Milling – Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control

Seco Helical Milling Cutter delivers three times longer tool life

tzenlong — Wed, 15 Jan 2025 07:42:33 +0000

The new Seco LN4-11 Helical Milling Cutter provides up to three times longer tool life per edge and boosts productivity to achieve the lowest cost per part. The cutter ensures high material removal rates in applications requiring a helical milling cutter 32 – 63 mm in diameter.

Economical and user-friendly
The LN4-11 provides shops several avenues to cut costs and improve profitability. Its adaptability to a variety of applications enables shops to reduce tooling inventories and costs. Operators simply change out the cutter’s inserts to go from one application the next. The tool’s front and helical insert pockets also eliminate the risk of incorrect insert placement to improve efficiency and reduce waste.

“The new Seco LN4-11 Helical Milling Cutter is the answer to the challenges shops face today,” said Seco Product Manager Magnus Engdahl. “It’s impossible to load the inserts of the cutter incorrectly, and every cutter body and insert feature an individual Seco Data Matrix code that provides access to cutting data and spare part tracking. It’s an excellent opportunity for shops to improve productivity and efficiency while overcoming the challenges created by lesser skilled operators.”

Four cutting edges for cost-effective milling
The milling cutter has two different inserts. There are two cutting edges on the front inserts and four edges on the helix inserts. The design allows robust machining operations and aggressive material removal rates. Cost performance is enhanced, and tool life is improved. Inserts are available in a broad range of grades and geometries for a variety of operations and materials. The LN4-11 meets the demands of general engineering and automotive applications as well as those in the aerospace sector.

Each cutter’s individual Data Matrix code ensures easy access to all relevant tooling information including individual data metrics, cutting data, compatible products and spare parts.

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Schaeffler Expands Range Of Rotary Table Bearings, Torque Motors, And Linear Motors

Christellee — Fri, 22 Sep 2023 12:26:48 +0000

Schaeffler is meeting the challenges of the machine tool industry with new automation solutions that are characterised by even greater dynamics, precision, energy efficiency, and longer machine runtimes.

Axial/Radial Rotary Table Bearings Up To 650 mm

Two new YRTS-series axial/radial bearings in sizes 580 and 650 now round off the range. These rotary table bearings are double-direction axial bearings with a screw mounting facility and a radial guidance bearing. They are very rigid, have a high load carrying capacity, and run with particularly high accuracy. Series YRTS is optimised for use at very high speeds and runs with low, uniform frictional torque across the whole speed range, making it particularly suitable for use in combination with high-speed torque motors.

All three rotary table and rotary axis bearings, YRTS, YRTC, and ZKLDF, can be used in any combination with the three RIB, RKIB, and SRV torque motor series from Schaeffler. As an additional option for these rolling bearings, the company also offers incremental and absolute angular measuring systems, which are integrated into the rotary table bearings.

Torque Motors With An Air Gap Diameter Of Up To 690 mm

As a fitting accompaniment to the size increase in the rotary table bearing range, Schaeffler will be offering its torque motors from the RKIB-series up to size 690. The range now includes air gap diameters from 298 to 690 mm.

Linear Motors Up 24,300 N

With the release of the new L7 series in twelve sizes, Schaeffler expands its range of linear motors with peak motors of up to 24,300 N, with the result that Schaeffler linear direct drives can now be used to a considerably greater extent both in handling systems and in the main axes of machine tools.

Compared with the current benchmark, the water-cooled, high-efficiency L7 linear motors offer a reduction of up to 50% in the power loss with the same drive force or an increase of up to 40% in the nominal force compared to the current benchmark. Depending on the operating strategy, the new linear motors can drastically reduce energy costs or cycle times.

The single row cylindrical roller bearing series N10 and double row cylindrical roller bearing series NN30 (ribs on the inner ring) and NNU49 (ribs on the outer ring) are an established part of Schaeffler’s super precision range. They are used in applications where the highest precision is required under very high radial load. One typical area of application is providing radial support for the main spindle. In this application, the bearings facilitate bearing arrangements with very high precision, high radial rigidity, and very high load carrying capacity.

