November 2010 Product Spotlight
Water jet manufacturers Jet Edge and Tecnocut S.p.A. are pleased to introduce the energy-efficient ECUBE 6200 servo-driven intelligent water jet pump. The ECUBE 6200 made its North American debut this week at FABTECH in Atlanta.
Developed through Jet Edge and Tecnocut’s research and development partnership, the 90KSI (6200 bar) ECUBE 6200 utilizes an electrically controlled servo-driven intelligent pump; the completely electro-mechanical system uses 30% less electricity and has 80% fewer components than a hydraulic waterjet intensifier pump. Depending on the application, 90KSI water jet pumps make it possible to cut up to 50% faster and reduce garnet consumption up to 50% compared to 60KSI waterjet pumps. The ECUBE 6200 produces 0.7 gpm (2,61 lpm) of ultra high pressure water and supports water jet orifices up to 0.011” (.28 mm).
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Jet Edge
Tecnocut
Sandvik Coromant has introduced the CoroMill 170 cutter that offers the potential for optimization of milling applications for large gears in modul 12 ¬ 22. The cutter is specially designed to excel in this area, which has traditionally been covered by indexable inserts and HSS tools. In combination with insert grades GC 1030 and GC 4240, the CoroMill 170 can minimize machining times and the need for subsequent operations.
Available in diameters ranging from 8.27² ¬ 19.69² (8.268 mm ¬ 19.685 mm), the CoroMill 170 features a shape designed for the highest quality of rough gear wheel profile, in accordance with DIN 867 and DIN 3972-4. Designed for one of the toughest existing metal cutting applications, the CoroMill 170 is inherently robust. The cutter provides the greatest impact on applications requiring precision and reliability in roughing operations, such as slewing rings for windmills, cranes and other heavy equipment, as well as planetary gears.
Two insert geometries are offered for medium and heavy machining. Secure and stable insert seats reduce runout and improve tool life. Additionally, high performing Sandvik Coromant grades can significantly increase metal removal rates compared to existing market standards.
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Sandvik
ATI Stellram has introduced a new chevron-style milling cutter, the Stellram® 5230VS12, designed specifically for machining titanium and other difficult to machine materials, such as nickel-based alloys and cobalt-based alloys.
In comparison studies, the Stellram 5230VS12 cutter achieved metal removal rates up to two times greater than comparable cutters on the market. This is vital in aerospace applications where part design often calls for up to 80% metal removal.
The 5230VS12 chevron cutter positions multiple inserts along the cutting edge of each helical flute. This advanced design of the insert placement provides smooth, progressive penetration and cutting action for extended tool life, lower power consumption and up to a 30% improvement in surface finish.
Cutters range from 2.5 inches to 4.0 inches in diameter, with four to six flutes. Depending on flute length, 6 to 14 inserts can be positioned along each flute. Individual coolant jets to each insert provide constant chip evacuation and temperature stability in the cutting zone. Two insert grades are available for the Stellram 5230VS12:
Grade X500 is a member of ATI Stellram’s high performance premium X-Grade™ Technology family of carbide inserts designed for the toughest applications in Nickel-based alloys, Cobalt-based alloys, Titanium, and Titanium-based alloys.
Grade SP6519 offers the combination of a tough substrate with the latest generation of TiAlN super nano coating. This versatile grade is equally suited for both High Temperature Alloys and Stainless Steels.
The Stellram 5230VS12 cutter represents a combination of advanced tool design and high technology insert grades, resulting in a tool capable of substantially increased productivity and surface finish quality.
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ATI Stellram
For exact machining of thin-walled rings on rotary tables, cylindrical grinding machines, and lathes, SCHUNK now offers a vast program of standardized magnetic chucks with radial pole pitch. MAGNOS radial pole plates work with electrically activated permanent magnets and are proven for hard and finish turning, as well as grinding and rough machining.
The workpiece can be machined from three sides without a changeover and since the magnetic field is active up to the outer fringe areas, extremely large workpieces can now be clamped securely and deformation-free. Due to the two-dimensional acting holding force, vibrations are greatly reduced during machining. This prevents the cutting edges of the tools from damage and improves the surface quality of the workpiece.
Depending on the individual application, three different sizes of standardized radial pole plates are offered. For grinding operations, an AlNiCo single magnet system with automatic demagnetization, for turning operations, an AlNiCo double magnet system with high holding forces. The third one is for demanding volume machining during rough turning, an extra strong AlNiCo neodymium magnet system.
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Schunk
Helical Solutions’ new HEVR-5 and HEVR-RN-5 five-flute, variable-pitch end mills are designed for roughing and finishing of steel and exotic materials with increased feed rates and reduced chatter.
