ISO-EcoTurn – the downsized insert series for reduced tooling costs is expanding to include VNMG inserts and holders

ISO-EcoTurn inserts, while downsized for tool economy, incorporate the identical chipbreaker geometry and thickness of regular-sized inserts to maintain the same cutting performance at a depth of cut up to 3 mm (0.12”). In conventional wisdom, when an insert is downsized the thickness of the insert is reduced as well. ISO-EcoTurn inserts, however, preserve the thickness of standard inserts in order to maintain the fracture resistance.

Thanks to reduced volume per insert, ISO-EcoTurn decreases cost per insert on a production line without compromising insert performance.

The new VNMG inserts and holders complement the existing ISO-EcoTurn series, offering a comprehensive ECO-tooling solution to the turning market. A VNMG1204 insert, among other new insert lines, is not only economical due to its reduced volume but also enables an ID turning as small as ø32 mm, versus a conventional VNMG1604 insert whose minimum ID turn-able is ø37 mm. The inserts are available in: a CVD grade T9100 for turning steel; a CVD grade T6100 and a PVD grade AH600, both for turning stainless steel; along with two cermet grades, NS9530 and GT9530. Chipbreakers for the new inserts include TSF for finishing steel, TM for semi-finishing steel, SS for finishing stainless steel, and SM for semi-finishing stainless steel. The new addition offers holders for OD and ID turnings, as well as holders with TungCap adaptations. TungTurn-Jet system is also available with holders for OD turning and with TungCap interface, which enhances swarf control and tool life through jet streaming coolant supply.

Features

• A comprehensive tooling solution is now possible with this addition of VNMG inserts to the existing lines of CNMG, DNMG, TNMG, WNMG, completing the ISO insert line up.
• Small size inserts with no compromise in performance, providing an economical benefit regarding cost per insert and an ecological advantage to conserve the limited tungsten natural resource.

Dormer Pramet has extended its Hydra range of replaceable carbide head drills by introducing a new option specifically for cast iron.

The R970 head has been added to the existing Hydra program, which already includes types for steel (R950) and stainless steel (R960). All three heads are suitable for use on the existing range of High Speed Steel drill bodies.

A key feature of the Dormer branded range is that it offers easy and quick head changes, without the need to remove the body from the machine, minimizing interruptions to the production process.

Available in 3xD, 5xD and 8xD lengths, all Hydra drills incorporate coolant holes to improve cutting efficiency and swarf evacuation. The exact fit between head and body maximizes tool rigidity for superior hole-accuracy and precise tolerances.

Each head type is made from micrograin carbide, providing an excellent combination of hardness and toughness. Its Titanium Aluminium Nitride based coating offers high resistance to oxidisation and wear, promoting additional protection in abrasive materials like cast iron.

A strong corner design increases stability during drilling and reduces the forces encountered when exiting the work-piece. This improves surface quality and prevents ‘exit burst’ which can occur when drilling granular materials.

The 140° split point geometry in the Hydra range provides good centering capabilities and low thrust forces when drilling most materials, resulting in a more efficient operation that requires less machine power.

A versatile new range of milling cutters and inserts form an important part of Dormer Pramet’s first product launch of 2017.

Expanding the company’s comprehensive range of milling cutters, the new addition adds an adaptable option to support a wide range of insert shapes and operations from roughing to finishing.

The new SOD05 cutter, developed under the Pramet brand, reduces tool change-over time and inventory costs with its universal pocket capable of carrying octagonal, round and square inserts.

It means that the user-friendly cutter, available in a wide range of diameters from 32 – 125mm, can perform face milling, shoulder milling, slotting, plunging and ramping in steel, stainless steel, cast iron and non-ferrous materials.

To support the new cutter, Dormer Pramet has added to its range of octagonal (OD), round (RD) and square (SD) inserts. The OD insert has eight cutting edges and low cutting forces, promoting an economical option for face milling, while the RD inserts are suitable for high feed roughing, shallow profiling and ramping.

Its SD inserts have four cutting edges and offers a 90° option for square shoulder milling, providing high depths of cut up to 10mm. All types of inserts have the same radial and axial positions of edges – allowing for easier CNC programming and manual operations.

Meanwhile, Dormer Pramet has announced a new range of small diameter cutters (12 – 40mm) to offer further economical milling options. The cutters, which have a high number of teeth to improve productivity, are ideally suited for turn-milling.

To support this new cutter, a range of economical SOMT 05 inserts have been developed. With four cutting edges for general machining, the single sided inserts offer depth of cut up to 4.5mm.

The inserts feature a sharp geometry with narrow positive T-land and support shoulder milling, face milling, shallow slot milling and plunging in steel, stainless steel and cast iron.