Favourable Temperature Behaviour Exhibited By The Bearing Courtesy Of New Cage Design

Schaeffler’s N10 series complete with new internal geometry and new cage made from PEEK (suffix PVPA1-XL) is displayed at EMO 2023. The optimised cage – like its predecessor, which was also produced from PEEK – ensures particularly low friction, a low noise level, and less strain on the lubricant, making it the preferred material choice for use in high speed cylindrical roller bearings. Further benefits include a longer grease operating life and higher limiting speeds.

Unlike other cage designs on the market, the cage in the new N10 series is guided unilaterally on the outer ring, leading to a more rapid grease distribution cycle with lower maximum temperatures and to a lower bearing temperature level with smaller scatter. As a result, the non-locating bearing function is more reliable even in the highest speed ranges.

Advantages Of Pneumatic Oil Lubrication

The unilateral guidance of the cage allows excess oil to flow freely out of the bearing when pneumatic oil lubrication is used, giving a highly uniform temperature behaviour of the bearing. The new cage is also designed in such a way that oil can be supplied both axially and at an angle, with the result that the position of the oil spray nozzles does not have to be adjusted when switching from spindle bearings supplied by other manufacturers to the N10…PVPA1-XL version from Schaeffler. One consequence of the modified internal construction is the use of smaller cylindrical rollers, with the resulting positive effects on both rigidity and the maximum speed capabilities of the new bearings.

Hybrid Cylindrical Roller Bearings With Half The Number Of Rollers

In hybrid cylindrical roller bearings of series N10, the rollers are made from a high performance ceramic. In addition, the number of rollers is halved. This bearing variant is characterised by even less friction and wear, significantly reduced strain on the lubricant, and considerably lower temperatures in the bearing.

When these hybrid bearings are used, spindles and machinery achieve a considerably longer life and the systems are significantly more viable. Ceramic rollers also lead to increased rigidity in both static and dynamic terms, which has a positive effect on the final machining quality.

Maximum Adaptability: Spindle Bearing Portfolio

A complete overview of Schaeffler’s spindle bearing portfolio is offered at EMO 2023 Hannover. Visitors can learn about the different variants, properties, applications, and other features of the spindle bearing series, which are available in three different ball element sizes.

The main principle of the portfolio is also to provide full coverage for the wide range of existing spindle solutions with maximum adaptability from the modular system. There are also alternative rolling bearing steels, coatings, cage designs, and ceramic rolling elements to choose from, allowing exactly the right bearing configuration to be offered for practically every turning, milling, and grinding spindle.

Precision Strain Wave Gears In Machining Heads For Wood, Plastic, And Light Metal

Precision strain wave gears of series RT1 and RT2 are particularly suitable for driving small swivel axes, for use in the A axes of milling heads, and for driving milling tables used in the machining of light metals, wood materials, and plastics. Schaeffler also completes the RT1 series of precision strain wave gears to customer specifications with suitable motors and rotary encoders, to create ready-to-fit drive units. A precision strain wave gear with integrated torque sensor system is also available in the form of series RT1-T. XZU-series angular contact needle roller bearings provide an especially high-stiffness support solution for output shafts.

Precision Planetary Gearboxes: Virtually Backlash-Free And Particularly Durable

The compact dimensions, high rigidity, and hollow shaft of PSC-series precision planetary gearboxes render them suitable for driving both milling heads in the C axis and larger swiveling rotary tables – applications in which they also take on the task of supporting the swivel axis in conjunction with the integral main bearing.

In many cases, a second gearbox and reciprocal bracing to compensate for torsional backlash is not required as the gearboxes feature a mechanism that automatically compensates for torsional backlash and wear on an ongoing basis and ensures an extremely low torsional backlash of ≤ 0.1 angular minutes. This extremely small torsional backlash also remains constant throughout the entire operating life of 20,000 hours.

With just one gearbox and the integrated main bearing arrangement, an extremely streamlined mechanical structure is achieved with comparatively few components, providing a highly economical drive and bearing solution for swing bridges. PSC gearboxes are available as mounting kits with a solid or hollow shaft, with or without a helical input stage, and as closed units with or without a right angle pre-stage for motor attachment.

