Walter Prototyp easily reduces the cost of thread cutting, providing a solution that allows a single tool to complete a machining task that previously required multiple tools, reducing machining time and downtime.
Solution 1: Walter Prototyp TMD three processes - a tool to easily reduce the cost of thread cutting
The versatile tooling solution offers significant cost savings. A single tool can complete a machining task that previously required multiple tools, which means shorter machining times and fewer downtimes. One of the solutions is the use of the new Walter Prototyp TMD solid carbide thread milling cutter.
This tool combines drilling, boring (90 degrees) and thread cutting to machine the internal threads of M6 to M16. For hole and blind hole threads, the maximum standard thread depth is 2 times the diameter.
The designed Walter Prototyp TMD thread milling cutter is used to machine threads on cast aluminum and grey cast iron. As a secondary application, it can be used to process magnesium and copper alloys. It can also be used to drill hard materials or cast holes. In order to achieve maximum tool life, the thread milling cutter features two optimized coatings, a TAX coating for cast iron and an NHC coating for non-ferrous metals. The tool features three milling edges or three cutting edges to ensure high chip removal rates. A special spiral groove design with a helix angle of 27 degrees helps to transport chips. Another important feature is the ability to remove chips (especially when machining blind holes): a central coolant supply with three Y-shaped outlets.
The steps of threading are as follows: 1. Positioning; 2. Drilling and boring; 3. Entering the starting position of the thread; 4. Radial cutting into the depth of the thread; 5. Inverting the thread cutting in a spiral form; 6. Returning to the beginning position. Follow the above steps when using other tools of this type. Users can get recommended cutting parameters, CNC programming and TEC-CSS professional software from Walter. Therefore, this tool is very easy to integrate with the entire process.
The time saved (50% of the actual value) proves that the tool is particularly suitable for industries that are serialized and mass produced, such as the automotive industry. Another advantage is that it can produce high quality threads. The positioning of the threaded core hole is very precise. Surface quality and process tolerances have also been optimized.
Option 2: Walter Prototyp new Protodyn ® S ECO plus extrusion tap – high performance transformation
Walter Prototyp's products are the first when threading high-strength materials. Unmatched process reliability and efficiency with the new Protodyn ® S ECO plus tool.
The versatile, high-performance HSS-E extrusion tap is suitable for processing materials with a tensile strength of 1200 N/mm 2 or materials with a tension of at least 7%. The new TiN coating is perfect for thread forming and can be pre-treated to ensure longer tool life and prevent cold welding. In order to achieve long life and high efficiency in the processing of carbon-containing steel or ground aluminum alloys, Protodyn® S ECO plus can also be used with TiCN composite coatings.
The tool can also use coolant, and products with a depth of 4xd have a radial cooling system. The newly developed chamfered groove ensures smooth operation and enhanced wear resistance. Special surface treatments use optimized polygons to reduce vibration and use minimal lubrication (MQL).
Protodyn ® S ECO plus extrusion taps are blind holed in steel, stainless steel, long chip aluminum, aluminum alloy (Si: <12%), long chip copper and copper alloys and GGG materials and up to 3.5xd through hole Preferred.
The new tool is economical and has a wide range of applications, not only for through holes but also for blind hole machining, which reduces tool inventory. The extruded threads have a high dynamic and static tension.
The advantage of this tool is that the machining of deep and blind holes is reliable and does not accumulate, while the Protodyn ® SECO plus also offers the highest process stability even at the smallest diameters.
Solution 3: Protodyn ® S plus New Groove Prototyp's new extrusion taps Economical all-rounder: The new Protodyn ® S plus extrusion taps from the core brand WalterPrototyp The universal HSS-E extrusion taps are suitable for almost all extrudable workpiece materials. For machining, the tool product can be used for through and blind hole machining, available in sizes from M1 to M24. Protodyn ® S plus with TiN coating provides excellent wear resistance. The optimized multi-angled edge improves tool life. The new chamfered groove makes the tool run smoother and at the same time enhances wear resistance. The tough tool geometry also results in higher machining accuracy and a more reliable machining process, as well as machining small workpieces.
The chipless production of thread processing ensures high process reliability, even for deep hole machining, without the problem of iron filing and conveying. The highly static and dynamic pull-up avoids a series of side effects in high-quality machining, and the tool cost is greatly reduced due to the long tool life and wide processing range.
For the performance of the new Protodyn ® S plus, there is an example of high-speed threading on a column milling machine with a steel St37 workpiece with a blind hole depth of 20 mm, 2xd. Cooling: Emulsion. At a speed of vc=18m/min, Protodyn ® S plus has a tool life of 183 holes, while the previous tool life was only 80 holes and tool life increased by 125% – a considerable improvement, far exceeding customer expectations!
Three strong brands under the same banner by Walter, Walter Titex and Walter Prototyp:
As a global group company, Walter develops, manufactures and markets precision tools for metalworking. Walter has three industry-renowned core brands, Walter, Walter Titex and Walter Prototyp. Headquartered in Tuebingen, southern Germany, Walter employs approximately 2,800 people worldwide and has approximately 50 subsidiaries and sales partners.
Founded in 1919, the brand Walter is a well-known manufacturer of indexable carbide and PCD tooling systems for metalworking in the fields of turning, milling and drilling. The brand Walter Titex is a well-known manufacturer of high speed steel and solid carbide drills and reamers. The brand Walter Prototyp is known for its innovative, high-tech coated high-speed steel, solid carbide threading tools and milling cutters in the metalworking industry. The Walter brand has been updated with the addition of the MODCO series, expanding the range of non-standard tools such as composite motion tools.
Hand Automatic Cutting Machine
Fast and accurate
The latest cutting technology, such as intelligent speed adjustment, provides fast and accurate cutting. Select the hardness of the material to be cut and the machine will automatically set the correct speed.
When the cutting wheel is blocked by the cleared material, the choice is between automatic direct cutting mode, which uses constant feed rate or impact cutting. ExciCut Manual cutting mode is used for cutting harder and larger workpieces. The automatic X cutting table option allows the user to access a multi-knife cutting mode to cut slices of the same or different thickness, or to cut precisely at a specified position.
Multi-function knob for setting cutting process parameters quickly and easily. Automatic speed Settings save time and allow users to apply the same cutting wheel for different materials to avoid time-consuming cutting wheel change operations. The mobile cutting arm locking system quickly switches between manual and automatic cutting and gives you a complete overview of all the necessary information based on the color display of the icon.
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