Walter is increasing the diameter range of its Color Select WKK45SC high-speed range for Xtra·tec® B401x point drills.

The new indexable inserts will be available in diameters of up to 37.99 mm, giving users the opportunity to buy all their inserts – even those over 31 mm in diameter – from a single source. This means that the range specially developed by Walter for machining cast iron can now be used to drill all holes from 12 to 37.99 mm in diameter at hole depths up to 7 × Dc and holes from 18 to 25.80 mm in diameter at hole depths up to 10 × Dc.

The typical properties of cast iron, such as brittleness, an irregular structure, inclusions and crusty surfaces, exert a great deal of stress on the cutting edges, which results in high operating temperatures. The substrate, coating and geometry of the P6005-WKK45C insert work to counteract this. Its multilayer PVD coating combines wear-resistant layers with supporting layers and ensures that the ratio between hardness and toughness is optimised to suit ISO K materials as best as possible. This layer also provides an excellent shield against heat. The red ISO K coating used on the Color Select WKK45C range not only indicates the insert’s main area of application but also shows the amount of wear it has sustained. Up to 100% more power on the cutting edge and outstanding resistance to wear and high temperatures, not to mention great process reliability when drilling and withdrawing from deep holes, are further advantages that users of the new insert sizes can now benefit from – even at very large diameters.

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.