Nine sizes ranging from 030 to 500 Nm, with planetary stage transmission ratios between 9 and 20, input stage transmission ratios from 3.4 to 15.7, and outside diameters from 155 to 405 mm, are available as standard. With the PSC range of precision planetary gearboxes, Schaeffler also covers drive solutions beneath the direct-drive swivel tables.

In addition to demanding, dynamic five-axis simultaneous milling operations, other applications include precise five-sided machining with a highly cost-effective and precision drive that has been subjected to large-scale testing.

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Tesla Leverages Malaysia Tariff Liftings For A Later Grand Entrance

Christellee — Thu, 27 Jul 2023 02:49:40 +0000

Tesla’s Model Y has made it into Malaysia – according to reports priced at about RM 200,000 (S$88,000). The cars are still assembled in China for obvious reasons. However, manufacturing may shift to Malaysia in due course.

Malay Vehicle Importers and Traders Association of Malaysia (PEKEMA). PEKEMA plans to import at least 500 Teslas a year, buoyed by the recent removal of road tax, sales tax, and excise and import duty for electric vehicles in Malaysia. The Malaysian government has moved to catalyse the adoption of EVs, giving 100% duty exemption for completely built electric cars up to 31 December 2024. Chinese suppliers supporting Tesla will still be grinning their way to the bank (for now).

They have also put in place 100% duty exemption for completely knocked down kits for electric cars for local assembly up to 31 December 31 2025. Thailand’s The Nation reported the Malaysian government is actively promoting EV adoption, with Prime Minister Anwar Ibrahim holding a virtual meeting with Elon Musk, Tesla’s CEO. They discussed investments in the EV industry and satellite internet services by SpaceX, another company owned by Musk.

Malaysia is placing great importance on developing the infrastructure for an environmentally friendly automotive industry and provides incentives for electric vehicle purchases through various benefits, such as tax exemptions. The strategic goal is to move towards net zero carbon emissions by the year 2050.

Malaysia aims for electric and hybrid cars to make up 15% of all new registered vehicles within the next 7 years. Malaysia’s Ministry of International Trade and Industry (MITI) announced that it has approved Tesla’s application to import battery electric vehicles into Malaysia. MITI says Tesla will now proceed to establish:

An Office
Tesla Experience and Service Centres
A Supercharger Network

MITI also says that Tesla is the first applicant of MITI’s BEV Global Leaders Initiative, aimed at boosting BEV demand in the country. Malaysia’s Minister of International Trade & Industry, Tengku Zafrul, welcomed the development and said this will help create skilled and better paying jobs for Malaysians.

Jumpstarting The Metalworking Tool Sector

When Malaysia starts assembling Tesla’s cars, there will be a range of metalworking tools in demand, plus the skilled operators. For a start, the following classes of machine tools may enjoy a demand:

CNC Machines (Computer Numerical Control): Versatile and widely used in the manufacturing of EVs. They include CNC mills, lathes, and routers, which can precisely cut and shape various materials like metal, plastic, and composites to create parts such as chassis, motor components, and body panels.

Injection Molding Machines: Used to produce plastic components like interior parts, dashboards, and covers. Injection molding machines melt and inject molten plastic into molds to form the desired shape.

Metal Stamping Presses: They are needed to produce large quantities of metal components with consistent quality. Stamping presses can create body panels, structural parts, and other metal components used in the EV assembly.

Welding Machines: Welding is crucial for joining metal components together. Various types of welding machines, such as MIG (Metal Inert Gas), TIG (Tungsten Inert Gas), and spot welders, are used in EV manufacturing.

Battery Assembly Equipment: They are specialised machines are required for assembling lithium-ion battery packs, including spot welding machines for battery cells and modules, electrolyte filling equipment, and battery testing systems.

Electric Motor Manufacturing Equipment: Electric motors require specific manufacturing processes, such as winding machines for creating coils, lamination stacking machines, and magnet assembly equipment.

Battery Cell Production Equipment: If the EV manufacturer produces its own battery cells, they will need equipment for processes like electrode coating, calendaring, electrolyte filling, and cell assembly.

