In this article, MEGA Tech presents the next generation of its milling tools in the form of Xtra·tec® XT. “Xtended Technology”, or “XT” for short from Walter, is designed to achieve increased productivity and process reliability. It is not just the black look of these products which distinguishes them from the previous Xtra·tec® tools; they are in fact a completely new generation of milling cutters.
Low costs per cutting edge combined with long tool life
In addition to the M5009 (к 45°) and the M5012 (к 88°), Walter is now launching another Xtra·tec® XT face milling cutter in the form of the M5011 (к 75°). All three milling cutters can be equipped with the tough, double-sided SN.X1205 system insert. An additional system insert (SN.X0904) is available for using the M5009 and the M5012 with smaller depths of cut. The inserts are coated with Walter’s own Tiger·tec® Gold grades, making them incredibly wear-resistant. Depending on the material or machining objective, the user can choose between five geometries for: Large batch sizes, high stability and process reliability or long tool life and high productivity with almost all ISO materials. The Tübingen-based manufacturer is adding the M5011 to its range of milling cutters.
Equipped with either roughing or wiper inserts, the Xtra·tec® XT M5011 face milling cutter can be used for roughing and finishing, reducing the process costs and tool requirements. Walter offers the milling cutter with a diameter of 50 to 160 mm in two different tooth pitches and with a depth of cut of 8 mm. In the version with fewer teeth, the indexable inserts are mounted on a carbide shim. This protects the milling body and the remaining unused cutting edges against damage and maintains their usability, even with long machining times. Inclined clamping screws make the indexable inserts easy to access and shorten their indexing time.
Six is the magic number for cost-efficient milling
Walter introduces a shoulder milling cutter that brings with it incredible benefits for machining ISO materials P and K. Firstly, users benefit from double-sided indexable inserts with six usable cutting edges and, in turn, an attractive price-to-cutting edge ratio. Secondly, the milling cutter has an approach angle of 90 degrees and is capable of ramping, circular interpolation milling and pocket milling. This is a combination the market had never seen before now. Following on from the successful launch, Walter is now expanding its M5137 range to include the new G27 indexable insert geometry for universal use.
Whilst the G57 geometry that was available up to now primarily excelled in good to average conditions, low cutting forces and average feeds (e.g. for pre-machined workpieces), the sintered G27 now completes the Walter range. A geometry that can be used for challenging jobs as well as unstable clamping arrangements, interrupted cuts or forged skin. Both geometries are suitable for face milling, shoulder milling and pocket milling, as well as circular interpolation and ramping in steel and cast iron workpieces, and in stainless and difficult-to-cut materials. The Walter range now includes the cutter body itself with bore adaption and Weldon shank, also available in new inch-diameters (1–4″). The high process reliability and cost-efficiency achieved through low cutting tool material costs and the wear-resistant Tiger·tec® grades make the milling cutter a particularly good choice for users producing mid-range quantities.
Secure against inadvertent twisting.
With the Xtra·tec® XT M5468, Walter AG is breaking new ground to prevent inadvertent twisting of round indexable inserts. Indexing of indexable inserts using rigid clamping has been replaced by indexing using facets on the flank face of the indexable insert. This protects the inserts against inadvertent twisting and enables chip evacuation without interference contour on the tool. The cutting edges on the rake face of the indexable insert are labelled in the same way as the number of facets. According to Walter, this allows up to eight cutting edges (from insert size 10 mm) to be reliably used, thereby extending the tool life and increasing the cost-efficiency. Walter currently offers the Xtra·tec® XT M5468 round insert milling cutter in diameters from 10 to 125 mm, including oversize milling cutters for long overhangs, and in two tooth pitches for a wide range of applications.
The adaptors range from ScrewFit, Weldon shank and bore adaptor through to cylindrical-modular – an interface that is used frequently, particularly in mould and die making. Walter currently offers the round, positive indexable inserts with up to eight cutting edges in two insert sizes, with another five sizes to follow by the end of the year, according to Walter – each available in a version with fully sintered circumference and fully ground circumference. The wide range of adaptors and insert sizes enables virtually universal application of the M5468 with regard to application and material. Walter’s own indexing and anti-twist protection for the round indexable inserts using facets increase the process reliability. When combined with the wear-resistant Walter Tiger·tec® cutting tool materials, this results in a long tool life and a high level of cost-efficiency.
Article by: MEGATech & Walter (Thailand) Co., Ltd. << Click here