It is not only new developments that are important to a leading precision tool manufacturer – optimising successful systems is just as vital. As is the case for the KOMET KUB K2 replaceable head drill.

With the replaceable head system for the double-cutting KOMET KUB K2, the KOMET GROUP has introduced a system of replaceable drill heads which benefits from the cost-effectiveness and flexibility of replaceable cutting heads. Thanks to changes that have been made to the manufacturing process, the precision tool manufacturer has now succeeded in technically improving the replaceable heads even further. These offer optimised point thinning and cutting edge rounding. The ground chip space guarantees smooth swarf removal. The torque transfer is also completely ground. The length of the screwdriving head has been reduced slightly compared to the previous model, contributing to increased stability.

The process for fitting the new replaceable head has also been improved and now requires just one assembly wrench for the entire range of diameters. However, the basic holders for the drilling tool can continue to be used, as the new replaceable heads are compatible with the existing patented attachment point. This ensures that the screwdriving heads are self-clamping and self-centring, which means they can achieve a high repeat accuracy, reducing tool replacement times to a minimum.

The new KOMET KUB K2 heads can be used in a variety of non-standard special variants. KOMET can also produce special geometries or different tip angles according to customer requests. Additionally, there is a range of carbide types to choose from, which enhances the versatility when it comes to the materials to be machined.

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.