Catch up with WNT’s new developments at MACH 2014

For example, WNT's turning range has seen many changes, key among which is the addition of a series of positive geometry inserts in the HCN 2125 range for machining stainless steel. These new inserts are said to open up many possibilities for productivity and tool life improvements. Available in two geometries for fine finishing and medium roughing applications, the inserts can operate at feed rates of 0.06-0.35 mm/rev, and at depths of cut up to 4.8 mm. HCN 2125 inserts can deliver these gains thanks to a new carbide substrate and Dragonskin PVD tool coating, which claim to provide high wear resistance at elevated cutting data. This is a major benefit for customers machining austenitic, ferritic, martensitic or duplex stainless steels. New developments in WNT's solid carbide milling range include the MCR Monstermill, an end mill which the company says is generating significant performance gains when compared with existing cutters. These gains include up to four-times the feed rate and three-times the tool life of WNT's standard cutters. MCR Monstermill forms part of WNT's HPC range, and is designed for rough milling utilising a highly evolved roughing profile and special cutting geometry. According to WNT, this combines with irregular pitched flutes to create optimum cutting performance and an extremely soft cutting action that generates smaller chips and less stress on the machine tool. This is particularly advantageous when used on machines with lower spindle power. The ideal application for MCR Monstermill is the dry machining of steel or cast iron, where WNT says the TiAlN tool coating enhances tool life significantly. However, the MCR Monstermill can also be applied to machining stainless steel if coolant is applied. It also claims to be an exceptional cutter for vortex milling strategies, offering cycle time reductions of up to 50%. MCR Monstermill cutters are available from 1-20 mm diameter, with three flute lengths available in certain sizes. The cutters are capable of slot milling to 1.5xD. Another new solid carbide milling cutter is the SCR Torus cutter, which combines the advantages of WNT's existing solid carbide SCR (Steel Cutter Roughing), HPC (High Performance Cutter) and HFC (High Feed Cutter) tools. WNT says SCR Torus is capable of full slot milling to 1xD, as well as other conventional milling operations such as ramping, profiling and pocket milling. It also claims to be capable of high feed (waterline) type milling. The secret behind SCR Torus is the geometry both of the end face and radii, and also of the cutter flutes. The cutter is ground with two large 'actual' radii and one theoretical radius on the cutting edge. The first, larger radius provides the SCR Torus cutter with its high feed capability, while the smaller radius generates extended tool life by protecting the cutting edge from premature wear when conventional milling. These combine to create the theoretical radius (R3D) for use when programming the cutter path in a CADCAM system. The high feed capability of the SCR Torus cutters is aimed at reducing cycle times during rough milling strategies, but can be used for finishing vertical surfaces using the outside diameter of the tool. According to WNT, SCR Torus cutters are generating significant cycle time reductions when compared with indexable insert button tools. One example highlighted a cycle time reduction of 2.5 hours when machining a mould. Using an indexable insert tool, the operator had to be available by the machine to change inserts when they became worn. The previous cycle time was 3.5 hours. Running the SCR Torus cutter at a typical 160 m/min cutting speed, 0.12 mm/tooth feed rate and 0.3 mm depth of cut, the component was completed in a cycle time of 60 minutes without the need for a tool change (so the operator was free to undertake other duties). WNT's range of indexable insert milling systems has also seen change, an example of which is the introduction of HFC06 milling cutters. Typically, high performance milling with indexable inserts has been restricted to diameters above 25 mm. However, with the development of HFC06 inserts and cutter bodies, users can now benefit from the performance and cost savings delivered by indexable inserts down to 16 mm diameter. With an insert edge length of just 6 mm, HFC06 cutters fill the gap between the economical 16 mm size of solid carbide tools and the more usual 25 mm start range for indexable insert cutters. WNT says that performance has not been compromised, with HFC06 still capable of achieving feed rates of up to 1.5 mm/tooth, with a maximum 0.8 mm depth of cut. At their smallest diameter, HFC06 cutters feature twin flutes, with three