Tungaloy has expanded its DrillMeister exchangeable-head drilling tool system by adding 16 new modular drill bodies with chamfering inserts with a TungFlex connection.

Incorporating the performance of a solid-carbide drill with the efficiency of an indexable-insert drill, the DrillMeister exchangeable-head drill system now includes modular drills with chamfering inserts that enable drilling and chamfering in a single operation. These new drills are said to improve machining efficiency and offer versatility in operations like pre-thread drilling. Conventionally, this process requires either two separate tools — a drill and a chamfering tool — or a specially designed combination tool with integrated drilling and chamfering features. The new modular drills come with a TungFlex connection, which makes it possible to build an optimized, tailored drill assembly for a specific application using just standard items.

The new modular drills are designed to produce M8 to M18 ISO M standard pre-threads holes in diameters from 6.5 mm – 16.9 mm (from 0.256″ – 0.665″). For through-hole drilling, the drills are available with two different step sizes: 25 mm (0.984″) or 40 mm (1.575″), representing the distance from the drill corners to the chamfering edge.

The new modular body can hold all five styles of standard DrillMeister drilling heads, enabling greater flexibility for optimum performance across various materials and applications. The chamfering edges use Tungaloy’s standard AOMT06 double-edged inserts with chipbreaker for better chip control and cost-per-edge economy.

Open Mind Technologies has introduced its latest HyperMill 2024 CAD/CAM software suite, which includes enhancements to its core toolpath capabilities as well as new functionality for increased NC programming efficiency in applications ranging from 2.5D machining to five-axis milling.

An optimized deep-hole drilling CAM strategy offers improved machining reliability with an interface that clearly defines process-relevant parameters. New capabilities enable coolant and dwell time stages to be identified, enable a chipbreaker to be integrated into a drilling process and more. A new single-tip gun-drill tool simulation provides precise collision checking and a detailed visualization of the stock removal.

HyperMill 2024 includes a new algorithm for three-axis and five-axis, Rest Machining, which provides automatic, complete detection of all rest material areas, in addition to optimized toolpath calculations for faster, more reliable machining. Tool paths are now optimally divided to ensure more efficient machining, and the detection of intersection areas where paths meet has been optimized for collision avoidance.

An additional toolpath improvement is an enhanced path layout for the 3D Plane Machining cycle. The new strategy has a smoother path and fewer pickups. While the toolpath length (distance) may be longer in some cases, the machining time has reportedly been reduced.

A new generation of programming assistance and analysis, CAM Plan, is introduced in HyperMill 2024 to simplify various programming tasks and identify possible sources of error. Pre-defined workflow steps safely guide users through the preparation and programming process, while the geometries and features required are automatically created. Also, potential errors are flagged for removal, such as double surfaces or gaps between model patches.

Once the data is organized, the CAM workflow can be processed with more intelligence and higher efficiency. HyperMill CAM Plan enables component topology analysis to produce a precise tool path that has command locations aligned with key geometric features and with optimized point distribution for milling. The result is improved surface finishes, easier processing by NC controllers and reduced machining times.

For easy generation of three-axis and five-axis NC programs with axis change and an optimized use of the workspace, the NC Optimizer feature in the HyperMill Virtual Machining strategy now offers the option to transform X- and Y-axis movements into a single movement with the rotation axis in the table. By swapping axes, an XY movement is transformed into a simultaneous CX movement which eliminates rewind movements during machining. According to the company, this is especially beneficial for machines that have a limited linear-axis range.

The reading back of measuring points when using HyperMill Virtual Machining is a new feature that enables graphical representation of measured points on the part model, rather than comparing a list of measurement results. Users can also quickly identify measuring points that are out of tolerance on a 3D part model and compare trends over sequential measurements. As a result, it is much easier to analyze and compensate for inaccuracies and tool wear after milling.

Horn has developed the new SG66 grade for turning workpieces with varying hardness zones. Featuring a fine-grain carbide, the aluminium-titanium-silicon-chromium-nitride layer delivers high performance when machining hardened steels up to 58 HRC. The maximum allowable temperature is 1,200 °C (2,192 °F). Due to the high flexural strength of the carbide substrate, interrupted cutting is also possible in hardened materials. In addition to hard machining, the carbide grade is also suitable for reliably processing highly temperature-resistant and other difficult-to-machine steel alloys.

