Salah Taoufik, Kennametal’s global product manager for turning, said KY4300 tools have excellent high-temperature strength and hardness, and speeds can be increased 10 percent to 20 percent in most applications, compared with other ceramic grades, and produce results that include better surface finishes at lower cutting forces.

Walter has signed an agreement to acquire the U.S.-based GWS Tool Group, a manufacturer of solid carbide endmills and drills as well as HSS taps and PCD products. GWS is focused on highly engineered customized cutting tools for the American market.

The company said the end mills are extremely durable and can provide 50 times more tool life than conventional carbide end mills. Emuge PCD and CBN end mills are available from stock, in ball nose, torus and flat-end designs, in sizes from 0.1857 in. to 0.500 in. and in metric sizes from 4 mm to 12 mm.

The acquisition supports Walter’s growth strategy in North America. “I am very pleased that we have reached an agreement to acquire GWS, as it will significantly increase our presence in the US and strengthen our solid carbide tools offer in this key market”, says Richard Harris, President of Walter.  GWS has a strong focus on the aerospace industry and provides a complementary product portfolio.

Available in two major types: tungsten high-speed steels (designated by letter T having tungsten as the principal alloying element) and molybdenum high-speed steels (designated by letter M having molybdenum as the principal alloying element). The type T high-speed steels containing cobalt have higher wear resistance and greater red (hot) hardness, withstanding cutting temperature up to 1,100º F (590º C). The type T steels are used to fabricate metalcutting tools (milling cutters, drills, reamers and taps), woodworking tools, various types of punches and dies, ball and roller bearings. The type M steels are used for cutting tools and various types of dies.

When developing aluminum oxide (Al2O3) coating materials, it is preferable to use the alpha form of for most applications. Unfortunately, it is much easier to deposit the kappa form. Consequently, producers have deposited the kappa form and then heat-treated it in a coating furnace to transform it to alpha. However, this heating process results in an unavoidable contraction in volume, resulting in the formation of cracks in the coating.

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Rick McIntyre, who will remain president of the Company, says: “We are excited to pair our North American manufacturing presence and commitment to service with the vast capabilities, resources and expertise of Walter. This is a big win for our customers, who have always been our most important stakeholder.”

When it comes to machining hard, difficult-to-machine materials, it’s tough to beat poly-crystalline diamond (PCD), cubic boron nitride (CBN) or ceramic inserts.

This is a strategic opportunity to increase Walter’s and GWS’ position in the manufacturing of advanced components and light-weight materials. In addition, GWS’ products will expand the overall offering for Walter in North America.

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These tools effectively machine highly abrasive, non-ferrous materials, including graphite, highsilicon aluminum alloys, fiberreinforced synthetics and copper alloys.

CBN is the hardest known substance next to diamond, and provides the cutting edge for long-lasting tools that proficiently machine hard steels to 66Rc, as well as hard castings, Inconel, Monel and Stellite.

GWS will continue operating as a standalone entity with its own salesforce and brand. The parties have agreed not to disclose the purchase price. The transaction is expected to close during the fourth quarter of 2021 and is subject to relevant regulatory approvals.

GWS Tool Group is a North American-based, vertically integrated manufacturer of highly engineered custom, standard, and modified standard cutting tools. The group with headquarters in Florida, is currently owned by a private equity company and has about 500 employees. GWS Group was founded in 2014 as the start of the acquisitive journey from the foundation of the GW Schultz company founded in 1984. To date, these acquired entities include numerous industry-leading specialty manufacturers.

Emuge Corp. (www.emuge.com) has announced the expansion of its hard milling end mill line to include new PCD and CBN end mills.

PCD is a matrix of randomly arranged diamond crystals that are bonded to form an extremely hard film or wafer.

About three years ago, Seco Tools Inc. (www.secotools.com) metallurgists hypothesized that if they could directly deposit the alpha form in the beginning, they could avoid the cracking issue and produce a more homogenous and tougher structure. Eliminating cracks would also make the coating a more effective thermal barrier, reducing the amount of heat getting to the substrate.

KY4300 inserts are composed of aluminum oxide reinforced with silicon carbide whiskers. These whiskers have high mechanical strength and act like reinforcing steel bars in concrete, improving the strength and fracture toughness of the cutting insert.

Cutting tool material consisting of natural or synthetic diamond crystals bonded together under high pressure at elevated temperatures. PCD is available as a tip brazed to a carbide insert carrier. Used for machining nonferrous alloys and nonmetallic materials at high cutting speeds.

The tools are pre-engineered and precision manufactured for optimum performance for cutting challenging cutting applications. The PCD shaped cutting edges are affixed to carbide shanks by a sophisticated microwavebrazing technique that forms bonds that are able to withstand temperatures to 1,100° F.

When machining Inconel 718, for example, the company said speeds can be increased four to five times compared with cutting speeds when using carbide inserts. The inserts are equally productive in the automotive industry, machining alloyed gray cast-iron brake disks, and in the roll products segment removing casting crust or heavily worn rolling surfaces.

Ceramic inserts can run at high speeds, so they reduce machining times. They resist oxidation and maintain hardness at elevated temperature, and are ideal for hard machining carbon steels, alloy steels, tool steels and cast irons.