Latest milling cutter developments include a Z-axis plunge mill that maximises metal removal rates and solid carbide end mills for machining SS and alloys and hard materials up to 67 HRc

Kennametal introduced three developments in milling cutters at last year’s EMO exhibition, as follows. * The Kennametal Z-axis Plunge Mill offers maximum metal-removal rates in plunge milling. * A solid-carbide End Mill Harvi II, which reduces chatter when machining stainless steels, titanium and heat-resistant alloys.
solid carbide milling cutters for machining hardened steels up to 67 HRc.

** Kennametal’s Z-axis plunge mill provides maximum metal-removal rates with its novel, optimized chip evacuation.

The tool eliminates vibration and improves metal-removal rates in roughing applications.

With these performance features, Kennametal has once again set a new standard in the field of milling increasing the competitive edge for our customers The Z-axis plunge mill has nine integrated coolant nozzles allowing the coolant flow to be optimised per application.

It also features easy to change positive cutting inserts, needs only a single screw, and ensures stable cutting at high metal removal rates.
The tool has applications in the die and mold industry, but is also used aerospace industry and general engineering, said Kennametal.

KDMR is an extended flute drill mill for drilling, pocketing and shouldering.

In addition, KDMR is also suited for deep slotting and facing with diameters from 16 mm to 50 mm and grades for all ferrous materials.

** Solid-Carbide End Mill Harvi II - with Harvi II, Kennametal said it has set new standards for the machining of stainless steels, titanium and high-temperature alloys such as inconel with solid carbide end mills The variable flute geometry of the five cutting edges and a helix angle of 38 deg guarantee chatter-free performance and improved material removal rates, said Kennametal.

The solid-carbide end mills of the Harvi II programme are available in two different point geometries.

The geometry UCDE is specifically designed for machining stainless steels; it is offered as standard in a range from 4 to 25mm.

The geometry UDDE is designed for machining titanium alloys and high-temperature alloys.

Solid-carbide mills with UDDE geometry are available in diameters from 6 to 25mm.

Both geometries are available with cylindrical and in Weldon shank options.

The five-edged tools can be applied for both slotting with cutting depths up to 1xD (D = diameter) and side cuts with a maximum engagement width of 0.5xD and a maximum cutting depth of 1xD.

When cutting titanium and high-temperature alloys, these performance features enable the user to achieve maximum metal-removal rates and reduced machining times, said Kennametal to manufacturingtalk.com.

The Harvi II programme has applications in the aerospace , medical and general engineering markets.

** Roughing Programme up to 67 HRc - Kennametal has extended its well-proven KenFEED milling cutter series with the introduction of two new types of solid-carbide milling cutters having diameters from 6 to 25mm.

The solid-carbide KenFEED mills are available in two geometries; the tools have been developed specifically for machining hardened steels of 37-52 HRc (KMDA geometry) and 52-67 HRc (KHDA geometry).

With an innovative point geometry on each of the six cutting edges, solid-carbide KenFEED tools work with feeds per tooth of up to 0.6mm, increasing metal-removal rates by up to 200%.

The tools are also relieved to allow improved access when machining cavities or complex shapes The solid-carbide KenFEED milling-cutter program is available in thegrade KC639M, a PVD AITiN-coated fine-grain carbide combining very high hardness with extreme cut toughness, providing an excellent balance of wear resistance and durability.

** About Kennametal - Kennametal Incorporated (NYSE: KMT) is a leading global supplier of tooling, engineered components and advanced materials consumed in production processes.

The company improves customers’ competitiveness by providing superior economic returns through the delivery of application knowledge and advanced technology to master the toughest of materials application demands.

Companies producing everything from airframes to coal, from medical implants to oil wells and from turbochargers to motorcycle parts recognize Kennametal for extraordinary contributions to their value chains.

Customers buy over US$2.4 billion annually of Kennametal products and services - delivered by our 14,000 talented employees in over 60 countries - with almost 50% of these revenues coming from outside the United States.

Rough milling cutters for machining steels and SS cut cycle time/workpiece by one-third, said a manufacturer, which has also introduced a new supernitride PVD coating for insert tooling

Kennametal said that its KSRM milling cutter can reduce milling cycle times by up to one third and delivers a consistent performance in roughing applications. The insert is designed to resist rotation in cut, which guarantees excellent stability even at maximum cutting speeds, said Kennametal.
Three indexable-insert sizes (20mm, 0.750in and 1in) are available for the KSRM milling system.

The screw clamping enables fast and accurate insert change.