Robotic Automation: Robots are employed in various aspects of EV production, including assembly, welding, painting, and material handling. They help improve efficiency and precision.

3D Printers: Additive manufacturing, or 3D printing, is increasingly used in the automotive industry to create prototypes, custom parts, and certain tooling.

Testing and Quality Control Equipment: To ensure the safety and reliability of EVs, testing and quality control equipment, such as dynamometers, leak testers, and metrology tools, are essential for conducting thorough inspections.

Assembly Line Equipment: Conveyor systems, robotic arms, and automated assembly stations are used to streamline the production process on the assembly line.

Manufacturing electric vehicles requires a diverse range of specialised machine tools and advanced manufacturing processes. From CNC machines that shape various components with precision to robotic automation that streamlines assembly, the EV industry relies on cutting-edge technology to meet the demands of sustainable transportation.

Furthermore, battery assembly equipment and electric motor manufacturing tools play a critical role in the development of efficient and powerful EVs. As the automotive industry continues to embrace innovation and sustainability, the evolution of machine tools and manufacturing techniques will undoubtedly lead to more efficient, reliable, and accessible electric vehicles for a cleaner and greener future — at least for Malaysia in this case.

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Milling Instead Of Grinding With The Hand Angle Miller

APMEN Editor — Wed, 01 Sep 2021 11:28:19 +0000

The wide range of milling discs, special techniques when milling by hand, as well as the use with hand angle millers and in (partially) automated processes. The milling discs are available in the three different kinds “milling disc”, “double sided milling disc” and “doubleworker”, which aim different areas of application.

For all of those the following applies:

The surfaces processed with the discs are metallic bright, and therefore prevent cavities while welding. While working, the discs produce neither (unhealthy) dust nor heat, and thus no structural changes that come with heat. The amount of material removed and the fineness of the result depend on the toothing. The fewer teeth, the coarser the chips and the greater the amount of material removed. The more teeth a disc has, the finer the chips and the smoother the surface, but less material is removed. The specific toothing depends on the material to be machined and the disc size.

The discs can be used for the following tasks:

The milling disc gets used for bevelling, deburr and flatten as well as working out weld roots.
The double sided milling disc (DMD) is used to open weld roots, according to the literal translation of the German original description, that would be “weld root opener”. Due to the teeth geometry, it is not made for the tasks performed by a single sided milling disc.
The Doubleworker (DW) combines the scope of single and double sided milling discs, without the need to frequently change the tools. The teeth geometry of the double sided milling disc had been adjusted to resolve the problem of chips getting stuck in the chip chamber.

Maija-Frästechnik GmbH, founded in 2012, develops, produces and sells high-quality milling tools made of hard metal. The company owns the patent for milling discs, which was registered in 2000 by the later company founder.

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TMR: CNC Market to Reach $115B by 2027

Admin — Fri, 19 Jun 2020 01:43:43 +0000

The increasing focus on production efficiency is aiding the uptake of computer numerical controls (CNC) technologies as these machines streamline various operational processes by reducing production time and minimizing human error.

The highly competitive environment has compelled players to focus on efficient manufacturing techniques. They are also trying to gain competitive advantage by redesigning their manufacturing facilities to include CNC machines. The integration of 3D printing with CNC machines is one such addition to some of the new production units, which is expected to offer better product design with little to no resource wastage.

Fuelled by these factors, the global market for computer numerical controls is projected to grow from a value of $64 billion in 2018 to $115.1 billion by 2027, according to a study by Transparency Market Research (TMR). If these values hold true, the CNC market is expected to register a CAGR of 6.7 percent during the forecast period.

READ: Are Cheaper CNC Machine Tools More Cost Effective?

READ: COVID-19 Updates: Auto Makers Revving Up Production To Drive Market Recovery

Automated Manufacturing Driving Demand for CNC in Industrial and Automotive Sectors

Based on type, the global CNC market is led by lathe machines, and the segment is poised to dominate the market throughout the forecast period. The demand for lathe machines can be attributed to a wide application area.

