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WORLD FIRST WITH TWO CUTTING EDGES

The Walter exchangeable-tip drill Drion·tec® D-Spade D5142

 

With the new Drion·tec® D-Spade D5142 exchangeable-tip drill, Walter AG is launching the world’s first drill of its kind with a double-sided indexable insert. The special feature, the flank face of the first cutting edge serves as a support surface for the second, which doubles the service life of the exchangeable tip and significantly reduces the costs per metre of drilling. Designed for maximum cost efficiency, the holemaking drill is designed for Ø 12 to 32 mm and lengths from 3 to 8 × D(c). Four lands and the self-centring point geometry ensure high precision and surface quality of the hole with exact centring, straightness and diameter tolerance.

Ground and polished chip clearance spaces optimise chip evacuation and increase process reliability. Six coolant outlets ensure precision cooling on the cross-cutting edge, main cutting edge and circumference on both teeth. The combination of fine-grain substrate and the gold-coloured HiPIMS coating of the DS42 indexable insert enables very good wear resistance and easy wear detection. The symmetrical design of the double-use exchangeable tips not only doubles tool life, but also reduces the amount of carbide used per cutting edge by 45% compared to conventional drills on the market. Walter is therefore positioning the Drion·tec® D-Spade D5142 as the new standard for both cost-conscious and sustainable holemaking, particularly suitable for mass producers with steel and cast-iron materials, for example in the automotive industry, the energy sector or the rail vehicle industry.

The symmetrical Drion·tec® D-Spade design with 2 cutting edges per exchangeable tip is completely new on the market. The flank face of the first cutting edge forms the contact surface for the second cutting edge. Two radial screws clamp the exchangeable tip securely in place.

For more information, please contact Spectra Carbide Tooling Technology – Tel: 021 555 4144.

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NEW TECHNOLOGY FROM UNITED GRINDING GROUP

C.O.R.E. – Customer-Oriented Revolution

When the public discussion about the fourth industrial revolution, Industry 4.0, intensified a few years ago, the UNITED GRINDING Group made the decision to invest more in the digital future together as a group — not only in the future of the group but above all the future of its customers. And thus the development of C.O.R.E. began. The aim and central focus of this development were to ensure increasing connectivity, i.e. the exchange of data between people, machines and the production environment plus to create the basis for the operation of modern IoT applications. In addition, an intuitive operation was to be enabled to make the work easier for machine setters, machine operators and maintenance staff. C.O.R.E. has turned this vision into reality in a revolutionary way.

Intuitive Operation

It is reminiscent of a gigantic smartphone: The 24-inch full HD multitouch display identifies the next-generation machine tools equipped with the new C.O.R.E. technology. Navigation works like on a smartphone, using “touch” and “swipe.” Customers can also configure the user interface according to their individual requirements and arrange the most important functions and operating displays according to personal preferences similar to the app overview on a smartphone home screen.

Thanks to the new access system, which works via a personalized RFID chip, the individual user profile is automatically loaded. This not only makes it easier to log in and out of the machine, but is also significantly more secure. Another advantage is that a  roles profile is stored for each user, so users only see information relevant to them, which reduces complexity and helps prevent errors.

When it comes to reducing complexity, it is also noticeable that the new C.O.R.E. panel has virtually no keys. There is a prominent rotary switch for feed rate override, allowing the axes to be regulated with a simple turn.

The uniform use of the C.O.R.E. Panel across all brands also simplifies machine operation and makes training easier, meaning that anyone who knows how to operate one UNITED GRINDING machine can operate all of them.

C.O.R.E. is “More than Just an Innovative Control Panel”

The eye-catching new control panel is, of course, only the visible aspect for machines equipped with the new C.O.R.E. technology. “There were also major innovative developments behind the machine enclosure,” stresses Christoph Plüss, CTO of the UNITED GRINDING Group. C.O.R.E. OS. A full operating system is installed on a high-performance industrial PC, the C.O.R.E. IPC which serves as an IoT gateway and is home to all software applications. C.O.R.E. OS is also compatible with all CNC controls used at UNITED GRINDING.

Furthermore, the new technology opens up a wealth of opportunities for connectivity. Not only can all machines with C.O.R.E. technology from the UNITED GRINDING Group be networked, but also third-party systems via implemented interfaces such as umati. This opens up direct access to UNITED GRINDING Digital Solutions’ offerings on the machine from remote service to the service monitor and production monitor. For example, support from the Group’s Customer Care Team can be requested directly at the C.O.R.E. panel. A chat feature ensures fast and easy support, and the integrated front camera even enables video calls.