Mitsubishi Materials Corporation, Advanced Materials & Tools Company (President – Fumio Tsurumaki, Headquarters: 1-3-2 Otemachi, Chiyoda-ku, Tokyo) has launched C4LATB, a new carbide taper neck ball nose end mill for machining aluminium impellers.

Impellers used in automobile water pumps have complex shapes and are usually made from aluminium alloy for weight saving purposes. The complex shape of impellers can cause chip jamming and breakage of the tool during machining and can be one of the problems that prevents high-efficiency.

To help solve this problem, the C4LATB carbide taper neck ball nose end mill with high rigidity for improved fracture resistance has been released.

Features of the C4LATB

• Two flutes of the four are centre cutting and enables smooth chip discharge. The overall four flute design realises high rigidity.
• C4LATB can achieve high efficiency machining parameters such as high depths of cut and high feed rates when compared to conventional products.
• C4LATB can also be available as a made to order item. (Special geometry, coatings etc for different applications.)

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%.

In the early industrial days of cutting tool development, metalworking was very limited. It was a slow task until the nineteenth century when the industrial age brought the availability of machine power from the steam engine and, later, electricity.

Machine tools developed considerably in response and with the introduction of High Speed Steel (HSS) in the twentieth century, the modern metal cutting era began.

Today, there are two types of cutting tools, rotary and indexable. Rotary, also known as solid round tools, forms one entire piece made up of the cutting edge and shank. It is typically associated with drilling, threading and milling applications.

Indexable tools are predominantly made of inserts or tips, where the cutting edge is a replaceable shaped piece which is welded or clamped on to a tool body. These are generally used for turning, milling and hole-making operations.

Fabio Sala is product manager for round tools and Lukas Pavlis, product manager for indexables, at global manufacturer Dormer Pramet. Both discuss the key elements which make up the differences between the two types of cutting tools, including the material, performance and versatility.

Material – indexable

At the beginning of the twentieth century, cutting tool material was sometimes only slightly harder than the material being cut. Therefore tool-life was poor and cutting speeds had to be kept very low.

As cutting tool materials developed, they allowed for increased machining parameters and the ability to withstand higher temperatures while maintaining hardness.

The harder the tool substrate the more wear resistant the cutting tool, resulting in longer tool life. The compromise here is that harder tool substrates are more brittle and more likely to fracture or break under adverse operating conditions.

Softer tool substrates mean the tool will be tougher, allowing successful machining even under adverse conditions. Although, tougher substrates are less likely to fracture or break, they operate at lower performance parameters and so tool life is not as long.

An ideal cutting tool material should resist flank and point wear, as well as deformation, be tough to resist breakage, does not chemically interact with the work piece material, resist oxidation and diffusion and have good resistance to sudden thermal changes.

Inserts are made from tungsten carbide, which is the most commonly used material for indexables. Other available material used for inserts includes cermet (CT), ceramics (CC), cubic boron nitride (CBN) or polycrystalline diamond (PCD). CT has good flank and crater wear resistance and is not prone to built-up-edge. Because of this, the cutting edge maintains its sharpness over a longer time.

CC has a wide application area in cutting hard materials (45-55 HRc) and has high resistance to abrasive and thermal conditions. CBN is an excellent cutting tool material and offers extremely hard high thermal resistance. CBN is utilized in materials such as hardened steels and cast iron.

PCD exists in two types (natural diamond or industrial diamond) and is utilized for non-ferrous materials, such as high silicon aluminum due to its high resistance to wear. As PCD is extremely hard and brittle, it is not a good choice for high hardness or impact applications.

Material – rotary

Round tools are traditionally made from High Speed Steel (HSS), High Speed Cobalt (HSCo or HSS-E) or Solid Carbide.

Carbon, Chromium, Tungsten, Molybdenum, Vanadium and Cobalt all make up the main alloy elements used within high speed steel cutting tools.

HSS is a medium alloy that has good machinability and performance. It offers toughness and is a cost-effective option for a wide variety of large scale drilling and threading applications in multiple materials.
However, it is not very wear resistant and so not suited to demanding, difficult conditions.

Cobalt high speed steel offers a good combination of toughness and hardness, providing good machinability and wear resistance. This makes the material suitable for drills, taps, milling cutters and reamers.

Solid Carbide is the most widely used and wear resistant cutting tool material today and is suitable for both round tool and indexable applications.

Performance & versatility – indexable

From a cost perspective, indexable inserts and tool holders represent a significant investment, however, they have the potential to last for longer periods of time. Also, when a replacement is needed, this is more time and cost efficient because of the need to only rotate or change the insert.