The KSRM milling cutter, is suitable fo ramping, slotting, helical ramping, profiling and plunging operations This cutter, said Kennametal to manufacturingtalk.com, is ideal for applications in general engineering when machining steels and stainless steels.

It is also well suited for difficult-to-machine components made of titanium or high-temperature materials in aerospace applications.

** Supernitride PVD coating for standard indexable milling inserts - Kennametal now offers a supernitride PVD coating with low residual stress between coating and substrate.

It provides excellent adhesion allowing thicker PVD coatings and, therefore extended tool life.

It is available on standard indexable inserts in the grades KC510M and KC520M with a hone size of 0.025mm (0.0001in) or larger.

This hard coating guarantees longer tool life even in the most demanding applications, said Kennametal.

The upgrade of KC510M completes the transition from a cast-iron and aluminium grade to a market-leading cast-iron grade for wet or dry finishing operations.

On show at MACH 2008 for the first time in the UK will be indexable cutting tools for turning, milling, drilling, boring and reaming, solid carbide and high-speed steel drills, taps and end mills

Walter GB will be showing at MACH 2008, for the first time publicly in the UK, the latest Walter, Titex and Prototyp tooling. The company said that these ranges offer an unrivalled single-source of market-leading tooling, including indexable cutting tools for turning, milling, drilling, boring and reaming, solid carbide and high-speed steel drills, taps and end mills.
The MACH stand will include Walter Tiger.tec and Xtra.tec series indexable tooling, Titex drills, and Prototyp solid carbide and HSS taps, end mills and threadmilling tools.

For example, they include the following.

* Tiger.tec inserts for turning as well as milling.

* Xtra.tec milling with Tiger.tec inserts.

* Titex X.treme/X.treme Plus solid carbide drills.
Protostar Ti solid carbide end mills.

* Prototyp Paradur taps.

The innovative Tiger.tec inserts - claimed to be the world’s first PVD aluminium oxide coated carbide - can achieve up to 75% more components per edge than competitor products, said Walter.

In some cases they can double output, due to their improved process reliability courtesy of a high resistance to flank wear, cratering and thermal cracking.

The Tiger PVD aluminium oxide coating is available on ISO indexable inserts for turning as well as milling.

Designated Tiger.tec WSM30, the new turning insert range embraces all standard ISO shapes in positive and negative geometries.

The product is targeted in particular at high-alloy and stainless steel machining tasks as well as titanium alloys and super alloys such as Inconel.

The benefits of Tiger.tec have also been applied to the expanded range of Xtra.tec milling cutters, with a host of new tools as follows.

* A trio of side and face milling cutters.

* Three shoulder milling cutters.

* New octagon cutter.

All feature four-edged Tiger.tec indexable inserts in staggered tooth formation and approach angles of 90 deg.

There is a variety of insert geometries is available to cover all relevant applications.

* tapping - the Walter GB stand will also highlight the continually-expanding Protyp range of taps, which include the new Paradur Ti Plus and Prototex Tini Plus models for the high-productivity, high-quality machining of titanium alloys.

The HSS taps feature AlCrN coating that is specially designed for high-strength alloys - as used in the aerospace sector - which have a tendency to jam, and the Paradur Ti Plus and Prototex Tini Plus ranges are available in UNJF styles 10-3 up to 3/8-24.

They offer high process security (via considerable clearance for reduced friction), outstanding tool life as well as excellent quality threads.

* Drilling - also to be shown at MACH 2008, the Titex X.treme Plus sets new standards in solid carbide drilling through an innovative double-coating (Double Performance Line) that promises to double tool life on steel and cast iron applications.

The new drill is available in diameters from 3mm to 20mm and is capable of drilling up to five times diameter.

* Milling titanium - from the Prototyp Protostar Ti family (of four different end mills).

the Ti 40 solid carbide high-performance end mill is available in diameters from 12mm to 25mm and is targeted at the roughing and finishing of titanium workpieces.

The new tool, with ACN coating, can operate at double the cutting speeds compared to conventional tools, said Walter GB.

Milling insert overcomes problems associated with ball nose copying style inserts where zero cutting speed at the centre causes error of form and premature failure of the insert

LMT’s Kieniger tooling division has developed milling inserts that overcome problems associated with ball nose copying style inserts, where zero cutting speed at the centre causes error of form and premature failure of the insert. The FlatBall indexable insert combines the advantages of ball and toroidal style indexable inserts for die and mould and aerospace type applications in what LMT (UK) of Coventry, UK, describes as a ‘double-edger’ geometry.
At zero cutting speed - the design of the FlatBall features a 2mm flat on a 10mm diameter insert, which overcomes the absence of cutting speed as the spindle rotates around the centre line of the tool.

