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

U.S. Cutting Tool Orders Slip in April

Caution about sluggish growth as U.S. cutting tool consumption fell to $173.6 million for the month.

Razor Tool Opens New Facility

Beyond specials, regrinds, and high performance standard cutting tools, their new plant also offers high-precision five-axis machining to help shops with challenging jobs.

U.S. Cutting Tool Orders Up Slightly

March orders of $184.08 million were up six percent over the previous month.

 

Cutting Tools: Products

Solid Carbide Thread Mills for General Purpose Machining

Niagara thread mills provide cost effective, highly accurate production of Unified, National Pipe Tapered and Metric thread forms. All of the thread mills feature a standard AlCrN coating, but are also available with optional coatings of TiN, TiCN, TiAIN, AlTiN and CVD-diamond.
Niagara solid-carbide thread mills provide cost effective, highly accurate production of Unified, National Pipe Tapered and Metric thread forms.

PCD Insert Increases Productivity and Cost Efficiency in High-Speed Machining of Non-Ferrous Materials

WDN10 PCD inserts achieve excellent surface in the high-speed machining of non-ferrous materials through their exceptional cutting edge sharpness. This high degree of sharpness results from their PCD grain size and the manufacturing process. The inserts boast chip breaker geometry, are laser marked with grade designation and ISO and ANSI corner radius designation, and are backed by worldwide support from Walter PCD specialists.
WDN10 polycrystalline diamond inserts from Walter USA have superior wear resistance that delivers outstanding hardness for exceptional cutting edge sharpness to achieve excellent surface finishes.

Steel Milling Grade Overcomes Challenging Machining Conditions

When repeated shoulder milling is required, the combination of GC1130 with CoroMill 490 provides a suitably light cutting action and smooth profile that can efficiently reduce the need for a finishing operation.  Also available for the CoroMill 390, this grade is best when multiple component features are required. Bringing an added dimension of security and predictability to machining in challenging conditions, the assortment includes many different types of tools and a wide selection of corner radii. Applications such as shoulder milling, linear and helical ramping, turn-milling, deep shoulder milling, edging and pocketing can be performed.
The GC1130 insert from Sandvik Coromant uses Zertivo technology to provide a clean and intact edge that delivers high metal removal rates and performance levels in both wet and dry machining operations.