On the other hand, milling machines are anticipated to register a strong growth rate during the forecast period. Milling machines are compatible with a wide range of materials and surfaces and help improve overall efficiency. Furthermore, technological innovation has led to the development of advanced milling machines that can provide a more consistent finish to the products.

In terms of application, the industrial segment held the dominant share and is likely to retain its lead through 2027. The growing demand for automated manufacturing in the industrial sector resulted in the increasing uptake of CNC machines. The establishment of manufacturing facilities in developing regions such as Asia Pacific has also spurred the usage of CNC technologies in this sector. The automotive sector, on the other hand, is set to be the most rapidly developing segment in the coming years thanks to the soaring rate of automated automobile manufacturing.

North America Continues to Present Immense Scope Despite Market Saturation

From a geographical viewpoint, the global market for computer numerical controls is led by Asia Pacific, with the region accounting for a share of approximately 35 percent in 2018. Developing economies such as China and India have been witnessing robust growth in terms of industrialization, thereby propelling the regional market. The automotive sector has been estimated to register rapid growth in the Asia Pacific CNC market during the forecast period owing to the rising demand for automobiles in the region. In addition, the easy availability of labour and the declining prices of components have resulted in manufacturers shifting their production units in this region. This is further propelling the APAC CNC market.

READ: CNC Control for Rolling Machines

READ: Standardisation of Mould Bases

Meanwhile, considering that the United States is the one of the earliest adapters of new technologies, the North America market for CNC machines is relatively saturated. Be that as it may, rising concerns over global warming and depleting energy reserves have led to the production of alternative sources of power such as solar, water, and wind, and this has significantly upped the demand for CNC machines in the region. CNC machines are actively used in power generation as the process requires wide-scale automation.

Key Driving Factors, Promising Avenues, and Challenges

Some of the key growth dynamics in the CNC market are:

The drive for automated manufacturing in various industries is a key trend driving the expansion of the CNC market.
Industries, notably automotive, have increasingly adopted automated machine control technologies to improve operational efficiencies and reduce overall costs.
In numerous developing and developed countries around the world, growing emphasis on reducing the carbon footprint of manufacturing has spurred growth in the CNC market.
Over the past few years, deployment of 3D manufacturing technologies have been at the forefront for industries, bolstering demand for CNC.

Despite the attractive potential of CNC in industrial automation, such technologies require substantial investment. The maintenance and servicing is also cost-intensive, resulting in small-scale enterprises to avoid the adoption. All these are proving to significantly constrain the growth of the CNC market.

On the other hand, the incredible drive for efficiency gains is a key business proposition for the rise in demand in the CNC market.

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Walter Tools Releases White Paper on Dynamic Milling

Admin — Mon, 11 Nov 2019 06:42:34 +0000

Walter Tools has released a new white paper on the advantages and benefits of dynamic milling. Higher process reliability, and shorter machining times at ever lower costs—many industries, especially suppliers, are in this dilemma. In addition, there are always new materials, driving the need for weight savings, corrosion resistance and resistance to very high temperatures. And then there are materials that are often difficult to machine.

For all of these, dynamic milling offers a solution that promises both higher productivity and higher process reliability under the right conditions. In a new whitepaper, Walter Tools discuss the advantages of dynamic milling compared to other milling processes. It also highlights all the facts that you need to know about the process, including prerequisites, technologies in comparison, and effects, among others.

For more information, click here.

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ISCAR Launches Chipformer For Finish Turning On Superalloys

Admin — Mon, 19 Aug 2019 02:45:44 +0000

Intended mainly for aerospace industries as well as for the oil and gas market, the F3S chipformer—the new efficient chip breaker from Iscar—is designed for working with unique and tough-to-machine nickel-based alloys, such as Inconel, Waspaloy, etc., as well as other exotic materials such as titanium-based alloys.

The new F3S chipformer from Iscar has a positive rake angle to ensure a smooth and easy cut, with significant reduction in cutting forces and notable chip breaking results. The F3S chipformer has been designed with geometric features to improve tool life, with a reinforced cutting edge at the area where VG (notch wear) wear tends to occur when machining superalloys and exotic materials, which causes poor surface finish and risk of edge breakage.

