With its M4000 family, Walter has made huge advances towards achieving maximum cost effectiveness in milling. The M4000 system inserts can be used in a variety of tools, which means that they can be used for various types of milling operation.

They reduce not only the cost per cutting edge, but also the work and costs involved in procurement and storage requirement. With the new M4256, M4257 and M4258 porcupine milling cutters, Walter is now offering the same advantages for slot milling too. The new milling cutters are incredibly versatile in terms of both the range of applications and the materials for which they can be used, such as steel, cast iron, stainless steels, and difficult-to-cut materials. They are available with Weldon shank, modular ScrewFit interface and bore adaption.

Their compact length and half-effective design with comparatively low cutting pressure allows for incredibly smooth operation. This reduces the tendency to oscillate and vibrate, making them the perfect problem solver in the face of unstable conditions. These benefits pay dividends particularly in combination with the D51 geometry insert. The generous chip clearance integral to these porcupine milling cutters makes for particularly effective chip evacuation, especially the flute design, where chips cannot fly out to the side. In addition, the milling cutters can be used for ramping, pocket milling, shoulder milling and circular interpolation.

These porcupine milling cutters are likely to be of interest to users operating in the general mechanical engineering sector, for example; these may be users who are already taking advantage of M4000 tools and indexable inserts, or they may be users who are looking for a cost-effective solution to constantly changing machining tasks.

Excellent cutting and extended tool life mean more parts at higher quality

Numerous precision parts in transportation, moldmaking, general engineering, and more require true 90-degree shoulders and floors with superior surface finish. Economic and competitive pressures require manufacturers of all parts to maximize metal removal and tool life. The new VSM490 double-sided shoulder milling platform from WIDIA is a powerful advantage for achieving all this and more.

“Go ahead and get aggressive with feed rates,” says Global Product Manager Juan Seculi. “Not only will you see the depth of cut is much bigger (up to 15mm or 0.590 inches), scallop or stepdown marks are barely noticeable. Poor surface quality means additional operations and higher cycle times. Take the VSM490 performance upgrade and add that double-sided inserts deliver a sizeable cost benefit over single-sided tools and the VSM490 advantages become compelling.”

Designed for low horsepower draw and free machining, VSM490 delivers an effective one-two punch of reduced horsepower at the machine and higher speed and feed rates that get jobs done faster and/or with an improved surface quality.

State-of-the-Art Design

With four cutting edges and multiple corner nose radii available, the robust VSM490-15 inserts provide added stability and reliability in addition to delivering true 90-degree shoulders and floors. Two insert geometries are available: MM (universal), making it the first choice for a range of work materials; and ML (light) with sharper cutting edges resulting in lower cutting forces for mild steels and stainless.

VSM490 cutter bodies made with tight tolerances to ensure minimum run-out have an integral chip gash design for excellent chip evacuation along with hardened-steel construction and hardened pocket seats for improved resistance to deformation. They are available in shell, screw on, cylindrical shank, and Weldon shank models with internal air and coolant capability.

“The VSM490 portfolio is engineered for multiple applications in multiple materials, making it a go-to milling tool,” Seculi says. “Users should expect true 90-degree shoulders and floors, superior surface finish on both, and higher metal-removal rates at lower horsepower for savings all around.”

The new disc milling cutters is named 335.25, for large slot widths (which will progressively replace the existing 335.18).

The milling insert features a V-shape concept that creates an optimum cutting geometry, reducing cutting forces and noise. Thus, cutting data can be increased for maximum productivity even in unstable conditions. The V-shape also creates a strong and reliable connection between the insert and the cutter body.

Insert corner radii are available from 0.4 to 6 millimetres, with four cutting edges to reduce the cost per part. Insert geometries and grades are available for all materials, and a built-in wiper flat produces fine surface finish, eliminating secondary operations. The cutters are available with fixed pockets with central coolant or adjustable pockets for maximum flexibility.

Following the fixed pocket version, Seco’s 335.25 disc milling cutter is now released in a version adjustable in width. The cutting width can be adjusted with high precision from 13.5 to 32 millimetres with size 14 inserts. Cutters are available from diameter 80 to 315 millimetres with an optimised chip space and number of teeth to get a productive and reliable machining operation.

The adjustable disc milling cutter incorporates replaceable cassettes, making it easy to quickly adjust cutting width with precision. The cassettes feature a coating for extended durability, and two sizes of cassettes provide an optimised chip space and number of teeth to achieve a productive and reliable machining operation. Additionally, all cutters in the 335.25 line offer a unique insert geometry that reduces cutting forces and noise levels, while maximising chip flow.

All the inserts feature four cutting edges, optimised free cutting geometries and a built-in wiper flat. Together with a complete range of grades and corner radii, this allows the disc cutter to meet all application needs with high productivity at the best cost.

From 13.5 – 32 mm groove width
Dc = 80 – 315 mm
re = 0,4 – 6 mm
Full range of geometry choices and grades.

