At the EMO trade fair in Hanover, LMT Tools is expanding its broad product portfolio with a number of innovations for milling, threading and gear cutting. Users from the automotive, aerospace, energy technology, mechanical engineering, medical technology and mold and die making industries will be able to witness new solutions to increase productivity in their individual machining applications.
Regardless whether, for example, in copy milling, a single cutting edge – like the new CopyMax® 1 milling cutter gives the desired result, or 12 usable cutting edges per insert – like the Acu-Jet Double6 Premium: The perfect tool for every application is available. New precision tools are also being presented for machining high-strength or hardened materials, for example, the two positive face-milling cutters MultiFace H45 PRO4 and P45 PRO8 or the MultiEdge 2Feed mini. These are characterized by low cutting forces and a large material removal rate.
The new top performer for gear cutting is the extremely robust UNIFY indexable insert hob cutter. It covers the module range from 6 to 12. It’s low diameter from 150 mm allows the advantage of very short process times, even on smaller machines.
The new modular threadformer HPF Max is an efficient partner for serial production in the automotive industry and in mechanical engineering. A new carbide substrate, new coating, and the optimized former geometry are decisive factors in its long service life.
The CopyMax® product family has grown. Now that the double-sided CopyMax® 2 insert has proved its worth in mold and die to make, LMT Kieninger has also developed the one-sided CopyMax® 1 plate. The carrier tools have also been supplemented. Cylindrical steel shaft versions, available in two different lengths, and the cylindrical bolt-on milling cutter are new to the product range. The extra tools are available with internal coolant supply.
Their particular strength is demonstrated by the CopyMax® family when it comes to roughing and semi-finishing larger molds and in the removal of rest material (Fig. 1). Depending on the nature of the component, the customer can use either the one-sided or double-sided version of the CopyMax® indexable inserts and thus determine their specific advantages themselves. In any case, the user achieves maximum process reliability in terms of quality and service life.
The long life of these tool designs – which has been increased by a factor of 4 when using both cutting edges on the Copymax® 2 – is based on both the innovative high-performance Nanomold Gold coating and on the patent-pending HQS (High-Quality Sintering) manufacturing process. With this process, even more, stable cutting edges can be achieved thanks to the increased mold pressure and a special design.
Many tool systems quickly reach their limits when roughing tool steel, stainless steel or even super alloys. LMT Kieninger has optimized the ACU-Jet Double6 Premium milling system especially for this purpose and added the 12mm dia. indexable insert.
A result is a tool which offers maximum stability and process reliability and which impresses with improved economy due to the double-sided use of the cutting inserts. The indexable inserts can be used up to 12 times.
Cost-effective roughing depends on one thing: The maximum possible material removal rate. For modern machining centers, this doesn’t just presume innovative milling tools rather it also requires a selection of cutting materials for modern materials. However, these requirements are not a problem for the two new MultiFace H45 PRO4 (figure 2) and MultiFace P45 PRO8 face-milling cutters from LMT Fette. The inserts of the first version are set up high-positive and have four cutting edges. The second version has positive turning inserts with eight cutting edges each. These tool geometries markedly reduce the spindle load. Even on low-power machines, it is possible to achieve large material removal rates. This saves production time and machine costs and conserves resources.
In the practical application, machining has been taken to a new level. In the face-milling of a copper block, different requirements were clearly exceeded. Due to the low power consumption of the high-positive version, it was possible to increase the diameter of the tool used from 100 mm to 160 mm and thus increase the radial infeed ae to 102 mm – previously it was 48 mm. Using optimized cutting values it was possible to more than double the material removal rate to 676 cm³/min. The service life per cutting edge also increased from 18 hours to 24 hours, meaning that wear didn’t stand a chance.
The efficient machining of hardened and high-strength materials is a particular challenge for cutting tools. Both the demand for long service life and the maximization of removal rates are rapidly driving development to its limits. But this is not true of the MultiEdge 2Feed mini high-feed cutter from LMT Fette. New indexable inserts complement the range of already established milling tools.
A special carbide substrate combined with a TiAlN-based high-performance coating easily overcomes material hardness, material strength, and comparable competitors’ products. The tried-and-trusted high-feed geometry of the 9 mm small inserts for infeed depths up to a maximum of 1 mm with a thickness of 3 mm allows for a veritable flood of chips during roughing. The slightly positive angle of attack of the indexable inserts also makes a decisive contribution.
In practice, this leads to a considerable reduction in machining times. During the high-feed machining of highly tempered steel 1.2343, it was possible to halve the machining time compared to a competitor’s tool. The long service life of 165 minutes also contributes to reducing costs. The MultiEdge 2Feed mini works very reliably and economically, even with large projection lengths.
A combination of efficiency and Precision
The engine experts at LMT Fette have created a comprehensive product portfolio for the various performance and quality requirements of gear cutting for vehicle transmissions through to drives in wind turbines. One hundred years of experience combined with the latest research and development results constantly generate innovative solutions to further reduce your costs per part.
This is how the new UNIFY indexable insert hob cutter came to be. It strengthens the area of application of the proven gear hob family CarbideLine-I (I= Indexable) in the module range from 6 -12 and is the preferred choice when high performance and high quality are a requirement for the machining of gears. The new design of the UNIFY has created a single-part, compact, very robust base plate which works with extreme precision due to the minimum number of interfaces. The compact design enables the use of indexable inserts for gear hobbing from a diameter of 150 mm which brings many benefits: It can be used on smaller machines, fewer limitations due to collisions and advantages with regards to processing time.
The new gear hob with indexable insert has already passed a crucial test in a practical application with flying colors. It was used for the machining of module 9 skew gears from 18 CrNiMo 7-6 material with 88 teeth and a gear width of 220 mm (figure 3).
The UNIFY which was designed especially for this application used a protuberance plate with 4 cutting edges to achieve a gear quality of 9 with its first attempt. The smooth running and extremely even surface of the component as well as the short machining times impress the customer. The UNIFY combines precision and efficiency and has proven to be a new, strong partner for series production in the medium module range.
Modular tool life
Efficient internal thread production is the result of intensive tool research and repeatedly challenges the creativity of engineering experts anew. LMT Fette presented the first generation of HPF forming taps years ago and in the meantime has made a name for itself in the area of chipless internal thread production with its unique selling point of the modular design. HPF stands for High-Performance Forming and combines the advantages of the wear resistance of a carbide thread head with the toughness of a steel shaft. This guarantees a new performance standard in terms of quality and cost-effectiveness.
Now, with the further developed HPF Max threadformer, an even higher performance dimension has been opened up (Fig. 4). In addition to the modular design, further significant design features are now making decisive contributions, especially the new micro-grain carbide, the new TiCN coating and the optimized former geometry.
The field of application of the HPF Max is in the serial production of the automotive industry and mechanical engineering.
Article and image courtesy: LMT Group