Inserts for improved turning; thread tapping tools; interference-free five-axis machining.
Inserts for Improved Turning
What: Tiger.tec Silver ISO P generation indexable inserts for turning operations. There are two geometries of the coated inserts: MP5 for medium machining operations and deep cuts and RP5 for roughing.
Who: Walter Tools (walter-tools.com)
Important to note: Said Gerd Kußmaul, turning global product management at Walter of tests they’ve conducted, “We have results with average tool life improvements of up to 75% and, in individual cases, even up to as high as 600%, when compared with the existing state of technology.”
Pertinent data: The MP5’s depth of cut ranges from 0.6 to 7 mm. Thanks to its basket arch cutting edges, open chip breaker groove behind the cutting edge, and reinforced chip breaker blades it can handle smooth and interrupted cuts. The depth of cut is 12 mm for the RP5. Its positive 3° chamfer reduces power requirements. In addition, the chamfer widens in the central area of the main cutting edge, providing stability even on relatively deep cuts. The RP5’s open groove design produces a lower cutting temperature—reducing wear.
Thread Tapping Tools
What: CoroTap and Spectrum Tap tools.
Who: Sandvik Coromant (sandvik.coromant.com)
Important to note: The tapping tools offer increased productivity through higher cutting speeds.
Pertinent data: CoroTap 210 and 370 are designed for through-hole and blind-hole operations in steel (hardness up to 350 HB). The tools’ edge design, treatment, and grade provide reduced axial forces and torque—making the tools run more smoothly while reducing the risk of chipping. The Spectrum Tap tools are available in a choice of DIN, DIN/ANSI, ANSI and ISO types for both through and blind holes. They provide high performance thanks to good chip evacuation due to the flute profile and a constant rake angle. Additionally, the optimized flute profile generates low torque and results in a smooth surface on the finished thread.
Interference-Free Five-Axis Machining
What: Mikron HPM 450U milling machine.
Who: GF AgieCharmilles (gfac.com)
Important to note: This five-axis machine is capable of performing operations from simple drilling to complex five-sided and simultaneous five-axis machining processes.
Pertinent data: The HPM 450U offers machine travels of 23.62-in. X, 17.2-in. Y, and provides a 17.2-in. clearance between the table surface and spindle nose (Z). Its table rotates at up to 140 rpm and has a tilting range of -120/+45. Its Step-Tec spindle is available in two types: a 12,000-rpm version with an ISO 40 taper and a 20,000-rpm version with an HSK-A63 taper. Both versions have a vector control for full torque in lower speed ranges, a ceramic hybrid spindle bearing, and spindle casing cooling system. An internal tool changer, which integrates into the machine’s base, has a storage capacity of up to 60 tools (an optional external circular magazine stores up to 220 tools). Chips are evacuated via a 13.8-in. scrap conveyor.
As OEMs and suppliers seek lightweight solutions to meet higher fuel economy standards through multi-material structures, conventional welding techniques are beginning to give way to new solid-state joining methods better suited for creating strong bonds between dissimilar metals.
As vehicle manufacturers look for the ways to save mass in vehicle structures, the amount of advanced high-strength steels used is increasing.
Automotive components could see significant process improvements.