Highest Benchmark – User Experience

In the development process of C.O.R.E., which lasted several years, software and process experts from all brands of the UNITED GRINDING Group pooled their expertise to design an unparalleled software architecture. “The user experience, i.e. the immediate experience of the users, has always been our top priority,” explains CTO Plüss. It is for a good reason that the abbreviation C.O.R.E. stands for Customer Oriented REvolution.

In the area of operating systems and software architectures of machine tools, C.O.R.E. is a quantum leap, emphasizes company CEO Stephan Nell. “This means that our machines are ready for the digital future.” The C.O.R.E. technology presented for the first time at the EMO 2021 in Milan is still under development. “It lays the foundation upon which we can build,” explains Plüss. “Development will continue on an ongoing basis. Thanks to the flexible, modular structure of the software architecture, we will continuously add new features and applications. We intend to harness the concentrated software development power of our group for the benefit of our customers.” Our goal is to inspire customers with a regular stream of new C.O.R.E. software releases and thus actively help to shape the digital future. In this way, the Group remains true to its ultimate goal of making its customers even more successful.

The industrial production of the future is connected. Machine connectivity is the key phrase. A number of requirements must be met before networking is either possible or usable. UNITED GRINDING C.O.R.E. – Customer Oriented REvolution ensures these requirements. “The digital future begins with C.O.R.E.,” stresses CEO Stephan Nell. The groundbreaking new hardware and software architecture was developed by the group’s specialists and premiered at the EMO 2021 in Milan. It opens up remarkable possibilities for networking, controlling and monitoring the production process and thus also for process optimization. And more: C.O.R.E. brings the user experience of operators into the world of the smartphone generation.

For further information, please contact RETECON – Tel: (011) 976 8600.

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HUSH-BORE – Extended Length 12xD & 14xD Shanks for the Anti-vibration Boring Bar Line

Since its introduction, the anti-vibration HUSH-BORE line, which can do deep internal machining, has received favourable feedback from many customers. TaeguTec offers even deeper internal machining solutions by incorporating 12xD and 14xD shanks in addition to the already existing 7xD and 10xD shanks.

The steel and carbide-based 12xD and 14xD shanks offer outstanding machining performance even during deep internal machining because they have improved rigidity and hardness, which prevent shank breakage caused by bending.

For more information please contact TaeguTec – Tel: 011 362-1500.

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MODULAR TYPE SHANKS FOR VARIOUS TURNING APPLICATIONS

TaeguTec has introduced a new modular type of head changeable holders, compatible with both external and internal turning applications. The line is available in two modular types, a square shank for external turning and a C-adapter for internal, external and Y-axis operations. In addition, the current HUSH-BORE head can be mounted to the HUSH-MODU shanks, thereby widening the range of applications even further.

The HUSH-MODU’s Y-axis turning head provides excellent machining stability and a dramatic productivity increase. Further, the new Y-axis head demonstrates high performance machining as it is compatible with TaeguTec’s TNMV and ZNMV insert lines.

For more information please contact TaeguTec – Tel: 011 362-1500.

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DRILLING AND MILLING CAPABLE – DRILL-MILL

TaeguTec has introduced milling and drilling capable SDM end mills and MXDM heads, which are high-efficiency machining tools designed for both, general milling and drilling operations. Their wide flute design ensures smooth chip evacuation, even at drilling depths of 1xD. Additionally, the tapered core’s reinforced rigidity and optimal helix angle ensure smooth cutting and stable machining without performance degradation during milling operations. Furthermore, this new line quickly transitions from drilling to milling at the drilling depth, improving productivity by reducing the number of machining passes.

While capable of milling immediately following drilling, drilling is possible at feed rates comparable to standard drills. Other features include excellent performance on general carbon steel, alloy steel as well as stainless steel, optimized flute design for smooth chip evacuation during drilling, tapered core with reinforced rigidity, suited to various milling operations and unequal helix angle design for smooth and stable cutting performance. Add to this helix-type internal coolant for excellent chip evacuation but solid end mill type only.

 

MXDM – MAXI-RUSH type

 

SDM – Solid end mill type

 

For more information please contact TaeguTec – Tel: 011 362-1500.

