Performing demanding milling tasks economically Walter’s milling cutter portfolio offers application-specific solutions

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Milling covers many application ranges, from the machining of large free-form surfaces in the aerospace industry and in the manufacture of wind turbines, to the milling of cavities, to highly automated mass production. Today, complex components are the rule rather than the exception. The range of milling tools used by customers is very broad. After all, the quality of the end result and the process reliability are highly dependent on the milling tools and their use. At the same time, the cost pressure on companies in the metalworking industry has increased significantly in recent months. Tool costs also play an often underestimated role here. Excellent support at the customer’s site or virtually using appropriate media help to optimise tool use. Machining specialist Walter is convinced of this. The Tübingen-based company considers the impressive expertise in advising and processes possessed by its technical sales and product management staff as a crucial factor in the company’s success.

 

 

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Machining materials with difficult cutting properties at high metal removal rates: Walter BLAXX milling cutters

 

 

With the Walter BLAXX, M4000 and Xtra·tec® XT product ranges, Walter addresses the very different requirements of specific applications: Walter BLAXX milling cutters are the optimum choice for maximum metal removal rates on milling machines boasting high power and high torque. In most of this product range, the indexable inserts are mounted in a tangential position on the milling tools. Due to the higher carbide volume in the cutting force direction, this position allows a higher feed per tooth compared to a radial indexable insert position. This allows the machine’s performance to be fully utilised without jeopardising process reliability and the quality of the results.

 

 

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The Walter BLAXX M3255 helical milling cutter is recommended for the powerful machining of titanium components, such as those found mainly in the aircraft industry. In heavy machining, the Walter BLAXX M3016 milling cutter impresses across the entire range of applications. Carbide stop pieces with an emergency cutting function protect the tool body from damage in the event that the indexable insert is worn or broken.

 

 

High flexibility in applications, low storage costs: The Walter M4000 milling system

 

 

 

 

The Walter M4000 range has been successful on the market for several years now. The trend towards smaller batch sizes and more frequent changes to components continues to open up many possible applications for milling cutters, as all types of milling cutters can be equipped with the same system insert: From face milling cutters to shoulder milling cutters, high-feed milling cutters, helical milling cutters, T-slot milling cutters and chamfer milling cutters. This allows users to respond quickly and flexibly to different applications in production. This also has an impact on tool management: The number of indexable insert types to be managed can be significantly reduced. This cuts the customer’s expenditure for procuring and storing the indexable inserts.

 

 

 

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Excellent process reliability for a high degree of automation: Xtra·tec® XT milling cutters

 

 

Process reliability with high output is the main quality criterion, especially in automated production with high time pressure. The Walter Xtra·tec® XT milling cutter range provides machining companies with a solution which covers almost all milling applications and boasts a design that is fully optimised for maximum process reliability paired with maximum performance.

 

If we take the M5130 shoulder milling cutter as an example, the most striking design feature of the Xtra·tec® XT milling cutters is clear to see. On this tool, the installation position of the indexable inserts is more inclined and has a larger contact surface. This reduces the surface pressure in the seat while increasing the stability. The larger screw hole cross-section stabilises the indexable insert and the longer screws hold it in place more securely. The milling body has also been made stronger, as it now has much more material behind the insert seat. Besides greater process reliability, the new installation position of the inserts also allows for the addition of an extra tooth, thereby increasing productivity.

 

 

Ideal indexable insert coating for difficult applications: Tiger·tec® Gold WSP45G

 

 

High-quality milling tools can only deliver top performance when they are used with the appropriate indexable insert coatings with long tool life. When milling, thermal cracks are one of the standard types of wear. They arise from the change of temperature between the entering and exiting cutting edge. In the worst-case scenario, the cutting edge will break and the indexable insert will fail. With the Walter Tiger·tec® Gold WSP45G, on the other hand, the wear is even. Thermal cracks and fractures are counteracted. The Tiger·tec® Gold PVD grade WSP45G has a very wide application range and is ideal for reliable milling of components from material groups ISO P (steels), ISO M (austenitic stainless steels) and ISO S (materials with difficult cutting properties such as titanium or nickel-based alloys).

 

 

Continuous expansion of the milling cutter portfolio

 

 

An indexable insert with WaveCut L65W geometry is available for the Walter BLAXX M3255 helical milling cutter. With the new cutting edge geometry, Walter’s focus is on addressing the requirements in the aircraft industry, where titanium machining with long tool overhangs poses a particular challenge.

 

 

The stable SDMX indexable insert in the E57 geometry for the M4002 high-feed milling cutter enters the workpiece extremely smoothly and, more than anything else, improves cost-efficiency and process reliability when machining austenitic stainless steels and other materials with difficult cutting properties.

 

 

 

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The Xtra·tec® XT face milling portfolio, specially developed for use in automated production, is rounded off by the new M5011 milling cutter with 75° lead angle. This provides users with the third face milling cutter in the Xtra·tec®XT range with SN.X inserts, in addition to the M5009 with 45° lead angle and the M5012 with 88° lead angle. The double-sided SN.X insert is extremely stable and boasts impressive performance and process reliability in particular, which can be further increased by combining it with the new optional carbide shim.

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