The international company Tubos Reunidos has its new facility ready with DANOBAT  machines for the manufacture of threaded pipes and hoses. The project is the result of the joint venture of Tubos Reunidos and Marubeni; the premises total some 31,500 square meters with, amongst others, a workshop where theDANOBAT machines manufacture the threaded pipes.

The new production line will manufacture highly technological pipes, specifically threaded pipes for drilling and production of oil and gas wells. DANOBAT machines finish off the pipes with patented PREMIUM threads, that provide superior performance compared to standard threads. “They are perfectly suited for work on sites at 4,000 or 5,000 meters depth”, explains Carlos San Martín, director of technology and development of Tubos Reunidos Industrial.

Among other facilities, the line will have several horizontal DANOBAT TTB lathes for machining of pipes. One of the most important features of this machine is the rigidity, high production and extraordinary chip removal capacities during turning and threading operations. In addition, it is provided with load-unload systems, positioning channels and solutions with specific tools for turning pipes. To top it all off, the line will be equipped with DANOBAT band saws to cut the pipes, thus offering a high value-added comprehensive solution to Tubos Reunidos.

In the new factory, DANOBAT machinery will also produce the necessary special couplings to join the pipes in the well: the couplings. The company will have sophisticated DANOBAT lathes to machine the couplings, in addition to a robotised load-unload system thus obtaining a near fully automated production system with minimum operator intervention.

The latest generation of the Walter Turn, Walter CaptoTM (C4-C6) and Walter Cut ISO turning tools have highly accurate precision cooling.

The special feature: the jet of coolant is directed onto the cutting edge or underneath the chip by the shortest route. The temperatures are at their highest at these points, and the cooling effect is therefore at its greatest. Another advantage: The precision cooling cools in two places at once – both on the rake and the flank faces. Consequently, these turning toolholders have two coolant outlets. Higher tool life (from 30 to 150 percent) and higher cutting data are achieved as a result.

The precision cooling works effectively starting at coolant pressures as low as 10 bar. As the pressure rises, chip breaking and process reliability improves. The upper limit is usually at 150 bar. If the appropriate technical conditions are in place, even pressures as high as 300 bar are possible. Cutting operations performed on stainless materials or materials with difficult cutting properties benefit in particular from this development. Another area of application is in mass production when cutting steel materials.

Seco has expanded its range of insert geometries for the turning of challenging materials, such as hardened steels and superalloys. The new geometries are available in the TH1000 PVD-coated grade and TH1500 Duratomic^®CVD-coated grade. Combining a Seco-Capto machine-side interface with rigid P-lever-clamping, the new holders accommodate larger inserts for heavy-duty applications, particularly in ductile materials.

Both the TH1000 and TH1500 offerings have been significantly expanded with new inserts shapes, chipbreakers and nose radius sizes. The addition contains optimal solutions for a range of applications in the aerospace, energy and automotive industry segments.

TH1000 inserts offer a TiSiN-TiAlN nanolaminate PVD-coated grade ideal for finishing operations or interrupted cuts in hardened steels from 50 to 62 HRC. The grade also excels in long, continuous finishing and semi-finishing operations in superalloys, such as Inconel 718, Waspaloy and Nimonic C263. The grade allows for faster cutting speeds in these applications and joins Seco’s carbide grades TS2000 and CP200 and CBN grade CBN170 to form a complete finishing package for superalloys.

TH1500 incorporates Seco’s unique Duratomic coating technology, which manipulates oxygen and aluminium at the atomic level to optimise the coating’s properties. The grade offers excellent performance in hardened steel applications with high cutting data, as well as continuous cuts in materials from 40 to 55 HRC. TH1500 also achieves superior finish turning of grey and ductile cast irons, making it an excellent complement to Seco’s TK1001 and TK2001 grades within that application area.

To support heavy-duty roughing operations in superalloys and long-chipping steels, Seco has introduced versions of its Seco-Capto P-lever holders that accommodate large CN and SN inserts. The Seco-Capto interface sizes range from C5 to C10 and insert sizes range from CN..16/SN..19 to CN..25/SN..25. The P-lever clamping system leaves the area above the insert free for maximum chip flow and unhindered chip evacuation. Additionally, Seco-Capto P-lever holders feature a new nozzle design, ensuring coolant pressure capabilities of up to 70 bar, for efficient heat removal from the cutting zone.

