The New Walter MC232 Perform solid carbide
milling cutters.
Milling cutters with corner radius introduced to the Walter Perform product range
With the launch of the new MC232 Perform solid carbide milling cutters, Walter is both rounding off its portfolio of products and opening up new possibilities. For the first time, the Tübingen-based tool specialists are bringing a milling cutter with a corner radius and reduced neck to the market as part of Walter’s cost-effective Perform product range. 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.
Solid carbide milling cutters with corner radii meet an important demand of the market. This is because the corner radius allows 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 – for example, 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.
For more information, please contact Spectra Carbide Tooling Technology – Tel: 0860 23 23 23.
Walter presents its new TC410 Advance thread former
With the TC410 Advance HSS-E thread former, Walter is rounding off its range of threading tools – and can now offer its customers more than 200 thread dimensions and tolerances. The TC410 Advance with TiN coating can be used universally for blind and through-hole threads (metric, metric fine, UNC/UNF and G), all formable materials from the ISO material groups P, M and N as well as for ISO K and S as a secondary application. In addition to the general advantages of thread formers as well as non-cutting machining (no wedging of the tool due to trapped chips consequently higher process reliability), Walter is primarily bringing economic benefits to the fore with the new tools.
Decisive factors for this include the new geometry and special post-treatment. Innovative mould edges reduce the cutting time in the material. This reduces friction and consequently the amount of heat generated, which in turn reduces wear and ultimately increases the edge life of the tool. The posttreated, extremely smooth surface of the tool reduces the torque and additionally increases the tool life as a result. Walter offers the TC410 Advance in two variants. Without lubrication grooves or with lubrication grooves for deeper threads up to 3.5 × DN. The excellent price/performance ratio makes the TC410 Advance an attractive choice for users with medium to large batch sizes in particular. This is because it can produce more threads with the same tool.
For more information, please contact Spectra Carbide Tooling Technology – Tel: 0860 23 23 23.
Walter presents the new HU5 geometry for ISO M and S materials
With the new single-sided indexable inserts with HU5 geometry, Walter has the answer to one of its users’ key questions: How can more components be produced using the same number of machines? In comparison to the indexable inserts that can be used on both sides, the HU5 has a larger contact surface to the tool holder. This increases the stability and allows for greater cutting depths, feeds and a larger metal removal rate – specifically, in the practical test, this comes to 18.36 l/h instead of 10.71 l/h. In addition to the stable fit, the decisive factor behind this is the combination of the geometry and Walter Tiger·tec® Silver cutting tool materials.
This allows for increases in tool life of up to 75 percent. The geometry itself has been specially developed for heavy roughing of stainless steels and high-temperature alloys. It is typically used for applications in the oil and gas industry, e.g. for large valves made from AISI 316 material, or in the aerospace industry with Inconel 718 or titanium materials. The main cutting edge, which is protected by a negative chamfer, prevents fractures when machining hard edge zones and optimises the performance for hard scale, e.g. of forged parts. Components with interrupted cuts and other demanding machining operations are equally feasible.
The curved cutting edge and a deep chip breaker groove produce low cutting forces with high feed rates, consequently reducing the machining temperature. The variable rake angle in the area of the corner radius allows for soft chip reforming and increases the tool life. Available in the standard basic shapes of CNMM, DNMM and SNMM, Walter rounds off its vast product range in the areas ISO S and M with the HU5 geometry. As a result, Walter now offers a total of 12 geometries in six grades as well as tools with precision cooling and ceramic or CBN inserts.
For more information, please contact Spectra Carbide Tooling Technology – Tel: 0860 23 23 23.
The upgraded CoroPlus® ToolPath for PrimeTurning™ software in use.
Upgraded CoroPlus® ToolPath for PrimeTurning™ software speeds up operations and planning processes
Manufacturers that use PrimeTurning™ technology from cutting tool and tooling system specialist Sandvik Coromant will welcome the upgraded CoroPlus® ToolPath for PrimeTurning software designed to help them speed up their operations and planning processes. Part of the Sandvik Coromant digitally connected CoroPlus® suite of solutions for machine shops, the software facilitates maximum turning productivity and output.