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LASER MARKING MACHINE – LASERMARK

Laser Marking Machine - Lasermark MCFA-30

The laser marker MCFA – 30, available from Duncan Macdonald takes full advantage of the power of the fibre laser to achieve great improvements in both, processing time and quality.

Go Tapping S.L. has developed and manufactured the MCFA – 30 based on unique oscillation methods. While the Lasermark is designed, featuring innovative technologies, other benefits include long life, ease of use and cost effectiveness.

For more information, contact Duncan MacDonald – Tel: 011 865 4090.

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MESTAB – THE ALTERNATIVE TO TENSIONS, MAKING STRESS RELIEF EASY

The MESTAB equipment from GOTAP in Spain represents the result of years of development work, trials and tests in the company’s own production of hydroforming presses. What was born as an internal treatment to guarantee the stabilization of residual stresses in frames, has advanced to become a cutting-edge technological solution.

Discovered in the 1940s, accidentally by the American Society of Naval Engineers in the USA, vibration stress relief has come a long way to become the standard of large aeronautical and industrial companies MESTAB, the intelligent alternative in tension stabilization.

Integrated and portable system

Just two cases, you can use it in field services, in remote locations and in extreme industrial environments. The robustness of the equipment stems from GOTAP’s own experience in the boilermaking sector.

The compact weight of both units allows for easy transport, even in-flight check-in for agile and unlimited handling and use.

Report as a guarantee of the process

The MESTAB system generates a comparative report of the stress state before and after treatment. The inclusion of a photograph of the actual part allows for easy identification and future traceability.

This way, you can guarantee the effectiveness of the process for your customers, avoiding production downtime, due to external suppliers.

For more information, contact Duncan MacDonald – Tel: 011 865 4090.

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RUSHING MACHINING WITH VERSATILE INDEXABLE MAXI-RUSH SOLID CARBIDE HEADS

With its innovative head-indexable feature and overall outstanding advantages, the SFEED-TEC MAXI-RUSH end mill replaces most of the existing conventional solid carbide end mills in its class.

Along with its exceptional accuracy and optimum grades, the line’s quick and simple head replacement makes it a perfect solution for today’s machining needs and a superior performer that boosts productivity on a range of applications.

MAXI-RUSH is available in a variety of head types and shank holder lengths, such as flat, ball, corner radius, chamfer and slot, to mention a few, while providing the greatest versatility in tooling solutions.

Its rigid and precise double contact fastening system houses a flat contact surface area for precise axial runout accuracy, has a conical taper contact for self-centring and precise radial runout accuracy and is highlighted by its quick and rigid unique threading.

TaeguTec has added oval and lens-shaped solid carbide heads that are 3D profiling capable in order to solve industry-wide disadvantages, such as excessive machining time and poor surface finish, which plague profiling operations.

The MAXI-RUSH 5-axis profile heads are designed for high-pitch, semi-finishing and finishing profiling parts used in the aerospace, power generation, medical and mould and die industries.

Even in high-pitch conditions, the same surface finish can be obtained compared to solid carbide ball type end mills, making the MAXI-RUSH 5-axis profile heads capable of high-productivity machining.

Machine shops of all sizes have taken a special interest in the metalworking giant’s highly rigid MAXI-RUSH line because of its excellent machining precision, simple indexable head replacement and shorter setup time. The line now includes a wider variety of tools that are capable of handling a broad range of operations.

The expanded features include a wider cutting edge contact area for improved machining stability and longer tool life, and are ideal for machining difficult-to-cut materials such as titanium alloys, Inconel, and stainless steel.

Recently, TaeguTec added the TT5513 grade to the technologically advanced MAXI-RUSH line. The ingenious grade has an ultra-fine substrate with optimum toughness features and excellent abrasion resistance. It has a nano-crystalline structured AlTiN layer, an anti-abrasion and cracking-resistant PVD-coated layer and is ideal for mould steels and pre-hardened steels.

The MAXI-RUSH’s versatility and range are only matched by its incredible machining prowess.

A range of shapes and lengths are available, including straight shanks with necks and tapered necks made of different materials. These are available in steel, carbide and tungsten and are internal through coolant capable.

For more information please contact TaeguTec – Tel: 011 362-1500.