A new range of inserts with positive NF geometry has been developed by Dormer Pramet for turning of stainless steel.

The double-sided inserts, marketed under the Pramet brand, are available for finishing to medium turning of stainless steel, low carbon steel and super alloys. More than 110 variations in insert shapes (C, D, S, T, V and W), sizes and grades have been developed.

Josef Bittner, Dormer Pramet product manager for turning, said: “The balanced shape of the chipbreaker provides a stable and sharp cutting edge, with a large area for chip formation and evacuation from the cutting zone. Also, its positive geometry allows for low cutting forces and minimises vibration occurring.”

“A combination of all these features promotes insert durability and reliability, enabling good productivity and a quality machined surface finish for the end user.”

The new inserts will be of interest to companies performing general turning applications, thanks to the low values of radial cutting force, making it suitable for unstable machining.

Meanwhile, Dormer Pramet has announced new wiper inserts for turning with W-MR geometry.

Available in CNMG12, DNMG15 and WNMG06 and 08 inserts, W-MR is suitable for longitudinal and face turning of steel, stainless steel and cast iron.

The double-sided inserts have a positive chipbreaker and a new shape on the smoothing edge to achieve low roughness in turning. This enables reduced cutting forces and higher feeds, increasing productivity while retaining the same surface finish as with standard inserts.

If used correctly, their use can completely eliminate the need for grinding.

Both NF and W-MR geometry further strengthens Dormer Pramet’s portfolio for machining stainless steel, with a wide range of indexable and rotary products now available.

Dormer Pramet’s additions to its turning range forms part of a wider product launch in April 2015 – the first combined unveiling since Dormer and Pramet merged last year.

When Seco introduced Duratomic technology in 2007, it was the industry’s first textured, α–based Al₂O₃ coating and one that set a new standard in machining performance. Today, after years of continuous research and development in material processes and design, the company has further advanced the technology’s aluminium oxide coatings as well as incorporated used-edge detection to make its latest TP insert grades for steel turning the most reliable, predictable and productive of their kind.

TP2501, TP1501 and TP0501 insert grades represent the next generation of Duratomic coating technology, providing improved toughness, heat resistance and chemical inertness for the longest possible tool life, while also offering the potential for even higher cutting speeds.

According to Seco, the latest Duratomic technology used in TP2501, TP1501 and TP0501 improves productivity by at least 20 percent in average turning applications as compared with Seco’s original TP2500, TP1500 and TP0500 grades. The company’s team effort has made it possible for these new grades to handle a wider range of speeds, allowing manufacturers to apply them to applications requiring higher or lower speeds while maintaining comparable tool life.

Also as part of the next-generation Duratomic technology, the new TP grades feature used-edge detection so machinists can quickly and accurately identify used edges with the naked eye. Seco determined this as a necessary benefit for today’s manufacturers as the company’s survey data revealed over 10 percent of the edges on discarded inserts go unused.

The key benefit of the Chrome used-edge detection on TP2501, TP1501 and TP0501 is that its high-contrast used-edge marks do not impact tool performance or machining-related parameters such as cutting data. As a result, manufacturers can process more parts per edge, limit production interruptions and reduce waste.

Accommodating finishing, medium and roughing operations in a broad range of insert sizes and geometries, TP2501, TP1501 and TP0501 represent the best grade selection in steel turning, whether the desired result is versatile, balanced or high-speed productivity.

TP2501 is a versatile grade with highly secure edge toughness behavior that brings dependable productivity and reliable part production to general steel turning applications. It is the preferred grade for operations that involve a variety of workpiece material requirements and unpredictable working conditions.

TP1501 is a general grade with well-balanced properties that make it ideal for applications requiring high wear resistance in low-alloy steel workpieces. Furthermore, the grade offers the potential for higher cutting speeds, while the high reliability and accuracy ensures consistent part quality.

TP0501 is a general grade best suited for stable machining conditions and situations requiring high output. Of the new TP grades, it provides the highest possible wear resistance and/or cutting speeds in high-alloy and abrasive steel turning applications. Furthermore, the extreme heat resistance of the TP0501 makes it possible for users to achieve high metal removal rates without the need for coolant.