The carbide grade SG66 is available for all common Horn insert systems. The in-house coating also enables a short delivery time for special tools. SG66 cannot replace cubic boron nitride (CBN) grades; however, Horn says the grade fills the gap for difficult grooving applications. In comparison, the CBN grade achieves twice the cutting speed and more when machining through-hardened materials.

Sandvik Coromant has introduced two new physical vapor deposition (PVD) insert grades, GC1205 and GC1210, designed for secure, high-precision turning of aged, nickel-based, heat-resistant superalloys (HRSA).

The new insert grades GC1205 and GC1210 cover a large application area within last-stage machining (LSM) and intermediate-stage machining (ISM) when turning aerospace engine components.

Several key features help in working with the high-level performance of HRSA materials, including a hard, fine-grained new substrate, the latest PVD coating technology and optimized edge-line integrity. These features provide increased flank wear and secondary notch wear resistance, superior edge-line security and reduced flaking.

“For our customers, this translates into possibilities to run the inserts at higher cutting speeds with GC1205 and increased tool life with GC1210. Additionally, it ensures consistent and predictable tool life while reaching the required surface integrity demands for critical aerospace components,” says Martin Saunders, global product application specialist for turning at Sandvik Coromant.

The insert grades GC1205 and GC1210 are well suited for machining typical aerospace components, such as gas turbine discs, casings, blisks, spools, shafts and blades, and are said to perform well in more demanding applications including power generation turbines and medical implants made of cobalt-chrome.

GC1205 is a finishing grade for machined surfaces in LSM and ISM applications. GC1210 complements GC1205 when more toughness is required and is mainly used in ISM applications for non-machined surfaces.

Heule Precision Tools introduces Solo L tooling for spot facing and counterboring projects over 25 mm. Front and back counterbores up to 1.95-times bore diameter can be produced in bores ranging from 25.0 - 45.0 mm in diameter.

Solo L features a simple, reliable design which functions without an anti-rotation device, change in spindle rotation, coolant pressure or contact mechanism. This sealed system prevents coolant contamination, and the pin-driven cutting blade, which moves in and out radially, prevents chips from jamming the system. Solo L is designed to be customizable, with the tool’s blade housing, blade control and blades individually designed to meet specific project requirements. This specialized system cuts interruptions and difficult materials like nickel, titanium and other exotic alloys, making it well suited for a wide range of CNC, transfer, multi-spindle and conventional machining applications.

The Solo L uses two centrifugal weights installed in a sealed tool head. With an activation speed rate of 1,600 rpm or higher, the weights start moving outwards and turn the gearwheel, which drives the blade out by rotating the blade control. When the spindle is stopped and then actuated to cutting speeds, a pullback spring pushes the centrifugal weights back to the center and the blade extends to the cutting diameter. Maximum machining speed is 900 rpm.

In addition to the L model, three other Solo models are available, each is capable of counterboring two times the bore diameter minus 1 mm. Possible applications up to 40 mm through hole depending on the counterbore to bore ration and parameters. In most cases through-coolant is optional, with a 280-psi maximum.

Methods Machine Tools Inc. has released the Nakamura-Tome WY-100V to the U.S. market. The two-turret, twin-spindle precision CNC multitasking lathe is the first of the V series. New AI-infused software releases, enhanced multi-processing features and faster simultaneous operations reduce cycle time up to 30%.

The WY-100V features Nakamura-Tome’s specialized ChronoCut technology to deliver high spindle speeds and milling speeds.

In addition to ChronoCut, the WY-100V’s NT Smart X control features a new 3D Smart Pro AI programming. The support function provides real-time 3D CAD drawing analysis for program creation for all processes from raw material to finished product.

Sergio Tondato, Methods’ senior director of Nakamura-Tome products, says the machines’ “updates to both hardware and software further raise the precision, speed, and overall operator experience. Like all Nakamura-Tome platforms, the world-class multitasking capabilities lead to superior parts at a lower cost per unit.”

Kyocera SGS Precision Tools’ MB45 Milling Series for general purpose milling features economical eight-edge inserts and a new helical body design, giving users a more durable and versatile cutter with better finish capabilities over conventional mills.

The MB45 series of milling cutters provide durable, reliable performance when used in general machining applications or for more specialized solutions. The MB45 series delivers the low cutting force benefits of positive inserts and the fracture resistance of negative inserts, providing an optimal surface finish, while making it well suited for smaller machining centers. The series is designed to cater to a broad spectrum of machining applications, giving customers a cost-effective solution for a wider range of possibilities.

