With MS3 and WSM01, Walter AG is presenting a new geometry and a new grade. The new WSM01 grade, manufactured using the HiPIMS method, enables extremely smooth surfaces to be achieved.

It is characterised by an excellent distribution of layer thicknesses and by outstanding layer bonding. The combination of the HiPIMS PVD hard layer and the new MS3 geometry is ideal for machining ISO S materials with difficult cutting properties such as high temperature alloys, titanium alloys, cobalt-based alloys and nickel-based alloys (e.g. Inconel 718). A secondary application of this new grade is materials in the ISO material groups P, M and N.

The negative inserts with MS3 geometry are available with both sintered and fully ground circumference. Its smooth surface and extremely sharp cutting edges keep built up edge to a minimum and ensure high surface finish quality. This makes it significantly easier to manufacture burr-free components with reliability. The new insert is particularly suitable for machining unstable or thin-walled components and setups with long overhangs, as the low cutting pressure prevents vibration. The MS3 insert – much like the RM5 – is equipped with jet guiding geometry to ensure optimum cooling directly on the cutting edge. It is particularly well-suited to copy turning applications and to medium machining applications in general mechanical engineering, the automotive industry and the aerospace industry.

With its T2711/T2712 indexable insert thread milling cutter, Walter is launching a completely new tool for machining larger threads with nominal diameters of 24 mm and above, with multiple cutting rows and an adjustable coolant supply with selectable radial or axial coolant outlets.

The new milling cutter is equipped with specifically developed thread milling inserts having three cutting edges apiece, soft-cutting geometry and a special chip breaker designed for thread milling. It can be used universally for thread depths of up to 2.5 × DN and a pitch range of 1.5 mm to 6 mm or 18-4 TPI, and is suitable for all materials from the ISO material groups P, M, K, S and H up to 55 HRC.

Multiple thread sections can be machined simultaneously with high cutting parameters, enabling machining times comparable to those of thread tapping and forming to be achieved. However, in addition to quick machining, users also benefit from the high process reliability of the thread milling process and the cost benefits of an indexable insert tool. Alongside ease of handling and excellent thread quality, the high level of productivity at low cost per thread is the greatest benefit of this tool for its users. In a test involving large-scale crankshaft machining, the new thread milling cutter reduced costs by 60%.

With the DC150 Perform, Walter brought a high-quality solid carbide drill family with an excellent price/performance ratio to market.The aim of the Perform line is to offer customers the same outstanding Walter quality they have come to expect, but without having to pay for a level of performance that offers them no benefits at all. The DC150 Perform affords significant advantages primarily where users need to machine small and medium batch sizes due to its universal use in all common materials. Coated with a material grade developed specially at Walter, it also boasts excellent wear resistance and chip evacuation: For shallow drilling depths (3 x Dc and 5 x Dc), it features a WJ30RE coating, and for deep holes, it features the even lower-friction WJ30TA version.

The addition of the 12 x Dc with internal cooling and 3 x Dc with internal cooling join Walter’s existing DC150 Perform range, which comprises the 3 × Dc without internal cooling and 5 × Dc and 8 × Dc with internal cooling. This means that the DC150 Perform is now available in around 1000 sizes for all conventional drilling adaptors. Its proven merits, such as high precision and process reliability coupled with maximum cost effectiveness, have been retained in the new models. A valuable addition for all users forwhom performance is not about theoretical values or top cutting speeds, and who instead favour versatility, cost effectiveness and guaranteed process reliability.

Stainless materials are becoming increasingly important, and not only in the food industry and medical engineering. Walter is providing a completely new type of coolant jet guiding insert geometry for machining both ISO M and ISO S materials in the form of the RM5 geometry: Deep, parallel twin coolant channels convey the coolant even closer to the cutting edge, directly beneath the chip. The result: Maximum cooling – and therefore a considerably longer tool life for roughing operations than was previously possible.

The new RM5 geometry in the current ISO basic shapes combines design features, such as the double positive macro-geometry, with Walter’s own Tiger·tec® Silver coating featuring a PVD-Al2O3 heat shield. In addition to the unique profile of the coolant channels, the RM5 geometry includes two other features which increase tool life. The new cutting edge design also reduces crater wear, as well as the formation of workpiece material build-up on the cutting edge and the occurrence of notching.

The new RM5 geometry roughing turning insert is the first of its kind in the new ISO M family. Other geometries for medium machining and finishing are to follow. It achieves optimum results when used in combination with Walter precision cooling toolholders. This is because these toolholders feature both rake and flank face cooling. In addition to this advanced method of cooling, the insert can also be used in conjunction with standard ISO turning toolholders on any lathe with standard coolant supply setup.

The new Walter Titex DB133 Supreme solid carbide micro twist drills are the key to establishing precise, reliable working processes and achieving significantly longer tool life.

The use of grades WJ30EL and WJ30ER, developed by Walter specifically for micro drills, ensures that the drills exhibit superior wear resistance. In addition to this, the new cutting edge geometry increases process reliability, and optimised dimensions allow for maximum stability, even with the smallest drills. The incredibly uniform finish on the drill cutting edge and extremely tight tolerances ensure that the surface finish on the workpiece is exceptional. Thanks to the special flute geometry, the swarf is evacuated effectively, even without through coolant. This means that hole depths of up to 8 x Dc can be easily achieved.

