Production Machining Product News: Tooling, May. 18, 2020
The latest technology from BIG KAISER, Tungaloy America, Inovatools USA, Emuge, and Walter USA
Big Kaiser Chip Breaker Inserts Improve Surface Finish
Chip breakers designed for finishing aluminum components.
Big Kaiser’s two insert chip-breaker types are designed to improve surface finish in long-chipping materials. Long chips that are difficult to evacuate can lead to poor surface finishes when they are dragged around by the tool. Insert life can be severely reduced if these chips are recut by and, in small-diameter applications, stringy chips can wrap around the tool to the point where a crash occurs.
The company’s FLM 3D chip-breaker design is used on PCD-tipped inserts, which the company says is well-suited for finishing of aluminum components. This compares to traditional flat-top inserts that may produce a large continuous nest of chips that is difficult to remove from the bore and/or tool, even with high-pressure coolant. It comes in three radius options, including .008", 0.016" and 0.031" for the insert TCGT2 (1.5).
For finishing of mild or construction steels, cermet inserts with a chip-breaker form ELM should be used. Available in 0.008" radius and combined with a light depth of cut, this chip breaker creates a high-shear angle to shorten the cutting chips for better evacuation and is said to give superior surface finishes in these traditionally difficult materials.
Tungaloy’s Coolant-Through Holders Well-Suited for Small-Bore Internal Grooving
These holders accommodate a variety of diameters, while providing reliable chip evacuation.
Tungaloy’s SNG series of indexable internal grooving tools includes 12 coolant-through holders that are designed for the internal grooving of bores with diameters as small as 8.0 mm (.315″) and up to 24.0 mm (.945″), while providing reliable chip evacuation. The shanks are made of either steel for economy or tungsten carbide for long reach areas where tool steadiness is vital. Combined with the GMR-style chipbreaker, the SNG coolant-through holders are devised to virtually eliminate chip nests, reducing part scrap and machine downtimes to improve machining efficiency. The tools are suited for steel, alloy steels, stainless steel and superalloys.
Inovatools’ Solid-Carbide Cutters Designed for Medical Components
Inomed tools machine medical components made from hard-to-machine materials.
Inovatools’ Inomed line offers a selection of solid-carbide premium tools and customized special tools for medical components, including mills, drills, engravers, deburrers and special tools. According to the company, the line is designed for complex drilling and milling tasks with micron-level precision, and precise drilling for diameters between 0.1 mm and 20.0 mm on medical components made from titanium, chromium cobalt and INOX.
According to the company, the solid-carbide engraving and deburring tools are suited to microchamfering and deburring difficult materials such as titanium and stainless steel as well as machining areas that are hard to reach. The solid-carbide drills are said to offer precise drilling for titanium and other noncorrosive and hard-to-machine materials. The solid-carbide INOX mills, mini mills, reamers and drills are designed for machining titanium bone plates, which can have difficult-to-access geometries.
The company says the Inovatools Curvemax enables shorter production times because its curve segment mill features special geometries to permit larger path distances and line jumps during prefinishing and finishing. Although the working radius is larger than that of a traditional full-radius mill, the tool still has the same diameter, leading to reduced process times. The larger and flatter overlap is said to reduce roughness and ensure surface finishes that are better than those created by traditional full-radius mills. The Curvemax mills can also be used to create undercuts, freeform surfaces and variable setting angles. Complex contours can be prefinished and finished, even on narrow inside radii.
Emuge's Line of Roll Form Taps for Medium Strength Steels
Emuge's Innoform–Steel-M is a line of HSSE-PM taps designed for forming threads.
The Innoform-Steel-M line of HSSE-PM taps from Emuge feature polygon geometry for low torque and longer life. A powdered metal substrate and TiN-66 coating with increased hardness reduces friction and extends tool life, according to the company. The taps are recommended for forming cold-extension steels, cementation steels, castings, heat-treatable, nitriding and cold work steels and high-alloyed and hot work steels.
Taps are available in styles for blind or through-hole applications in lead taper forms C/2-3 and E/1.5-2 threads, and in solid or coolant-through capability, over 80 models in total. Inch taps are available in UNC and UNF thread sizes, feature 2BX class of fit and DIN length and ANSI shanks, while metric taps feature coarse and fine thread sizes with 6HX class of fit and DIN length and DIN shanks.
Xtra·tec XT M5008 Indexable High-Feed Milling Cutter
High-feed milling cutter in the diameter range of 5/8–2" permits high feed per tooth at low axial depths of cut.
Walter USA’s Xtra·tec XT M5008 indexable high-feed milling cutter, in the diameter range of 5/8 – 2½" (16 – 66 mm), permits high feed per tooth at low axial depths of cut. Application areas range from pocketing, grooving and surface machining. A variety of grades and chipbreakers are available for use with steel, stainless steels, cast iron and hard materials with difficult cutting properties.
With its shallow approach angle, low radial load on the tool and a short, stable peripheral cutting edge, stability and process reliability are enhanced, according to the company. Vibration tendency is reduced for long tools.
These high-feed tools incorporate an insert design that allows more teeth in a given diameter for increased productivity, making them suitable for die and moldmaking, as well as for the aerospace, energy and medical device industries.