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SMART COOLING & CHIP CONTROL – A NEW ERA IN MACHINING

“A good tool improves the way you work. A great tool improves the way you think.”(Jeff Duntemann)

 

Learn how ISCAR’s innovations in direct cooling and chipbreaker geometry are reshaping tool performance, process stability and surface quality. In the world of metal cutting, the key to efficient, high-quality machining lies in two critical factors, such as thermal management and chip control. At ISCAR, engineers have tackled both challenges simultaneously by developing advanced internal coolant delivery systems alongside high-performance chipbreakers. The result is a cutting-edge (literally) solution that delivers smoother operations, longer tool life and superior surface finishes, even under the demanding conditions of mass production.

Direct Cooling – Born from a Real Need

The challenge was set for ISCAR’s Turning and Groove-Turn development teams – design tools that offer smoother cutting, greater process stability, extended tool life and improved surface finish, particularly in mass production environments. The solution centred around an innovative approach to coolant channel design by optimizing outlet angles, exact positioning and flow rate to achieve exceptional results in targeted, high-efficiency cooling.

Advantages of Direct Cooling to the Cutting Edge

  • Significant Heat Reduction on the Insert

Excessive heat causes plastic deformation of the insert, altering its geometry and negatively impacting machining accuracy, surface finish and tool life. Direct cooling maintains a stable temperature at the cutting edge, preventing these effects.

 

  • Efficient Chip Evacuation

Improper chip evacuation leads to part damage, built-up material and unnecessary cutting forces. Focused cooling facilitates continuous chip flow, improving process stability and surface quality.

  • Prevention of Built-Up Edge Formation

Difficult-to-machine materials tend to stick to the cutting edge, forming a built-up edge. Direct cooling significantly reduces this tendency, keeping the cutting zone clean and effective.

  • Maintaining Dimensional Stability of Long Parts

Direct cooling lowers overall temperature, helping prevent thermal distortion and bending in long or slender components.

Coolant Channel Design – A Precise Science

Though internal coolant channels are hidden from view, their impact is dramatic. ISCAR develops smart coolant geometries that deliver fluid precisely to the cutting zone. This targeted cooling extends insert life, reduces machine downtime, shortens setup time and optimizes the overall machining process.

Chipbreakers – The Critical Link to Machining Success

The chipbreaker is a fundamental component with a direct impact on cutting performance. Despite its vital role, its importance is often overlooked. One of the most common challenges in machining is poor chip control, especially during finishing, semi-finishing, or operations involving variable cutting depths.

ISCAR has taken the lead in this domain by developing new chipbreaker geometries suitable for a wide range of materials, including steel, stainless steels and superalloys.

How a Chipbreaker Works

Chipbreakers with an arched groove near the cutting edge force the chip to curl and break into a short length. This prevents chip entanglement, reduces vibrations, extends tool life and minimizes tool breakage. Effective chip breaking also lowers resistance, decreases heat generation and slows insert wear. A well-designed chipbreaker contributes directly to longer insert life and improved process reliability.

 

Choosing the Right Chipbreaker – Material, Conditions, and Application

When selecting a chipbreaker, several parameters must be considered:

  • Material type (e.g., steel, stainless steel, superalloys)
  • Cutting conditions: cutting speed (vc), feed rate (f), depth of cut (ap)
  • Required surface quality: Finishing or roughing operations

The proper combination of chipbreaker design and direct cooling is the key to machining accuracy, consistency, and efficiency.

Conclusion

ISCAR remains committed to developing intelligent solutions that deliver real value to its customers. Direct cooling at the cutting edge, combined with application-specific chipbreaker geometries, represents a technological leap that enhances every critical performance metric—from tool life to surface quality. Coolant channel design and chip control are no longer optional, they are the foundation of modern metal cutting.

For more information, please contact TaeguTec – Tel: 011 362 1500.

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HIGHLY EFFICIENT LASER CUTTING WITH THE BYCUT STAR

Featuring ultra-fast speeds and an expanded cutting spectrum, the ByCut Star now cuts with 30 kilowatts of laser power.

Impressive high cutting speed, intelligent cutting process and a new design – this is how the new ByCut Star presents itself. With 30 kilowatts and an optimized cutting process, it now cuts steel, aluminium, stainless steel, brass and copper precisely and reliably for even more quality.

Higher cutting quality and productivity is provided thanks to more laser power and smart features. Bystronic has advanced into a new dimension of fiber laser cutting, the ByCut Star with impressive 30 kilowatts of laser power. The high-end fiber laser stands for high-precision Bystronic technology, a stable cutting process up to the highest laser powers and for a wide range of applications.

