end user full control over storage while also being easy to implement. Furthermore, its powerful software does it all with a range of easy to use and clever features.

The other service, the CTMS, is a business unit dedicated to delivering tool management services and systems to help customers reduce their production costs. The CTMS team comprises tool management professionals in the key areas of logistics, engineering and IT, all critical to cost reduction in the supply chain and manufacturing processes affected by cutting tools.

“We believe that we should get our tools from one company and we believe that they should manage our inventory. It reduces are tooling time and makes sure we always have tools in stock and also the newest tools in stock,” said a manager at another auto parts company.

At the end of the customer seminar, guests left armed with a plethora of information that cater directly to their industry and needs and like one machinist said, “this will help us increase our output and cut our cost, in our business, we need to find ways to beat the competition and I believe TaeguTec has those tools.”

With the increasing application of composite materials in the market, TaeguTec is pleased to supply new PCD milling inserts, diamond coated solid carbide end mills and drills for effective machining of composite materials.

In recent years, the demand for strong, lightweight materials from industries ranging from aerospace, motorsport to power generation, has led to the development and implementation of composite materials.

Composites, such as CFRP (carbon fiber reinforced plastic) are 70 percent lighter than steel and 40 percent less than aluminum alloy. For aerospace, in particular, CFRP is a very popular material because of its reduced weight, which equates to higher fuel efficiency.

In various industrial fields such as automotive, wind power energy and recreation industries, the advantages of using composite materials are more effective due to the material’s lighter weight and superior stability over conventional counterparts.

These new tooling solutions satisfy the unique cutting conditions of difficult materials as they have been designed to combine the specific grade, required geometry and high technology diamond coating for processing composite materials.

Polycrystalline diamond (PCD) inserts allow for faster speeds and feeds compared to other conventional cutting tool materials. TaeguTec specifically designed its PCD inserts to prevent surface delamination of composite materials.

To offer a wider range of option while machining CFRP, TaeguTec’s diamond coated solid carbide end mills come in four different types.

Ideal for splitter routers, the RRFE type eliminates delamination, offers low cutting force and less vibration and is a high productivity tool for roughing applications.

Another diamond coated solid carbide end mill offered by TaeguTec used to machine CFRP is the RCFE type, which like the RRFE eliminates delamination, offers low cutting force, less vibration and is a high productivity tool for roughing applications – the difference being that it is used on multi flute routers.

For finishing applications, TaeguTec recommends the diamond coated solid carbide end mill RCOM which eliminates delamination and comes in a left and right handed helix type.

The fourth offering by TaeguTec to machine CFRP, which is also for finishing applications and eliminates delamination and splintering, is the low helix RDCF type.

As for diamond coated solid carbide drills, TaeguTec’s CFRP drills are a perfect choice when looking for a tool that eliminates delamination during through hole machining.

To ensure the tools last longer while increasing productivity, TaeguTec has made available two new grades for the CFRP line.

The TD830, with its ultra-fine diamond grit size PCD grade, has excellent wear resistance, edge strength and quality and has exceptional abrasion resistance and good thermal stability.

The other recommended grade for the CFRP line is the TTD610. With its advanced nano diamond coating, this outstanding grade provides longer tool life and machining stability, has excellent abrasive wear resistance (hardness is over Hv 8,000) and has one of the highest thermal conductivity, impact resistance and processing stability in the entire line.

TaeguTec has launched two new five-cutting edge insert lines – RTMX and RTHX – with related cutters specifically dedicated for the stainless steel and difficult-to-cut materials used, but not exclusive, in the aerospace, oil and gas and power generation industries.

ChaseMold’s RTMX and RTHX inserts including the line’s optimal cutter design were born through rigorous trial and error as well as performance testing in order to attain excellent performance in stainless steel, difficult-to-cut materials and turbine blade machining under severe machining conditions and in unstable fixtures.

The RTMX is a press-to-size type line for economy while the RTHX ground type is dedicated towards high precision machining with both line’s offering a high positive rake angle for low cutting resistance.

Both inserts come in 10 and 12 millimeter sizes and their chip formers are available in three types: MM, ML and MLL. The MM chip former is recommended for unstable conditions, the MLL for stable conditions and the ML covers the middle range between the MM and MLL types.

Furthermore, both lines are available in standard and special grades; the special grades are made for any machining environment, even under harsh conditions due to their high wear resistance and toughness capabilities.