To support the long-term investment of indexable inserts, they are also interchangeable and versatile. Machinists have the ability to keep the cutter (or tool holder) in place while easily switching the inserts with varying alternative grades more suited to machining different work-piece materials.

Indexable cutting tools offer greater versatility in terms of performance than rotary tools, providing stable results even in adverse conditions and are able to perform multiple operations.

For example, the operational versatility for milling inserts includes plunging, helical interpolation, profiling and enlarging a hole. Indexable cutting tools can also offer much larger diameter capability than round tools.

Performance & versatility – rotary

Although round tools generally involve a large initial investment compared to inserts, this investment can be spread over the long-term with the added possibility of regrinding. This is not an option with inserts.

The geometry, substrate and coating of a round tool determine performance. Application specific tools have the potential to produce greater accuracy than general purpose tools. Also, the overall design allows the machine operator to achieve much smaller diameters.

The four-facet Split Point geometry, for example, used on rotary drills, was originally developed for deep oil holes in automotive crankshafts. Today, it is used on many drill designs for a wide variety of hard and soft materials. It can be applied to a variety of drill point angles, the most common being 135°.

This highlights the evolution of round tools where key features, developed for specialist and unique applications have, in time, expanded for use in a wide number of applications and materials.

A key benefit of the split point is easier and more precise self-centering and to prevent the tool from “walking” before penetrating the work-piece. The web thinning or split point greatly reduces thrust and adds a positive rake cutting edge that extends to the center of the drill.

In many materials the point will also act as a chip breaker to produce small chips which can be ejected more efficiently through the flutes. This is a distinct advantage in most applications, but especially when portable drilling or in a drill press where bushings cannot be used.

Summary

Both round tools and indexable tools have their own distinct advantages based on material, operation and user requirements. Each one continues to see on-going developments and improvements, including new geometries, coatings, substrates and manufacturing processes, such as edge preparations, surface finishing and other treatments.

As cutting tools, they present a collective offer to end-users by providing an overlap in diameters and applications, so that tooling engineers can assess and advise where and when it is appropriate to apply each.

Dormer Pramet has a range of support services, including printed publications, an E-shop and product selector tool, as well as face-to-face advice, to help make choosing the right cutting tool simple.

Sandvik Coromant is now offering tooling dedicated to the challenging operation of machining valve seat pockets in oil and gas applications. Comprised of a combination of an elliptical Silent Tools adaptor and CoroTurn® SL cutting head, this solution is designed to overcome prevalent issues such as narrow flow bore diameters, vibration tendencies and long overhangs.

The challenges of machining valve seat pockets in the oil and gas industry encouraged Sandvik Coromant to create a tool with extended radial reach that offered high levels of security, repeatability and performance into this demanding back-turning operation. With elliptical Silent Tools adaptors designed to reach deep seats, and CoroTurn SL cutting heads featuring a lightweight structure, a stable tooling configuration minimises vibration and offers extended reach in both roughing and finishing operations.

“The thicker back-end base and elliptical shape of the adaptor is purposefully designed to gain access to the seat pocket through the narrow flow bore diameter,” says Åke Axner, Global Product Manager for Machine Integration. “In addition, the use of CoroTurn SL cutting heads gives users the potential to reach maximum cutting depth while Coromant Capto tool holders are recommended for stability and precision.”

A recent back-turning trial in cladded Inconel 625 highlights how the solution can eliminate vibration and promote surface quality. Using an elliptical Silent Tools adaptor, 25 mm CoroTurn SL cutting head and Coromant Capto C6 tool holder for one roughing and two finishing cuts, the final pass witnessed a surface finish of 0.2Ra (9 cla) achieved at a cutting speed of 27 m/min (90 ft/min), feed rate of 0.02 mm/rev (0.008 in/rev) and 0.1 mm (0.004 in) depth of cut.

The elliptical adaptors are part of the Silent Tools standard assortment and are available within a 24 hour delivery time if required.

Machining tools are becoming increasingly efficient. This is what the KOMET GROUP is demonstrating at AMB 2016, where the precision tools manufacturer is presenting numerous innovations under the trade fair slogan “TOTAL PRODUCTIVITY SOLUTIONS”. Highlights include the growing range of milling tools that can also be used in generative manufacturing processes, as well as a completely new indexable insert reaming tool and unique expansions of the KOMET KUB Pentron^® drill. Other attractions include the numerous innovations in mechatronic tools and ultra-hard cutting tool materials as well as the KOMET^® ToolScope assistance system, which bridges the gap from machining to Industry 4.0.

