Extending Tool Life Creates Competitive Advantage
Leverage advances in coatings and other technologies and processes to achieve the highest process parameters and productivity.
Posted: August 18, 2023
Achieve the highest levels of tool life by taking advantage of the innovations in multi-layer coatings, new designs that result in easier chip evacuation, and high-pressure coolant-thru technology, as examples. There are also reconditioning services offered for major tool brands that restore cutting quality.
Reamer Reconditioning Service Delivers Lower Cost-Per-Unit
Diatool and Monaghan Tooling Group (Dayton, OH) offers a Reamer Reconditioning Service that can retip, renew, and restore most major brands of high-performance reamers to OEM specs. This unique service includes replacing all blades, grinding a fresh bevel geometry, refurbishing the body of the reamer, and coating of the blades if required. The Diatool Reamer Reconditioning Service is ideal for solid and expandable monoblock reamers, expandable cutting rings, and replaceable head reamers. Diatool can provide multiple options in advanced coatings and blade materials using cermet, coated carbide or PCD. Unlike some major competitors, Diatool does not limit the times a reamer can be reconditioned, providing an even longer service life of the reamer with no compromise in tool life or cutting quality. Offering standard deliveries of four-to-six weeks and cost savings of 40% over new, the service is ideal for machining operations struggling with long lead-times or non-responsive tooling vendors.
In addition to refurbishing, Diatool offers application consultation to improve existing tooling by offering the latest alternative geometries or coatings. Typical results are higher bore quality of the part, reduced cycle time, and significant CPU savings without reinvestment in new tooling.
Diatool has more than 35 years of experience in building and reconditioning of high-performance reaming systems.
https://monaghantooling.com/express-reamer-reconditioning/
New Ceramic End Mills for High-speed Roughing, Milling of Heat Resistant Super Alloys
EMUGE-FRANKEN USA (West Boylston, MA), a leading manufacturer of high-performance taps, thread mills, end mills, drills, and other rotary tools, has introduced Cera-Cut End Mills featuring a high-hardness cutting ceramic head brazed to a carbide shank for optimal vibration dampening and longer tool life compared to one-piece ceramic tools. Featuring a high-feed duplex cutting-edge geometry, Cera-Cut produces high metal removal rates in challenging nickel-based alloys, resulting in machining parts 200%-to-400% faster than conventional carbide end mills. Also, the tool life of Cera-Cut is up to five times higher than regular carbide end mills.
Cera-Cut End Mills are designed for the consistent cutting of high-temperature resistant materials such as Inconel, Hastelloy, and Nimonic, as well as the machining of hardened tool steels. Cera-Cut is also suitable for making interrupted cuts and offers a tight cutting diameter tolerance ranging from -0.0008″ to -0.0016″ (-20 to -40 microns), depending on the tool diameter.
Cera-Cut End Mills can be used for roughing or pre-finishing, and can produce 2D or 3D contours, and are suitable for face milling, slot milling, helical milling, contour milling and pocket milling. They are offered in different diameters from .24”-to-.79” (6-to-20 mm). Corner radius, modular and special designs are also available.
High-performance End Mill Improves Chip Evacuation in Dynamic Milling Operations
Hanita™ (Latrobe, PA), a WIDIA™ brand, has announced the addition of metric VariMill™ Chip Splitters end mills to its high-performance tooling solutions, increasing the accessibility of efficient dynamic milling tools to customers in general engineering, automotive and aerospace industries.
The new metric VariMill Chip Splitters feature a design that actively controls chip size resulting in easier chip evacuation in deep cavities. The end mills include five- and seven-flute configurations from 8 mm-to-20 mm metric standard diameters. The five-flute tool maximizes performance in steel materials, while the seven-flute tool excels in stainless steel and high-temperature alloys.
“With the new VariMill Chip Splitters end mills we are giving customers the highest speeds and performance for side milling, shoulder milling and helical milling, and especially for dynamic milling applications,” said Tamir Sherif, WIDIA and Hanita Global Portfolio Manager for Solid Carbide Milling. “We strive to offer solutions that result in increased productivity and are proud to broaden access to more efficient dynamic milling for our customers.”
The new Chip Splitters are the natural evolution of the successful VariMill II and VariMill III series.
Company Announces a Coolant-thru Feature for all Line Items
Heimatec, a world leader in live tools, angle and multi-spindle drill heads, recently announced the availability of its newest development, a coolant-thru feature on all of the company’s current line items.
Coolant-thru technology is often the answer for faster, cleaner cutting on larger and deeper parts, where the chips and excess heat build-up are significant challenges. Heimatec now offers high-pressure coolant-thru designs up to 1,000 psi on straight, and 2,000 psi on angle head tools.
Platinum Tooling Technologies, Inc. (Prospect Heights, IL) is the North American importer of Heimatec. “Production drilling should almost always be done with internal coolant tools and this development means we’ll be able to satisfy more customer needs in that area,” said Preben Hansen, president of Platinum Tooling Technologies.
Solid Carbide Drill Maximizes Productivity due to Multi-layer Coating
With its new X·treme Evo Plus drill, Walter USA LLC (Greer, SC) has launched a new tool in the DC180 Supreme product range. Designed to boost productivity and process reliability, the solid carbide drill with internal coolant is highly effective for drilling steels, stainless steels, cast irons, non-ferrous metals, heat-resistant super alloys and hard materials (ISO P, M, K, N, S and H workpiece groups). Being a Supreme category drill, the drill is designed not just for the highest tool life, but for the highest process parameters and productivity.
Users can achieve maximum productivity with the DC180 drill due to the Krato·tec™ aluminum titanium nitride (AlTiN) multi-layer coating technology, which was specifically developed for drills and reamers. The drill features a straight cutting edge to ensure process reliability and stability. The drill has a 140°-point angle and is suitable for hole making with emulsion, oil or minimum quantity lubrication.
When compared to competing drills, the DC180 Supreme has a tool life that is about 50% longer. An additional benefit for the DC180 drill is universal application at the highest cutting speeds. The drill is suitable for high production volume applications with a large number of holes, such as in the automotive industry. Other areas of use include the aerospace and energy industries, mold and die making, and general mechanical engineering.
The WJ30EZ-grade drill is comprised of the K30F fine-grained carbide substrate and available in diameters from 0.118-to-0.787” (3-to-20 mm). The DC180 Supreme in dimensions of 3 × Dc is in accordance with the DIN 6537 short standard, and the DC180 Supreme in dimensions of 5 × Dc is in accordance with the DIN 6537 long standard. Walter Xpress specials with short delivery times (maximum of three weeks) can be ordered for drilling up to 5 × Dc, as well as in step drill styles. The tool shank is in accordance with the DIN 6535 HA standard, and the shank end is in accordance with the DIN 6909 standard.
Walter, a global leader in the metalworking industry for more than 100 years, offers a wide range of precision tools for milling, turning, drilling and threading applications.
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