Solid-carbide drills for deep-hole drilling
Sandvik Coromant Co., Fair Lawn, N.J., (www.sandvik.coromant.com/us) introduced its CoroDrill 861 solid-carbide drills for deep-hole drilling 12 to 30 times diameter without pecking. Featuring advanced flute geometry, the drills produce small, manageable chips.
The tools’ chip management, combined with a point geometry that reduces thrust forces and a double-offset margin geometry, helps provide the high stability necessary for drilling deep holes, according to the company. The edge preparation protects the cutting edge from premature chipping and flaking. Using a high-precision chuck, IT8 to IT9 is the achievable hole tolerance in steel, stainless steel, cast iron and nonferrous metals. Tool ports deliver coolant directly to the tip of the drill, even at deep drilling depths. The drill is also capable of producing cross-holes and holes in angled faces.
In a customer performance trial, using a 0.406 "-dia. CoroDrill 861 for horizontal drilling operations in alloy steel produced good results, the company reported. Drilling to a depth of 5.5 " (14 times diameter), the tool achieved 60 percent higher productivity than a comparable competitor’s drill in 30 minutes of machining time. The feed rate increased from 22 ipm to 36 ipm, resulting in a drilled length of 90 ', compared to 55 ' for the competitor’s drill, according to Sandvik Coromant.
Milling cutter for difficult-to-fixture workpieces
Walter USA LLC, Waukesha, Wis., (www.walter-tools.com/us) has expanded its Xtra•tec F4045 milling cutter line with a new medium-pitch tool for use on lower horsepower machines and for difficult-to-fixture workpieces.
Stable machines, workpieces and clamping arrangements are required for maximum cutting rates. However, sometimes feeds and speeds need to be scaled back because workpieces with complicated shapes do not always permit rock-solid clamping. That’s where a tool with medium pitch comes in. The medium pitch allows the tool to deliver optimal performance in conditions of limited stability.
The milling cutter’s other features enable it to boost productivity in different applications. These features include negative-shaped inserts with 14 cutting edges, seven per side. The inserts are pressed with a positive rake face, which allows for freer cutting geometry for high cutting volumes in lower horsepower machines. Also, its insert clamping system locks the inserts securely in their seats. The clamping wedge pivots to the side after just a few turns of the clamping screw, allowing rapid insert change, according to Walter. Three geometry shapes (stable, universal and easy-cutting) enable adaptation to a range of different applications.
Facemills for roughing to semifinishing
Iscar Metals Inc., Arlington, Texas, (www.iscar.com) has introduced its Helido S890 FSN line of right-hand indexable facemills for roughing to semifinishing, primarily when cutting cast iron and steel components.
The facemills have an 88º cutting edge angle (2° lead) with eight helical cutting edges, which can be used for DOCs up to 9mm. The facemills are available in diameters from 50mm to 160mm in coarse- and fine-pitch configurations. Every cutter body features coolant holes directed to the cutting edges. The inserts feature a cutting geometry with positive rake, which ensures smooth milling with soft entry into and exit from the material. The facemills work with general milling applications, especially those requiring machining close to shoulders or fixture constraints.
Cutting tool for square-shoulder milling
Seco Tools Inc., Troy, Mich., (www.secotools.com/us) offers an advancement in square shoulder milling with its Turbo 10 cutting tool for most roughing, semifinishing and finishing operations.
The cutter is for slotting, contouring, helical interpolation and ramping with cutting diameters from 0.625 " to 4 " and a maximum DOC of 0.354 ". The Turbo 10 employs a coated, prehardened cutter body with two pitch configurations for achieving tight tolerances and high reliability. Mounting types include cylindrical, Weldon, arbor and Combimaster. With strong, highly positive geometries, optimized edges, a range of carbide grades and two corner radii, the inserts for the Turbo 10 offer maximum levels of adaptability, accuracy and reliability, the company says. Also, inserts can be set to true 90° cutting.
Carmex adds to CMT vertical thread milling line
Carmex CMT, Richfield, Wis., (www.carmexusa.com) has added C10 (10mm diameter) and C25 (25mm diameter) inserts and toolholders to its line for vertical thread milling.
Available in a variety of thread forms and groove widths, the inserts, which are equipped with multiple and spiral flutes, deliver short cycle times, low cutting pressure and smooth cutting operation, according to the company.
Threading tools for all materials in a range of sizes
The Bass line of HSS machine taps and roll form taps from Komet Group, Schaumburg, Ill., (www.komet.com) is the latest addition to the company’s line of threading tools.
The tools thread all materials and are offered in a range of sizes. In partnership with Bass, Komet has developed a stocking program to offer its customers a complement to its Jel brand of solid-carbide and PCD threading and milling tools. The Bass HSS-E and HSS-E P/M-grade machine taps and roll form taps reportedly enhance performance for low- to medium-volume production in all industries.