Renowned as a leading innovator in high-precision drilling, reaming and threading, the KOMET GROUP presented a significantly expanded range of milling cutters just last year that transformed the tool manufacturer into a single-source supplier. Alongside the KOMET^® solid carbide milling cutters for all requirements in the diameter range of 3.0 to 25.0 mm, the KOMET^® indexable insert milling cutters have primarily been subject to further improvements.

The cutter holders in the completely redesigned KOMET^® PCD milling cutters are manufactured using the generative process of laser melting, which means that these new tools can offer feed rates up to 50% higher than before. 3D printing enables up to twice as many cutting edges to be created – regardless of diameter. KOMET^® is also utilising the structural flexibility provided by the additive manufacturing process to create a perfect design for the course of the coolant channels inside these milling cutters. Curved channel routes now reduce pressure loss in the coolant and are positioned precisely in such a way that every cutting edge is supplied with coolant from a separate channel.

Aside from the new production process, KOMET^® is also expanding its milling range with new designs, such as the KOMET^® hi.aeQ 45° face-milling cutter, which has a feed rate of up to 40% higher than a shoulder milling cutter. KOMET^® is also launching new PCD milling and thread milling tools to standard versions that can be particularly productive when used in applications involving lightweight construction materials.

Dimensionally accurate – even for large drilling depths

For years, the KOMET KUB Pentron^® solid drill has stood for precise drilling under extreme conditions. This tool was previously only available in the 4xD and 5xD length/diameter ratios, but the Besigheim tool specialists have now also developed 2xD and 3xD versions so that the high-performance indexable insert drill can be used in an even more versatile manner. The CS (Custom Solution) variant has drawn particular attention with its diameter/length ratio of 6xD. As a result, the KOMET KUB Pentron^® CS, which has been optimised for Key Account and industry segment requirements, does without guide elements and is extremely competitive compared to its guided counterparts on the basis of its performance data.

Indexable insert reaming: Simplified index exchange
Indexable insert technology has revolutionised reaming with multiple cutting edge reamers and has set new standards in terms of cost efficiency and functionality. The KOMET GROUP has now successfully developed new high-precision indexable insert reaming tools that are even easier to operate. In previous tools, each insert was assigned a specific insert seat identified by the letters A, B, C, etc., but this positioning has now become redundant. Users can fit the indexable inserts into the new KOMET^® indexable insert reaming tool in any order – making errors virtually impossible and reducing the logistical effort required.

Increase in performance with diamond cutting materials
As already mentioned with milling, the KOMET GROUP is focussing on developing tools with ultra-hard cutting materials. One example of this is the expansion of the range of ISO indexable inserts with diamond cutting edges to a total of more than 900 items. In addition to KOMET^® PCD products, CVD thick film diamond-tipped inserts can now also be supplied. All variants are manufactured using the latest production technology, such as laser machining and high-vacuum soldering, which results in high-quality cutting edges and variable geometries as well as improved cutting results and longer tool life.

Facing head with direct position measuring system
Mechatronic tools such as precision adjustment heads, facing heads and the KomTronic^® U-axis systems, available in several variants, are one of the specialities of the KOMET GROUP. A patented direct encoder has been available as an optional extra for U-axes and the purely mechanical KomDrive facing heads for two years. In order to enable encoding to take place directly on the slider, the encoder also takes disturbance variables of mechanical elements into account, such as the drive element tolerances, the temperature range and wear. The control system can respond to the measurement data immediately, providing accuracy to +/- 3 µm and thereby enabling outstanding machining quality to be achieved.

Tool and process expertise from a single source
KOMET BRINKHAUS GmbH has been part of the KOMET GROUP for more than three years. As a result of the interaction between tool experts and process monitoring specialists, it has been possible to further develop the ToolScope process monitoring system into an integrated assistance system in terms of Industry 4.0. It monitors the internal signals from the machine, detects events such as tool changes or machine stoppage and is able to calculate parameters and deduce trends. At AMB 2016, KOMET^® is demonstrating how easy ToolScope is to use: Customers can select the solutions they require from the broad range of applications – from tool monitoring to an automatic tool change log through to adaptive feed control – and license them individually. Operation of the system has also become more flexible: Users can now view and operate their custom assistance system on mobile terminals such as tablets and smartphones. 

Tungaloy Corporation is launching the BXA20 series, a new coated CBN grade for hardened steel.

BXA20 delivers predictable and long tool life in a wide range of applications from roughing to finishing, including de-scaling of case-hardened steel, which usually requires a large stock to be removed. This innovative CBN grade exhibits excellent wear and fracture resistance in a low to medium cutting speed range, with enhanced tool life in continuous as well as interrupted cuts.

