Form of milling that produces a flat surface generally at right angles to the rotating axis of a cutter having teeth or inserts both on its periphery and on its end face.

A large part of turbocharger machining can be implemented using tools with ISO indexable inserts. Including many machining processes on the challenging hot side. MAPAL has developed a cutting material specially matched to the machining of heat-resistant cast steel and that offers long tool lives and therefore high cost-effectiveness, despite the abrasiveness of the material.

It is necessary to machine the V band on every turbocharger. Along with the material properties, an interrupted cut is often a challenge here during pre-machining. MAPAL relies on a complex boring tool with ISO indexable inserts to pre-machine the V band as well as to pre-machine the internal contour of the turbine. The tool therefore machines internally and externally simultaneously. Multiple steps are machined. The tool operates counterclockwise to transport the chips out of the component and to prevent damage to the internal contour of the turbine.

In times of high time and cost pressure in the die and mould industry, MMC Hitachi Tool’s Production50 manufacturing concept and the in-house developed TAR database with over 15 000 reference reports, are dedicated to meet the customer’s challenge for shorter process times and more efficient machining methods. MMC Hitachi Tool offers innovative tool technologies and individual service to meet these high demands.

Mitsubishi Materials (MMC) of Japan acquired a 51% shareholding in Hitachi Tool Engineering Ltd, a leading Japanese cemented carbide cutting tool and wear part manufacturer in April 2015. Hitachi Tool Engineering Ltd was a division of Hitachi Metals Ltd and Hitachi Metals retains the remaining 49% shareholding.

Material: 1.4849 | Cooling: Dry machining | Diameter: 125 mm, 14 inserts | Cutting speed: 80 m/min | Feed: 0.12 mm | Tool life: 125 parts

Material: 1.4837| Cooling: MQL | Diameter: 49; 70.5; 73; 90 mm; chamfer 10° | Cutting speed: 70 m/min | Feed: 0.4 mm | Tool life: 75 parts

Enlarging a hole that already has been drilled or cored. Generally, it is an operation of truing the previously drilled hole with a single-point, lathe-type tool. Boring is essentially internal turning, in that usually a single-point cutting tool forms the internal shape. Some tools are available with two cutting edges to balance cutting forces.

According to the announcement at the time production of carbide tools by Hitachi Tool became part of MMC’s Advanced Materials & Tools Division and the acquisition was expected to help MMC achieve a 10% share or higher of the global carbide tool market.

It was stated that Hitachi Tool will benefit from MMC’s considerable global sales network, and will also be able to take advantage of MMC’s raw material procurement, integrated supply chain and recycling network.

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Endless band, normally with serrated teeth, that serves as the cutting tool for cutoff or contour band machines.

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The turbocharger has been state-of-the-art in diesel vehicles for some time. And almost all automotive manufacturers offer a turbocharged petrol engine. Why? The turbocharger makes comparable performance with a smaller engine capacity possible and that contributes to the advance in downsizing. Turbochargers also help to achieve lower fuel consumption and are therefore fundamental in meeting strict emission limits. MAPAL offers the complete process for machining these parts, including tools.

Cutting tool repeatedly enters and exits the work. Subjects tool to shock loading, making tool toughness, impact strength and flexibility vital. Closely associated with milling operations. See shock loading.

Material: 1.4837 | Cooling: MQL | Diameter: 119 mm | Cutting speed: 80 m/min | Feed: 0.3 mm | Tool life: 100 parts

CNC machine tool capable of drilling, reaming, tapping, milling and boring. Normally comes with an automatic toolchanger. See automatic toolchanger.

MMC Hitachi Tool Engineering is now one of Japan’s leading tool manufacturers of end mills and drilling tools. The company’s business has been focused on tool and mould construction for decades, developing a considerable tool range that covers the entire process chain. With over 70 application engineers operating, the company has more than 30 years of experience in the European die and mould industry.

Workpiece is held in a chuck, mounted on a face plate or secured between centers and rotated while a cutting tool, normally a single-point tool, is fed into it along its periphery or across its end or face. Takes the form of straight turning (cutting along the periphery of the workpiece); taper turning (creating a taper); step turning (turning different-size diameters on the same work); chamfering (beveling an edge or shoulder); facing (cutting on an end); turning threads (usually external but can be internal); roughing (high-volume metal removal); and finishing (final light cuts). Performed on lathes, turning centers, chucking machines, automatic screw machines and similar machines.

Having successfully acquired a majority shareholding of Hitachi Tool Engineering Ltd and the subsequent renaming of the company as Mitsubishi-Hitachi Tool Engineering, Ltd the company has now announced that in future it will market its products under the name of Moldino. According to the company the new name represents technology that thoroughly applies in the service of people and goods, technology that values the accumulation of results and technology that brings marvels and smiles.