Nomally, this causes a normal carbide insert to suffer from the rapid rise in temperature generated by the resulting ‘rubbing’ rather than a cutting action.

The rubbing action also lincreases wear on the insert, which progressively changes its geometry under cutting conditions.

The result is lost machining time as components have to be checked and new offsets inputted at the machine control - or tools have to be changed frequently, said LMT.

LMT’s solution is to flatten the shape of the ball or more technically, reduce the radius of the insert until it becomes a double-edged cutter.
This modification of form, said LMT to manufacturingtalk.com, means the insert works at a constant speed in its centre but without loss of any advantages gained by the ball shape.

This design also prevents any accumulation of chips or built-up edge at the tip of the ball when an initial cut is made into a slope or a helix.

In addition, it can also reduce the number of individual cutting paths required, thus shortening cycle times when complex contours have to be machined.

* Impressive unmanned trial results - recent trials at the Polish subsidiary of Comau, the Italian corporation that supplies the automotive industry with large cast iron, cast steel and tool steel alloy moulds, a LMT FlatBall was recorded with an in-cut running time of over 70h.

The material was a GH240 steel casting with hardened inserts and was machined using LMT’s WPB 16FB-70 der CBN faced cutting insert.

The 5-axis milling centre was run at its maximum cutting speed of over 600m/min and due to the improved security of the process, was able to be left to run unmanned.

In a further hard milling trial to produce a trimming tool out of P20 tool steel, the LMT FlatBall was run at 400m/min to produce a cutting distance of 3,60m over an 11h period and after that time displayed no appreciable signs of wear, reported LMT.

Using the finest ultra-fine granulated solid carbide available, a range of coated end mills can machine pre-hardened steels up to 70 Rc

NKO is producing its ‘Hard-Cut’ series of carbide end mills from the finest WC-Co ultra-fine granulated solid carbide (0.003mm) available. The WC-Co carbide is noted for its hardness, toughness and wear resistance. NKO has designed end mill geometry, with CAD and grinding sotware, to guarantee a maximum of stability and excellent performance.

The end mills are more precise with regards to the cutting diameter tolerances (h9) as well as the tool run out (<5 micron) and cylinder shank tolerances (h6) for easy clamping in a shrink-toolholder.

A nano-composited coating offers outstanding heat-resistance and a lubricating ability for machining pre-hardened steel of up to 70 Rc.

Claimed to be the smallest and lightest CO2 laser on the market, a 4kW model with improved beam quality and stability, can cut sheet metals up to 25mm thick

Fanuc GE has introduced a 4kW laser source with enhanced processing performance. TClaimed to be the smallest and lightest CO2 laser on the market, it offers high speed and high precision for increased productivity when cutting a range of materials, including sheet metal up to 25mm thick. Enhancements applied to the new C4000i-Model B from Fanuc GE include the following.
* Improved beam quality.

* Improved beam mode stability.

* High speed laser control synchronised with servo motor control.

These developments, said Fanuc GE, enable the increase in precision and cutting speed, and deliver an improved cut edge quality at lower running costs.

An optional high-speed control function offers improved precision in synchronisation between the axis command of the laser cutting machine and the ON/OFF command of the laser beam.
It reduces the time delay for the beam ON/OFF command: the distance travelled by the cutting head before/after the ON/OFF command is less than the beam spot size and only 1/16th of its previous size.

* As fast as a turret punch press - Fanuc GE claims that in continuous hole cutting processes, the laser offers the same high speed processing as a turret punch press machine.

The latest model complements the existing C1000i-A, C2000i-B, C5000i-A and C6000i-A models of 1kW, 2.5kW, 5kW and 6kW power respectively.

The full range of Fanuc GE lasers are offered as laser packages.

Laser source, CNC and servomotors are integrated and interfaced as a complete system to optimise the machine performance, offering high speed and high accuracy.

All necessary laser control and diagnostics are integrated into the CNC.

Historical data for maintenance purposes is logged and can be accessed via the CNC screen.

The laser source communicates with the CNC via an optical bus.

No additional controller is required, and no further work is required by the machine manufacturer to link the laser and CNC.

The package ensures quick, faultless start-ups of laser machines, said Fanuc GE in a report to manufacturingtalk.com.

All laser control screens are available on the CNC.

Direct control of the laser source by the CNC allows simplified handling for operation and maintenance purposes.

Control of laser and machine are always synchronised as this is carried out by only one processor.

When used with linear motors, extremely high speed cutting can be achieved.

