Scientists at the Center for Research and Development at the University of Applied Sciences in Zvikow are pleased to see such good results and after extensive experimentation they are convinced that Walt is now able to offer the only surface milling application on the market that can be used with unlimited double- Contour contouring and helix roughing applications.
This has brought the gospel to users of general mechanical engineering, especially the energy industry, which is a new concept milling cutter based in Walter, Tübingen, dedicated to the machining of turbine blades. To date, Unparalleled achievement: the eight cutting edges of the indexable inserts (four on each side) are very practical and very different from the milling tools available on the market today.
Cutting material costs up to 15%
This is the economic benefit of a new solution: Dr Vikki Franke, Walter's energy manager, says: "The results show that cutting material costs can be cut by as much as 15% while maintaining the same outstanding performance and power requirements. No need to use any of the eight cutting edges on the indexing insert.
The M2471 Profiler is cost-effective and has a total of eight cutting edges for face milling (contour) applications and milling applications without any restrictions (image courtesy of Walter)
Walter Energy Department Manager Dr Vikki Franke (Photo by Walter)
The new Walter M2471 Profiler with a 12mm circular insert, which is the technical basis for this milling tool, is equipped with a sintered indexable insert with a negative geometry and a positive rake angle profile made of Tiger ∙ tecSilver WSP45S The cut depth of the profiling cutter can reach 6.0mm. In order to ensure a certain reduction of milling efficiency and low cost, Walther's R & D personnel recommend a maximum depth of cut of 4.0mm.
With this configuration, the tool is ideally suited for the machining of steel parts, stainless steel workpieces and difficult-to-cut materials, and is also suitable for helical roughing and contouring of turbine blades. However, due to the cost-effectiveness of this solution it is used in face milling applications Is also very prominent.Even the use of low-performance machine tools, but also to achieve a relatively high metal removal rate.The stability of the indexable blade to ensure the reliability of the process.
Cutting light
Dr Vikki Franke said: 'The cutting edge flute with a positive rake results in less cutting, and the cutting force is much less than the grooves that are commonly used in these applications.' 'She said that as tool performance improves, it is particularly beneficial Roughing and semi-finishing of the turbine blade's root, head and entire blade. "For example, these machining processes account for 60% of the cost in turbine blade production, and the cost of the tool can be significantly reduced with a new cutter. '
According to the energy department manager, the new cutter represents its cost-effectiveness and is particularly suitable for machining small and medium-sized turbine blades with a length of about 500 mm under stable machining conditions. Ultimately, it relates to the single-edged cost.
Eight cutting edges play a decisive role
In traditional roughing or semi-finishing, costs include fixed costs as well as machine costs, labor costs and tool costs.To compare performance, Walter's developers and Zwickau University of Applied Sciences experimented with different tools that For both sides, the following machining parameters are identical: cutting speed, infeed and machining time. "Unlike all other milling cutters, all of our new concept milling cutters use all eight cutting edges, Cut tool costs by about 15%. '
During the development of the new tool, Walter engineers ensured that the effective rake angle of the double-sided tool in the installed position was almost identical to the existing conventional machining scheme.
The usable diameter range of the M2471 profiled milling cutter is 32-63mm. The milling cutter can be fitted with either the ScrewFit adapter or the drill adapter. The new cutter from Walter offers two indexable inserts: D57-19 °, common under normal machining conditions; F67-rake angle of 24 °. The latter is best for good machining conditions and the amount of normal feed, due to its cutting force is small, the performance is particularly prominent.
Can be used on both sides, a total of all round blade effective cutting edge; Left: D57 - Universal blade; Right: F67 - Easy to cut blade (Photo: Walter)
obvious advantage
The results of the comprehensive commissioning analysis show that the machining concept using the M2471 Profiler has significant advantages over all other two-sided cutters on the market:
Tool life longer;
Cut deeper
Cutting force lower;
Cutting noise lower;
More available cutting edges;
During the test, experts were able to document the uniqueness of at least one Walther cutter in every test. Other indexable insert cutters can also be used on both sides, however, in most cases, The use of the lower cutting edge is very limited, for example, in helical roughing applications, the cutting edge tends to be damaged before use.
The scientists at the University of Applied Sciences in Zwickau conclude that Walter's solution is the only two-sided milling cutter that can be used for face milling applications, contour applications and milling applications without any restrictions.
Walter M2471 profile milling cutter advantages summary
Due to the high metal removal rate, the milling cutter is extremely cost-effective and can even be used on low-performance machine tools;
Each blade has a total of eight cutting edges, lower cutting material costs;
Stable indexable inserts ensure reliable machining;
Due to the use of positive rake angle cutting groove can be easily cut the process;
PVD coated WSP45S material, without coolant, can be used micro-mist lubrication, and can be applied to wet processing (emulsion).