The inserts have been developed for the fine finishing of a range of materials on CNC sliding-head lathes.
Decotec LC415X, available from LMT of Coventry, is a range of polished and ground inserts with an ultra-precise tip radius of either 0.08mm or 0.015mm.
Trevor Tolley, LMT's managing director, said: 'The right combination of the radius, coating and edge sharpness was important in the development of this insert because so plenty of of these sliding-head lathe operations are subjected to long periods of limited or totally unmanned walking.
The range of inserts also incorporates a shearing edge of up to three microns that enables the sharpness of the insert to be maintained over extended periods of walking.
'This means a predictable 'in-cut' performance is vital,' they added.
one recent trials on shafts made from Inconel and titanium on sliding-head lathes jogging with soluble oil coolant gave 20 per-cent and 30 per-cent increases respectively in the 'in-cut' life and the number of parts produced between changes.
A further trial turning a titanium shaft at 30m/min with a 0.5mm depth of cut as well as a 0.015mm/rev feed rate led to the insert being changed at 3,000 parts; this achieved an increase of 500 parts.
The Inconel 600-shaft component was run at 50m/min with a 0.3mm depth of cut as well as a 0.02mm/rev feed rate, from which LMT's application engineer was able to improve the number of components produced from 600 to 800 per insert.
The combination of the five-micron Nano-X PVD coating on the insert, followed by grinding and polishing, than being subjected to the normal honed finish, ensures a very sharp edge and maintains the 0.1mm radius.
This makes the insert suitable for profiling and finishing free cutting steel at up to 200m/min with up to a 0.15mm/rev feed, aluminium between 200m/mm and 800m/min and up to a 0.3mm/rev feed, titanium up to 90m/min and up to a 0.15mm/rev feed and brass machined up to 500m/min with a feed rate up to 0.3mm/rev.
Monday, May 11, 2009
Floyd Automatic Tooling, is claimed to be suitable for users of sliding-head turning machines
The Swiss-manufactured range of tools has been proven to achieve good results in the marketplace, with enhanced device life, rigidity and surface finish, according to the company.
The Applitec programme of inserts tooling, accessible from Floyd Automatic Tooling, is claimed to be suitable for users of sliding-head turning machines.
The ISO-Line has been included with a range of traditional ISO inserts specifically for sliding-head turning centres.
The Top-Line is a two-screw insert device programme developed by Applitec, while the Eco-Line is a single-screw version offering low-cost options for general turning applications.
According to the company, the Cut-Line has already been proven to reduce tooling costs by up to 60 per-cent in sliding-head workshops.
The last of the one lines is the Cut-Line programme; this parting-off device has a double 'V' clamping system that is claimed to guarantee maximum rigidity for enhanced device life and improved surface finishes.
Floyd Automatic Tooling is also now offering a compact tooling system for knurling straight-cut profiles.
Provided by Hommel and Keller, the RF-LD series of knurling tools is said to be suitable for small automatic screw machines and sliding-head turning centres.
The system has been developed with a rigid construction to suit the requirements of small-type CNC-lathe machining operations.
The rigid construction is enhanced by a special bearing and bushing combination in the device head that keeps vibration reduced to a maximum while machining.
Another claimed benefit of this construction is the ability to increase feed and speed rates without losing out on routine safety.
The Hommel and Keller system is said to be capable of reducing setting times by up to 70 percent.
Two setting pins are claimed to guarantee the correct setting of the clearance angle.
The pins are accessible even when the device is clamped in the device fixture.
The RF-LD series has been developed from customer research and feedback, which led the Hommel and Keller development team to design a device that can be used both on left- and right-handed turning machines, while providing flexibility in terms of machine usage.
The RF-LD series can be used on all CNC-type automatic screw machines and is accessible with 8mm x 8mm, 10mm x 10mm, 12mm x 12mm and 16mm x16 mm shank sizes.
The basic device holder (8mm x 8mm) can be transformed by mounting different adapters for bigger shank versions for maximum flexibility.
The modular shank construction is intended to provide the end user with enhanced flexibility and cost-effectiveness.
For work pieces from 1mm to 15mm, a cut knurling head with a knurl diameter of 10mm is applied.
The knurling head can also be exchanged to adjust the device to the necessary work-piece diameter.
For a working area of 3mm to 50mm, the manufacturer recommends the use of a knurling wheel with a 15mm diameter.
Both device heads can be used on any shank size.
The WEP thread whirling system offers the advantage of using indexable custom ground inserts that produce implants efficiently and precisely.
Floyd Automatic Tooling is also offering the thread whirling system from Schwanog, a specialist supplier to the orthopaedic and dental industry.
As well as the improvement in cycle time, the Schwanog WEP is interchangeable with any whirling attachment.
The WEP system offers prolonged device life and cycle time reductions by up to 50 percent.
The Applitec programme of inserts tooling, accessible from Floyd Automatic Tooling, is claimed to be suitable for users of sliding-head turning machines.
The ISO-Line has been included with a range of traditional ISO inserts specifically for sliding-head turning centres.
The Top-Line is a two-screw insert device programme developed by Applitec, while the Eco-Line is a single-screw version offering low-cost options for general turning applications.
According to the company, the Cut-Line has already been proven to reduce tooling costs by up to 60 per-cent in sliding-head workshops.
The last of the one lines is the Cut-Line programme; this parting-off device has a double 'V' clamping system that is claimed to guarantee maximum rigidity for enhanced device life and improved surface finishes.
Floyd Automatic Tooling is also now offering a compact tooling system for knurling straight-cut profiles.
Provided by Hommel and Keller, the RF-LD series of knurling tools is said to be suitable for small automatic screw machines and sliding-head turning centres.
