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

Compact Burnishing Tools for Swiss-Type Machines

Booth W-1292: Monaghan Tooling offers New 5918 series Swiss ID Burnishing Tools by Elliott Tool Technologies that are ideal for accurate sizing, low micro-finishing, and surface hardening of ID holes down to 4 mm.
Monaghan Tooling offers cost-effective, easy-to-use Swiss ID Burnishing Tools by Elliott Tool Technologies that improve surface irregularities and tool marks for optimum surface finishes of 4 Ra to 8 Ra in a single pass.

New Geometry Tackles the Toughest Rough Turning Applications

The double-sided indexable insert with RP7 geometry features a specially designed T-land for protection against chipping, a ground seating surface, center curve design for extra cutting edge strength, and a deeper chip groove that enables higher feed rates. This geometry is particularly suited to working on applications that include heavily interrupted cuts or forged parts with variable machining depths, and is also ideal for roughing steel materials.
Double-sided ISO indexable inserts with RP7 geometry from Walter combine a ground contact surface with an optimized profile that has a tailored protective chamfer to guard against fracturing.

Compact Burnishing Tools for Swiss-Type Machines

These compact burnishing tools from Monaghan are ideal for applications where the machine working envelope is limited, such as in most Swiss-type turning centers,
small CNC turning centers and when burnishing parts in sub-spindles where
the machine working envelope is reduced.
Monaghan Tooling offers Swiss ID Burnishing Tools by Elliott Tool Technologies that are ideal for accurate sizing, low micro-finishing and surface hardening of ID holes down to 4 mm.