SORALUCE milling, boring and turning machining solutions are expanding worldwide with the appointment of DUROC as a full SORALUCE products dealer. SORALUCE machines are today present in all five continents and they are a world reference for cutting edge milling-boring and vertical turning machines. Complete design, assembly and verification of the machines is carried out in four assembly plants in Basque Country (Northern Spain) and one Technology Centre in Limburg (Germany), in addition to an advanced head manufacturing centre providing high level technology and working with the most demanding industries, from capital goods to energy.

SORALUCE milling, boring and turning machining solutions are expanding worldwide with the appointment of DUROC as a full SORALUCE products dealer. SORALUCE machines are today present in all five continents and they are a world reference for cutting edge milling-boring and vertical turning machines. Complete design, assembly and verification of the machines is carried out in four assembly plants in Basque Country (Northern Spain) and one Technology Centre in Limburg (Germany), in addition to an advanced head manufacturing centre providing high level technology and working with the most demanding industries, from capital goods to energy.

DUROC MACHINE TOOL is one of the leading players in the market for machine tools and accessories in Northern Europe. Duroc Machine Tool is active in totally seven countries including Sweden, Norway, Denmark, Finland, Estonia, Latvia and Lithuania. The mother company Duroc AB is a public company registered on the Swedish stock exchange NASDAQ-OMX. Duroc Machine Tool offers reliable solutions for a cost efficient production process with high availability and disruption-free production.

With the appointment of this new partner, SORALUCE looks for a closer approach to customers with an increased service portfolio before and after sales in Finland, Denmark, Estonia, Latvia and Lithuania. That for, DUROC MACHINE TOOL renders a highly skilled sales and service team with a strong background and long experience in machine tool business, all supported by the expertise of SORALUCE, a leading brand providing engineering solutions far beyond machine tools.

This alliance will help companies in these countries to boost business and productivity.

New High-pressure Coolant Bursts through Groove-turning, Parting Operations

In order to meet the machining needs of difficult-to-cut materials such as titanium, Inconel and other heat resistant alloys, TaeguTec has introduced the T-Burst high-pressure coolant tool for groove-turning and parting.

In parting and grooving applications, the ability to supply high-pressure coolant generates good chip breaking, reduced cycle times and increased tool life on most materials but on difficult-to-cut materials, the rules change because it becomes harder to ensure effective chip breaking specifically with standard external coolant in low feed rate operations.

The new addition to the T-Burst line fixes those challenges and helps machinists excel in creating superior highly productive parts at a lower cost when working with exotic materials under low feed rate conditions.

With the coolant outlet located on the upper jaw, directly over the insert, TaeguTec’s T-Burst high-pressure coolant, which is supplied through the tool holder’s internal coolant channel, shoots out with enough force and speed to the insert’s cutting edge thus allowing for lubrication of the material and cutting tool, as well as effective cooling, excellent chip breaking and increased tool life while preventing built-up-edges.

The T-Burst high-pressure line is available in two tool holder types: TTER/L-TB, TTER/L-SH-TB holders and TQHR/L QuadRush tool holders.

Square shank TTER/L-TB holders are available in both 20 and 25 millimeters while the inserts’ width of cut ranges from 3.0-8.0 mm. TTER/L-SH-TB holders come in 12 and 16 mm square shank size and features a side clamping design for fast and easy indexing on Swiss type tooling machines. The square shank QuadRush holders are available in 12, 16, 20 and 25 mm while the inserts’ depth of cut ranges up to 5.2 mm.

The T-Burst tool holders apply through coolant up to 340 bar and achieves improved tool life compared to normal coolant pressure external type tool holders.

In quality tests designed to compare the effectiveness of the new T-Burst line’s groove-turning and parting operations on difficult-to-cut materials against tools that supply normal external coolant of 10 bar, TaeguTec increased tool life on grooving operations conducted on Inconel 718 by as much 75 percent in one test, by 400 percent while machining titanium alloy on another test, 50 percent on stainless steel and an incredible increase of 800 percent tool life on aluminum alloy.

On a separate comparison test using the highly-popular QuadRush insert series, the T-Burst line increased tool life by 180 percent versus normal external coolant tools while performing shallow grooving operations.

