The latest innovation offered by Bromsgrove-based Walter are circle segment milling cutters — solid carbide end mills incorporating a curved flank geometry that requires high-quality CAM software to simplify programming and toolpaths.

To meet the need of CAM vendors that are developing cycles for circle segment milling cutters, Walter has introduced the new MD838 Supreme and MD839 Supreme series of end mills that can deliver cycle time reductions of up to 90%.

When conducting finish machining, the circle segment tools can reduce cycle times by increasing the tool step-over significantly. In comparison to ball-nosed end mills that typically step down at a rate of 0.1mm to 0.2mm when applied to profile milling, the circle segment milling cutters can achieve a step-down rate of more than 2mm.

This step-down rate can be increased depending upon the chosen tool diameter and tool flank radius. This innovation reduces tool path movements to slash cycle times. With the facility to engage the entire flute length, the new MD838 Supreme and MD839 Supreme Series improve material removal rates, enhance surface finishes and extend tool life significantly.

The two new MD838 Supreme and MD839 Supreme circle segment milling cutters can deliver 90% productivity improvements credit to the new geometry that features both a large radius in the cutting area and a higher number of flutes. Thanks to the new tool geometry, large step-overs are possible when semi-finishing and finishing.

The MD838 Supreme is available with the choice of anything from 4 to 8 effective flutes and the conical design boasts an effective radius from 250 to 1000mm along the flute length. This range also includes a version with ConeFit exchangeable heads to minimise tool set-ups and costs.

The tangential MD839 Supreme series is a 4-flute variant with an effective radius of 100mm. This tangential tool is the first choice in applications where space is limited, such as blisk production.

The two new circle segment milling cutters are available in the WJ30RD grade for machining steel and cast iron materials. The tools are also offered with Walter’s high-quality WJ30RA grade for highly productive machining of stainless steel, titanium and heat-resistant alloy grade materials.

Thanks to the specially developed geometries, both milling cutters are ideal for semi-finish and finish machining of components with steep walls, deep cavities, prismatic surfaces and transition radii.

The diverse range of applications and materials makes the MD838 Supreme and MD839 Supreme ideal for extremely productive finish machining in the energy industry, the general mechanical engineering sector and also the mould and die-making sector.

As well as short machining times and impressive surface finishes, the high degree of stability and process reliability, as well as component accuracy and productivity, make the new additions to the Walter milling programme perfectly suited to the diverse demands of the industry.