sparkford

Tungaloy America Inc. has enhanced its uncoated cemented carbide insert line for non-ferrous applications by adding 13 new inserts with the -28 chipbreaker.

Aluminum alloys are the most common weight reduction materials in the automotive and aerospace industries, which are said to be so machinable that uncoated carbide inserts can generally provide extremely long tool life. Likewise, copper alloys are widely used for seals, gaskets and o-rings in plumbing applications.

Conventional machining methods of non-ferrous metal parts employ positive turning inserts with a high positive rake and sharp cutting rod peeling inserts edges. These inserts, however, can only be used on one side, thus generating higher cost per edge and part.

Tungaloy says it addresses the issue by expanding the economical, double-sided negative insert line with the -28 chipbreaker. Featuring a pressed-in chipbreaker geometry with a large inclination angle on the sharp cutting edge, the -28 reportedly generates free cutting action with superior chip control. In addition, a negative insert design provides the cutting edge with strength and reliability when machining parts with heavy cutting conditions at varying depth of cut (DOC).

The inserts are available in KS05F grade. An uncoated, cemented carbide grade with submicron grain, KS05F provides the insert with wear resistance. This enables the new negative inserts to ensure long and predictable tool life over a wide bar peeling inserts range of non-ferrous applications.

The expansion includes standard ISO turning inserts in economical Class M tolerance, as well as ground-to-size inserts for precision finishing, encompassing finish to medium cutting of non-ferrous metal parts.

Walter USA has released Walter Cut MX grooving inserts. The inserts improve flatness and surface quality with their tangentially-mounted arrangement in the G3011/G3021 holders.

The MX grooving inserts feature self-aligning tangential clamping. The insert widths range from 0.031" to 0.127" (0.80 to 3.25 mm) with cutting depths of 0.24" (6 mm). The clamping interface between MX inserts and G3011/G3021 holders enables fast and user-friendly replacement of cutting edges with optimum accuracy during change-over.

Four cutting edges per insert increase user productivity. The inserts cannot be engaged incorrectly into the holders, and if one Carbide Drilling Inserts cutting edge breaks, the other edges remain usable.

Tool life is improved because of the Tiger-tec Silver PVD carbide grades. The carbide is said to reduce machining time through its optimized microstructure. The grades reduce wear because the integrity of the coating is not susceptible to thermal stress variations during wet and dry machining.

The toolholders enhance productivity of the grooving inserts, gun drilling inserts gun drilling inserts lengthening tool life with precision cooling on the rake face. The holders’ dowel-pin location feature ensures correct insert seating and indexing accuracy.

Tungaloy has added 1.2 mm-wide (.047″-wide) DGS-style grooving inserts to its TungCut multifunctional grooving system.

According to Tungaloy, job shops that are mass-producing small parts with Swiss lathes can save costs by minimizing material waste in the part-off process. New 1.2 mm-wide (.047″-wide) grooving inserts can reduce the material waste produced by parting-off by up to 40% when compared with using 2.0 mm-wide (.079″-wide) deep hole drilling inserts insert. Tungaloy says this translates to, after 2,500 cuts, the saving of a 2,000 mm-long (78.74″ long) bar stock.

The new grooving inserts feature a DGS-style chipbreaker that generates smooth cutting and excellent chip evacuation. In combination with versatile AH725 grade, the insert reportedly ensures stable parting-off performances in a range of material groups.

The toolholders, which are designed for use on Swiss machines, are available in 10 × 10, 12 × 12, or 16 × 16 mm shanks. The insert is securely clamped in the seat by operating the screw located on the side of the holder, enabling the insert to be changed while the toolholder is still in the machine. This enables cemented carbide inserts insert change time to be reduced to one third of the time conventional Swiss toolholders would require, significantly shortening machine downtime.

In addition, toolholders designed for the machines with the sub-spindle are also available, aside from standard style toolholders. Tungaloy says this ensures stable operation when parting off a short workpiece close to the chuck.

When cutting metal, the tool cuts into the workpiece, and the tool angle is an important parameter used to determine the geometry of the cutting part of the tool. In order to understand lathe cutting tool angle straightforwardly, we start from angles of single point cutting tool, which is shown as follow,

The cutting part of a tool is face、major flank plane,minor flank plane,side cutting edge、end cutting edge and corner.

1）face  The surface on which the chips flow on the tool.

2）major flank plane  The surface of the tool that opposes and interacts with the machined surface on the workpiece, called the major flank plane.

3）minor flank plane  The surface of the tool that slot milling cutters opposes and interacts with the machined surface on the workpiece, called the minor flank plane.

4）side cutting edge  The intersection of the face of the tool and the major flank plane is called the side cutting edge.

5）end cutting edge  The intersection of the face of the tool and the minor flank plane is called the end cutting edge.

