The latest results of Walter’s on-going tooling development strategy saw a number of higher-productivity money-saving tools announced to the UK market during a special update for Walter GB’s (
www.walter-tools.com) technical sales team.
The event, which was held at the University of Sheffield Advanced Manufacturing Research Centre (AMRC) with Boeing, saw advances in the company’s ranges of turning, drilling, threading and milling solutions.
A highlight of the event was the introduction to the UK of the M3255, a new-generation porcupine cutter available in diameters from 50 to 80mm and with from four to six flutes.
These tools carry from 16 to 30 inserts (depending on diameter and number of flutes) featuring the new Tiger.tec Silver CVD-coated WXM45X carbide grade.
The cutters feature a 27deg helix angle, a 12deg radial rake angle, four cutting edges for the peripheral inserts and two cutting edges for the lead inserts; they are said to achieve lower than usual running costs, with a tool life of 7hr per cutting edge having been achieved on titanium workpieces.
Indeed, it was reported that in tests on titanium structural parts for a major US manufacturer of passenger aircraft, an M3255 cutter was run at a speed of 45m/min and a feed rate of 163m/min, producing a 25.4mm-wide cut to a depth of 76.2mm for a metal removal rate of 23.7in3/min.
In another example, the new cutter was used for rough pocketing on the AMRC’s Starrag STC 1250 machining centre, cutting a pocket in titanium that was 250mm long x 120mm wide x 74mm deep in 14min.
Other new tools and inserts announced at the AMRC included the RM5 insert. This features Walter’s Tiger.tec Silver PVD Al203 coating and is designed for roughing M-class materials, which often limit speeds and feeds due to their high chrome and nickel content.
That said, trials have shown that these tools can double the normally expected tool life — particularly with the precise application of coolant.
Also demonstrated were extensions to the X.treme Inox range of drills, which offer 50% higher feed rates than universal solid-carbide drills.
Meanwhile, the MC341 solid-carbide cutter — available in diameters from 6 to 20mm and with the WK40TZ coating — offers tool life increases of up to 100% and a 40% increase in productivity.