>TOOLING & WORKHOLDING Dry run In the rough
The new Horn DAH high feed milling system, available from Horn Cutting Tools offers enhanced productivity for roughing operations. Horn DAH has been specially developed for roughing with high feed rates at low cutting depth. The sophisticated geometry of the triple-edged inserts ensure favourable distribution of cutting forces as it has been developed to direct cutting forces axially. Horn claims that this reduces the spindle load in shear and offers significant productivity and tool life advantages.
High feed milling strategies generally allow suitable tooling to absorb very high loads using tooth feeds of up to 1mm per
tooth, comparing favourably with the relatively low cutting depths of 0.5mm to 0.8mm for conventional tools. Horn DAH milling cutters provide significantly better values. The special cutting geometry, which combines ‘soft’ cutting with fast plunging, enables cutting depths up to 1.2mm and, depending on the material, feed rates up to 3mm per tooth can be sustained with a maximum cutting depth of 1.2mm The triple-edged milling inserts are currently available in the carbide grade SA4B which offers particularly high wear resistance for milling steel and cast materials, allowing DAH tooling to combine improved productivity with extended tool life.
Along with other Horn milling systems the holders are titanium nitride (TiN) coated which minimises chip adhesion and works in conjunction with the internal coolant supply to ensure optimum swarf evacuation. The shanks are available as end mills with Weldon toolholder and as industry standard threaded connection cutters with the MD holder design already proven in the DA system.
With cutting edge diameters of 20mm, 25mm, 32mm and 40mm, the new DAH milling system expands Horn’s product range for toolmaking, mould making and general milling applications in the direction of larger diameters and higher feed rates.
>HORN CUTTING
TOOLS
www.phorn.co.uk
Developed to maximise performance and insert tool life when milling without coolant, LMT’s Boehlerit division has launched Nanolock Black, an advanced heat and wear resistant ceramic coating layer.
The new coating, that extends the Nanolock field of application not only provides high protection against wear and extends the in-cut life of the insert due to its elastic damping effect, but also helps to withstand the severe impact stresses created by high productivity milling processes. Nanolock Black milling inserts, now available through LMT UK capitalise on LMT’s expertise in chemical vapour deposition (CVD) to deposit the Kappa-A1203 ceramic layer to the titanium carbonitride (TiCN) coating. Due to the ‘zip- fastener’ bonding of the nanostructure, the effects of abrasion on the insert are minimal and any tendency for ‘thermal comb’ cracks to develop are resisted. The new coating also means any surface oxidation is prevented when used in dry milling applications.
The introductory Universal Nanolock LC230E milling insert was initially applied to demanding applications such as machining the edges of steel plates for pipelines and resurfacing manganese-steel railway lines, where the Black coating has been successfully run at cutting speeds up to 300m/minute.
Central to Nanolock’s performance capability is the ultra-fine needle shaped surface adhesion characteristics achieved through development of its coating technology that was originally pioneered by LMT’s Boehlerit division and launched some two years ago on the LMT Steeltec LC215K turning insert.
At that time the company
perfected the technology to work at nanostructure levels (1 nanometre = 1 billionth of a metre) that enabled the crystallite size of particles to be reduced. Also by mixing the elements of carbon and nitrogen used in TiCN coatings it was able to strategically improve the bonding of the different material particles. Last year a claimed world first was credited to LMT with Nanosphere Red, a nanocomposite multi-layer coating of titanium, aluminium and nitrogen (TiAlSiN) for milling hardened materials and high tensile steels up to 68 HRC. Nanosphere Red has the capability to be worked at temperatures over 200°C higher than existing aluminium nitride coatings, which typically cannot exceed 850°C. The coating also enables the working life of LMT’s inserts to be significantly improved. Since the original launch of the Steeltec LC215K indexable insert for turning, LMT’s application engineers have repeatedly demonstrated the advantages of the extreme levels of hardness without brittleness achieved with Nanolock coatings when machining steel at over 300m/minute. Even when running at these high cutting speeds, the applications have still recorded improvements of over 50% in the effective cutting life of the insert. As a result, over 1,000 successful installations of Nanolock coated turning inserts have been achieved.
The Nanolock Black coating is now available in a wide range of ISO indexable milling inserts and is acceptable on all common tool systems freely available on the market.
PROFITABILITY Building Customer
Milling Intelligently
Cost Saving Milling with High Productivity Superior Fine Pitch Endmills
>LMT
www.lmt-tools.com
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www.pesmag.co.uk www.iscaruk.co.uk Production Engineering Solutions • August 2010 17
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