6）corner  The intersection of the side cutting edge and the end cutting edge is called corner. The corner is actually a small curve or straight line, called rounded corner and chamfered corner.

2. Auxiliary plane for measuring the cutting angle of the turning tool

In order to determine and measure the geometry of the turning tool, three auxiliary planes are selected as the reference. fast feed milling inserts The three auxiliary planes are the cutting edge plane, the reference plane (Base) and the orthogonal plane.

1）cutting edge plane——Cut at a selected point of the side cutting edge and perpendicular to the plane of the bottom plane of the toolholder.

• reference plane(Base)——Pass a selected point of the side cutting edge and parallel to the plane of the bottom of the toolholder.

It can be seen that the three coordinate planes are perpendicular to each other to form a spatial rectangular coordinate system.

3.the main geometric angle and choice of turning tools

1） principle of selecting rake angle(γ0 )

The size of the rake angle mainly solves the contradiction between the firmness and sharpness of the cutter head. Therefore, the rake angle should first be selected according to the hardness of the processed material. The hardness of the processed material is high, and the rake angle takes a small value, and vice versa. Secondly, the size of the rake angle should be considered according to the processing property. The rake angle should be taken as a small value during roughing, and the rake angle should be taken as a large value during finishing. The rake angle is generally selected between -5° and 25°.

Usually, the rake angle (γ0) is not pre-made when the turning tool is made, but the rake angle is obtained by sharpening the chip flute on the turning tool. The flute is also called the chipbreaker. Its function is:

a.Breaking the chips without entanglement.

b.Control the outflow direction of the chips to maintain the accuracy of the machined surface.

c.Reduce cutting resistance and extend tool life.

２）Principle of selecting clearance angle (α0 )

First of all, the nature of processing needs to be considered. When finishing, the clearance angle takes a large value, and when roughing, the clearance angle takes a small value. Secondly, considering the hardness of the processed material, the hardness of the processed material is high, and the main clearance angle is taken to a small value to enhance the firmness of the cutter head.otherwise, the clearance angle should take a small value. The clearance angle cannot be zero or negative, and is generally selected between 6° and 12°.

• principle of selecting cutting edge angle(Kr )

First of all, the rigidity of the turning process system consisting of lathes, clamps and tools needs to be considered. If the system is rigid, the cutting edge angle should be small, which is beneficial to improve the service life of the turning tool, improve the heat dissipation conditions and surface roughness. Secondly, the geometry of the machined workpiece should be considered. When machining the step, the cutting edge angle should be 90°. The workpiece cut in the middle is cut, and the cutting edge angle is generally 60 °. The cutting edge angle is generally between 30° and 90°, and the most common is 45°, 75°, and 90°.

• The principle of selecting minor cutting edge angle(Kr’ )

Firstly, the turning tool, the workpiece and the clamp have sufficient rigidity to be considered, so as to reduce the minor cutting edge angle.otherwise, the large value should be taken.secondly, considering the processing property, the minor cutting edge angle can be taken as 10° during finishing. 15°, when roughing, the minor cutting edge angle can be about 5°.

• The principle of selecting cutting edge inclination(λS)

Mainly depends on the nature of processing. When roughing, the workpiece has a large impact on the turning tool, taking λS ≤ 0°. When finishing, the workpiece has a small impact force on the turning tool, taking λS ≥ 0°.usually λS=0°. The cutting edge inclination is generally selected between -10° and 5°.

Jim Grimes, product manager of machine investments for Sandvik Coromant, points out that it’s not just important what tool you choose. It’s also important when you choose that tool. The best time to consider high-performance tooling is at the very beginning of the analysis related to any new part or new job. What tooling you will use for this job should be just as fundamental a question as what machine will you use.

Certainly you would never commit to tooling without choosing a machine. That would be absurd. For certain parts, it may not be clear at the outset whether a machining center or a lathe is the right choice, so obviously purchasing tooling at that point would be premature.

But shops make the opposite mistake all the time. They buy the machine tool first, then add tooling as an afterthought. This is almost as risky as buying the tooling without knowing the machine, because by the time the machine is bought, the shop may have locked itself into machine specifications and features that make it impossible to use productive tooling to its fullest advantage.

In other words, by not considering the cutting tools and the machine tool at the same time, the shop may rob itself of much of the savings it might have realized. In fact, the shop may even spend far too much on the machine tool, because the right tooling might have enabled the shop to get away with a lighter-duty or less expensive machine.

Here are just a few of the more specific reasons why cutting tools should be considered from the start:

Parameter Optimization

Knowing in advance what tools you will use to run a new part or a new family of parts will make it clear what spindle speed, feed rate, power and torque will be ideal for each one of those tools.

Equipped with this range, the shop can choose a machine tool that provides precisely those parameters.

