Cutting Tools

Solid Ceramic Endmills Provide Stellar Performance

To deliver Inconel parts on time with zero scrap, this aerospace supplier uses 4-flute and 6-flute end mills constructed of SiAlON KYS40 grade ceramic for roughing nickel-based high-temperature alloys.
Experts
Cutting Tools: Articles

Fulfilling Modern Micromachining Demands on a Legacy Machine

The RBX12 Air Power Spindle provides variable spindle speeds of 100,000 rpm to 120,000 rpm with standard shop air running through the spindle or the stop block, depending on the machine type and taper size. A lack of heat buildup allows air spindles to run the long cutting cycles common in micromachining. There are also significant cost savings to exhausting air pressure into the atmosphere as opposed to driving the spindle with a motor.
Looking for a creative way to achieve the requested specifications for a potentially lucrative micromachining job without having to invest in a very expensive specialized machine tool? A spindle speeder may be your best – and only – way to secure the deal.

Smart Tooling for Greater Efficiency

The Tool-ID system from Walter improves process reliability by automatically transferring data from the tool to the machine control unit to eliminate time-consuming and error-prone manual data entry. The tool provides production information that can be read by the machine tool to monitor and control tool life, presetting data and individual production steps to detect potential problems early on and remedy them promptly. 
In a major step toward the smart factory of the future, the Tool-ID system from Walter controls tooling plant-wide, saving time, boosting productivity and increasing process reliability.

Efficiency Reigns Supreme

The 5ME solid carbide cryogenic end mill allows super-cooled LN2 to flow through the spindle and inside the tool just below the cutting edge to provide optimum cooling when machining. The reduction of temperature facilitates faster cutting speeds, which makes liquid nitrogen-based cryogenic machining ideal for tough-to-machine materials used in aircraft. Test cuts performed by Lockheed Martin on 6AI4V titanium produced an impressive 52 percent increase in cutting speeds. (second view)
In the aircraft manufacturing supply chain, one thing is certain: process improvements – both large and small – can have a massive impact on the bottom line.

Grinding Gamma Titanium Aluminide

Titanium aluminides possess many characteristics that make them very attractive for high-temperature structural applications in aerospace industries. For example, their high specific strength, high-temperature stability and oxidation resistance relative to conventional titanium and nickel alloys, make them beneficial for use in low-pressure turbine blades for aerospace engines.
New grinding technology is being researched on this intermetallic to help lower the costs of manufacturing aerospace engine components, develop grinding expertise, and design custom-bonded abrasive and superabrasive grinding solutions that are ideal for efficient and damage-free grinding of components made of titanium aluminides.

Breakthrough In Aluminum Face Milling

Ward Production Engineering uses a Mazak 6800 horizontal CNC with a 10,000 rpm spindle to machine aluminum diesel engine manifolds with Tedimill PCD face mills from Ingersoll Cutting Tools. Face milling setup on diesel manifolds at Ward Production engineering, Fort Wayne, IN. The shop was able to double throughput on this 24/5 operation by using the simple drop-in replacement cutters.
This machine shop halved its cycle time on producing diesel engine manifolds and rocker arms, saved $300,000 a year in machining costs and sidestepped a $500,000 capital expenditure. All with one tool.

 

Cutting Tools: Industry News

Management Changes at Whitney Tool

Bob O’Callaghan retires as GM, Scott Baker is their new CEO, and Sam Dean now directs sales and marketing.

Cutting Tool Orders Up in June

Orders totaling $175.4 million were up almost six percent over the previous month.

Haimer and Mapal Reach Licensing Agreement

(l-r) Dr. Jochen Kress, a member of the senior management of Mapal; Dr. Dieter Kress, the managing partner of Mapal; Claudia Haimer, managing partner of Haimer and Andreas Haimer, the managing director of Haimer.
Starting in October, Mapal will offer selected cutting tools for high-performance machining with the Safe-Lock shank from Haimer.

 

Cutting Tools: Products

Ramping Cutter for Aluminum Machining

The Walter M2131 Skẏ·tec Ramping Cutter has two sizes of indexable inserts with various corner radii and employs the new milling grade WNN15, known for its extremely long tool life. This new cutter boasts protection against centrifugal force at the insert contact surface to help ensure a high level of process reliability even at maximum speeds, and its V-shaped cutting edge for ramping promotes rough milling and semi-finishing of pockets with high chip volume.
The M2131 Sky·tec from Walter is ideal for machining non-ferrous metals, such as the aluminum wrought alloys or aluminum lithium alloys often used in aircraft structural components.

Medical Machining: Tooling

With a height of only 20 mm, the VERO-S NSE mini pneumatic quick-change module from SCHUNK is extremely thin, making it ideal for retrofitting existing machines to achieve full utilization of the machine area and direct clamping of small precision workpieces being manufactured for use in medical technology.
Take a closer look at some of the newest tooling that can help contract manufacturers meet the machining, micro machining, and laser processing demands for smaller and more complex surgical implants, orthotic devices and medical instruments that are being made from newer materials – and still hold their costs down.

PVD Inserts for Medical Parts Made from Difficult to Machine Materials

Tiger·tec Silver PVD aluminum oxide coated inserts from Walter can efficiently machine and finish turn small, delicate components or bore internal diameters in stainless steel, high temperature alloys (ISO-M and ISO-S) and other materials with properties that are difficult to machine. The coating protects the inserts from wear, particularly at high temperatures.
Tiger·tec Silver PVD coated inserts from Walter USA efficiently machine stainless steel, high temperature alloys and other materials with challenging properties.