MAPAL recently announced a milling range with pressed, radial ISO indexable inserts. The milling cutter for roughing the face surface on the turbocharger housing comes from this range. The ISO indexable inserts with 16 usable cutting edges are the highlight of this facemilling cutter. As such the usage of the tool is particularly economical.

MAPAL has taken up these challenges and developed new cutting materials and tools. The company offers the complete process for machining turbochargers, including all tools, for example, drills, milling cutters, reamers and mechatronic actuating tools – matched to the related geometry of the turbocharger. The company also assists its customers during the continuous further development of processes, to reduce cycle times and to increase tool lives. As such, combination tools that undertake multiple machining operations in one machining step form part of the portfolio.

Any controlled equipment that allows an operator to program its movement by entering a series of coded numbers and symbols. See CNC, computer numerical control; DNC, direct numerical control.

Loosely, any milling tool. Horizontal cutters take the form of plain milling cutters, plain spiral-tooth cutters, helical cutters, side-milling cutters, staggered-tooth side-milling cutters, facemilling cutters, angular cutters, double-angle cutters, convex and concave form-milling cutters, straddle-sprocket cutters, spur-gear cutters, corner-rounding cutters and slitting saws. Vertical cutters use shank-mounted cutting tools, including endmills, T-slot cutters, Woodruff keyseat cutters and dovetail cutters; these may also be used on horizontal mills. See milling.

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A particular challenge during the machining of the turbine housing for exhaust gas turbochargers is the main turbine bore. Its manufacture is subject to close tolerances in relation to shape, position and surface finish. The bore is bell-mouthed shaped to generate the best possible flow characteristics. MAPAL undertakes this machining operation using TOOLTRONIC with the LAT attachment (linear actuating tool). TOOLTRONIC, a mechatronic tool system, is a full NC axis integrated into the existing machine controller. The mounting tool is fitted with three inserts, one for roughing and two for finishing.

Most turbochargers are exhaust gas turbochargers. These look different at almost every automotive manufacturer and have a special geometry. Common to all: there are very high temperatures when they are used in vehicles with petrol engines. For this reason the turbine housing, the so-called “hot side” is manufactured from very abrasive, heat-resistant materials. These materials represent a particular challenge for every machining tool.

For further details contact Multitrade Distributors on TEL: 011 87 803 2377 or visit www.multicarb.com

The new tool from MAPAL for pre-machining the catalytic converter flange is also particularly cost-effective. Tangential technology is used on this diameter turning tool. Due to the upright and horizontal installation of the LTHU inserts, in effect eight cutting edges can be used per indexable insert.

Hitachi Tool specialises in the production of carbide tools for a variety of difficult-to-cut materials and complicated shape products for power generation equipment, aerospace materials and other applications. Prior to the acquisition by MMC Hitachi Tool had been concentrating on the mould and die industry for over a decade and now offers a tool range which covers the entire process chain.

The four tools mentioned demonstrate, on the one hand, the different machining tasks on a turbocharger and, on the other hand, symbolise the variety of tools and know-how available from MAPAL. From standard milling cutters, through mechatronic actuating tools, to complex boring tools, the programme includes all the tools necessary for machining turbochargers, including the tool clamping systems. MAPAL designs the complete machining process such that the most reliable and cost-effective strategy for the customer is used. There is always a close eye on accuracy down to the μm so that the turbochargers achieve the highest possible efficiency in operation.

The Advanced Materials & Tools Business conducts its business in two primary categories; cemented carbide products and sintered parts. The cemented carbide products department provides an extensive lineup of cutting tools used in processes including lathe turning, milling, and drilling, as well as abrasion-resistant tools and construction tools.

Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

Material: 1.4837 | Cooling: MQL | Diameter: 40.5-57.295 mm | Cutting speed: 140 m/min (roughing), 120 m/min (finishing) | Feed: 0.15-0.4 mm | Tool life: 50 parts

Replaceable tool that clamps into a tool body, drill, mill or other cutter body designed to accommodate inserts. Most inserts are made of cemented carbide. Often they are coated with a hard material. Other insert materials are ceramic, cermet, polycrystalline cubic boron nitride and polycrystalline diamond. The insert is used until dull, then indexed, or turned, to expose a fresh cutting edge. When the entire insert is dull, it is usually discarded. Some inserts can be resharpened.

Substance used for grinding, honing, lapping, superfinishing and polishing. Examples include garnet, emery, corundum, silicon carbide, cubic boron nitride and diamond in various grit sizes.

A recent product announcement has been the launch of the new indexable milling tool TD4N, an extension of the proven range of high feed cutting tools. TD4N are the newly developed high-feed geometry and the double faced, 4 corner inserts for economic machining. The special cutting edge geometry optimises chip formation and minimises undesired residual material for subsequent operations. As a result the TD4N ensures a high process reliability with smooth machining, low costs per cutting edge and a long and stable tool life.