Cutters are available in end mills (ø32 mm), modular types (ø25-40 mm) as well as face mills (ø40-80 mm) and all are coolant capable for easy chip evacuation.

During the product testing simulating real-world conditions, TaeguTec’s new ChaseMold lines achieved higher tool life and productivity than the competitors’ similar offering.

For tool life during the roughing operation of the airfoil, shroud and the root part of the blade component made from martensitic stainless steel (X20Cr13, AISI 420), TaeguTec’s new 5-teeth RTMX line outlasted a leading competitor’s tool by 65 percent, while on a blade shroud and root roughing operation made from stainless steel (1.4923), the same RTMX line increased tool life by almost 30 percent.

In another test that emulated real-world machining conditions, TaeguTec’s RTMX completely annihilated the competition by increasing tool life by 100 percent while performing a spiral roughing operation on the blade’s airfoil part of the component made from alloy special martensitic creep-resisting steel (1.4938 + QT, X12CrNiMoV12-3).

Concerning productivity, TaeguTec’s tests using the ChaseMold RTMX line on an aerospace engine case made from Waspaloy and Inconel 718 increased productivity by 65 percent on a leading competitor’s similar offering.

TC3020 & TC3030 New Ceramic Grades for High Temperature Alloy Machining

The demand for cutting tools to increase productivity and cut the cost of machining high temperature alloys is always increasing, that is why TaeguTec has launched two new SiAlON ceramic grades – the TC3020 and TC3030 – that offer superior performance.

Both the TC3020 and TC3030 ceramic grades are suitable for high temperature alloy machining where difficult-to-cut materials such as Inconel, rene and titanium are used. These ceramic grades are characterized by their excellent toughness and anti-chipping capabilities making them the best choice for both interrupted and continuous machining.

With the introduction of both these grades, the Asian metalworking giant has gone a step further by supplying even more optimal solutions for machining high temperature alloys than its current whisker ceramic grade.

The new grades are available for insert lines in turning, milling and grooving applications.

The TC3020 is ideal for high temperature alloy machining and runs in the same conditions as the whisker ceramic grade. Its superior wear resistance is due to its high stability while it offers better flank and notch wear resistance compared to the competitor’s similar grade. Furthermore, the TC3020 has excellent high temperature strength and fracture toughness.

The other new offering, the TC3030, is also created to handle high temperature alloys with the difference being that the grade’s extreme toughness enables it more for higher feed and heavier depth of cut machining and is suitable for scaling and roughing applications while offering excellent thermal shock resistance and thermal conductivity.

By combining silicon nitride and aluminum oxide, TaeguTec’s SiAlON grade offers incredible chemical stability in order to reduce notch wear in demanding operations and has the capability to run at 4-6 times the speed of conventional carbide inserts.

Product testing in real-world machining conditions demonstrated increases in productivity and tool life.

While performing a continuous grooving operation on an engine casing made from Inconel 718, the TC3020 grade’s productivity increased by 40 percent over the competitor’s similar ceramic grade.

For an engine casing made from the same Inconel 718 with external interrupted turning and interrupted grooving operations, TaeguTec’s TC3030 increased tool life by 23 percent and 56 percent respectively.

The biggest improvement over the competition was on a rene 108 material, the TC3030 performed incredibly well on a face milling operation of a shroud workpiece when it increased tool life by 100 percent.

As one of Asia’s leading metalworking companies, TaeguTec is a highly regarded and respected supplier of cutting tools, tooling systems and industrial products for the metalworking and steel industries and is present in over 50 countries.

Advanced Coating and Substrate Design Enables Improved Wear Resistance and Toughness

The machining of cast iron material has a tendency to generate deviation during operation due to the nature of the material. Moreover, the usage of ductile cast iron has grown as a trend and has become more pervasive as a material of choice in every industry.

In order to respond to these two simultaneous machining conditions, TaeguTec has launched the improved TT7015 Life+ CVD grade which is geared towards turning operations.

The advanced coating and substrate design of TaeguTec’s new TT7015 Life+ enables improved wear resistance and toughness during the machining of parts made from cast iron.

The improved grade provides higher stability on a wide range of applications and generates longer tool life due to the grade’s anti-chipping capability.

The Asian metalworking giant’s new TT7015 Life+ grade is specifically geared towards general purpose machining of gray cast iron and ductile cast iron materials.

