obr1New ball nose milling cutter for far higher cost-effectiveness. Numerous automobile manufacturers and suppliers rely on ball nose milling cutters from MAPAL's CPMill product range for the production of hardened steel constant-velocity joints.

For years these have been successfully used for roughing (soft milling) and fine machining (hard milling with PcBN) and have undergone permanent optimisation. A new, comprehensive further development of the milling cutter for roughing is now providing users with a significant boost in cost-effectiveness.

The new high-spiralised geometry ensures an optimum discharge of the chips. Instead of four, the new solid carbide ball nose milling cutter now has five cutting edges. Furthermore, not only the base substrate but also the coating has been optimised. For easy changing of the milling heads, they are now equipped with the CFS connection. The exact balance of taper and face surface ensures a high radial run-out accuracy of ≤ 5 μm, very good rigidity and consistently high quality.
Examples in practice show: The new CPMill ball nose milling cutter allows the machining time per part to be significantly shortened. Where to date, for example, 75,000 parts were machined a week it is now possible to machine around twelve percent more, namely 85,000 parts, using the five-bladed milling cutter with the same machine capacity and without additional machine investments. Why? Significantly higher cutting and feed rates can be used. In addition, the milling cutter has a roughly 25 percent longer tool life than its predecessor model.
The new solid carbide CPMill ball nose milling cutters are immediately available in various diameters.


Boehlerit developed an entirely new high-end milling programme
obr2The new milling range of Boehlerit comprises 10 innovative tool systems and 11 new milling grades. All modern materials can be reliably and economically machined with the new tools that are fine-tuned to the requirements of face and step milling.
The quality standards in milling have been defined by the Boehlerit cutting experts for decades now – and the latest proof of their expertise was presented at EMO 2015 in Milan. The development engineers in the Austrian steel industry town of Kapfenberg put all their technical know-how into a dynamic FEM design (finite-element method) for Boehlerit milling equipment to create stable milling tools with excellent fatigue strength properties, optimum chip formation and precise concentricity characteristics. All tools are nickel-implanted and owe their long tool life to special materials and heat treatments.
The basis of the new high-end milling range are 10 innovative tool systems, including multi-purpose tool systems where one base body makes two types of machining possible. This reduces the carrier body costs and saves warehousing expenses. The range includes highly economical high-feed tools and face-milling cutters with 16 edges. A total of 11 new milling grades cover all the many milling tasks of face or step milling in all current materials. They combine machining reliability and economic efficiency.
Various carbide substrates are used to produce the range of milling grades, or indexable milling inserts, fine-tuned to cover an extensive range of face and step milling operations: from roughing to finishing, from cast to steel, stainless materials and aluminium. The milling grades guarantee minimal wear on free areas and a higher resistance to chipping of the cutting edges. Resistance to thermal cracking or crater wear is also ensured. A special point to note here: Boehlerit uses exclusively no-conflict (fair) resources for the production of its carbides.

The patented, innovative TERAspeed 2.0 AlTiN layer, deposited by means of HR-CVD technology (HR = High Reactivity) is a special highlight of the new milling programme. The high aluminium content of this AlTiN layer and its innovative nanostructure make it possible, for the first time, to combine properties that are conflicting by definition – such as remarkable toughness, outstanding layer hardness and wear resistance. The modern layer is available in the milling grades BCP20M (HC ISO P20), BCP30M (HC ISO P30) and BCK15M (HC ISO K15).
Another innovative carbide layer, specially designed for milling, is the thick PVD AlTiN Goldlox layer. Its high wear resistance at high temperatures improves tool life for steel materials. And its particularly smooth yellow Goldlox top coat makes wear recognition easier. It is available in the steel milling grades BCP25M (HC ISO P25 / M25), BCP35M (HC ISO P35 / M35) and the tough BCP40M (HC ISO P40 / M40) grade for steel.
The wear-resistant milling grade BCM35M (HC ISO M45 / S35) is extremely tough and has been tailored to stainless steel and super alloys; the tough BCM40M (HC ISO P40) milling grade is ideal for stainless steels.

