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On Mfg - April 2014

New Inserts for Machining Cast Iron  What: Two Tiger•tec Silver geometries and two grades for cast iron machining: RK5 for roughing and RK7 for interrupted cuts.


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New Inserts for Machining Cast Iron 


What: Two Tiger•tec Silver geometries and two grades for cast iron machining: RK5 for roughing and RK7 for interrupted cuts.

Who: Walter Tools (walter-tools.com)

Important to note: The geometries increase output up to 75%, Walter says. The RK5 and RK7 have a “plateau step” between the location face and the cutting edge, which enables the location face to be ground after coating; consequently, the inserts can be seated in the toolholder with maximum stability so cutting-edge wear is reduced, tool life enhanced, and reliability increased. The geometries of the RK5 and RK7—flat-topped inserts—are similar, but RK7 also includes a protective chamfer on the cutting edge, making it suitable for interrupted cuts of cast iron as well as hard/soft machining of hardened steels from 40 to 62 HRc. 
Pertinent data: Enhancing the new geometries are two Tiger•tec Silver grades. WKK10S is the harder of the two, primarily for use on grey cast iron and suitable for continuous cuts through to light interrupted cuts. WKK20S is a universal cutting grade, suitable for 50% of all tasks, with ductile cast iron machining being its primary application.  It can handle workpieces with interrupted cuts, cast skin, or cross holes. 

More Efficient Wire EDM Machines


What: Two wire EDM machines, the SL400G and the larger SL600G.
Who: Sodick (sodick.com)
Important to note: Both machines use rigid linear motor axis drives coupled with glass scales of the X, Y, U, and V axes to ensure fast, precision cutting and positioning accuracy because the linear motors have no backlash. A “Smart Pulse Generator” reduces the number of cuts to achieve the required accuracy and surface finish, thereby reducing both machining time and cost. A new “Smart Pulse Wire” control uses the standard Windows 7 operating system; it features an enhanced 19-in. touch screen, which can be switched between a traditional screen and a new “tablet-style” screen customizable by the operator. Sodick also provides a 10-year positioning accuracy guarantee for both machine models. 
Pertinent data: The SL400G has X, Y, Z travels of 15.75, 11.81, 9.84 in. The SL600G has X, Y, Z travels of 23.62, 15.75, 13.78 in. 

Power Chuck for Quick Tool Changes
The highly reconfigurable DURO-NCSE Flex power chuck 
Who: Röhm (rohm-products.com)
Important to note: The DURO-NCSE Flex enables switching jaws and clamping tools without being removed from the machine tool. The three-jaw chuck allows switching from mandrels to collet chucks to face drivers and centers.  The chuck also provides increased workpiece support at the tool spindle for short-bar-feeding applications. 
Pertinent data: The DURO-NCSE Flex features a “bayonet-style” connection so it is necessary only to change an attachment system to switch clamping devices. The case-hardened steel chuck features individual unlocking jaws that can be readily moved, changed or turned. 

New Insert Grade for Cast Iron Milling


What: A wear-resistant insert grade for cast iron milling, GC3330
Who: Sandvik Coromant (sandvik.coromant.com)
Important to note: The GC3330 uses Sandvik Coromant’s “Inveio” technology, which orients the direction of the crystals in the coating in one direction to promote endurance, predictability, and long tool life. Inserts coated with CVD alumina, on the other hand, have a random crystal orientation, which is said not to be as effective as the tailored approach. 
Pertinent data: GC3330 works for both dry and wet cast iron milling, from roughing to finishing. The new grade works for gray and nodular cast iron materials. GC3330 is available for face-, shoulder-, profile-, high feed-, parting, and grooving milling.