Tamworth-based Industrial Tooling Corporation (www.itc-ltd.co.uk) has extended its portfolio of tools for machining super-alloys with the introduction of the Widia WS40PM indexable-insert range.

The cobalt-rich substrate of the inserts is said to provide robust fatigue-resistance and edge integrity, while the multi-phase AlTiN-TiN PVD coating reduces tool wear.

This combination makes the Widia WS40PM grade suitable for machining a range of high-temperature steel alloys, austenitic and PH stainless steels, and nickel-based super-alloys such as Hastelloy, Nitronic and titanium.

Using a cutting speed of 53m/min, the WS40PM is said to achieve productivity gains of 25-35% with consistent tool-life improvements, even when milling tough materials.

Widia says that trials have seen an aircraft manufacturer achieve a 90% reduction in machining time and a 50% improvement in tool life when performing face-milling operations on Ti-6Al-4V.

Meanwhile, a UK workshop machining Inconel 625 reduced insert flank wear by more than 90% and achieved a 70% reduction in tooling costs.

In China, a turbocharger manufacturer increased tool life by 80% during the machining of austenitic stainless-steel components, while keeping speeds and feeds the same. Further tests using increased cutting data highlighted WS40PM’s resistance to wear and thermal cracking.

Widia says that customers should always use a robust tool-body platform, such as the company’s VSM490 shoulder
mill, and that they should also take account of the rigidity of the machine tool,the tool-holder and the spindle interface.