Holemaking MetalTech Report
- February 29, 2012
Emuge Corp.’s MultiTap is what the company describes as the industry’s first high performance tap designed to cut a wide range of materials including carbon steel, steel alloys, stainless steel, aluminum, cast iron, copper, brass, and bronze.
It is also designed to produce threads within both 2B and 3B classes of fit, eliminating the guesswork of calculating H-limits.
Emuge has designed MultiTap to offer job shops and other manufacturers an affordable, high performance tapping solution for a wide variety of common materials and applications.
"It will significantly improve thread quality and boost output while reducing production costs, because one high performance MultiTap will handle most common materials and applications. MultiTap eliminates the need to stock numerous types of taps in the tool crib” says Peter Matysiak, Emuge's president.
Constructed of a proprietary grade of high speed steel (HSS-E), Nitrided with a Ne2 surface treatment, the tap is available in both spiral point and spiral flute configurations for through-or blind-hole applications. Tap sizes cover a full range for UNC or UNF threads, from #4-40 to ¾ in. to16 in. sizes, to metric sizes from M4 x 0.7 to M16 x 2.0.
Because of their high strength-to-weight ratio, carbon-fiber-reinforced polymer (CFRP) parts are appearing more often in aerospace applications and are emerging in such fields as auto racing, sporting equipment (longboards and rowing shells), and many others.
But the properties that make such parts so useful make them very difficult to machine. The resins are light, but break and snap, rather than shear off in chips like metals and alloys. The carbon-fiber reinforcements are extremely strong, which can dull cutting tools quickly. They also can be layered in different directions, causing these layers to delaminate when drilling holes.
Kennametal is now introducing a line of Beyond solid carbide KCN05 routers specifically engineered for successfully machining CFRP.
Four router styles are available:
a ball nose router for pocketing and profiling; a down cut style with left-hand flutes that compress fibers as it cuts; a compression style router with left hand flutes on the shaft and right hand flutes at the bottom, which also compresses fibers into the material; and burr style router with many thin flutes for increased productive cutting.
Each have unique geometries specifically geared to working in CFRP, but all possess a solid carbide substrate and HP diamond coating for higher speed capabilities and longer tool life.
“Many industries are trending toward lighter, stronger, and recyclable materials, and many different kinds of composites are being developed for them,” says Oliver Sax, senior global product manager, Solid End Mills at Kennametal. “These routers have the geometries and the sharp cutting edges for high quality machined surfaces and improved tool life when working in CFRPs.”
Bluetooth for drilling
By incorporating Bluetooth wireless technology to the Komet MicroKom BluFlex tool system, tool developers have isolated the display from the tool head, making it easier, safer and more convenient to read off the settings. When dialing-in the micro-adjustable head, the operator can affix the magnetic, external display unit anywhere within the field of view, outside of the machine tool.
A specially designed adjustment key, with integral Bluetooth interface, is also part of the system. The same display unit and adjustment key can be used for multiple MicroKom BluFlex micro-adjustable heads, thus reducing costs when investing in several heads.
An improved integral part balancing system also allows the precision adjustment head to achieve rotational speeds up to 20,000 rpm, while the modular ABS interface provides for easy adaptation to different machine spindles.
The tool system also features an energy-saving function with an automatic shutoff after 30 seconds, and uses common AAA batteries.
High tolerance holemaking
Sandvik Coromant has introduced a range of drills used for rivet and bolt holes in carbon reinforced plastics and metallic stack materials.
Each carbon fibre material has its own demands, which increases the risk for delamination or splintering. These new CoroDrill geometries reduce this risk, ensuring the stringent hole tolerances are met with exceptional finish and quality. The range includes reamer geometries and a countersink tool with microstop for chamfering.
Boring and reaming
Seco boring heads that extend from 0.3 to 2,155 mm in diameter (.012 to 84.843 in.), are user friendly and offer positioning accuracy and hole diameter precision. Since finish boring heads can use turning-type inserts, Seco makes it possible for shops to choose between a wide variety of insert grades for increased flexibility.
Seco boring tools include: the A750 series of rough boring heads with strong twin cutters, Axiabore fine boring heads with axially fitted tools, the A780 and A790 lines of radial fine boring heads, the Liteline series of fine boring heads with assemblies that are 30 to 60 per cent lighter than classic boring assemblies, bridge bars for large diameter boring, and custom-made boring solutions.
When it comes to reaming, Seco has several easy-to-use, high precision reamers that range between 3 and 154 mm in diameter (0.1181 and 6.060 in.), bringing increased productivity to a variety of applications. Seco offers three grade options for its reamers: the RX 2000 coated carbide, RX1500 coated cermet and the basic, uncoated H 15.
Deep hole micro drills
Walter USA, LLC has expanded its popular line of Walter Titex X·treme deep-hole micro drills with three new high performance variants: the X·treme M, X·treme DM8 and the X·treme DM12. The designation M stands for “micro” and the D for “deep.”
Though used extensively in die and mouldmaking, primarily in the drilling of cooling and ventilation holes required, high performance micro drills are also widely employed in the automotive and power generation industries, as well as general machining. Because the X·treme micro drills are so versatile (they can handle material groups ISO-P, M, K and N), they are suitable for these as well as a wide array of other metalworking applications.
The new Walter Titex X·treme M covers drilling depths of up to 5xD, while the DM8 and DM12 are engineered to handle depths of up to 8xD and12xD respectively. Available in diameters ranging from 2 to 2.95 mm, these solid carbide drills have been optimized to ensure an extremely high level of process reliability - particularly important where small diameters are involved. For instance, optimized point geometry ensures precise positioning on entry, while internal cooling and polished flutes with special profiling ensure heat removal and reliable chip removal.
From its advanced VDS point geometry designed to reduce chipping on the cutting edge to its precision shank engineered for low runout, the VariDrill from Widia is a new multi-application drill engineered to deliver acceptable hole finish and extended tool life across a wide range of materials. VariDrill features an advanced point geometry and “marginless” design that reduces chipping on the tool’s edge and stabilizes cutting forces. The point and flute design enables chips to roll smoothly and evacuate easily, resulting in noticeably less friction, heat, jamming, and scratching. Minimizing these drilling issues means users can expect an optimum surface finish with every hole across a wide range of work materials without fear of catastrophic failure due to chip jamming