The all directional turning methodology, introduced by Sandvik Coromant through the unique PrimeTurning™ concept, enabled increased metal removal rates, offered significant time savings and boosted productivity while eliminating many of the misconceptions associated with small entering angles and chip control. The concept proved especially beneficial in mass production industries such as the automotive sector. It was also ideal for short batch production – for example in aerospace and oil and gas – of components in difficult-to-machine materials that require frequent set-up and tool changes.
To get the best out of the process – including more efficient and faster programming – the company launched its CoroPlus® ToolPath for PrimeTurning™ software which has now been enhanced with a host of new features, functions and an easy-to-use interface. Available in stand-alone and CAM-integrated versions, the software provides the correct grade, geometry selection and cutting data while ensuring optimal productivity and tool life as well as maximum output.
Among the main benefits of PrimeTurning™ tool path software are faster operations and planning processes as well as constant chip thickness and correct entry into a component, ensuring greater process security. Also, compatible with a wide range of CNC turning machines that use ISO codes, the software provides automatic storage for component profiles.
Packed with new features designed to enable users to gain all the benefits offered by PrimeTurning™ method and CoroTurn® Prime tools, CoroPlus® ToolPath for PrimeTurning™ now supports profiling and facing for external turning in addition to existing programmable support for longitudinal turning. The software also enables CAD models to be imported (in STEP and IGES formats, among others) and offers 3D simulation with collision detection.
A key new feature is an improved and intuitive interface for machinists who don’t have CAM software with PrimeTurning™ support or those doing shopfloor programming, with the option of operating on desktops or mobile devices. The user is able to generate NC code in few quick and easy steps. After the user specifies the operation, machine parameters, workpiece details and material information, the software automatically recommends the right tools to use along with the cutting data. The operator can simply use the suggested solution or alter parameters to get customized results.
Before creating the final NC code, the PrimeTurning™ tool path software enables the user to run a simulation to verify no collisions and change any parameters as required, then generate a new program within seconds and run another simulation until the user is satisfied enough to produce the correct code. The software enables the user to stop anywhere they like in the process, running a simulation block by block or going back into the code if preferred.
CoroPlus® ToolPath for PrimeTurning™ is a subscription-based software and a one-month free trial is available for users to get hands-on experience before committing to the annual subscription.
For more information, please contact Sandvik Coromant – Tel: 011 570-9615.
ISCAR is introducing the CHAMFMILL family of indexable milling cutters carrying PNMT 06 pentagonal inserts with five cutting edges for front chamfering and five for back chamfering, providing an economical machining solution.
The new economical cutters carry star-shaped (pentagonal) double-sided inserts with 10 cutting edges and are produced from ISCAR’s advantageous IC830 SUMO TEC carbide grade.
The CHAMFMILL family ensures cost-effective milling of 45° chamfers and productive machining due to the high cutting speed. Main applications include machining main engineering materials: steel (ISO P), stainless steel (ISO M) and cast iron (ISO K). The tools are intended for front chamfering, back chamfering and removing burrs, which eliminates hand de-burring. The maximum width of a machined 45° chamfer is 1.5 mm.
Two shank configurations are available: cylindrical shank and replaceable milling heads with MULTIMASTER adaptation. The tools are available in 11.70, 16.70 and 18.70mm tool diameters and are suitable for back milling chamfers in 10mm minimum diameter holes. A polish coating ensures better chip flow and tool protection from corrosion and wear.
For more information, please contact ISCAR South Africa – Tel: 011 997-2700.
The engineering of lightweight vehicles requires manufacturers to combine functional metal components with lightweight, highly durable carbon fiber reinforced plastics. Fraunhofer researchers have developed a variety of solutions for joining such disparate materials – and will be showcasing their technology at this year’s Hannover Messe.
Whether it is buses, cars, scooters or bicycles, it seems certain that electromobility will power the future. One of the biggest hurdles at the moment, however, is how to increase vehicle range – a challenge that will depend on making vehicles as light as possible. The lighter the vehicle or transporter, the longer the energy storage lasts. In this domain, Carbon Fiber Reinforced Plastics, or CFRP for short, are the material of choice – as strong as steel and yet some eight times lighter and even three times lighter than aluminium. The general practice is to manufacture individual components, the vehicle frame for instance, using CFRP, and then join them to the functionbearing metal components using screws or adhesives. In other words, components that connect long expanses and transfer loads can be manufactured using CFRP, while metal is reserved for the functional components and attachment points for the steering mechanism, for example.