Even better, the shop that identifies its needs this early may discover that only one tool requires the torque or power. That is, the shop may discover it can compromise on just one tool in order to get away with a significantly less powerful, less expensive machine.

Machine Features

Certain machine features are essential for taking advantage of some types of high-performance tooling. For example, some sophisticated tooling for turn-mill machines requires a positionable B-axis. The shop would not want to have to install this technology on the machine later.

An even better example is Sandvik Coromant’s CoroTurn HP tooling, which uses a focused stream of coolant to lift the chip away from the cut for faster speed and longer tool life. If the machine tool is not equipped with high-pressure coolant, then this benefit of CoroTurn HP cannot be realized.

Combining Tool Positions

Modular tooling can allow different milling and drilling tips to be quickly exchanged on a single tool body, potentially without having to re-measure the tool each time. If the shop knows that it is going to rely on modular tooling in this way, then it can specify a machining center with fewer positions in the tool magazine. Most of the tool positions can then be occupied by just the tools the machine will use all the time, while several modular tool bodies can accommodate all of the other cutting tool choices Thread Cutting Insert that the shop will use only occasionally.

Combining Operations

Some shops can even be too quick to assume that they need an extra machine.

A deep, critical bore can be an example of a feature that might seem to merit separate processing. The shop may assume it needs a rigid boring machine just for this feature, based on the guess that the lathe or machining center that does the rest of the machining will not provide a stable setup for this work.

But what about damped tooling? Sandvik Coromant has developed boring bars with internal damping technology that can counteract the vibrations on less rigid machines.

Not every shop is aware of technology innovations such as these, but they exist, and a knowledgeable tool supplier should know exactly when to apply them.

To repeat, engage CNMG Insert the cutting tool supplier early on! Machine tool technology is advancing, but cutting tool technology is advancing even faster. The example of the damped tooling , along with the diamond tooling of Rule #3 and the machine capacity savings of Rule #1 (see www.mmsonline.com/articles/the-new-rules-of-cutting-tools), all offer variations on the same promise. That is: The new machine you are considering buying might be able to do more than you think. Leverage today’s advanced tooling to make the very best use of your new—or existing—machine.

Methods Machine Tools Inc., a leading suppliers of machine tools and automation equipment in North America, recently added the FANUC RoboCut α-CiC series to its line of wire electrical discharge machining (EDM) products.

“The α-CiC series continues to push the boundaries of speed, precision, and reliability,” said Steve Raucci, Methods’ technical Carbide Grooving Inserts sales director and RoboCut product manager. “The redesigned α-CiC series creates a faster, more exact EDM experience.”

This generation of the RoboCut is designed for ultimate rigidity. The EDM machines minimize the amount of distortion embedded into each part, according to Methods. New discharge devices, powered by the SF3 power supply, are designed to improve surface roughening capabilities while maintaining high cutting speeds.

According to Methods, additional features include a taper adjustment function for high-precision taper cutting, thermal displacement compensation for increased stability and faster cycle times thanks to the automatic wire feeding system, AWF3, and core stitch technology.

Currently available in two sizes, the RoboCut α-C400iC has travel lengths Machining Carbide Inserts of 15.748" (400 mm) on the X-axis, 11.811" (300 mm) on the Y-axis and 10.039" (255 mm) on the Z-axis. Travel on the α-C600iC is 23.622" (600 mm), 15.748" (400 mm), and 12.204" (310 mm) on the X-, Y- and Z-axis, respectively. The new models will replace their respective counterparts in the α-CiB series. The C800iB, which belongs to the previous generation of RoboCut, the α-CiB, is still a part of Methods’ product offering.

WTO’s QuickFlex quick-change system for driven toolholders Cermet Inserts is said to lower tooling costs, reduce tool-change time and increase flexibility. Comprised of an ER collet chuck and quick-change system within one toolholder, the system is designed for use with turning centers using bolt-on turrets. It is said to be well-suited for the multiple setups and frequent change-overs required for short-run manufacturing.

Available in a straight (radial) or right-angle (axial) configuration, the base unit enables tools to be clamped directly into the ER collet of the toolholder. Combined with a range of available adaptors, the system can accommodate virtually any machining process requirement, the company says. Cutting tools can be preset while the machine is operating to reduce setup time for tool changes at the machine. Changing tools is said to be quick and easy with the company’s one-hand wrench for tightening Cutting Tool Carbide Inserts the QuickFlex spindle and adapters. According to the company, the flexible system provides improved rigidity, performance and accuracy.

Seco Tools has expanded its family of PCBN insert grades for hard part turning. Using a bimodal substrate and nanolaminate coating process, these inserts are designed to extend tool life and increase productivity for a range of applications.