Related Glossary Terms
- arbor
arbor
Shaft used for rotary support in machining applications. In grinding, the spindle for mounting the wheel; in milling and other cutting operations, the shaft for mounting the cutter.
- chuck
chuck
Workholding device that affixes to a mill, lathe or drill-press spindle. It holds a tool or workpiece by one end, allowing it to be rotated. May also be fitted to the machine table to hold a workpiece. Two or more adjustable jaws actually hold the tool or part. May be actuated manually, pneumatically, hydraulically or electrically. See collet.
- coolant
coolant
Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.
- edge preparation
edge preparation
Conditioning of the cutting edge, such as a honing or chamfering, to make it stronger and less susceptible to chipping. A chamfer is a bevel on the tool’s cutting edge; the angle is measured from the cutting face downward and generally varies from 25° to 45°. Honing is the process of rounding or blunting the cutting edge with abrasives, either manually or mechanically.
- feed
feed
Rate of change of position of the tool as a whole, relative to the workpiece while cutting.
- fixture
fixture
Device, often made in-house, that holds a specific workpiece. See jig; modular fixturing.
- flutes
flutes
Grooves and spaces in the body of a tool that permit chip removal from, and cutting-fluid application to, the point of cut.
- gang cutting ( milling)
gang cutting ( milling)
Machining with several cutters mounted on a single arbor, generally for simultaneous cutting.
- high-speed steels ( HSS)
high-speed steels ( HSS)
Available in two major types: tungsten high-speed steels (designated by letter T having tungsten as the principal alloying element) and molybdenum high-speed steels (designated by letter M having molybdenum as the principal alloying element). The type T high-speed steels containing cobalt have higher wear resistance and greater red (hot) hardness, withstanding cutting temperature up to 1,100º F (590º C). The type T steels are used to fabricate metalcutting tools (milling cutters, drills, reamers and taps), woodworking tools, various types of punches and dies, ball and roller bearings. The type M steels are used for cutting tools and various types of dies.
- inches per minute ( ipm)
inches per minute ( ipm)
Value that refers to how far the workpiece or cutter advances linearly in 1 minute, defined as: ipm = ipt 5 number of effective teeth 5 rpm. Also known as the table feed or machine feed.
- interpolation
interpolation
Process of generating a sufficient number of positioning commands for the servomotors driving the machine tool so the path of the tool closely approximates the ideal path. See CNC, computer numerical control; NC, numerical control.
- milling
milling
Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.
- milling cutter
milling cutter
Loosely, any milling tool. Horizontal cutters take the form of plain milling cutters, plain spiral-tooth cutters, helical cutters, side-milling cutters, staggered-tooth side-milling cutters, facemilling cutters, angular cutters, double-angle cutters, convex and concave form-milling cutters, straddle-sprocket cutters, spur-gear cutters, corner-rounding cutters and slitting saws. Vertical cutters use shank-mounted cutting tools, including endmills, T-slot cutters, Woodruff keyseat cutters and dovetail cutters; these may also be used on horizontal mills. See milling.
- pitch
pitch
1. On a saw blade, the number of teeth per inch. 2. In threading, the number of threads per inch.
- polycrystalline diamond ( PCD)
polycrystalline diamond ( PCD)
Cutting tool material consisting of natural or synthetic diamond crystals bonded together under high pressure at elevated temperatures. PCD is available as a tip brazed to a carbide insert carrier. Used for machining nonferrous alloys and nonmetallic materials at high cutting speeds.
- rake
rake
Angle of inclination between the face of the cutting tool and the workpiece. If the face of the tool lies in a plane through the axis of the workpiece, the tool is said to have a neutral, or zero, rake. If the inclination of the tool face makes the cutting edge more acute than when the rake angle is zero, the rake is positive. If the inclination of the tool face makes the cutting edge less acute or more blunt than when the rake angle is zero, the rake is negative.
- slotting
slotting
Machining, normally milling, that creates slots, grooves and similar recesses in workpieces, including T-slots and dovetails.
- threading
threading
Process of both external (e.g., thread milling) and internal (e.g., tapping, thread milling) cutting, turning and rolling of threads into particular material. Standardized specifications are available to determine the desired results of the threading process. Numerous thread-series designations are written for specific applications. Threading often is performed on a lathe. Specifications such as thread height are critical in determining the strength of the threads. The material used is taken into consideration in determining the expected results of any particular application for that threaded piece. In external threading, a calculated depth is required as well as a particular angle to the cut. To perform internal threading, the exact diameter to bore the hole is critical before threading. The threads are distinguished from one another by the amount of tolerance and/or allowance that is specified. See turning.
- tolerance
tolerance
Minimum and maximum amount a workpiece dimension is allowed to vary from a set standard and still be acceptable.