At the same time, all the usual features of the CNC can be used by the machine tool.

* laser function integration - the package enables the integration of many useful laser processing functions.

These include diagnostic functions, processing parameter controls, and other special functions for efficient processing.

For example, there are the following.

* At a sharp corner the power and feed-rate are carefully controlled to optimise machining.

* Thermal loading is controlled when cutting thin material.

* The gap between the cutting nozzle and the workpiece surface is kept constant.

* Different beam properties can be compensated for on all axes.

* The Fanuc GE laser package can simultaneously control up to 6 axes to enable highly efficient 3D machining.

There is also an Open CNC option enabling the connection of a PC via a serial high-speed optical fibre link, enabling the two-way transfer of large volumes of data.

This enables MTBs to customise machines to suit individual customer demands.

* About Fanuc GE CNC - Fanuc GE CNC is a leading global supplier in factory automation.

These include products and solutions for the machine tool market based on a wide range of CNCs, motion control products, monitoring and control software products, CO2 lasers and services.

Fanuc GE CNC is a joint venture between GE and FANUC Limited and the company’s European headquarters are at Fanuc GE CNC Europe in Luxembourg.

A hybrid-style CO2 laser cutting system for cutting and profiling sheets up to 4m x 2m has a highly rigid, high-precision drive system, which provides precise motion and position control

LVD Company has introduced the Orion 4020 as an expansion to its Orion Series Laser Cutting Systems. The hybrid-style CO2 laser cutting system is engineered for economical processing of large sheets up to 4m x 2m. The Orion laser cutting systems feature a highly rigid, high-precision rack-and-pinion drive system which provides precise motion and position control.
This rigid design permits the machine to maintain high processing speeds without loss of cut quality.

Orion 4020 is part of the Orion product family, cost-effective machines offering the best features and performance available in a value-minded package.

* Fast set-up - Orion 4020 employs a simple beam delivery system comprised of three mirrors, ensuring easy alignment and a stable beam path.

The standard laser cutting head accommodates a 5in or 7.5in quick-change lens.

These water-cooled quick-change lenses can be installed or exchanged easily, using a self-centering system.
Lens calibration is programmable and quick to achieve, said LVD.

A built-in capacitive height sensor automatically maintains a constant distance between the head and the plate, automatically compensating for any unevenness in the material.

For additional ease in set-up and loading, the machine table is positioned at a comfortable working height and offers full access and visibility on three sides.

Standard features include automatic cutting gas selection and automatic cutting gas pressure control with servo valve to further simplify machine set-up and operation.

* Cut quality is consistent - Orion 4020 is equipped with a high-pressure cutting head that produces exceptionally clean cuts, said LVD to manufacturingtalk.com.

A crash-protection system protects the head from damage after collision with the workpiece.

A total power control feature automatically adjusts the laser power in relation to the cutting speed, ensuring an optimal cut at every contour width and minimizing the heat-affected zone.

The machine’s edge function feature processes sharp corners cleanly, particularly in thicker materials.

Laser and CNC are integrated - Orion 4020 employs the highly reliable GE Fanuc RF excited fast axial flow CO2 laser.

The laser, CNC control, drives and motors are fully integrated, providing superior processing speed, high reliability, and low operating and maintenance costs.

The integrated GE Fanuc control provides perfect reproduction of programmed contours, claimed LVD, producing acute angles at high speed.

The laser power is matched to the vectorial speeds to achieve a constant cut width and a small heat-affected zone.

All parameters, diagnostic and start-up procedures are conveniently displayed on a single color screen.

The 32-bit control features powerful mathematical capabilities and an extensive material library.

* More control functionality - the Orion 4020 is also available as a ‘Plus’ version.

The Orion 4020plus provides automatic focal positioning and greater process control functionality in addition to all standard features found on the Orion standard series.

* Offline programming - optional CADMAN-L 3D offline programming software provides a comprehensive laser-cutting CAM package.

This includes an integrated 3D design and unfolding module, which allows easy importing of 2D and 3D designs, automatic unfolding and generation of flat patterns from 2D or 3D files.

CADMAN-L 3D also incorporates fully automatic, semi-automatic or manual nesting and optimizes cutting and machine parameters to maximize sheet utilization.

Advanced features include cutting path optimization, common line cutting and high-speed communications via Windows, networking or DNC link to maximize machine productivity.

* About LVD - the LVD Group is a leading manufacturer of a comprehensive range of sheet metal/plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotine shears and mid-level automation systems, integrated and supported by its CADMAN PC-based Windows compatible software.

