Visitors to the stand (H19-500) of WNT (Part of the Ceratizit Group) at MACH 2018 will be able to catch up on all the latest cutting tool, toolholding and workholding innovations that have been introduced by the company since the last MACH exhibition. Displayed alongside component examples, visitors will be able to relate to their own activities and recognise the productivity gains that can be achieved through application of the latest cutting tool technology. A selection of these ‘New to MACH’ products are highlighted below and are just a snapshot of the more than 55,000 articles available as standard from WNT.
WNT’s S-Cut UNI milling cutters feature a combination of an S-curve cutting edge and extremely irregular pitch that make it a highly innovative and high-performance solid carbide cutting tool. The geometry, which creates a variable helix angle, creates an extremely smooth cutting action, which in turn has a highly positive impact on tool life and surface quality of the workpiece, as fewer vibrations are produced during milling. A further advantage of this cutting action is that cutting data can also be increased. to reduce cycle times.
Further assisting the elimination of vibration is the S-Cut UNI’s extremely irregular pitch of the cutting edges, which counteracts the induced vibrations from tool to workpiece to machine tool system caused by entry and exit frequencies when making the cut. This results in an extremely stable machining process with hardly any visible chatter marks. “There was a visible improvement in the surface quality compared with conventional solid carbide milling cutters,” emphasises WNT Product Manager Daniel Rommel. “Not only does this increase process stability, it also ensures that the spindle output of the milling machine is fully exploited.” One final benefit of this extreme irregular pitch also makes possible higher depths of cut at large angles of engagement, which increases the maximum cutting depth significantly.
The WNT S-Cut UNI series of cutters is suitable for universal applications taking in materials such as steel and stainless materials and, were service life and high-quality machining are of high importance.
BT-FC double contact toolholder system
WNT has recognised the growing importance of face-contact spindles with the introduction of its BT-FC double contact toolholding system. One of the key benefits of the WNT BT-FC system is the increased rigidity that is generated through taper and face contact, with the additional face contact counteracting any lateral forces, thereby greatly reducing axial deviation. For example, under heavy cutting conditions generating lateral forces of 5 kN, a standard taper only holder would deviate by over 100 micron, under the same conditions a WNT BT-FC holder reduces that deviation to around 60 micron. Similarly, movement in the z-axis is eliminated, which can amount to as much as 0.03 mm at high spindle speeds when using conventional toolholding systems, affecting accuracy and repeatability.
The design of the WNT BT-FC toolholders also leads to extended spindle life and reduced vibration. In high speed machining environments spindle and toolholder wear is partly caused by oxidation of the spindle bore and toolholder taper, this oxidation is made worse due to the friction between toolholder and spindle. With the addition of face contact that friction through vibration is reduced, if not eliminated, which in turn reduces the possibility of oxidation occurring thereby extending service life of both the spindle and toolholder. The reduce vibration also enhances the surface quality of the part being machined.
Monstermill PCR UNI
WNT’s Monstermill PCR UNI solid carbide milling cutters enable precise, process-secure, ramping/plunge milling at high angles or, with extreme chip volumes during full slot milling. This is achieved thanks to a new four-flute, tip centring geometry, which delivers powerful and extremely quiet milling across a range of materials including steel, stainless steels and cast iron.
MonsterMill PCR UNI cutters excel at roughing and finishing, as well as providing exceptional performance when vertical plunging. This is achieved thanks to the patented 142° centring tip in the centre of the end cutting edge, making rapid centring possible without having to perform helical milling in advance. Users can now create holes on sloping surfaces without for separate milling and drilling operations.
With its four cutting edges MonsterMill PCR UNI has a distinct advantage in terms of cutting data over conventional plunge milling cutters with only three flutes. Feed rates can be up to a third higher, with feed/tooth rates of up to 0.137 mm/rev achievable for ramping/plunging, slotting and profiling operations. Despite the high cutting data process security remains high thanks to the special core geometry that has been designed to break chips and prevent spiral chips forming during plunging and drilling. This helps to reduce or eliminate chip jams and ensure reliable swarf removal via the flutes. This cutter design also creates a quieter cutting process, thanks in part to the irregular flute pitch and helix angle on the milling cutter that has the effect of preventing the tool from oscillating and starting to vibrate, even when high ramping angles of up to 45° are being used.
In developing MonsterMill PCR UNI WNT has produced a true all-round cutter that exhibits high chip removal rates during roughing with four cutting edges and achieves and excellent surface finishes as a finishing cutter. Users benefit from its very quiet running, stable and precise machining processes, and the ability to achieve angled plunging, rapid centring owing to the patented centring tip and vibration-free ramping up to a ramping angle of 45° at elevated cutting data.
MiniMill carbide grooving
WNT range of MiniMill carbide grooving, back-chamfering and thread milling cutters have seen further development since the last MACH exhibition, with new geometries delivering improved performance, surface quality and process security when milling grooves and slots. These changes include ‘Twisted teeth’ that create a much softer cut as the cutter enters the material. In addition this cross-pitch on the cutting edges helps in reducing vibration, even where large overhangs are required to access the component being machined or, the part has thin walls or maybe unstable. The cross-pitch design also aids swarf removal, which in turn improves surface quality of the machined part, eliminating the need for finishing cuts in many applications. By efficiently removing swarf from the work area the new geometry also enhances tool life and process security.
The extended range is available in WNT’s proven CWX500 grade of carbide, which is renowned for its exceptional toughness/hardness ratio, making it an ideal all-round grade for a wide range of materials including steel, stainless steel, cast iron and non-ferrous materials. The carbide cutting heads are available for circlip and general groove milling from 1.5 mm up to 6 mm width, back chamfering and in Metric and Whitworth thread forms. The carbide cutters can be attached to a wide variety of holders, allowing grooves and threads to be cut in bores as small as 10 mm diameter dependent upon application. The cutter design also ensures precision location of the cutting edge when mounted on the holder.