Sandvik Coromant’s new steel turning insert grade helps THK Rhythm take

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

“VariMill Xtreme will dominate the shop floor through productive output due to its versatile offering and ability to machine a broad range of materials in aggressive machining conditions” said a company spokesperson.

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.

To launch VariMill Xtreme Widia Hanita will hold a webinar – Discover WIDIA Hanita VariMill Xtreme – on 21 January 2021 (2PM CET). To register for this webinar visit https://attendee.gotowebinar.com/register/8464220142692582672

Hanita is a solid end milling brand devoted to delivering high-performance tools for the most demanding operations and applications in the aerospace, energy and general engineering industries.

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.

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.

Key features of the VariMill Xtreme are a twisted end face, an asymmetrical divided flute and variable helix angle and a parabolic core.

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

The coating of the tool is a Victory WS15PE grade and custom solutions are available. Regrinding is offered through the existing global centres.

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.

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

Key characteristics of VariMill Xtreme are its versatility whereby it is capable of machining a broad range of materials (steel, stainless steel, cast iron, super alloys), provides high-performance and tool life in a variety of operations including ramping, slotting, plunging, drilling, helical interpolation, dynamic milling, is productive with improved chip evacuation and increased edge/corner strength to reduce any risk of breakage while pushing the cutting parameters to the limit and exceeds expectations in aggressive cutting parameters.

Engineered to excel in a variety of aggressive machining conditions the product design uses key features of the already successful VariMill I but enhances chip evacuation and corner stability to exceed performance expectations on a wide range of materials.

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.

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.

After the iconic VariMill I design, Widia Hanita are pleased to present the recently released VariMill Xtreme, the next generation of versatile high-performance end mills.

The product offering of the 4-flute solid carbide end mill is it is available in metric (57 sku) and inch (57 sku) standard diameters, straight and Weldon shanks and square-end, sharp edges, chamfers and corner radii designs are available.

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.

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.

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.

Target markets include the aerospace and energy industries as well as a host of general engineering industries.

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.

For more information contact Widatech on TEL: +27 11 450 2108, email: info@widatech.co.za or visit www.widatech.co.za