flutes available at 20 mm diameter, four flutes at 25mmm and five flutes at 32 mm. Shanks styles can be either screw or cylindrical, and all feature through-tool coolant as standard. The inserts are available in two geometries, one for steel, and one for heat resistant materials, and they sit in the cutter body in a positive presentation to the workpiece. The insert geometry is designed to provide an extremely soft and quiet cutting action that promotes a stable and vibration-free machining process. When it comes to drilling, WNT has the popular C900 High Feed Drill in its portfolio. These indexable drills make use of a single, universal carbide grade, while the centre and peripheral insert are identical in design (four cutting edges per insert). According to WNT, these features reduce tooling cost and simplifying the drilling process. Now, the C900 High Feed Drills are being made available in diameter-to-length ratios of 3xD, 4xD and 5xD as standard. The design of the drill body and insert geometry are said to ensure maximum stability and performance at these extended lengths. Changes to the range of toolholders from WNT include the extension of Modifix driven tooling systems. These toolholders claim to address the cost of replacing driven tooling, which can be prohibitive. WNT's Modifix eliminates the need to purchase new spindle units as the adaptors will fit any standard ER collet-type driven tooling system. They also have the added advantage of being available with side-lock and shell mill fittings, as well as the conventional collet chuck. Using Modifix, tools can be pre-set in a separate holder and exchanged quickly when required, with the accuracy of the units said to give greatly reduced setting times and increased machine run time. The rigidity of the tool set-up is also enhanced by the short distance between the tool and the spindle bearings of the driven tool unit. Further versatility is provided by the fact that Modifix units are available with either an internal and external thread connection to suit the ER system. To install, the operator simply removes the ER collet nut and attaches the Modifix adaptor, tightening it as they would an ER collet. Recent additions to WNT's portfolio of vices and fixtures include the H5G and the ESG Mini vices, which sit at opposite ends of the scale. The H5G system offers clamping forces of up to 40 kN and, depending on the configuration, a gripping width of up to 499 mm, while the ESG Mini is designed for smaller components and has a maximum gripping force of 12 kN, making it suitable for multiple clamping set-ups using zero-point pallets. A key feature of the H5G series is its pre-set clamping force, which eliminates the risk of over or under tightening the component in the vice. According to WNT, this makes it suitable for everything from heavy duty to thin-walled components. To lock and unlock the vice, the mechanism only needs to be moved through an arc of 160°, meaning clamping can be completed in less than one second, says WNT. Other design features of the H5G series include a low vice height of 125 mm, making it practical for smaller machine tools. The clamping mechanism is fully sealed to protect against swarf and other contaminants, thus prolonging the life of the vice. Furthermore, the location of the clamping spindle ensures minimal deflection of the clamping jaws, even at maximum gripping force. ESG Mini vices feature a small, 40 mm jaw width as standard with a 100 mm option available. The range also features a variety of vice jaw types with several functions that are designed to help with machine/component set-up. For example, jaws are available with precision ruled marks and stops, or with indentations to allow rapid positioning of parts. This also allows the removal and repositioning of components for inspection part-way through machining. The operating mechanism of the ESG Mini series is completely encapsulated, as it is with the larger H5G vices Other benefits of the ESG Mini series are its design, which has the fixed jaw manufactured from the same block of material as the vice base, making it much stronger and resistant to deflection. The vice jaw system is also modular, allowing great variations in clamping options, while the clamping mechanism can be specified as a manual or hydraulic system. Both systems feature tenon or zero point locations, making them suitable for most machine tools or set-up applications. In particular, the ESG Mini series is said to be suitable for multiple vice applications on base plates or tombstone-type fixture blocks. WNT's catalogue of over 45,000 items is available ex-stock for guaranteed next day (before noon) delivery, if ordered before 18:30. MACH 2014 - Birmingham NEC, 7-11 April