EWAG Compact Line - cnc machine diamond tungsten carbide insert

Hoffmann Group USA has expanded its tool family for Parabolic Performance Cutting (PPC) to include a new PPC indexable insert and Garant PPC solid-carbide barrel milling cutters for high-alloy and hardened steels. The PPC process represents a further development of ball-nosed slot drill cutting and is also known as barrel milling. It is primarily used for finishing free-form surfaces in machining tool building, tool manufacturing and die making and achieves either up to nine times shorter processing times or a significantly improved surface quality.

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.

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The chipbreakers range from the LK and MA breakers with a positive land for lower cutting resistance, the MK type for a balance between sharpness and edge strength, through to the RK, GK and flat top types with stronger geometries for interrupted heavy cutting and for the removal of scale on the surface of the cast iron material.

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.

The MC5105 grade is designed for high-speed cutting of grey cast iron (500 – 1,000m/minute) as it is a harder grade with excellent wear resistance. To achieve this, an ultra-thick top coating layer of Super Nano Al2O3, that is twice the thickness of conventional coatings, is used.

The usability over a wide application range is enhanced with the availability of CNMG/A to WNMG/A negative rake inserts and CCMT and DCMT positive rake inserts.

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The MC5115 grade is ideal for ductile cast iron and displays excellent durability due to its resistance to impacts. MC5115 features the new Sub-Grip adhesion layer that effectively binds the carbide substrate to the thick TiCN layer above, thereby providing both resistance to peeling and the ability to cope with the hardness of ductile cast iron.

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The series also introduces an innovative new Sub-Grip layer that ensures a highly effective adhesion of the base TiCN coating layer to the carbide substrate. This development increases the resistance to peeling even during strong intermittent cutting when the forces exerted on the insert are at the highest level. Sub-Grip is employed to create the maximum benefit on the grades for medium speed machining (MC5115) and interrupted cutting (MC5125).

For high performance turning of cast iron, Mitsubishi Materials has launched the MC5100 series, a brand-new range of three different insert grades that are optimal for each type of cast iron machining application.

For high performance turning of cast iron, Mitsubishi Materials has launched the MC5100 series, a brand-new range of three different insert grades that are optimal for each type of cast iron machining application. The series also introduces an innovative new Sub-Grip layer that ensures a highly effective adhesion of the base TiCN coating layer to the carbide substrate. This development increases the resistance to peeling even during strong intermittent cutting when the forces exerted on the insert are at the highest level. Sub-Grip is employed to create the maximum benefit on the grades for medium speed machining (MC5115) and interrupted cutting (MC5125). The MC5105 grade is designed for high-speed cutting of grey cast iron (500 – 1,000m/minute) as it is a harder grade with excellent wear resistance. To achieve this, an ultra-thick top coating layer of Super Nano Al2O3, that is twice the thickness of conventional coatings, is used. This combines with a TiCN layer that is bound by Mitsubishi’s patented Super Tough-Grip technology. This combination produces an overall result that prevents peeling and eliminates edge chipping that often occurs with conventional grades. Working in tandem with an enhanced carbide substrate, the result is significantly improved tool life and component surface finishes, together with greater process reliability and reduced tooling costs. The MC5100 series has a comprehensive choice of insert geometries The MC5115 grade is ideal for ductile cast iron and displays excellent durability due to its resistance to impacts. MC5115 features the new Sub-Grip adhesion layer that effectively binds the carbide substrate to the thick TiCN layer above, thereby providing both resistance to peeling and the ability to cope with the hardness of ductile cast iron. This feature packed grade also has the proven Tough-Grip layer binding the Super Nano texture Al2O3 top coating layer to the thick TiCN layer below. The MC5125 is an ideal grade for heavy and interrupted cutting of ductile cast iron. Featuring all the same benefits of the coating layers as the MC5115 grade but with an optimised, less thick TiCN layer. The outer Tough-Grip layer (pink) incorporated in the MC5100 series creates extremely high levels of adhesion to prevent delamination. The inner Sub-Grip layer (yellow) greatly increases the level of adhesion between the carbide substrate and the coating layer The MC5100 series also features several chipbreakers to ensure peak performance can be achieved across a wide range of cast iron turning applications. This is easily achieved by matching the correct grade with the ideal chipbreaker using a simple cross reference chart. The chipbreakers range from the LK and MA breakers with a positive land for lower cutting resistance, the MK type for a balance between sharpness and edge strength, through to the RK, GK and flat top types with stronger geometries for interrupted heavy cutting and for the removal of scale on the surface of the cast iron material. The usability over a wide application range is enhanced with the availability of CNMG/A to WNMG/A negative rake inserts and CCMT and DCMT positive rake inserts. Mitsubishi Materialswww.mitsubishicarbide.com

The MC5100 series also features several chipbreakers to ensure peak performance can be achieved across a wide range of cast iron turning applications. This is easily achieved by matching the correct grade with the ideal chipbreaker using a simple cross reference chart.

The MC5125 is an ideal grade for heavy and interrupted cutting of ductile cast iron. Featuring all the same benefits of the coating layers as the MC5115 grade but with an optimised, less thick TiCN layer.

All new Garant PPC indexable inserts, including tool bodies and the new GARANT PPC solid-carbide barrel milling cutters for hard machining, are available immediately. The precondition for PPC is a CAD/CAM software coordinated to the milling strategy, which allows the tool geometries to be processed as a data model.

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.

In addition to the new PPC indexable insert, the Hoffmann Group has optimized three versions of its PPC solid-carbide barrel milling cutter for hard machining. The new tools have a tangential, conical or stub point conical form and are suitable for finishing flat faces and large surfaces with interference contours, as well as deep and hard-to-access cavities. Due to these qualities, they show their full potential on the 5-axis machine. The new Garant PPC indexable milling inserts are also available to users for finishing components made from high-alloy or hardened steels with freely accessible surfaces without interference contours.

This combines with a TiCN layer that is bound by Mitsubishi’s patented Super Tough-Grip technology. This combination produces an overall result that prevents peeling and eliminates edge chipping that often occurs with conventional grades. Working in tandem with an enhanced carbide substrate, the result is significantly improved tool life and component surface finishes, together with greater process reliability and reduced tooling costs.

With its new PPC indexable insert which is compatible with the Garant precision copy milling cutters as tool bodies, the Hoffmann Group is launching an alternative to PPC solid-carbide barrel milling cutters with a straight or stub point conical-shaped main cutting edge onto the market. The PPC cut-off inserts are suitable for processing flat faces and freely accessible surfaces without interference contours on the 3-axis machine and are available for steel, high-alloy and hardened steels, stainless steel and aluminium. Garant precision copy milling cutters, which are suitable as tool bodies, are available in steel and solid-carbide versions, including a Garant PowerCard.

This feature packed grade also has the proven Tough-Grip layer binding the Super Nano texture Al2O3 top coating layer to the thick TiCN layer below.