FEATURE ON TOOLING

Floyd ‘on form’ with new Schwanog system

Now available from Floyd Automatic Tooling is the flexible new MSIK modular tooling system from Schwanog for external and axial grooving operations. Unlike rival systems, Floyd Automatic says the new MSIK system enables the delivery of coolant straight to the cutting edge, thus enhancing tool life, surface finishes and swarf evacuation.

With the Schwanog MSIK modular system, the dual-coolant channels supply fluid internally to the cutting edge from two directions via the tool base body and cartridge. This capability eliminates the need for external coolant lines that can disrupt operations and often fail to deliver fluid to the cutting edge when undertaking intricate machining within a compact work envelope.

MSIK exchangeable tool holdersare completely modular to demonstrate high levels of flexibility for the end user. The tool base body is adaptable with different standardised cartridges for grooving. Securing the cartridges to the tool body is an interface that bolts cartridges to the side of the base body, ensuring a stable and secure connection.

Cartridges from Schwanog’s WEP and PWP cartridge systems are interchangeable with the MSIK system. For both the WEP and PWP cartridge systems, the range of indexable inserts is extremely diverse with dimensions, geometries and grades to cater for all applications. Furthermore, as specialists in small part turning, grooving and parting, it is possible to grind inserts to forms in accordance with customer drawings.

The tool base body is available in a range of sizes and types to suit all turning centre tool-holding set-ups. The system comes in polygonal Capto in sizes: C3, C4, C5 and C6 with or without serration; HSK-T63; and in the TS system configuration to TS40, TS50 and TS60.
For further information www.floyd-automatic.co.uk

Versatility when milling tough materials

To address the challenges of difficult and unstable machining conditions caused by long tool overhangs, Seco says that its JS754 stub series end mills feature short protrusion lengths that maximise tooling value while increasing tool life by 20-40%.

The four-flute end mill is for mill-turn and multi-tasking machines, and incorporates the industry-proven JS754 cutting geometry and proprietary HXT coating for high-performance machining. This design makes the Seco JS754 suitable for difficult applications involving ISO M (stainless steel) and S (heat-resistant superalloys and titanium) materials. The shorter length of the JS754 Stub adds strength and vibration control for increased tool stability when machining with main or sub-spindles, as well as with milling heads and driven tools.

Many CNC mill-turn and multi-tasking machines have a limited machining envelope that can prohibit the use of longer end mills. The short protrusion lengths of the JS754 stub series require less room in the sub or second spindles of these machines. Notably, the end mills provide freedom of movement to maneuver around workpieces with increased tool stability in tight workspaces, which allows shops to maximise the benefits that mill-turn and multi-tasking machines offer, including shorter set-up times and better part quality.

The JS754 stub series is available in both chamfer and corner radius configurations, in diameters from 3 to 16 mm, and comes in cylindrical and Weldon shanks.

“Within all manufacturing segments, especially general machining and aerospace, the high-mix/low-volume (HMLV) production environment continues to drive the need for automation and efficiency, achieved most commonly through mill-turn and multi-tasking machines,” says Rob Mulders, product manager – solid milling, atSeco Tools. ”The JS754 stub series contributes significant flexiblility for the single set-up part manufacturing that these multi-purpose machines provide.”
For further information www.secotools.com

Fivefold increase in machine productivity

Having over 50 years of experience in engineering, Team Inc (UK) is a company that specialises in leak-sealing services and solutions. With offices in Carlisle and throughout the UK, Team Inc has grown into a global brand with a reputation that extends from here to its headquarters in the US.

Among the company’s best-selling components are high-pressure injection adapters, which are finish-machined using reamers against a 24/7 schedule. The reamers used previously to machine these high-pressure injection adapters, made from high-tensile alloy steel (A193B7 and A320-L7), allowed Team UK’s engineers to produce between 1500-2000 parts a year. However, reamer wear was prone to causing component damage, leading to scrapped materials and waste. Ceratizit therefore recommended its Fullmax reamer.