The two new members of the M4000 milling cutter family are the M4575 T-slot milling cutter and the M4792 routing cutter. Together with the M4002 high-feed milling cutter, the M4132 shoulder milling cutter and the M4574 chamfer milling cutter, they make for a costeffective, flexible system that allows the user to tackle almost any milling task.

In addition, the cutting material costs per component can be reduced by up to 50 per cent because the same indexable insert can be used for all milling cutters. The only exception to this is the M4792 routing cutter, owing to its design: To enable the cutting edges to overlap, in addition to a square system insert, the tool is equipped with a rhombic indexable insert on its front face.

Special properties: Drills downwards and then continues by milling in the y/z direction. The M4575 T-slot milling cutter specialises in cutting T-slots in accordance with DIN 650 and, like the routing cutter, features a weldon shank and internal cooling. The M4000 milling cutter family was developed not only with an eye to maximising the savings potential for the machining process, but also with sustainability in mind: Walter offsets 100% of the CO2 emitted when producing the M4000 series.

Tungaloy Corporation is pleased to announce the expansion of TungSlot, indexable slot milling cutter.

Slot milling cutters are used in various industries for slot milling of automotive-related components and large components often found in heavy equipment and power generation industries. In slot milling operation, where slot usually being deep and narrow creating hard and large chips, the cutting edge suddenly fractures due to poor chip evacuation and chip jams. Therefore, the reliability for good chip evacuation and cutting edge with high fracture resistance is strongly required.

TungSlot is the slot milling cutter that achieves remarkable cutting performance and reliability to meet the demand. The economical insert has a total of 6 cutting edges available, with 3 right- and 3 left-hand cutting edges, which delivers excellent chip control. The gullet on the cutter body is optimized for excellent chip evacuation. With the combination of the insert and the cutter body, TungSlot provides highly efficient slotting operations for a wide variety of workpiece materials.

The insert series with the edge width range from 6 to 16 mm is already in the market and enjoys favorable reputations in machining of many different types of components. This expansion will add the series for 4 and 5 mm edge width and ø80 – ø160 mm tool diameter range, which broadens application area to deep slotting with small width and parting-off. TungSlot is highly reliable and economical tool series that overcame the problems many customers face in slot milling operation, which will help customers improve their productivity.

Main features:

• Indexable slot milling cutter and the economical insert with 6 cutting edges
• Both right- and left-hand cutting edges are available with an insert, offering easy tool management
• Now available with edge width: 4 and 5 mm and tool diameter: ø80 – ø160 mm
• Optimized gullet on the cutter body delivers excellent chip evacuation.
• Close-pitch cutter provides highly efficient slotting operation.
• Cutter body:  Total 16 items
• Insert: Total 8 items

Tungaloy Corporation has recently expanded its wiper insert for DoFeed, the high-feed milling cutter.

DoFeed features inserts with low cutting force and close-pitch cutter bodies. This series enjoys high reputation especially in the die and mold industry for its ability to increase customers’ productivity.

Generally, high-feed cutting allows users to machine their workpiece materials efficiently but has a disadvantage in leaving rough surface finish. Thus, subsequent processes, such as semi-finishing and finishing applications, are usually required afterwards. In this respect, DoFeed was not an exception. Wiper insert is a new addition to the DoFeed series that solves this problem. It completely changes the common knowledge of high-feed cutting and upgrades the machining efficiency to an unprecedented level in the metalworking industry.

The new insert has a wide wiper edge in addition to the conventional main cutting edge. This combination provides excellent surface finish while maintaining the ability to machine at high feed rate. As a result, DoFeed wiper insert minimizes or even eliminates subsequent operations and drastically improves efficiency in the overall machining process.

Its main features include:

• Good surface finish with no reduction in feed rate
• Highly efficient machining due to elimination of semi-finishing or finishing applications
• Double-sided insert with 2 corners total

Wiper insert also helps increase the machining efficiency in the subsequent semi-finishing and finishing applications themselves, depending on the required surface quality. With a rough surface finish, the depth of cut in the finishing operation varies greatly, and the tool life becomes unstable. With a good surface provided by the wiper insert, such variation in subsequent processes is reduced and results in stable tool life as well as reduction in the number of tool changes and machine downtime.

DoFeed wiper insert is an innovative tool that overcame a major problem many customers faced with increased feed rate. The product provides outstanding surface finish in high-feed machining, which will ultimately help customers reduce their total manufacturing cost.

Late last year, Kennametal finalized its acquisition of the tungsten materials business from Allegheny Technologies Inc., including the full line of Stellram metalworking tools (formerly ATI Stellram). Now the full platform of Stellram products – with solutions specifically tailored to support energy, aerospace, transportation and other vital industries — are available as part of the Kennametal portfolio.

Driven by Kennametal’s commitment to “Different Thinking is Better Thinking,” the StellramTM group of products include such production-enhancing milling technologies such as the 7792 and 7793 high-feed milling cutter systems and the 5230 Chevron Long Edge mill cutter system, along with X-Grade carbide insert technology. High-performance materials such as titanium and other low-weight/high-strength alloys of particular interest to the aerospace industry are the materials of choice for these proprietary cutter designs, inserts, and grades.