Now, researchers from the Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV at the Technology Center in Augsburg have come up with a variety of innovative new techniques to join conventionally cast components with those made of CFRP. Looking beyond the thoroughly established foundry technology, there is a lot of potential in modern manufacturing techniques such as additive manufacturing and 3D printing. “We’ve combined the various new joining techniques in an electric scooter demonstrator. The goal is to cut down on the number of mechanical attachment points and simplify the joining process as much as possible,” explains Dr.- Ing. Daniel Günther, who heads the project at Fraunhofer IGCV. “There’s a lot of potential in combining metal and CFRP components, with a potential weight saving of up to 50 percent depending on the part.”
Clamping technique to join rear-wheel support
The rear-wheel support of an electric scooter contains a lot of parts integral to its functioning and, for that reason, it is made out of metal. To make it as lightweight as possible, the research team produced the part out of highly durable steel, optimizing the topology so the material is restricted solely to the places it is needed to support the functioning.
To produce the part, researchers drew on an additive manufacturing technique that uses a laser beam to form components out of a metal powder. The rear-wheel support is connected to the CFRP footboard using a screw system – making it easy to remove and disassemble for maintenance.
Adhesively bonded hybrid steering head
The steering head of the scooter is a hybrid component, with an aluminium base frame linking to the footboard behind and the handlebars at the front. This part of the scooter is full of parts integral to its functioning, with a significant expanse to bridge in-between. Using CFRP parts ensures the necessary rigidity. The two different materials are joined together using adhesive bonding. “In terms of a baseline load, we assumed a person weighing one hundred kilograms performing jumps with the scooter. To sup- port that sort of load using a pure aluminum cast part, you would need a huge amount of material to ensure sufficient rigidity,” says Günther. To manufacture the part, Günther and his team began by analyzing the available installation space. As a rule of thumb, the more room used, the larger the cross-section of the component – and the better its rigidity. The material has to be kept as thin as possible, however, to ensure that the component does not become overly heavy. The solution to this is to use CFRP in combination with cast metal. As a further step, the researchers calculated the load at various points of the component. The splices have been precisely positioned at the points with the least load. Rigidity is guaranteed thanks to the shaping of the CFRP component.
Fork system – the joining technology of the future
The load-bearing capacity and durability of CFRP comes from the fibers contained within it. Here, the main challenge lies in transferring the force acting on a component so it is absorbed by these same fibers. On top of this, engineers need to ensure that any metal parts are as securely attached to the CFRP components as possible, without any gaps or cavities. In response, the researchers have developed a completely new joining technique – best explained by taking a look at the components involved. In the example of the electronic scooter, you have a cylindrical piece connecting to the handlebars, a steel component made using an additive manufacturing technique. The bottom of the component has a plate that works as a base with small pins sticking out from its surface. Researchers then overlay this base plate with the prepregs for the CFRP component, made out of fibers coated with synthetic resin. Afterwards, they apply vacuum and increase the temperature. The resin encloses the carbon fibers, flows downwards and closes the gap with the metal plate, hardening to form an adhesive bond. Here, not only does the resin stick to the plate, the protruding pins are also enveloped and held in place by the fibers. This interlocks the components and supplies a solid bond – without the need for screws or additional adhesives. “The technique is fast, industry-ready and can easily be scaled up for mass production,” says Günther.
There is unprecedented interest in Automechanika Johannesburg from other African countries this year. This follows the attendance at the first four roadshow meetings in Tanzania, Zimbabwe, Zambia and Kenya to promote the event, which takes place at Expo Centre, Nasrec, from 18-21 September 2019. More than 75% of the floorspace has been booked already.
MIAZ, the Motor Industry Association of Zimbabwe, is planning on bringing a delegation of buyers to the show, as well as at least 30 buyers from Tanzania, Zambia and Kenya. Another three of these events are scheduled for, Rwanda, Botswana and Namibia which will ensure more visitors from Africa than ever before to the show.
While exhibitors will be taking the opportunity to announce new products and services, organizations and companies are also using Automechanika as the venue for meetings, conferences and workshops. Among those who have already booked events of this kind are Motor Industry Workshop Association (MIWA), Engine Remanufacturing Association (ERA), Collision Repairers’ Association (CRA), Motor Industry Staff Association (MISA), Fuel Retailers’ Association (FRA) and Safer Connected Mobility.
