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WS40PM’s cobalt-rich substrate provides robust fatigue resistance and edge integrity, while the multiphase AlTiN-TiN PVD coating reduces tool wear, making it the first choice for a wide range of hightemp steel alloys, austenitic and PH stainless steels, nickel-based super alloys such as Hastelloy and Nitronic, and titanium.
AlTiN-TiN PVD coating reduces wear,” says Mike Sperhake, EMEA-region Product Specialist for WIDIA. “Using an initial cutting speed of 175 ft/min (53 m/min) we’re seeing 25-35% productivity gains and consistent improvement in tool life, even when milling very tough materials like Ti-5553 and Super Duplex steels.” Sperhake recommends a balanced approach to cutting parameter selection. “As radial engagement increases, cutting speeds should be reduced proportionately,” he says. “That’s because the amount of heat entering the insert goes up substantially on heavy cuts. At around 90% engagement, for instance, you’ll probably want to reduce the RPM by 25% or so, depending on the material. Feedrates may also have to be lessened somewhat, depending on setup and machine rigidity. And smaller cut widths, of course, spindle speed and feedrates should be kicked up substantially.”
Finally, consider the machine tool, toolholder, and spindle interface. Rigidity across the board is needed for productive titanium machining. WIDIA offers the KM4X platform, which according to Global Product Manager Bill Redman is “the strongest connection available, period,” and is available on a wide variety of toolholders and machine tools alike. Says Sperhake, “From Tier 1 aerospace suppliers to the job shop on the corner, everyone wants the same things from a tooling solution: higher accuracy, better surface finish, reliability and productivity. All are critical factors to their success, and that’s what we intend to deliver. WS40PM is a big part of that.” www.widia.com
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“Going too easy” is a common mistake when machining titanium and other difficult materials, Sperhake says, leading to poor productivity levels and shortened tool life. For example, problems such as BUE and edge wear can often be eliminated by pushing the tool harder. “Tool life, especially in superalloys, is a three-legged stool of feed, speed, and cutter engagement. Each has a direct impact on the others.”
body for the application is likewise important. WIDIA’s VSM490 shoulder mill offers a state of the art insert and cutter design, one that supports WS40PM and other highperformance grades.
Success with superalloys takes more than a good carbide grade, however. Sperhake also recommends increasing the cutting fluid concentration, and using a high-pressure coolant pump wherever possible. Selecting the right cutter 07 | Industry EMEA | November 2016
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