The chipformer is available on the most popular inserts – CNMG, WNMG and SNMG – in two main grades, IC806 and IC804, and will be available in the future also on VNMG, DNMG, and TNMG inserts.

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Tungaloy Expands Copy Milling Cutter Diameter Lineup

Admin — Thu, 15 Aug 2019 02:10:46 +0000

Tungaloy is expanding its DoTwistBall line of copy milling cutters to include additional diameters of shell mills.

The DoTwistBall copy milling cutter is designed to ensure maximum machining reliability during complex 3D milling processes. The insert is constructed in a helically twisted structure that fits the seat constructed in a matching helical profile. This design provides secure insert positioning and fixation with anti-twist protection during machining. In addition, the strong, thick design of the insert helps to withstand machining impact preventing insert fracture.

The cutter body can accommodate either round LNMX-MJ inserts with 4mm, 5mm, or 6mm nose radius or LNMX-HJ inserts for high feed milling, making the cutter extremely effective for machining complex curved surfaces typical in die and mould industries.

The new cutter diameters include ø42mm, ø52mm, and ø63mm in popular shell mill bodies to accommodate the LNMX04 inserts. A total of three cutter bodies are added in this expansion.

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Walter Expands Perform Product Range With New Milling Cutters With Corner Radius

Admin — Fri, 19 Jul 2019 03:11:44 +0000

Walter has expanded its Perform product range with the launch of the new MC232 Perform solid carbide milling cutters. The MC232 milling cutter features a corner radius and reduced neck, allowing the user to better approach individual component geometries. It also improves the tool life of the milling cutter, as the edge stability is increased. The reduced neck in turn makes the milling cutter more flexible, as the user can use it with an even wider variety of cutting depths.

Other features of the Perform line have been adopted: the high level of cost efficiency for small and medium batch sizes, or Walter’s own WJ30ED grade, which provides a high level of wear resistance. ISO P materials are the primary application of the MC232 Perform, with ISO M and ISO K as secondary applications. The new milling cutters are likely to be of particular interest to job shops and manufacturers with frequently changing orders or quantities.

The Walter range in the MC232 Perform family now includes solid carbide cutters with or without a reduced neck and with or without a corner radius in a total of 126 dimensions, of 2–20mm in diameter. The milling cutters can be used for all typical milling applications (lateral milling, full slotting, pocket milling, helical plunging, ramping) and are suitable for a variety of materials and milling strategies.

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Sandvik Coromant Extends Advanced Insert Grades To Additional Milling Concepts

Admin — Thu, 06 Jun 2019 03:13:23 +0000

Following the successful introduction of its GC4330 and GC4340 steel milling grades, Sandvik Coromant is now extending the range of application for these advanced insert grades to additional milling concepts. The grades are now available for selection with the CoroMill 300 round-insert face and profile mill; the CoroMill 245 multi-purpose face milling cutter; and the CoroMill QD cutter, which is optimized for deep and narrow grooving and parting off.

GC4330 and GC4340, which feature a specially developed substrate, Inveio coating and enhanced post-treatment technology, allow users to enjoy substantially increased tool life and process security. The extension of these grades to additional Sandvik Coromant milling concepts brings their advantages to even more machine shops looking to optimize the milling of steel workpieces.

Among the many design attributes of GC4330 and GC4340 is the optimized Inveio coating. Inveio is the technical breakthrough of uni-directional crystal orientation in the alumina coating layer that gives inserts a new level of wear resistance and tool life. Furthermore, the substrate of the grades delivers highly controlled grain size distribution for more reliable and predictable insert behaviour.

GC4330 is a medium-hard grade for roughing to semi-finish face milling, while the GC4340 grade is for rough shoulder milling and groove milling. Both grades are also extended to the CoroMill 360 heavy-duty face mill, CoroMill 419 high-feed mill, and LPMH-PM plunge-cutter inserts. In addition, GC4330 is available for the CoroMill 365 high-security face mill, while GC4340 can be applied to the CoroMill 216 ball-nose end mill and CoroMill 415 small-diameter high-feed face mill.

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