The BXA20 series is available with a built-in wiper for a superb surface finish at high feed rates or a chipbreaker for smooth chip control in large stock removal, covering a wide variety of applications.

Main Features

• BXA20’s multi-layered PVD coating is twice as thick as the conventional grade to improve wear resistance. The top-most layer of the coating has a very low coefficient of friction to help reduce crater wear. This multi-layered PVD coating with enhanced adhesion strength increases chipping and peel-off resistances, thus assuring stable and long tool life.
• The dedicated carbide substrate withstands a heavy load of interrupted cutting and large depth-of-cut machining.
• With a bright silver finish, used corners can easily be identified
• 95 items in total

Rolled threads guarantee maximum strength and resilience in the most demanding situations.
LMT Fette has been developing rolling systems for chip-less thread forming for over 60 years now.

By utilizing numerous individual innovations and its wealth of experience with industrial applications, it has now created a completely new generation of rolling head: The EVOline sets the highest standards for efficiency, process reliability, precision and flexibility in thread rolling.

Whether it is fittings for pipe systems, connections for car bodies, jack screws for houses and bridge buildings or sucker rods for the oil and gas industry, threads are used in practically every sector.
Their job always remains the same, which is firmly holding together what belongs together.

However, there are great differences in the production and quality of threads.
Thread rolling has established itself as an efficient alternative and replacement to thread cutting for three main reasons:
 extremely short production times with the highest thread stability
 constant dimensional accuracy
 excellent surface quality

In addition, a thread rolling head can be used in a flexible way in almost all machining centers.
As a result of its modular layout and a completely new tool design, the EVOline rolling head sets new performance standards for the chip-less production of external threads. This is our solution to the increased demands being made on thread rolling as a result of rising production volumes, new materials and integrated processing on tool machines. It is crucial here that tools offer process reliability, precision, flexibility and ease of operation.

Fine adjustment to accuracy of a hundredth of a millimeter
The exceptional features of the new rolling head include its simple but extremely accurate fine adjustment of thread diameter and the system’s ease of assembly.

Adjustment of the rolling diameter is carried out using a spindle. The system is accurate to one hundredth of a millimeter and offers exceptionally high repeat accuracy of the effective diameter. The new rolling head guarantees the repeatability of the thread diameter with the same setting within a range of +/- 0.01 millimeters. LMT Fette has applied for a patent for its new adjustment system.

Process reliability and simple operation through modular design
The modular design ensures simple assembly. In addition to the thread rollers themselves, the rolling head consists of the roll cage assembly with transmission, coupling with central alignment and fine adjustment as well as flexible coupling joint for a large number of standard shanks, locking mechanism/locking pin and shank. The locking pin can be turned through 360 degrees and therefore optimally adjusted to the mounting situation in the respective machine. The joint between coupling and shank guarantees precise concentricity with secure torque transmission. It can be modified to users’ specifications: for example, a coolant-operated locking device can be very easily integrated as an accessory.

Special chip protection
Special chip protection is another feature that increases process reliability even further. The rolling head has a stable chip protection lid that secures the machine against chips and contamination from upstream processes – even when the coupling is open. The tool design itself – for example, the nickel-plated surface of the rolling head – also contributes to this protection.
Some highlights of all models of the EVOline Rolling Heads
 fast, simple and precise thread production
 short production times, high quality and thread stability
 simple and precise fine adjustment of thread diameter
 permanent protection against chips and contamination
 easy assembly and high standard of safety due to modular design
 trouble-free adjustment to customer-specific applications

Whats New and Updated: 2016
New: The closing process can be realized with the new closing device (CCD) for EVOline. Adapted between rolling head and shank and connected with the coolant supply, closing of the rolling head can be transferred from process time to the non-productive time of the machine. Closing by coolant (or even compressed air) can be integrated in the machine program by a simple function.
The setting of the rolling diameter has adjustments of 0.01 millimeters which allow for precise control and consistent repeatability of the pitch diameter, giving you the assurance of a secure and reliable process.

The modular design provides longevity of use with the ability to replace the thread rolls, rollers, rolling system housing, central fine adjustment, closing clip device and shanks, making it adaptable to any station or other machines in house. All common shank sizes are available.

The interface between the clutch and shank guarantees precise concentricity between the with safe torque transmission. Customized modifications are possible, for example a coolant driven closing device adding to the speed and automation of the entire process.
Huge progress towards increased process safety and reliability is incorporated by a new chip guard in the EVOline heads. Chips and other particles from preliminary processes cannot enter the rolling head anymore, even with the opened clutch.

Article Courtesy: LMT (India) Pvt Ltd