Experience, knowledge, technology: Expertise - Walter Tools · Walter Tools India Pvt. Ltd. Pune, India +91 (20) 3045 7300, [email protected] Walter (Thailand) Co., Ltd

Walter product innovations · Edition 2013-2

Prin

ted

in G

erm

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5353

(09/

2013

) EN

Walter GB Ltd. Bromsgrove, England +44 (1527) 839 450, [email protected] Walter Kesici Takımlar Sanayi ve Ticaret Ltd. Şti. Istanbul, Türkiye +90 (216) 528 1900 Pbx, [email protected] Walter Wuxi Co. Ltd. Wuxi, Jiangsu, P.R. China +86 (510) 8241 9399, [email protected] Walter AG Singapore Pte. Ltd. +65 6773 6180, [email protected] Walter Korea Ltd. Anyang-si Gyeonggi-do, Korea +82 (31) 337 6100, [email protected] Walter Tools India Pvt. Ltd. Pune, India +91 (20) 3045 7300, [email protected] Walter (Thailand) Co., Ltd. Bangkok, 10120, Thailand +66 2 687 0388, [email protected] Walter Malaysia Sdn. Bhd. Selangor D.E., Malaysia +60 (3) 8023 7748, [email protected] Walter Tooling Japan K.K. Nagoya, Japan +81 (52) 723 5800, [email protected] Walter USA, LLC Waukesha WI, USA +1 800-945-5554, [email protected] Walter Canada Mississauga, Canada [email protected]

Walter AG

Derendinger Straße 53, 72072 Tübingen Postfach 2049, 72010 Tübingen Germany www.walter-tools.com

Product innovations Edition 2013-2

Turning, drilling, threading,milling, adaptors

_INNOVATIONS

Experience, knowledge,technology: Expertiseon your side.

You will find the complete tool range of our three competence brandsWalter, Walter Titex and Walter Prototyp in the 2012 edition of thegeneral catalogue, in the 2013 edition of the supplement catalogueand in this new products brochure for 2013-2 “Experience, knowledge,technology: Expertise on your side”. It replaces the previous, 2013-1brochure “Advancing through innovative machining solutions”.

They contain all the precision tools you need in your production facilitiesfor turning, boring, milling and threading.

We will be pleased to send you the general catalogue on request.

= The full range of tools

Walter general catalogue+ supplement catalogue+ new products brochure

_INNOVATIONS




_A WEAlTh Of ExPERTISE IN MAChINING

General catalogue



Supplement catalogue


Turning your own ideas into reality requires the right tools. Tools for turning, milling, drilling and threading. But it also takes heart and soul. From the initial inspiration to the final application. With the competence brands of Walter, Walter Titex, Walter Prototyp and Walter Multiply, you acquire more than just tools from us, because we do all we can to understand and satisfy the requirements of our customers. We concentrate on the application and what the customer wants to achieve. We help customers to turn their ideas into a reality. In doing so, perfection is, for us, the most important thing. It is the easiest way to achieve productivity and efficiency, and the only way to turn vision into reality.

Expect more. Engineer what you envision.

TURNING VISIONS INTO REALITY.

TURNING Walter 3 ISO turning 4 Grooving 12

DRILLING, BORING AND THREADING

Walter Titex 19 Solid carbide drills 20

Walter 25 Point drills 26 Indexable drills 28 Boring tools 30 Precision boring 32

Walter Prototyp 37 HSS-E-PM taps 38 HSS-E taps 40

MILLING Walter Prototyp 43 Solid carbide end mills 44

Walter 49 The new generation of milling cutters 51 Cutting tool materials 58 PCD special milling cutters 60

Watch the innovations video: Scan this QR code or go

directly to http://goo.gl/cPIqR

Product innovationsEdition 2013-2

Turning

_TOOL INNOVATIONS IN TURNING

This is the way to cost-effective turning.

4

ISO TURNING

Walter Tiger·tec® Silver ISO K generation: Fast and reliable for maximum output.

NEW: Tiger·tec® Silver CVD coating – Aluminium oxide with optimised microstructure

for maximum crater wear resistance and cutting speed – Mechanical post-treatment creates compressive

stresses to prevent fractures on the cutting edge – Silver flank face as an indicator layer for easy wear

detection

NEW: Universal geometries – Wide, universal range of applications – Microedge technology for low flank face wear

NEW: Ground contact surface – Optimum process reliability

for interrupted cuts with double-sided inserts.