Renishaw focuses on measurement speed, accessibility and simplicity at EMO 2015
Renishaw, a world leader in precision engineering technologies, will be exhibiting its extensive range of metrology and additive manufacturing equipment at EMO 2015 which takes place in Milan, Italy, from 5th to 10th October. Products highlighted in hall 5, stand D15, will include new software for the Equator flexible gauge which allows users to create simple gauging routines in minutes, new MODUS 2 metrology software suite which simplifies the programming of co-ordinate measuring machines (CMMs), a new 'pay-as-you-go' machine tool probe system and a simple single-axis tool setter. Further new product announcements will be made ahead of the exhibition.
obr3Making its European trade show debut will be the Primo twin-probe system, which brings with it all the advantages of automated setting within a breakthrough 'pay-as-you-go' business model. Recognising that probe systems are the foundation of precision machining, the new Primo system brings high-end manufacturing within reach of companies of all sizes through a combination of minimal upfront costs, a free, comprehensive training package, and immediate parts replacement.
The twin-probe system comprises the Primo Radio Part Setter, Primo Radio 3D Tool Setter and Primo interface, plus three key additional elements – the Primo Credit Token, GoProbe software and Primo Total Protect which provides cover against accidental probe damage. The system is supplied with a six-month credit token which enables unlimited use of the Primo twin-probe system during that period; once the credit expires, users can simply purchase an additional credit token to extend usage.
Also new and supplied as standard with the Primo twin-probe system is user-friendly GoProbe software, which offers a unique combination of software, training materials and user reference tools, including new apps for Apple iOS and Android devices. Designed to make it simple to use Renishaw machine tool probes, GoProbe includes complete part setting, tool setting and probe set-up cycles, yet requires no previous probing experience.
The self-study GoProbe training kit, which includes an e-learning course and a training part to practice on, helps to build knowledge and confidence rapidly, so that processes can be optimised as soon as possible. It eliminates the need for extensive knowledge of G-codes, requiring only simple single-line commands which also makes it easy to progress from basic manual cycles to more complex automated cycles.
Also new for CNC machining centres is Primo LTS (length tool setter), a single-axis system which allows users to quickly set tool length, check for breakage and compensate for thermal growth. The automated system which is designed to operate in the harshest of environments will be up to ten times faster than manual setting methods.
A further innovation for EMO 2015, which brings 'intelligent speed' to machine tool probing, is Inspection Plus with SupaTouch optimisation. This new software package automatically determines and selects the highest feedrates a machine tool can achieve whilst maintaining metrological accuracy. It also uses intelligent in-cycle decision making to implement either a one or two-touch probing strategy for each measurement routine. The result is minimised cycle times and maximised productivity.
At EMO 2015 Renishaw will also show its new INTUO gauging software which is now offered with the unique Equator system to simplify and automate the gauging of a wide variety of parts, removing dependence on the skill of manual gauge users. This package also makes an ideal alternative to multiple manual devices such as vernier or digital callipers, micrometres and plug gauges.
With minimal training the INTUO software allows the programmer to create gauging routines using just a part with an engineering drawing. With the 'Feature Predict' function activated, the programmer uses the joystick to take points on each feature while INTUO does most of the work, by predicting the type of feature, the nominal value and a possible tolerance band. It is then easy to adjust the program to change the number of points taken or to space them evenly, and match nominals and tolerances to the engineering drawing. Shop-floor operators then simply select and run these programs within the user-friendly Renishaw Organiser front-end software.
Renishaw is also launching the Equator Button Interface (EBI), with simple push-button controls for shop-floor operators, removing the need for a mouse and keyboard. The EBI can be operated by staff wearing gloves and is not affected by shop-floor contamination.
Users of co-ordinate measuring machines visiting EMO 2015 will also be interested to see how the MODUS 2 metrology software suite brings new levels of clarity and efficiency to the programming and operation of CMMs. Based on the established and highly capable MODUS platform, and supporting Renishaw's range of three and five-axis CMM sensor technologies, MODUS 2 has been designed with usability in mind, including an innovative, easy-to-learn interface and faster programming, resulting in unprecedented levels of productivity with or without a CAD model.
The user experience for MODUS 2 is also designed to be identical whether the software is connected to a 'live' CMM or working in an offline environment where full simulation with speed control allows measurement sequence development and visualisation. Further innovations include 'Off Surface' motion technology, intelligent measurement strategies, automatic reporting and an interactive virtual CMM environment. From simple manual machine operation through to complex part measurement on multi-axis systems, MODUS 2 adapts automatically and only offers functionality relevant to the current task.

TEXT/PHOTO Mapal, Boehlerit, Renishaw