Cutting data for the new reaming process was 1722 rpm with a feed rateof 1722 mm/min (1 mm per revolution feed). Saving 50 seconds per component, Team UK managed to increase its throughput to between 8000 and 10,000, equating to a fivefold increase in productivity.

Ceratizit’s new Fullmax Reamer also meant that fewer components saw damage during the process. As another benefit, whereas the new Fullmax Reamers show when they need replacing, there was no way for engineers to tell if the old reamers were wearing.

Chris Mitchell, manufacturing manager at Team UK, says:“Normally, when you want to increase process efficiency as much as this, there is a huge expense either through providing more manpower or buying expensive equipment. However, the new reamer was actually cheaper than the one we were using previously and it has provided a fivefold increase in the production of this adapter, which is absolutely outstanding. As well as this, it has virtually eradicated any waste in terms of scrapping parts.”
For further information www.ceratizit.com

Howells on track forsuccess with ITC

Founded in 1946 as a radio and TV repair shop, Howells Railway Products has travelled a long way since its early days. Today the company has an extensive list of marque clients that include household names like Siemens, Network Rail, Alstom, Transport for London, Bombardier, Babcock Rail and others. To work at the cutting edge of technology, Howells Railway Products has added a new 40,000 sq ft CNC machine shop with 26 Haas machine tools and cutting tools from Industrial Tooling Corporation (ITC).

The company has worked with ITC since 2018. A recent project saw ITC introduce the Widia line of indexable cutting tools with modular drills and high-feed shell mills on CLA3 alloy steel castings (end bracket components for rail stretcher bars).

A 63 mm Widia M8065HD face mill set about removing 6 mm of excess casting stock in a single pass as part of a facing and shoulder milling process. With the previous high-feed face mill removing material at a rate of 1mm per pass, the M8065HD significantly improved cycle time.

Always looking to take productivity gains to the next level, ITC then introduced the benefits of aBig Kaiser system to the end bracket components, helping to produce an 88.1mm diameter bore at a depth of 65mm. Previously performed using a 50mm diameter indexable shell mill helical interpolating inside the bore, the process took 3 minutes 30 seconds.

The idea to change the process from helical interpolation to a plunging application paid dividends using a Big Kaisertwin-bore tooling system (SW rough boring head). Howells Railway Products runs the twin-bore head at 542rpm and 81mm/min feed rate, reducing the cycle time by 2 minutes 50 seconds per part.
For further information www.itc-ltd.co.uk

Floyd presents cool solution for ‘crazy milling’

Now available in the UK from Floyd Automatic Tooling is the new CrazyMill Cool Micro series of micro end mills manufacturing by Mikron Tool. With micro-machining applications increasingly commonplace in the electronics, medical, optics, automotive, aerospace and defence sectors, Floyd Automatic says the high-performance CrazyMill Cool Micro end mills are a game-changer.

For the first time, engineers at Mikron Tool have successfully transferred high-performance cutting tool geometries to micro-dimension end mills. Suitable for operations as diverse as sidemilling, helical interpolation, slot milling and drilling, the CrazyMill Cool Micro is available with three or four flutes, diameters from 0.2 to 1mm, and effective cutting lengths of 3xD and 5xD. The high-quality micro-grain carbide grade permits the grinding of special filigree geometries that maximise strength and performance, minimising the potential for tool breakages, especially when machining challenging materials.

The combination of innovative geometries, the high-quality carbide grade and a patented new cooling concept deliver double the tool life performance and three times higher productivity levels than rival product lines, reports Floyd Automatic. Integrated through-coolant channels guarantee high levels of cooling. Furthermore, with a cooling channel for each of the three or four flutes, swarf evacuation issues in micro-machining applications are now a thing of the past.

Also introduced is coating technology that prevents the loss of sharp edges which can be so critical in micro-machining applications. The new arrivals are available with an S geometry for machining stainless steel, steel, cast iron, non-ferrous metals and titanium alloys, while the SX geometry type is suited for particularly challenging materials such as Inconel, Monel, and CoCr alloys.
For further information www.floydautomatic.co.uk