HEVR-5 and the longer-reach, reduced-neck HEVR-RN-5 tools are crafted of certified premium sub-micron grain carbide and feature geometries specifically engineered to cut ferrous material. The tools are available with an AlTiN (titanium aluminum nitride) coating for oxidation resistance and extreme hardness for slotting, peripheral milling, ramping and helical interpolation of Stainless and other steels, cast irons, titanium alloys as well as cobalt- nickel- and iron-based high-temperature alloys.
The HEVR-5 tool series features corner radii for added strength and has a variable-pitch design for increased depth of cut, up to 1 times the diameter of the tool resulting in an increased metal removal rate along with minimizing any possibility of chatter. Additionally, and due to its unique design features, it is not uncommon for customers to utilize the HEVR-5 for both roughing and finishing, reducing the number of tools and setups.
The HEVR-RN-5 series is designed for applications requiring extended reach into pockets or machining around obstructions. The stub flute length and a reduced neck contribute to excellent tool rigidity even considering the greater tool length.
Speeds and feeds for the tools range from 80 to 250 sfm and 9 to 27 ipm for Stainless, 60 to 125 sfm and 2 to 10 ipm for high-temperature alloys, 500 to 600 sfm and 23 to 76 ipm for steels, 400 to 600 sfm and 24 to 73 ipm for cast irons, and 160 to 190 sfm and 7 to 15 ipm for titanium.
“Although these tools can be used for roughing applications, they are ideal for finishing the hardest and most-difficult-to-machine materials,” says Helical Solutions National Sales Manager Scott Tiehen. “And with the higher speeds and feeds, and increased tool life they provide, they offer significant benefits in efficiency and cost.”
Helical recommends using high-pressure coolant, flood, mist or dry milling with air blast when machining with these tools, which are available in 1/4-inch, 5/16-inch, 3/8-inch, 1/2-inch, 5/8-inch,
3/4-inch, 1-inch and 1 1/4-inch diameters.
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Helical
MultiFinish-America Inc. has announced the introduction of a new drag finishing machine for heavy industrial use. The MFD 300e system allows wet or dry polishing for honing and polishing tools, valves, gears, tablet punches, medical components, and turbine blades.
These systems are made to withstand heavy use in a multi-shift production operation. Six product heads are standard, and ten heads are optional. The Adjustable Rapid Head system reduces the operational process by approximately 1/3 of the time normally required in a drag finishing process, depending upon the product, resulting in higher productivity.
The MFD 300e machine has a stronger head lift motor and gearbox and is fitted with product depth control in manual or automatic design. In addition to the tooling industry, MFD machines have product applications in the automotive, aerospace and orthopedic industries.
Key benefits of the MFD 300e:
- Repeatable processing for long production runs
- Touch panel computer and SPS operating system
- Memory for up to 300 different operating menus
- Quick set up, easy operation
- Shorter processing times
- Custom designed product holders
- Guarantees no damage to work pieces
- Low maintenance and running costs
- Compact design with a small footprint
- Stable, warp-resistant main frame
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MultiFinish America
Walter believes there is room for even more improvement in the boring process. This is why the US tool manufacturer has expanded its range with a new indexable insert with E47 boring geometry for the Walter Valenite Boring Medium and Walter Valenite Boring Maxi tooling systems.
One prominent feature in particular is responsible for such improvement in quality and performance: behind the cutting edge is a variable chip breaker groove that produces perfect chip formation even when relatively deep cuts are required. This proves most beneficial with variable depths of cut, such as those often involved in the machining of cored holes. No matter how far the cutting edge penetrates, it always produces a perfect chip.
The new insert is circumference-sintered and conforms to basic shape CC. The E47 universal boring geometry has a 15-degree rake angle, moderately rounded cutting edge radius and a 7-degree clearance angle. The straight cutting edge makes it possible to machine dimensionally precise shoulders, typically of 90 or 75 degrees, without profile distortions.
The E47 insert is available in three cutting materials. The CVD-Tiger•tec® WPP20 grade is the first choice for cast iron and steel. The PVD-Tiger•tec® WSM20 and WSM30 grades are available for more difficult machining conditions. These cutting tool materials are extremely tough, making them suitable for steel, stainless steel and other materials with difficult cutting properties. Interrupted cuts, which are common to the boring process, are no problem for these grades.
The new insert was developed for the Walter Valenite Boring Medium and Walter Valenite Boring Maxi tooling systems, both of which support the entire boring geometry range from 0.787” to 25.20” (20 mm to 640 mm). The combination of tool, Tiger•tec® cutting tool material and E47 geometry ensures maximum process reliability for the shortest machining time.
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Walter