Productivity Gets An Extra Boost

F4033 Xtra-tec face-milling cutters use inserts with eight cutting edges.

The F4042 shoulder mill cuts soft and has plunging capabilities.

Xtra-tec drills are two-effective and feature high-stability insert-clamping.

Plaudits from users of a series of milling and drilling tools include claims of shaft-milling times cut in half, tool lives extended 53%, machining costs down by more than two-thirds, and productivity levels up almost 100%. Such benefits result from one cutting tool manufacturer's precise coordination of insert geometries and coatings, along with tool-body designs.

For its Xtra-tec series of face mills, shoulder mills, and drills, Walter USA, Waukesha, Wis., incorporates high-positive insert geometries for a free-cutting action. All tool bodies allow coolant through the spindle and are made out of high tensile strength tool steel with nickel-plating to resist corrosion and abrasive wear and reduce friction in chip flutes. For better torque transmission, all inserts are secured with TorxPlus insert screws.

Walter's high-performance Tiger-tec inserts for Xtra-tec milling cutters feature optimized carbide grades, geometries and coatings, which result in low carbide consumption. The inserts are available in grades WKP25/WKP35 for steel and cast iron and WAK15 for cast iron. WAK15 is relatively insensitive to temperature fluctuations and therefore well suited for wet milling applications.

Walter's Xtra-tec F4033 face mills have double-sided square inserts that fit cutters in diameters from 1 ¹ /2 to 8 in.

The insert's negative basic shape and positive top geometry provide stability and high edge security. Additionally, the eight cutting edges provide for economical cutting. The cutters achieve feedrates 3 those of conventional milling cutters, even at 2 X d.o.c., improving chip volume.

In test milling AISI/SAE 4140 annealed steel, a WKP35 carbide grade insert generated increased productivity rates over 100%, as compared with a competitive carbide grade. When machining No 30 B cast iron, the reduced wear on the WAK15 carbide insert, compared with a competitive silicon-nitride-coated insert, resulted in reducing insert costs by more than an 80%.

With an approach angle of 45°, the F4033 face mill diverts most radial forces axially.

A rhombic shape insert with four cutting edges can be utilized by the F4041 shoulder mill for machining cast iron and steel. The inserts have extreme spiral top-geometry providing a smooth running and low power consumption. The F4041 cuts a 90° shoulder eliminating the need for finishing operations and is available in diameters of 1 ¹ /2 to 6 in. for cutting depths to 0.500 in.

Walter's F4042 shoulder mills with plunging capabilities are for universal applications. The tool mills a true 90° shoulder, eliminating the need for finish passes. Inserts for the F4042 tools, which produce tightly spiraled chips, come in three sizes with positive top geometries and positive axial rakes for free-cutting action along the entire edge. These AD_T-inserts are available for cast iron, steel, stainless steel and non-ferrous materials. A shell-mill-version is available in diameters of 1 ¹ /2 to 6 in and a Weldon version ¹ /2 to 1 ¹ /2 in.

Walter's Xtra-tec B401x drill series with coolant-through, drill 3, 5, and 7 diameter holes (in semi-standard up to 10 diameter) and are available in diameters from 0.5 to 1.25 in.

The two-effective inserts allow higher feedrates and the high positive geometry leads to a soft cuttingaction and low horsepower consumption. High repeat accuracy and close bore tolerances are achieved through precise positioning of the insert with a self-centering prism-shaped insert and insert-seat. A Torx-Plus clamping screw secures the insert by passing at an oblique angle through the insert. This pulls the insert into its seat for an axially and radially backlash-free fixture.