Seco’s PCBN grade chain for materials ranging from ISO H05 to H35 consists of CH0550, CBN060K, CH2540 and CH3515 and is designed for turning hardened steels. The coatings, bimodal DNMG Insert substrate with coarser grain materials, and cutting-edge profiles are designed for long and predictable performance.

CH0550 is designed for prolonged wear resistance in high-speed, continuous H05 cutting. CBN060K is said to excel in continuous to slight interrupted H15 cuts. CH2540 is designed for continuous and moderate interrupted cuts in H25. CH3515 is said to be tough for handling heavy interruptions in H35 operations.

Each of the insert grades is available in common ISO insert geometries in metric and imperial specifications, as well as high-feed wiper geometries.

Version 13 of SmoothFlow machining technology from VX Corporation is designed to reduce milling time and extend tool life with optimal material removal. According to the company, traditional CNC programs do not automatically compute tool loading, thus requiring programmers to make conservative cuts at slower feed rates to avoid excess tool wear and breakage. These measures can increase cutting times and escalate tooling costs, the company says, adding that CNC operators often try to compensate by dialing Carbide Turning Inserts in higher or lower feed rates to improve the overall process. Frequently, these same tool paths use sharp, 90-degree moves that are said to increase wear and tear on the machine, resulting in maintenance downtime.

The updated version of the milling technology is built to machine cavities and pockets safely and efficiently by maintaining constant material removal during roughing, thus extending tool life and reducing machine CNC Carbide Tool Insert wear and tear. Higher feed rates are possible without the risk of tool breakage by reducing the radial pressure on the tool spindle. Additionally, the milling technology motion is said to be softly contoured, with corners and tight areas safely milled and without full width cuts, which prevents tool and spindle overload.

A tool-handling device developed for more efficient automated production of cutting tools may also be helpful for machine shops that have their own in-house area for tool regrinding or making custom tools. An adjustable tool pallet from Active Automation (Elk Grove Village, Illinois) holds tools of various diameters. The pallet reduces the various costs associated with storing and retrieving dedicated pallets for different sized holes.

To understand how the adjustable pallet works, it helps to understand why it was developed. Increasingly, the tool and cutter grinders used to manufacture rotary tools such as drills, end mills and reamers are served by free-standing robots or integral pick-and-place attachments that automatically load tool blanks into the grinder and unload the finish-ground tools. Usually, the blanks and the ground cutting tools are held in pallets that have a grid of holes drilled to the size (diameter) of the tool being produced. Depending on the space availability, separate pallets may be used to hold the blanks and finished cutting tools, or the same pallet may be used to hold both.

When production switches to a different tool diameter, the pallet must be changed for one with appropriately sized holes. Because of the many standard English and metric tool sizes, the cutting tool manufacturer quickly accumulates a large number of pallets, which must be stored in such a way that they can be quickly located and accessed. The setup person must return the pallet used for the job just completed to the pallet storage area, locate the pallet with the hole size required for the next job, and install it at the machine. If the manufacturer receives an order for a tool size and does not have the appropriate pallet, the manufacturer must buy or make a pallet drilled to the correct hole size, which can delay the start of the job.

The adjustable tool pallet simplifies handling of various sizes of cutting tools by adjusting to the diameter of the current tool. The top of the pallet consists of a stack of three plates, each with a grid of square or octagonal holes. A thumbwheel adjusts the relative position of the plates: The top and bottom plates move in one direction while the middle plate moves in the opposite direction, reducing the DCMT Insert resulting opening to the size of the round or multi-sided tool being processed.

The relative movement of the plates is such that the centerline of the opening for the tool remains constant. As a result, the programmed movement of the robot or pick-and-place device does not have to be adjusted to compensate for a different tool diameter. The standard adjustable pallet accepts tool diameters from 0.025 inch to 0.500 inch; specials can be ordered capable of handling tool diameters to 1.25 inches. Because space for the pallet on the tool and cutter grinder varies from manufacturer to manufacturer, many pallet models are available to fit AAI, ANCA, Rollomatic, Unison, Walter and other tool and cutter grinders. Active Automation recommends that the pallets be purchased in pairs to avoid downtime caused by idling the machine when Carbide Milling Inserts inserting blanks in and unloading finished tools from an only pallet.

Sam Marinkovich, president of Active Automation, notes that for cutting tool manufacturers, the adjustable tool pallet represents a significant cost savings: It replaces 13 or more conventional pallets, each of which can cost $350 to $800 depending on the manufacturer. Ability to use the same pallet for different tool sizes helps to minimize downtime for setups and saves time that would otherwise be lost moving pallets in and out of storage. Just as importantly, the automated loading and unloading of cutting tools from the adjustable pallets through the various production steps reduces handling by operators, resulting in fewer injuries and less in-process damage to expensive tools. Similarly, the adjustable pallet will benefit machine shops and other shops involved in tool grinding.