High Feed Milling Cutter Systems
The Stellram 7792 and 7793 milling cutters direct cutting forces axially into the spindle, lessening spindle wear and improving machining stability. Both modern and older equipment benefit from this cutting tool technology. These Stellram face mills operate at shallow depths of cut and very high feed rates, resulting in metal-removal rates up to 5 times greater than conventional cutters. In addition to high-feed face milling, the 7792 is capable of pocketing, slotting, and plunging.

High-feed milling nserts are available with proprietary Stellram X-Grade® technology. X-Grade technology uses ruthenium as a key ingredient, combined with a cobalt binder, for superior thermal-cracking and propagation resistance. The results are metal-removal rates up to three times higher than conventional cutting tools and longer tool life. X-Grade inserts are available in a variety of styles for a variety of applications.

X-Grade inserts are also designed to yield the highest levels of material removal rates in high-performance materials like titanium as well as other difficult-to-machine alloys such as nickel-based alloys, cobalt-based alloys and titanium-based alloys used extensively in aerospace and energy Markets.

5230 Chevron Long-Edge Milling
The unique Stellram 5230 Chevron Long-Edge Milling series of inserts and cutters work together to provide substantial reductions in machining time for titanium and other high-strength alloys. The advanced chevron insert design ensures that one cutting point is always in contact with the work material during entrance and exit. Single-line contact on the cutter body means no two inserts are contacting the workpiece on the same axial plane. Together this provides optimum harmonic stability, reducing power consumption and maximizing tool life.

Additionally, threaded coolant ports on the cutter body allow selective blocking to adjust pressure and volume. Each insert has its own coolant jet for optimum chip evacuation.

Sandvik Coromant, a global leading supplier of cutting tools, tooling solutions and know-how to the metalworking industry, introduces RAL90, an innovative tool for machining aerospace components made of aluminium and aluminium alloys. The new milling concept for machining operations on high-speed spindles has a high-strength tempered base body that increases tool flexural stiffness and natural frequency. Thanks to its high-speed stability, RAL90 allows manufacturers of challenging aero structure components made of aluminium copper, aluminium silicon, aluminium magnesium, aluminium zinc and aluminium lithium alloys to achieve excellent metal removal rates.

An optimally designed, high-precision insert seat with seat numbering ensures a maximum runout accuracy of 20 microns axially and 15 microns radially, a feed rate of 0.3 mm/tooth and cutting depths of up to 14 mm. In addition, RAL90 secures inserts with a specially engineered, high-strength screw (M4, 5.0 Nm tightening torque). (Sandvik Coromant Unveil Small Thread Milling Cutter Range)

The new insert geometries with polished surfaces are designed for maximum metal removal rates during roughing and semi-finishing operations. To guarantee a defined chip formation in the recut, the inserts provide a double remote entering angle on the inner front side – ideal for linear and circular ramping without having to reduce the programmed feed rate. The inserts can be employed with nose radii (0.5, 0.8, 2.0, 2.5, 3.1, 4.0 and 5.0 mm) specified for the aerospace industry with no need to modify the cutter or alter programmed tool length.

RAL90 is prepared for minimum quantity lubrication and high-pressure coolant (with replaceable nozzles). As standard the tools are supplied with a balancing quality of G6,3 (at 24,000 rev/min) or, by customer request, of G2,5. Depending on diameter, speeds up to 35,000 rev/min are possible. RAL 90 is available with cylindrical shank, screw coupling, HSK63A holding and TDA interfaces.

When machining complex parts made from expensive materials, secure performance is clearly vital. With this in mind, cutting tool specialist Sandvik Coromant has introduced a range of small CoroMill® Plura thread milling cutters designed to counter the threat of tool breakage and component damage associated with conventional taps.

The advantages of thread milling compared with tapping are well documented. For example, a thread mill can address a range of hole diameters instead of just one hole size. The thread mill can also place threads closer to the bottom of a blind hole, while more room is available for chips to fall away, thus aiding machine uptime by avoiding the entanglement of swarf around the tool.

However, the greatest benefit is the avoidance of scrapped parts. Few who have worked in a machine shop will have escaped the pain of a broken tap in an expensive component. Often, the part is ruined, along with the tool of course. Only occasionally will a trip to the spark erosion shop save the day, but at a heavy cost in terms of both time and finance.

Medical parts are no exception. Machined commonly from surgical grade stainless steels and hard cobalt-chrome alloys, threading is often one of the final operations. As a result, plenty of value has already been added to the component – there is no margin for error.

The new CoroMill Plura range of small thread mills are designed purposely for the type of components required in the medical sector. Ideal for both right- and left-hand threading in materials up to a hardness of 63 HRc, the tools can generate threads from M1.6 to M12 depending on hole depth and material. UNC and UNF type thread mills are also available.