The system has been developed with a rigid construction to suit the requirements of small-type CNC-lathe machining operations.
The rigid construction is enhanced by a special bearing and bushing combination in the device head that keeps vibration reduced to a maximum while machining.
Another claimed benefit of this construction is the ability to increase feed and speed rates without losing out on routine safety.
The Hommel and Keller system is said to be capable of reducing setting times by up to 70 percent.
Two setting pins are claimed to guarantee the correct setting of the clearance angle.
The pins are accessible even when the device is clamped in the device fixture.
The RF-LD series has been developed from customer research and feedback, which led the Hommel and Keller development team to design a device that can be used both on left- and right-handed turning machines, while providing flexibility in terms of machine usage.
The RF-LD series can be used on all CNC-type automatic screw machines and is accessible with 8mm x 8mm, 10mm x 10mm, 12mm x 12mm and 16mm x16 mm shank sizes.
The basic device holder (8mm x 8mm) can be transformed by mounting different adapters for bigger shank versions for maximum flexibility.
The modular shank construction is intended to provide the end user with enhanced flexibility and cost-effectiveness.
For work pieces from 1mm to 15mm, a cut knurling head with a knurl diameter of 10mm is applied.
The knurling head can also be exchanged to adjust the device to the necessary work-piece diameter.
For a working area of 3mm to 50mm, the manufacturer recommends the use of a knurling wheel with a 15mm diameter.
Both device heads can be used on any shank size.
The WEP thread whirling system offers the advantage of using indexable custom ground inserts that produce implants efficiently and precisely.
Floyd Automatic Tooling is also offering the thread whirling system from Schwanog, a specialist supplier to the orthopaedic and dental industry.
As well as the improvement in cycle time, the Schwanog WEP is interchangeable with any whirling attachment.
The WEP system offers prolonged device life and cycle time reductions by up to 50 percent.
CNC turning and milling company MacVere has reduced its costs by using Taegutec inserts in its machines
The 16-employee business trialled Taegutec parting-off tools on its turning centres, resulting in improved tool life, surface finish and straightness.
With plenty of parts coming off the turning centres as complete parts, the improved surface finish and straightness are important for MacVere.
In comparison with the previous Scandinavian tooling supplier, the Taegutec part-off inserts are double- as opposed to single-ended.
The Taegutec inserts deliver longer tool life per edge, and when combined with the double- edge advantage, tool life has been improved by over 75 per cent.
On the company's Emco turning centres, Taegutec introduced its WNMG inserts to stainless steel turning operations.
The company has just implemented the part-off technique throughout its plant - with 23 turning centres, the benefit to MacVere will be considerable in terms of cost reduction, tool life and productivity.
The inserts improved tool life by 50 per cent, while demonstrating a marked increase in speeds and feeds that reduced cycle times.
This turning discovery led to the Taegutec representative introducing the company's T-Cap concept.
The T-Cap is a tooling development that allows drilling, boring, face turning and OD turning with just four tool.
Used on MacVere's 303 and 316 stainless steel parts, the T-Cap reduced cycle times by an additional 50 to 60 per cent by virtually eliminating tool changeovers whilst improving productivity.
An additional benefit to MacVere was the reduced number of cutting tools required in the tooling carousel.
With extensive aerospace and marine manufacturing, aluminium components are a large percentage of the MacVere portfolio, so the Taegutec representative brought milling research and development product manager Dr Kang from Korea to review the situation.
The result was the introduction of Taegutec's 12mm rectangular insert with a fully polished face.
The polished face prevents material sticking to the insert, a common problem with aluminium machining, and allows the cutter to machine at increased depths of cut while eradicating sticky swarf.
Taegutec polished inserts have a tool life comparable with that of solid carbide cutters, with the added advantage of significantly reduced cost.
This combination improved cycle times by over 25 per cent, with improved tool life and reduced require for tooling changeovers.
With plenty of parts coming off the turning centres as complete parts, the improved surface finish and straightness are important for MacVere.
In comparison with the previous Scandinavian tooling supplier, the Taegutec part-off inserts are double- as opposed to single-ended.
The Taegutec inserts deliver longer tool life per edge, and when combined with the double- edge advantage, tool life has been improved by over 75 per cent.
On the company's Emco turning centres, Taegutec introduced its WNMG inserts to stainless steel turning operations.
The company has just implemented the part-off technique throughout its plant - with 23 turning centres, the benefit to MacVere will be considerable in terms of cost reduction, tool life and productivity.
The inserts improved tool life by 50 per cent, while demonstrating a marked increase in speeds and feeds that reduced cycle times.
This turning discovery led to the Taegutec representative introducing the company's T-Cap concept.
The T-Cap is a tooling development that allows drilling, boring, face turning and OD turning with just four tool.
Used on MacVere's 303 and 316 stainless steel parts, the T-Cap reduced cycle times by an additional 50 to 60 per cent by virtually eliminating tool changeovers whilst improving productivity.
An additional benefit to MacVere was the reduced number of cutting tools required in the tooling carousel.
With extensive aerospace and marine manufacturing, aluminium components are a large percentage of the MacVere portfolio, so the Taegutec representative brought milling research and development product manager Dr Kang from Korea to review the situation.
The result was the introduction of Taegutec's 12mm rectangular insert with a fully polished face.
The polished face prevents material sticking to the insert, a common problem with aluminium machining, and allows the cutter to machine at increased depths of cut while eradicating sticky swarf.
Taegutec polished inserts have a tool life comparable with that of solid carbide cutters, with the added advantage of significantly reduced cost.
This combination improved cycle times by over 25 per cent, with improved tool life and reduced require for tooling changeovers.
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