In the groove - round grooving insert

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Despite the elevated MRR and productivity, there is no compromise to surface finish when using the new high-feed CoroMill 745. A light cutting action from the innovative insert positioning provides excellent chip formation, a smooth, soft sound and low power consumption.

Dimensional accuracy, stability and process reliability are assured, as the torque generated during machining is dissipated into the body. Horn offers two body types, the first having a cutting edge diameter of 100mm. It is equipped with 14 type 406 indexable inserts, which produce seven effective cuts ranging from 9.6mm to a maximum of 12.9mm wide. Milling depth is up to 20mm.

The NeoMill-Alu-QBig indexable insert milling cutter from Mapal stands for top performance in high-volume milling of aluminium. The tool manufacturer thus offers a very economical solution for use on high-performance machines, such as those found primarily in the aerospace industry.

The second body type is equipped with 12 cutting inserts of type 409 and has a cutting edge diameter of 125mm. On this tool, the cutting width with six effective cuts can be adjusted between 12.9mm and 18.8mm. Maximum milling depth is 32.5mm.

Cutting tool and tooling system specialist Sandvik Coromant has unveiled a new high-feed version of the CoroMill 745 face milling cutter, featuring a 25° entering angle for additional productivity gains when milling steel and cast iron workpieces. The new high-feed version facilitates even higher metal removal rates (MRR) in applications with depths of cut up to 2.8 mm (0.110 in). The new cutter is set to benefit sectors such as die and mould, pump and valve, oil and gas, automotive, power generation and general engineering.

The high-feed CoroMill 745 is aimed at roughing to semi-finishing face milling operations on machining centres and multi-task machines. With its multi-edge concept, the tool is particularly suitable for large-batch production, flexible transfer lines and when maximum tool utilisation is important. Advantages will be provided when milling components such as valves, engine blocks, hubs, main frames, pump components and moulds, in fact, any type of general engineering component made from ISO P or ISO K materials. The presence of a short (0.6mm, 0.024in) parallel land ensures a good surface finish. The large screw ensures easy handling, while the insert position and the heptagonal insert shape make clamping exceptionally secure for reliable face milling operations. Internal coolant is available on all cutters, which range from 63 to 160mm (2.5 to 6.0in).

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Dimensional accuracy, stability and process reliability are assured, as the torque generated during machining is dissipated into the body. Horn offers two body types, the first having a cutting edge diameter of 100mm. It is equipped with 14 type 406 indexable inserts, which produce seven effective cuts ranging from 9.6mm to a maximum of 12.9mm wide. Milling depth is up to 20mm. The second body type is equipped with 12 cutting inserts of type 409 and has a cutting edge diameter of 125mm. On this tool, the cutting width with six effective cuts can be adjusted between 12.9mm and 18.8mm. Maximum milling depth is 32.5mm. The successful 406 and 409 type indexable inserts have been chosen for the application. They are precision ground and achieve outstanding surface quality at the base of the groove and on the flanks. Double positive axial and radial rake angles ensure a soft cut. The tangentially screwed cutting insert's trailing chamfer produces a secondary cutting edge, resulting in outstanding machined surfaces. An additional free-form surface chamfer provides a stable wedge angle and very smooth milling. www.phorn.co.uk

Tooling manufacturer, Horn has introduced a new carbide insert grade, SG66, for turning components from steel that has been case hardened to 58 HRC.

A new side milling cutter for stepless adjustment of groove width has been introduced by Paul Horn, and is available through the firm's UK subsidiary, Horn Cutting Tools, Ringwood. The milling body features a central sleeve that enables the required groove width to be adjusted easily on a pre-setter.

The successful 406 and 409 type indexable inserts have been chosen for the application. They are precision ground and achieve outstanding surface quality at the base of the groove and on the flanks. Double positive axial and radial rake angles ensure a soft cut. The tangentially screwed cutting insert's trailing chamfer produces a secondary cutting edge, resulting in outstanding machined surfaces. An additional free-form surface chamfer provides a stable wedge angle and very smooth milling.

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Providing an example of the potential gains on offer, a customer trial application showed impressive benefits when face milling a machine bed component made from cast CMC ST52 (165 HB) on an ISO-50 gantry mill. A 125mm (5in) CoroMill 745 with 25° entering angle reduced cycle time per component by 40 per cent in comparison with a competitor tool.

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“An important benefit of the new cutter is low cost per edge from its double-sided 14-edge insert design,” says Matts Westin, product manager, Sandvik Coromant. “In fact, purchasing departments will be pleased to learn that tool inventory costs are reduced because the CoroMill 745 with 25° entering angle uses the same inserts as its counterpart cutter with 42° entering angle.”