However, sheet metal workers not only need a lot of laser power, but also intelligence, reliability and sustainability; this combination makes the laser cutting process really satisfying and successful.

Thus, at Bystronic, customer success is built on a concept of three pillars, namely Power, Intelligence and Cutting Process Improvement, including MixGas technology.

Smart features, such as the “Intelligent Cutting Process (ICP)”, the “Nozzle Control Tool (NCT) with KerfScan” or the “Parameter Wizard” optimize the entire cutting process, while ensuring that it stays on track. Users enjoy optimum capacity utilization and remarkable production uptime.

30 kilowatt of laser power

The technological leap from the previously available 3- to 20-kilowatt levels to the new 30-kilowatt level is considerable and opens new possibilities for Bystronic customers to optimize production and thus remain at the forefront of the ever more fiercely contested competition.

The “Advanced Applications” option enables expanded applications in steel and aluminium of up to 50 millimetres (15 kilowatts laser power and above).

Cutting speeds on the ByCut Star increase twice as fast compared to 15 kW and MixGas with sheet thicknesses between 6 mm and 15 mm, and more than twice as fast with thicknesses starting at 20 mm. Piercing times are shorter for sheet thicknesses of 15 mm and above. Sheet metal processors thus benefit from higher productivity at low unit costs, because with 30 kilowatts, the new ByCut Star cuts steel, aluminium and stainless steel precisely and reliably. The 30-kilowatt laser power enables maximum flexibility for large series and spontaneous customer orders. Whether aluminium or steel, the powerful Bystronic cutting head impresses with maximum precision in thin and thick sheets. In addition, with the “Advanced Applications” option, high laser power (starting from 15 kilowatts) now also enables expanded applications in steel and aluminium of up to 50 millimetres. The new power level is exclusively available on the ByCut Star 4020.

Smart features make the difference

NCT & KerfScan is a smart feature package for oxygen cutting which increases process reliability, even in low-manned operations. This feature offers process monitoring, problem solving and continuation of the cutting process in a fully automatic way.

The “Parameter Wizard” ensures that the correct quality of the cut parts is always selected within minutes. This feature determines the perfect parameters with N2 and MixGas for steel from 4 to 15 mm in thickness.

Intelligent Cutting Process ICP is a new feature, where a coaxial camera is filming through the nozzle and looking directly into the cutting process. This feature currently offers the following functionalities:

  • Cut Quality Detection – The system automatically detects cut interruptions during the cutting process and re-cuts the area where it occurred.
  • Cut Quality Protection – AI-controlled cutting process maintains reliable quality throughout low manned production.
  • Nozzle Loss Detection – Down time and material waste caused by nozzle loss are significantly reduced.

While Bystronic customers benefit from outstanding cutting results with clever features, the new powerful Bystronic flagship is also controlled from a 21.5-inch touchscreen. Handling is as simple as operating a smartphone.

The new ByCut Star’s modern, sharp contours provide a striking appearance and match the performance of the machine.

Significantly increased user-friendliness and outstanding flexibility are major advantages provided by the new ByCut Star. Thus, there is front and/or side access as well as several windows with a view directly to the cutting process. In general, the new design offers better accessibility to the interior, and the machine is easier to place on the store floor thanks to more flexible layout.

Additional accessibility with the all new, sharp designed ByCut Star thanks to several gates.

Fiber laser cutting with mixed gas ensures better cutting quality and higher productivity

In laser cutting, cutting gas (especially N2 and MixGas) is used to keep both the laser and the sheet free of impurities and remove molten material. Nitrogen is used for so-called fusion cutting and oxygen for flame cutting. Gas mixing combines the benefits of O2 and N2 and thus is an alternative to pure nitrogen or oxygen cutting. Cutting with MixGas (a specific blend of Nitrogen/Oxygen) ensures perfect quality on steel at increased cutting speed. This helps even an inadequate steel to achieve a good result after the cutting process.

For in-house gas production with a N2 generator, Bystronic has a solution ready that is attractive from a cost perspective and environmentally friendly. The advantages are obvious: There is no need for transports by trucks when gas is delivered. One produces only as much nitrogen as is needed, and all the previous additional costs are eliminated – from filling the cylinders to replacing them. The sheet metal processor works completely autonomously and – independent from any gas supplier – is doing something for the environment in the process.

For more information please see www.bystronic.co.za or contact Bystronic on 010 410 0200.

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