Slash Cutting Material Costs When Machining Turbine Components

The M2471 copy milling cutter from Walter USA, LLC (Waukesha, WI) delivers excellent cost efficiency thanks to its high metal removal rate, even on low performance machines, coupled with lower cutting material costs resulting from its eight cutting edges (four per side) per insert. These 12 mm positive cutting geometry, round inserts with negative basic shape feature Tiger·tec® Silver coating that ensures maximum tool life. The M2471 also displays a high level of process reliability because of the stability of its indexable inserts, bolstered by Torx Plus screws. This copy milling cutter is particularly well suited for the machining of turbine blades, but also has applications in face milling steel, stainless steel, and difficult-to-cut materials.

The inserts for the M2471 are available in grade WSP45S and two geometries, D57 and F67. The D57 “universal” geometry is for medium machining conditions, while F67, “the light cutting one,” is for good machining conditions with low cutting forces and medium feed rates. Diameter range for these sintered design inserts is 2 in to 2.5 in (32 mm to 63 mm). Recommended depth of cut for the M2471 is 0.16 in (4 mm). It is available with modular ScrewFit interface or shell mill mount.

For medium and heavy duty roughing of forged parts used in power generator and turbine manufacturing, the Tiger·tec Silver HU6 is a round insert with a new geometry specifically developed to address chip control problems. This innovative insert geometry features specially formed chip dimples for ideal chip formation, facilitating chip breaking in the required area and providing up to 40 percent longer tool life. This round insert benefits from the proven Tiger·tec Silver coating that enhances cutting speed, reliability and tool life. These inserts are available in four different grades: three for steel and one for cast iron machining. Insert diameter selection ranges from 10 mm to 32 mm. The combination of coating, chip breaker geometry and strong cutting edge for process reliability in heavy and interrupted cuts boosts the productivity of heavy duty roughing operations in generator and turbine manufacturing, and forged components in general. In addition, Capto™ turning toolholders can be used with the HU6. This interface enables quick tool changes and easily handles the transfer of large forces.

The BLAXX M3024 heptagon milling cutter uses new wiper inserts that have two right-hand and two left-hand cutting edges that were specifically developed for finishing operations. Semi-finishing and finishing operations can now be combined into a single operation using a single tool, without adjusting the finishing cutting edges. This reduces the number of tools required and reduces machining time by minimizing time spent changing and adjusting tools. This combination of milling cutter and indexable inserts is exceptionally well-suited to the multi-step production of components such as turbine blades and other components made from stainless steels, cast materials or steel. Additional features of these negative indexable wiper inserts include excellent process reliability and soft cutting action due to the positive cutting edge geometry.

Designated as wiper insert XNGX0705ANN-F67, they may only be combined with periphery ground inserts XNGU0705ANN with secondary cutting edge. Additionally, to achieve similar results, the wiper insert LNHX13068R-L55T is provided for use with the F5141 indexable face mill. This insert has four right-hand cutting edges and may only be combined with periphery ground inserts LNHU13068R-L55T.

Walter USA, LLC, N22 W23855 Ridgeview Parkway West, Waukesha, WI 53188, 800-945-5554, www.walter-tools.com/us.