The new solid carbide micro twist drills, with their 140° point geometry, can be used universally on many different materials in ISO material groups P, K and N. Diameters range from 0.5 to 2.95 mm. Oil or emulsion can be used as a coolant. This new drill design will be of particular interest to users in general mechanical engineering, mould and die making, the energy and automotive industries and any other areas where small diameter, deep holes, are required.

The milling cutters from Walter’s new Advance product line increase tool life by up to 50%.

With this product line, the metal cutting specialist is setting a new benchmark in terms of cost effectiveness and profitability. This is very true of the MC251 Advance solid carbide milling cutters from Walter’s Prototyp brand, which have the ideal geometry for machining stainless materials from material group ISO M an​d for secondary applications in ISO S materials. The new MC251 tool family is designed to operate most efficiently on machines having only an external coolant supply.

The MC251 product family comprises a tough carbide substrate (WK40RC), which has been specifically designed to provide a high level of machining reliability. And because the coating is made from a combination of titanium aluminium nitrate (TiAlN) and aluminium titanium (AlTi), not only is the tool’s service life extended significantly, but it also exhibits particularly good anti adhesion properties, which means that the formation of build-up on the cutting edge is not significant.

The new M2131 90° ramping milling cutter from Walter AG is equipped with a PVD-coated insert variant that is manufactured using the HiPIMS method.

“HiPIMS” stands for “High Power Impulse Magnetron Sputtering”. This physical process produces extremely dense and smooth PVD coatings. Advantages of the insert coating: Less friction and build-up on the cutting edge, higher resistance to flank face wear and very stable cutting edges. The benefit for the user: Maximum metal removal rates and long tool life! With cutting depths of 15 or 20 mm, the HiPIMS-coated inserts are ideal for ramping and pocket milling.

The M2131 is impressive due to its high level of concentricity. The inserts are provided with integrated protection against centrifugal force. Inner coolant channels, which are suitable for both emulsion and minimum quantity lubrication, complete the precisely designed tool features. Increases in tool life of up to 200 percent can therefore be effortlessly achieved. The M2131 ramping milling cutter from Walter AG is particularly suitable for the HSC machining of aluminium materials, as well as for current aluminium-lithium alloys.

The properties of stainless and acid-proof steels, classified as ISO M materials, are such that specialist tools are required to machine them.

Tapping these materials using standard tools can often lead to tool breakage, because of their high level of toughness and tendency to fuse. The new high-end TC142 blind hole taps from Walter are precisely designed for machining ISO M materials.

The TC142 comes in two variants: The WW60RB grade HSS-E-PM variant impresses with a long tool life and high cutting speeds thanks to its wear-resistant coating – ideal for operators machining in large quantities. The second variant in WY80FC with a vaporised surface guarantees a high level of process reliability thanks to its excellent chip control.

If savings can be made in work operations, savings in time on the machine and therefore also in costs can be made at the same time. It is therefore likely that there is barely any CNC programmer who does not also entertain the idea of a drill with an integrated chamfering insert for carrying out chamfering operations. With the Xtra·tec® D4580, Walter makes this decision easier for production planners by offering a variable alternative to core hole chamfer drills and solid carbide chamfer drills with a defined hole diameter and fixed hole depth.

The new chamfering tool can be fitted with solid carbide drills with a diameter between 4 and 16 mm. The machine operator can switch easily between drills for different hole sizes and materials and also alter the drilling depth. Whether or not internal cooling is used is unimportant: The D4580 has the flexibility to enable both machining methods to be used. The hard-nickel plated surface of the tool provides a high level of protection against wear and corrosion.

The chamfer is cut by two securely anchored, double-edged universal indexable inserts. A long tool life is guaranteed by a multilayer coating. Using an adjustment mechanism that is easy to operate yet also precise, the position of the cutting edges can be quickly adapted to the diameter of whichever drill has been selected.

Chamfering is performed in only one operation. In this case, the central adjusting screw is positioned in order to save on machine time. Tool changes are reduced and machines are used at a higher capacity. Special tools can be replaced at the same time. The variable exchange of standard drills, combined with adjustable chamfering inserts, saves on tooling costs.

With the Xtra∙tec® F4049 multi-tooth finishing face mill, Walter is offering a new type of tool concept for cast iron machining. The basic body, indexable insert geometry and cutting tool material are designed to work in perfect harmony. For the user, the main benefit is: increased efficiency and lower costs. The face and shoulder mill produces precise 90° shoulders in its available diameter range of 50–160 mm and a cutting depth up to 6.5 mm. Once the cutting edges have been aligned, roughing and finishing operations can be performed without changing tools.

This saves valuable machining time. The F4049 has been equipped with square indexable inserts, each with eight cutting edges and developed especially for this milling cutter. Combined with the tried and tested Tiger∙tec® and Tiger•tec® Silver cutting tool materials for maximum tool life, these eight cutting edges not only remove metal efficiently, but also allow for considerable savings on insert costs. The insert retention with special clamping wedge provides reliable stability.

The precise position of the finishing insert/s can be set using a countersunk screw and expansion wedge. The adjustment mechanism is not only extremely precise, but also creates a very stable insert seat thanks to its form lock fixing. The new Walter milling cutter therefore achieves a particularly high workpiece surface quality during the finishing process. With two roughing geometries and a further two finishing geometries available in a negative basic shape, the Xtra∙tec® F4049 is perfectly equipped for a wide range of machining conditions. This tool is ideally suited for use in the automotive industry and for general mechanical engineering.