Cutting Tools

How to Double Throughput on Turning Large Scale Parts

Shops that turn large scale parts for power generation equipment and oil patch machinery are now achieving up to twice the material removal rate and extreme depth of cut, even while cutting forces stay the same as before or actually decrease and insert edge life improves. Here’s how they do it.
Cutting Tools: Articles

Great Expectations

Manufacturing engineer Ian Dotson of EMC Precision keeps an eye on the machining progress of a Daewoo Lynx 220 CNC lathe cutting a transmission gear shaft made of 1-1/4 in 8620 steel with the Beyond Evolution single-sided grooving and cut-off system.
This family-owned and operated machine shop explains how they found a grooving and cut-off system at a competitive price point that performed beyond their expectations by cutting their insert costs in half and tripling their tool life.

Solid Ceramic Endmills Provide Stellar Performance

Hot stuff. Cutting fluid is not used with ceramic, only an air blast. The SiAlON KYS40 4-flute and 6-flute full ceramic end mills operate at spindle speeds up to ten times faster than carbide and provide far greater tool life.
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.

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.


Cutting Tools: Industry News

Walter Appoints New Director of Marketing

Kurt Ludeking, Walter USA As the director of marketing for their World West Region, he is now responsible for strategic marketing planning, marketing communication, regional product management, pricing, and market analysis.
Kurt Ludeking is responsible for all aspects of marketing in the Americas and Great Britain.

U.S. Cutting Tool Orders Bounce Back

August cutting tool consumption of $175.2 million jumped 19.2 percent from the previous month.

U.S. Cutting Tools Orders Down

July cutting tool consumption of $147 million slid 16 percent from the previous month.


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.