Milling

The nine-edged milling systems M911, M913 and M928 are stocked in cutting widths from 1.5 mm (0.059") to 3 mm (0.118") as standard. The maximum milling depth is 3.5 mm (0.138") (M911), 4.5 mm (0.177") (M913) and 6.5 mm (0.256") (M928). The inserts are available with different coatings to suit the material to be machined. Due to its mass, the solid carbide tool shank ensures vibration damping during milling. All variants of the tool shanks are equipped with an internal coolant supply.

As with other tool systems, high-performance reaming systems are also subject to demanding requirements. In addition to high process reliability, long tool life and low tool costs, modern reaming tools must fulfil further criteria. These include, among other things, the modularity of the tools. While machining with an HSS reamer is partially limited in this respect, modern reaming systems can be improved by replaceable heads with carbide inserts, modular tool lengths and various adjustment options. These include, for example, µ-accurate adjustment of concentricity and runout. Precise concentricity of the reaming inserts is the path to success. In practice, this should be within 5 µm.

The new grade is Walter's response to the upwards trend towards milling steel with difficult machining properties and wear-resistant stainless steel, such as found in applications in the energy and aviation industries. WSM35G meets the most stringent requirement for process reliability, which is highly valued in the automotive sector, and is also suitable for general mechanical engineering applications.

Providing exceptional reliability and increased tool life in steel, the new AH3225 insert grade consists of a unique nano-multilayer coating featuring three distinctive characteristics for improved resistance to built-up edge, wear, and delamination, combined with a dedicated tough carbide substrate. AH8015 is another PVD grade, consisting of extremely hard PVD coating combined with a tough carbide substrate. The grade demonstrates excellent tool life stability in cast iron and heat-resistant superalloys.

Two key user advantages of the droPWR app are split-screen functionality and dynamic zoom. The split-screen capability allows users to multitask—having more than one application displayed at a time (the readout application on one side and part print on the other, for example).

The Zertivo 2.0 grades enable a 30 percent increase in cutting speed recommendations for the primary ISO P and ISO M application areas, as well as secondary ISO K and ISO S materials, thanks to their optimized flute shape, which offers effective chip evacuation. The grades designed for stainless steel machining come in two variants: one with internal coolant for improved temperature control and chip flow, and one without internal coolant.

EMUGE MultiDRILL™ is made of a unique sub-micro grain carbide grade that is harder than conventional carbide grades for drilling, yet it retains the ability to withstand shock and chipping. MultiDRILL features advanced TIALN-T63 coating utilizing nano-layer technology with surface hardness exceeding standard TIALN-based coatings, for reduced friction at high temperatures.

A German research team has developed a system that can be used to predict and reduce part distortion.

One of the main advantages of the new CoroMill Dura aluminum-specific end mills is their versatile performance in all different types of roughing applications, while also offering finishing capabilities," Wikström continues. "Up to 2×D full slot, pocketing, 5–20° ramping, shoulder milling and more — all with the same end mill.

The PCD inserts impart the finest surface finishes while shoulder, face and slot milling. The tools enable precise machining with reduced cutting forces and minimal vibration tendencies. They have a low cost because of their extremely long tool life as a result of the cutting edge being made of the hardest known material. In addition, the PCD inserts provide the shortest machining times due to their ability to mill at high cutting speeds. The inserts can be used dry, with emulsion of MQL (minimum quantity lubrication).

So how does Y-axis turning work? As the name implies, the new method makes use of the Y-axis, and all three axes are used simultaneously when machining. The tool rotates around its own center, the insert is placed for machining in the Y-Z plane and the milling spindle axis interpolates during turning. This allows intricate shapes to be machined with a single tool.

Mastercam announced its 2022 Wildest Parts Competition winners. The Wildest Parts Competition is held each year to encourage student interest and participation in manufacturing.