At Hall 18, Stand 210, focus will be on improved productivity, with launches that include the range of SilverLine solid-carbide milling cutters, as well as turning grades and tool-holding systems that help drive down manufacturing costs. In addition, visitors will see High Dynamic Turning with FreeTurn tooling, which combine to maximise the capabilities of modern turning centre technology.
High Dynamic Turning and FreeTurn deliver a solution that allows traditional turning operations, such as roughing, finishing, contour turning, face turning and longitudinal turning, to be completed with just one tool. For over 100 years turning techniques have changed little, if at all; yes, there are always new chip breakers and carbide grades, but methodology has largely remained the same. Now, exploiting the dynamics of modern turning centres, Ceratizit has created a process that allows the approach of the tool to the workpiece to be varied by making use of a machine’s B axis.
This strategy gives the FreeTurn tool 360° of freedom to produce the ideal workpiece approach angle. By rotating the cutting edge around its own axis, changes in approach angle can be achieved without interrupting the cutting process. This infinitely variable angle of approach enables the flexible machining of almost any workpiece contour, and generates optimum chip breaking, higher feed rates and increased tool life. Live demonstrations of High Dynamic Turning can be seen on the Ceratizit stand and around the halls in conjunction with machine-tool suppliers.
WNT’s SilverLine range of solid-carbide milling cutters gets completely updated with significant changes to the substrate, geometry and Dragonskin coating. However, most significant is the development of the cutter core, which sees increased rigidity, and improved chip flow and process security. The change in cutter core results in increased cutting data, which in turn means greater requirement for swarf evacuation, particularly when roughing. Therefore, the updated range now includes ripper cutters for the first time, the geometry of which creates smaller chips so that performance can be maximised.
Another benefit of the change in core design is that a wider range of flute options can be offered, with cutters now available featuring either 3, 4, 5, 6 or 8 flutes. To meet the needs of the growing aerospace sector, the series also benefits from an increased choice of corner radii. Other changes see the shank choice increase with HA-style now available, making SilverLine cutters suitable for use in hydraulic and shrink-fit chucks to allow the application of elevated cutting data. In addition, the Dragonskin coating has been enhanced to improve tool life by up to 50%.
“To make significant changes to what is one of our most popular ranges was a major decision, but these modifications have brought significant gains with the upgraded SilverLine cutters far exceeding the performance of the original tools,” says Tony Pennington, managing director of Ceratizit UK & Ireland.
The second innovation from the WNT brand is MultiLock, an exchangeable-head milling system that combines a solid-carbide head with a steel body to deliver cost and productivity gains, especially in high-feed, long-overhang applications. Suitable for machining titanium alloys, tool steels and light alloys, Multilock delivers cost benefits as carbide cutting heads are manufactured using a precision sintering technique that creates a good cutting edge without the need for secondary grinding operations. The flute design also means increased chip flow and tool life, with gains of 400 to 550% compared with competitor products, says the company.
MultiLock’s environmental impact is less as the amount of carbide required is greatly reduced. By using a solid-carbide head instead of indexable-insert technology, WNT has maximised cutting performance through increased cutting edges and, with the positive locking mechanism and additional process security through the use of clamping screws, MultiLock gives the performance of solid carbide but at reduced cost. MultiLock heads are available in a range of sizes between 12 and 25 mm, as well as a variety of cutter styles including torus, high feed, ball nose and deburring cutters.
The second turning development comes from Cutting Solutions by Ceratizit, in the form of its CTPX710 grade. Developed as a multi-application grade utilising the latest Dragonskin coating technology and newly developed carbide substrate, CTPX710 allows just a single grade to be used across many material groups, covering super alloys to general steels and non-ferrous materials. The result is reduced tool inventories and simplified tool changing for machine operators, with just the insert geometry changing to suit specific applications – the grade remains the same.
CTPX710 benefits from a partnership between the carbide substrate and the latest Dragonskin coating technology, which are then enhanced by a secondary finishing process. The substrate is a fine-grain carbide with optimised microstructure creating a hard, wear resistant base, on to which the Dragonskin coating is applied. Performance is further enhanced by increasing the coating thickness, which provides an additional damping/shock absorbing effect, further protecting the substrate and improving process security.
CTPX710 inserts are available in a variety of standard ISO insert shapes with three insert geometries, including -M34, which is aimed at turning super alloys due to the low cutting forces it generates, along with its resistance to built-up edges. For non-ferrous materials, steels and cast iron there are two available geometries, -25P and -25Q, the former having a sharp cutting edge providing good swarf control on softer materials, and the latter featuring wiper technology to deliver higher feed rates and improved surface finish.