Furthermore, the TT7015 Life+ grade minimizes unexpected insert failure even under interrupted cutting conditions while offering excellent surface roughness during machining due to its fine coating layer.

During the testing phase of the TT7015 Life+, the new grade increased tool life by as much as 117 percent.

While working on disk brakes made from gray cast iron, the TT7015 Life+ increased tool life by 100 percent while performing facing operations. On a front hub made from ductile cast iron, the new grade increased tool life by 100 percent. But the big eye opening test came with the internal roughing operation of a differential case cover made from ductile cast iron which increased tool life by an amazing 117 percent.

TT8080 PVD Crack Resistant and Eliminates Delamination on Turning Applications

TaeguTec has unveiled the TT8080, an excellent PVD coated grade for superior performance in turning of stainless steel and high temperature alloys.

The TT8080 grade has been adapted to turning applications and is particularly well suited for stainless steel and the machining of high temperature alloys under low cutting speeds and interrupted cutting conditions.

Characterized by excellent toughness and high anti-chipping capability, the TT8080 grade is the perfect choice for interrupted and rough machining.

Compared to the existing TT8020 grade, the TT8080 grade guarantees longer tool life and higher machining stability due to improved wear resistance.

The strong coating adhesion that envelopes TaeguTec’s TT8080 is not only is crack resistant but also eliminates delamination.

Product testing on different forms of machining resulted in incredible increases of tool life over the competition.

Most notably, while conducting an interrupted facing operation on a valve body, TaeguTec’s TT8080 PVD coating increased tool life by a whopping 160 percent. On another test, but this time on a pipe fitting made from the same material, the new coating increased tool life by 71 percent on an external interrupted operation.

For external continuous machining of a ring on SUS 316, TaeguTec’s TT8080 PVD coating increased tool life by 33 percent over the competition.

Recent trends in complex shaped component machining and high-speed cutting conditions for productivity improvement have proven to be a challenge for cast iron.

To adapt to these trends including some of the more common challenges like flank and crater wear, notch wear and build-up-edges caused by abrasion, adhesion and diffusion, TaeguTec has introduced the TT7505 grade for high-speed grooving applications on cast iron.

The Asian metalworking giant’s new coating grade is introduced to meet both the high hardness and strong toughness requirements demanded by cast iron machining.

The TT7505 grade is optimized for high-speed cast iron machining – including continuous cutting applications – while guaranteeing stability and longer tool life.

An additional advantage of the TT7505 grade is the application of a special CVD coating technology and a newly developed substrate for improved wear resistance and toughness for overall better performance.

The new grade’s features offer overall improved machining on a wide range of applications for all customers no matter the industry.

During several case studies, TaeguTec’s TT7505 grade increased tool life by 25 percent while machining ductile cast iron GGG 40.3 and by 13 percent on the gray cast iron of GG 35 materials.

TaeguTec has introduced a new solid carbide drill – the NHD Drill – which outperforms the existing SHD and SHO drills.

The new H-Drill NHD’s optimized cutting edges are designed for improved drilling stability while its sharp straight cutting edges, with precise web thinning, generates low cutting force and excellent self-centering capability for higher hole accuracy.

Furthermore, in order for the NHD to evacuate chips smoothly, TaeguTec has designed the new addition to the drilling family with polished flutes and a wide chip gullet.

In general, solid carbide drills are designed specifically to enhance the machinability and tool life for most materials including high alloy and stainless steel due to high hardness and thermal conductivity.

These features strengthen the cutting edge longer and dissipate generated heat rapidly but unfortunately, carbide bits are very brittle and chip if they are handled without care.

In order to remedy this negative factor and prolong tool life during high efficiency machining, TaeguTec has added the new TT9030 multi-layered coating technology to the NHD line, which maximizes toughness as well as increases wear resistance.

TaeguTec’s NHD drills are offered in 3 millimeter to 12 mm diameter range and available in 3xD and 4-5xD depth of cut range. TaeguTec’s NHD drills are listed as standard items and come with or without coolant holes.

Tailor made NHD drills, such as over 12 mm diameter, are available upon request.

To make sure that the H-Drill NHD line is ready to be sold by Asia’s largest metalworking company, TaeguTec pitted it against SHD drills and other competitors’ similar offerings.

In every test, TaeguTec’s H-Drill NHD tool outperformed the competition and SHD drills by anywhere from 15-59 percent while machining alloy steel.