The MB45 series is enhanced by Kyocera’s new PR18 Series physical vapor deposition (PVD) coating, which extends tool life. These grades incorporate Megacoat Nano EX coating technology, which, in some cases, double the resistance and durability, according to the company. By using a specialized double-lamination technique with special nano multi-layers for abrasion, wear and heat resistance, this coating surpasses conventional grades, delivering superior performance and extending the lifespan of the tools.

Monaghan Tooling Group introduces MK Tools’ four-fluted Rambo Speed Drill series of solid-carbide drills, which are said to cut short-chipping material three times faster than traditional solid-carbide tooling. Available in standard sizes from 6 to 20 mm, 4 × D or 6 × D, with through-coolant or non-coolant fed designs.

Source: Monaghan Tooling Group

Standard models feature four-flute geometry with a 30-degree helix angle for optimal chip evacuation, and 130-degree-point self-centering geometry for precision holemaking in materials such as carbon steel, cast iron, grey cast iron, alloys and other short-chipping materials. Manufactured from premium carbide feedstock with the latest generation of CNC grinding machines, each Rambo tool features a chiseled cutting edge for more precise centering. MK Tools Speed Drills from Monaghan Tooling Group are well suited for high-speed applications where efficiency is key, including connecting rods, injection pumps, wheel carriers, guide wheel shafts and more.

With original OEM regrinding, including coatings, Rambo Speed Drills deliver new drill performance and a low cost-per-piece throughout their long service life. All MK Tools standard drills feature GTX coating, a multi-layer aluminum chromium nitride coating that reduces reaming resistance for longer tool life and better chip evacuation. This (and other advanced coating options for optimum performance, new tools and regrinds) is performed in-house to reduce lead times.

Sowa Tool & Machine Co.’s ShrinkSmart shrink-fit machine offers a number of features at an entry-level price point, along with the flexibility to add accessories to the same unit. Users can select their preferred cooling method with accessories that align to their specific needs while their business requirements evolve.

ShrinkSmart’s Smart Coil assesses the distinct resistance of each toolholder to prevent excessive heating, which can lead to hardening or tempering. By doing so, it applies only the correct and suitable amount of heat. Additionally, this feature supports a rapid 2-7 second shrinking cycle.

ShrinkSmart automatically saves energy and conserves toolholder life through the combination of easy-to-use pre-programmed cycles and its Smart Coil. Sowa says the ShrinkSmart machine is well suited for all sizes of machine shops, and now smaller shops can benefit from shrink-fit technology on a slimmer budget due to ShrinkSmart’s lighter sticker price and reduced first-time operator training costs.

Three additional air/water cooling options allow for one to six holders to be cooled up to 75% faster. A rotary table with stop rods gives users a quick way to set the depth of cutting tools easily, while safely switching from the heating to cooling position.

ShrinkSmart seamlessly pairs with Sowa subsidiary GS Tooling’s shrink-fit holders, and is equally compatible with other brands of holders.

Lyndex-Nikken’s MMC Mini-Mini collet chuck is designed to provide accuracy in small-diameter cutting for manufacturers that need more clearance and flexibility in machining. The MMC Mini-Mini collet chuck features a slim and compact body for precision machining with small-diameter tools (up to 0.500"). This will enable high runout accuracy with optimal surface finish and part tolerance.

The MMC collet chuck is well suited for high-speed machining applications where clearance is needed, such as die mold, aerospace and medical parts. The MMC collet chuck is also an alternative to a shrink fit system.

An easy-to-use draw-in collet clamping mechanism (no collet nut required) results in strong, high-precision gripping from the front nose that can access hard to reach areas. Because a collet system is used, tool changeover is faster and less expensive than a toolholding system that requires a machine in order to insert or extract the cutting tool. The collet system for the MMC also allows for a wider range of sizes, while a shrink fit system requires a toolholder for each size of cutting tool.

The MMC collet chuck is said to be precision ground and pre-balanced to 30,000 rpm at G2.5 with runout accuracy of 3 µm at four times the diameter, providing accuracy and reliability during high-speed operations.

The MMC collet chuck is also available in a Taper Plus version, which combines taper accuracy with flange rigidity. Additionally, MMC collet chucks have through-coolant capabilities offered in a standard-style coolant collet or jet slotted-style collet.