Automatic handling system for CNC laser cutting/profiling machines allows different materials to be programmed for cutting, ensuring maximum flexibility and minimum non cutting time

A single pallet system or one having up to ten bays in a tower system can be retrofitted to existing CNC laser cutting/profiling machines. Supplied by UK Machine Tools, the company said that its Tower systems provide automated production and increased safety by removing operators from the sheet loading and unloading area.UK Machine Tools told manufacturingtalk.com that with a Tower system, different materials can be programmed to be automatically selected for cutting, ensuring maximum flexibility and minimum non cutting time.

Cut parts are stored in the Tower until they are required or when the cut parts pallets are full.

Automated Systems are available for 3015 and 4020 size machines as standard systems.

Features are as follows.

* Automatic selection of material from raw material pallets.

* Automatic unloading of cut parts into Tower or onto single pallet.

* Each raw material Pallet can carry up to 3000 kg of material.

* Minimum floor space required as single Pallet or Tower system is designed to fit above existing change table.

* Software supplied in package.

* Programmable plate selection.

CNC laser cutting and profiling machines achieve cutting speeds of 140m/min and head acceleration of 12m/s2, for rapidly profiling a wide range of materials up to 25mm thick mild steel

Prima Industrie UK will demonstrate the speed, accuracy and productivity benefits of its Platino CNC laser cutting and CompactServer work handling technology at the UK’s MACH 2008 international machine tool show. Platino CNC laser cutting machines achieve cutting speeds of 140m/min and head acceleration of 12m/s2, making them ideal for rapidly profiling a wide range of materials up to 25 mm thick mild steel, said Prima.
The machines are available with 2.5, 3.0, 4.0 and 5.0kW heads and work areas of 3000 x 1500mm or 4000 x 2000mm.

* Advanced machine dynamics - the Platino’s high dynamics are backed by exceptional precision achieved through a fixed workpiece design and the use of advanced flying optics, said Prima to manufacturingtalk.com.

Consequently, the machine will consistently maintain positional accuracies of 0.03mm across its entire work area, along with a repeatability of 0.03mm.

Its productivity and performance are also enhanced by off-line programming capabilities, optional nesting software and an in-built anti-collision safety device.

* Sheet or tube - suitable for flat sheet or the processing of round, square or rectangular tube, with zero changeover time, the Platino has proved to be equally cost-effective for short batch or extended production runs, with more than 1000 machines sold to date worldwide, reported Prima.
Advanced work handling - the equipment’s versatility and productivity are further enhanced by a series of advanced work handling systems.

Prima’s presentation at MACH will feature the company’s CompactServer system, which enables the Platino, Syncrono and Domino series machines to be operated as independent, unmanned manufacturing cells.

Equally suitable for OEM and sub-contract manufacturers, the CompactServer is designed to integrate with the laser cutter’s pallet changer to provide highly efficient automatic operation, even under ‘lights out’ conditions.

* Small ‘footprint’ - with all components fitting above the machine’s pallet changer, the new CompactServer requires no additional floor space.

It is available as a factory-supplied equipment option or can be quickly and simply retrofitted to existing installations without the need for floor reinforcement or special foundations.

In operation, the new unit uses vacuum cup grippers to transfer unprocessed sheets to the pallet changer during the machine’s cutting cycle, enabling downtime during the load/ unload sequence to be minimised.

The CompactServer is controlled directly by the machine’s CNC system and incorporates a wealth of safety, referencing, sheet separation and measuring features to ensure trouble-free operation over an extended service life.

Suitable for standard sheet sizes up to 1500mm x 3000mm and up to 20mm thick, the CompactServer offers a maximum single shelf payload of 3000kg, with a maximum raw or finished material stack height of 150mm.

In addition, each of the unit’s two shelves can be replaced by guide-mounted motorised pallets to allow stack handling by a bridge crane.

Prima UK’s managing director, Joe Attuoni, said that ability to Prima equipment unattended under ‘lights out’ conditions allows users to dramatically increase their competitiveness, particularly against suppliers from low labour rate economies.

He added: ‘The Platino’s versatility not only allows them to produce high quality profiled products with minimal operator input, it also enables them to meet demanding delivery lead times that simply could not be achieved by sourcing overseas’.

* About Prima Industrie UK - Coventry-based Prima Industrie UK draws on the established track record of its Italian parent organisation, Prima Industrie, a world leader with 30 years experience in the design, development and manufacture of laser cutting machines and automation systems.

Prima UK provides sales, installation and servicing for a wide range of new and pre-owned 2D and 3D cutting machines that are used by customers in industries as diverse as aerospace, automotive, marine and electrical equipment manufacture.

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