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.

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Whereas carbide suffers a significant loss of hardness at around 800°C, the hardness of CBN remains almost unchanged at temperatures up to 1,200°C. Another significant advantage is good chemical resistance, even at these high temperatures.

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The single-edged tool type 315 is for external grooving from a width of 0.5mm. In the cutting insert system 229, the previous CBN substrate CB 50 is replaced by the higher performance substrate CB 35. Inserts are available with two different corner radii and cutting widths from 3mm to 6mm.

“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.”

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

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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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.

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The ultra-hard material is capable of smooth machining even during interrupted cutting when hard turning and grooving. By extending its existing standard ranges of Supermini 105, Mini 11P, 229 and 315 systems, Horn is able to deliver the CBN tools quickly from stock.

There are no different grades of CBN. Differentiation between tools is down to the CBN volume fraction, the fillers, grain size and the ceramic/metallic binder phase (cobalt/nickel). This results in different CBN substrates. Hard machining is usually carried out without coolant, as these cutting materials have high heat resistance and the elevated temperature within the chip formation zone has a positive effect.

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CBN is the second-hardest material after diamond. Tools made from CBN wear much more slowly than other cutting materials when used appropriately. It is consequently possible to achieve higher dimensional and profile accuracy, even when machining hard materials such as steel up to 70 HRC.

The Supermini system is available in left- and right-hand versions with different corner radii. The CBN-tipped variants are for internal machining from a diameter of 2mm. Different lengths of solid carbide body are available. Tools in the Mini family can be used from an internal diameter of 6.8mm and are also available in left- and right-hand versions.

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Horn has announced an expansion of its product portfolio to include tools tipped with cubic boron nitride (CBN) for machining difficult materials, such as superalloys and hardened steels. The ultra-hard material is capable of smooth machining even during interrupted cutting when hard turning and grooving. By extending its existing standard ranges of Supermini 105, Mini 11P, 229 and 315 systems, Horn is able to deliver the CBN tools quickly from stock. The Supermini system is available in left- and right-hand versions with different corner radii. The CBN-tipped variants are for internal machining from a diameter of 2mm. Different lengths of solid carbide body are available. Tools in the Mini family can be used from an internal diameter of 6.8mm and are also available in left- and right-hand versions. The single-edged tool type 315 is for external grooving from a width of 0.5mm. In the cutting insert system 229, the previous CBN substrate CB 50 is replaced by the higher performance substrate CB 35. Inserts are available with two different corner radii and cutting widths from 3mm to 6mm. CBN is the second-hardest material after diamond. Tools made from CBN wear much more slowly than other cutting materials when used appropriately. It is consequently possible to achieve higher dimensional and profile accuracy, even when machining hard materials such as steel up to 70 HRC. There are no different grades of CBN. Differentiation between tools is down to the CBN volume fraction, the fillers, grain size and the ceramic/metallic binder phase (cobalt/nickel). This results in different CBN substrates. Hard machining is usually carried out without coolant, as these cutting materials have high heat resistance and the elevated temperature within the chip formation zone has a positive effect. Whereas carbide suffers a significant loss of hardness at around 800°C, the hardness of CBN remains almost unchanged at temperatures up to 1,200°C. Another significant advantage is good chemical resistance, even at these high temperatures. www.phorn.co.uk

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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Horn has announced an expansion of its product portfolio to include tools tipped with cubic boron nitride (CBN) for machining difficult materials, such as superalloys and hardened steels.

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.