Joshua Low, Managing Director of Messe Frankfurt South Africa, says he is very pleased at the positive response from both exhibitors and the rate at which visitors are registering.
Danie du Toit, the Group Chief Executive of Denel says the company is busy with a comprehensive programme to restore good corporate governance, reduce costs and find new opportunities for growth, especially in export markets.
“The support given to us by the President in Parliament will help us to position Denel as a reliable designer and manufacturer of world-class defence and technology systems,” says Du Toit. “Our reputation took a severe battering with the revelations about state capture and widespread irregularities in the company, but we are taking determined steps to get it back on track.
“The positive sentiments expressed by both President Ramaphosa and Public Enterprise Minister, Pravin Gordhan, will help to restore confidence in Denel among existing and prospective clients, suppliers and employees,” says Du Toit.
In his remarks Gordhan described Denel as a crucial and strategic state entity that was substantially harmed by state capture. He also noted that Denel is improving the way that it contracts and is renegotiating existing contracts to improve the margins it earns on such business.
Du Toit says Denel supports President Ramaphosa’s vision of a new landscape in which state-owned companies have the expertise, leadership and appropriate financial models to fulfil their mandates. They have a critical role to play, together with the private sector, in driving economic growth and transformation.
Ford SA introduces third shift for Silverton Plant.
Ford Motor Company of Southern Africa (FMCSA) is introducing a third shift to its vehicle assembly operations at the Silverton Assembly Plant in Pretoria to meet the growing international and local demand for the New Ranger, Ranger Raptor and Everest.
The additional shift, which commences in August this year, will create 1 200 new jobs at the Silverton plant, taking Ford’s total employment in South Africa to approximately 5 500 employees. At the same time, it will significantly bolster supplier companies by adding around 10 000 jobs in this sector. In total, Ford’s local vehicle assembly operations will now support some 60 000 jobs within the total value chain.
“The R3-billion investment in our South African plants, announced in 2017, is now coming to fruition with the addition of a third shift to increase our production output,” says Ockert Berry, Vice President Operations, Ford Middle East and Africa.
“The investment enabled extensive reworks at the Silverton Assembly Plant to expand our production capacity from 124 000 vehicles per year to 168 000 units, which is 58 000 vehicles more than our original capacity when the current Ranger programme commenced in 2011,” Berry states. “The third shift will allow us to ramp up our production from the current 506 vehicles assembled per day to a peak of 720 units to satisfy the strong demand from customers in South Africa, as well as for our crucial exports to 148 markets around the world,” Berry states.
Kicking off at the beginning of August, the Silverton Assembly Plant will run around the clock using a three-shift pattern from Monday to Thursday, with the additional Friday third shift available to address any potential shortfalls in the production schedule.
Steel and Engineering Industries Federation
of Southern Africa (SEIFSA) Economist
Marique Kruger.
While the increase in overall business activity in the broader manufacturing sector – as reflected in the latest ABSA Purchasing Managers’ Index (PMI) data – is encouraging, nevertheless the trend remains volatile, highlighting the underlying constraints faced by business, Steel and Engineering Industries Federation of Southern Africa (SEIFSA) Economist Marique Kruger said recently.
Based on a survey of purchasing executives, the composite PMI data for June 2019 shows that industrial activity improved to 46.2 points, up from the 45.4 points recorded in May 2019. A reading above the benchmark level of 50 indicates an expansion when compared with the previous months, while the reverse is true for a reading below 50.
Speaking after the release of the data, Kruger said it is encouraging to note that the majority of the five seasonally-adjusted sub-components correspondingly registered increases in June 2019 when compared to May 2019. Of the five sub-components, the new sales orders and the inventories subindices increased the most, surging from 44.4 points in May 2019 to 46.2 points and from 41.6 points to 43.4 points respectively in June 2019, while the worst-performing sub-index was the employment sub-index (41.9 points).
Despite the improvement, Kruger said the PMI trend is still very volatile, highlighting the underlying constraints faced by business.
“Against the backdrop of low domestic demand, companies still have to deal with fluctuating input costs, increasing fuel and energy costs, carbon tax and volatility in the exchange rate. These are very challenging,” concluded Kruger.