SCHUNK, the competence leader for clamping technology and gripping systems has developed the highly flexible manual chuck ROTA-S flex particularly for users, who want to machine a possibly wide workpiece range on milling/turning machines. It is a combination of the proven lathe chuck of the serie ROTA-S plus with extended guideways, and transforms them into large, light chucks, which are particularly versatile in use.

Compared to conventional lathe chucks used for large clamping diameters, the weight with ROTA-S flex drops down to 60%. At an identical table load much heavier workpieces can be machined, and due to the low height enough space remains for the workpiece and the tools. On the other hand, for machining smaller workpieces the extended guideways can be easily disassembled, so that the workpiece accessibility has been considerably improved compared to a clamping application with conventional large chucks. A special lubrication system ensures for permanently high clamping forces of both variants. Dirt seals prevent chips and dust from entering the workpiece. The ROTA-S flex can be easily assembled on a machine table, and by using the optimized jaw quick-change system, retrofitting can be done within seconds. The chuck clamps small parts as reliably as large ones, and thereby ensures maximum operator’s safety. The clever clamping solution is available in the sizes 700, 1000, and 1200 for ROTA-S plus, and the manual chuck ROTA-S plus 2.0 is available in sizes 315, 400, and 500. Depending on the size, the chuck (without top jaws) weighs 170 kg, 360 kg, or 490 kg. The ROTA-S flex can be combined with numerous chuck jaws from the 1,200 types of the world’s largest standard chuck jaw program from SCHUNK.

High precision nozzles put coolant pressure exactly where it’s required

Sandvik Coromant has announced that its CoroTurn® SL cutting heads now feature CoroTurn HP (high precision) nozzles that direct cutting fluid precisely where it is needed – at the exact interface between the tool and the workpiece. This innovation ensures CoroTurn SL users can be assured of reliable chip breaking, which facilitates both good chip evacuation and extended tool life in back-boring operations.
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The extended product range offer includes cutting heads for coolant up to 70 bar pressure. Designed to suit back-boring operations with clearance between body and component, the heads are available in 25 and 40 mm sizes, to suit positive D and V style inserts.

CoroTurn® SL is a universal and modular system of adaptors with exchangeable cutting heads where customers can build customized tools for a variety of machining applications. The ingenious Serration Lock (SL) interface is extremely robust and lets users create a range of tool combinations from a small inventory of adaptors and cutting heads: just three bars and three heads allow up to nine different configurations. What’s more, CoroTurn SL cutting heads have four stages of offset up to 23 mm. This enables reach and the largest possible boring bar diameter, making it ideal for challenging operations in the aerospace and oil and gas industries, such as bottle boring (also called chamfer boring). Here, SL adaptors are ideal in combination with Silent Tools dampened boring bars for operations with long overhangs or vibration tendencies.

The CoroTurn HP fixed, pre-directed high precision nozzles featured on the new heads deliver parallel laminar jets of coolant with high velocity. While positive effects start at low coolant pressure, more demanding workpiece materials can be machined as the pressure climbs.

Ultimately, for efficient coolant delivery, Sandvik Coromant offers solutions all the way from the machine to the cutting edge, through clamping units, adaptors and holders – empowered of course by dedicated insert geometries.

With new technological developments, emerging on the automotive horizon, manufacturers are faced with extremely high demands in terms of quality, security and productivity. The new Sandvik Coromant grades GC4315 and GC4325 with Inveio are designed to support the automotive industry with outstanding reliability and process security.

Large batch production with low unit cost
Transmission manufacturing is a large volume production with a low cost per part. Therefore, requirements such as high process security, short cycle times and consistent quality are critical for achieving faster lead times and lower production costs. Soft stage turning is performed before the case hardening process. Offering high wear resistance and excellent tool life, this is where the steel turning grades GC4315 and GC4325 are to show a marked step up in performance.

Predictable performance for secure production
First choice grade for soft stage turning in stable conditions, GC4315, is designed for high-speed steel turning with a long and predictable tool life. Grade GC4325 is a tougher steel turning grade that manages interrupted cuts and uneven depths of cut at high speeds. Both grades enable high cutting data without sacrificing component quality. If the spindle speed limit prevents the full use of their capacity, maximum productivity can be achieved by applying higher feed rates. These two grades are excellent choices for outer-diameter turning, copying and profiling and guarantee predictable performance for secure transmission manufacturing.