The newly developed tool is the latest addition to Walter’s ever-expanding grooving and parting-off range that offers users increased tool life and high process reliability in quick cycle times, says the company. Suitable for parting diameters of up to 35 mm, DX18 features a positive engagement system – the insert geometry lends itself to being locked securely – as opposed to conventional screw clamping where the characteristics of the cutting forces mean that existing clamping forces are insufficient, with negative effects on machining quality and process reliability.
Another innovation with the Walter Cut DX18 is the use of the SmartLock system in the G4014 tool holders, which simplifies insert changeover. Rather than having to remove the entire tool (often in cramped and ‘oily’ machine conditions), SmartLock’s insert clamping screw is changeable to either side of the tool for easy and quick insert change, with a blanking plug provided to protect the unused side. Thanks to the positive engagement, a new insert – even those of very narrow width – will always locate correctly.
The potential of the system has been successfully proven in tests on a Swiss-type automatic lathe, where the customer particularly liked not having to remove the tool for insert changing. An outer diameter of 12 mm was parted off from 1.4057 high-tensile martensitic stainless steel – the cutting-edge width was 2 mm. DX18 more than doubled tool life compared with the single-edged alternative, and with maximum process reliability and productivity.
The trend towards miniaturisation of complex components is one of the driving forces for Walter’s ever-evolving range, particularly in tasks where users consider an alternative only when there are problems with process reliability, or when machining strategies are changed. This situation, says Walter GB, is where its Walter Cut portfolio scores in terms of productivity levels and cost advantages (cycle times, tool life and process reliability).
Typical problem areas, particularly when grooving deeper into the workpiece, are the stable fixing of the indexable inserts, chip breaking and cooling. As a result, users often play it safe by reducing cutting data below recommended values. It is in such applications, adds the company, where the Walter Cut range can make the difference.