The Tiger·tec® Silver grades WKK10S and WKK20S, and the new MK5, RK5 and RK7 geometries, have been specifically developed for machining cast iron.

THE APPLICATION

Primary application:

– The grades WKK10S and WKK20S are used for grey cast iron (EN-GJL), ductile cast iron (EN-GJS) and vermicular cast iron (EN-GJV)

Secondary application:

– WKK10S is ideal for the machining of hardened steels (40 – 61 HRC)

– WKK20S prolongs tool life when machining steels with high tensile strengths (1000 – 1400 N/mm²)

NEW2013

Watch product video: Scan this QR code or go

directly to http://goo.gl/t0V7i

5Walter – Turning

16

10

6.3

4.0

2.5

1.6

1.0

0.63

0.4

0.25

0.16

0.10.025

0.040.063

0.10.16

0.250.4

0.631.0

1.62.5

ap [mm] Depth of cut

f [mm]Feed

good average unfavourable

WAK30

WKK20STiger·tec® Silver

WKK10STiger·tec® Silver

Wea

r res

ista

nce

Toughness

Tiger·tec® Silver ISO K generation

THE NEW CUTTING MATERIALS

WKK10S (ISO K10)

– Maximum wear resistance and cutting speed – For continuous cuts and occasional interrupted cuts – First choice for dry machining

WKK20S (ISO K20)

– Universal cutting material, for around 50% of all tasks – Process reliability for workpieces with interrupted cuts, cast skin or cross holes

– Ideal for wet and dry machining

YOUR ADVANTAGES

– Reduction in tooling costs due to an increase in tool life of up to 75 per cent, and in some cases, even higher

– Short process times resulting from maximum cutting speed thanks to Tiger·tec® Silver technology and MK5, RK5, RK7 geometries

– Greater process reliability thanks to the contact surface being ground after coating and to mechanical post- treatment for machining interrupted cuts and cast skins

New cutting materials for cast iron (ISO K) New geometries for cast iron (ISO K)

Up to

75% increase in output

RK7

RK5

MK5

Feed

Cutt

ing

dept

h

6

ISO TURNING

Walter Tiger·tec® Silver ISO K generation: Universal, classic or extremely robust.

MK5 – UNIVERSAL

• Robust 0° chamfer on the cutting edge

• Open, 14° positive chip breaker groove

RK5 – CLASSIC

• Radius on the cutting edge• 0° chip breaker groove for stability

RK7 – ROBUST

• Extremely robust negative chamfer on the cutting edge

• 0° chip breaker groove for stability

MK5: Medium machining – universal for all cast iron materials

– Open chip breaker groove for a soft cutting action – Can be used universally for all cast iron materials – First choice for ductile cast iron (GJS), machining unstable components or internal machining with low cutting pressure.

RK5: Roughing – classic flat top insert for cast iron materials

– Flat top .NMA indexable inserts with stepped plateau for greater process reliability in cast iron machining

– Ground contact surface on a flat top .NMA indexable insert that ensures maximum tool life and reliability under dynamic loading (e. g. interrupted cuts).

– First choice for grey cast iron (GJL).

RK7: Roughing – extremely robust when interrupted cutting

– Similar in design to the RK5 geometry, but with the addition of a “protective chamfer” on the cutting edge for the greatest possible process reliability.

– First choice for grey cast iron applications with extreme interrupted cuts, varying depths of cut or hard grey cast skin

– Machining of hardened steels (40 – 61 HRC)

THE NEW ISO K GEOMETRIES:

+ 1 µm

0 µm

– 1 µm

+ 1 µm

0 µm

– 1 µm

7Walter – Turning

Cutting dataCompetitionISO K20

Tiger·tec® Silver WKK20S

vc 240 m/min 240 m/minf 0.25 mm 0.25 mmap 3.0 – 5.0 mm 3.0 – 5.0 mm

Tool life Wet machining

20 components

28 components

Tool life Dry machining

30 components

50 components

Workpiece material: EN–GJS600-3 (GGG60)Tensile strength: 190 HBIndexable insert: CNMG160612–MK5Cutting tool material: WKK20S Tiger·tec® SilverTool: DCLNL3225P16

Comparison of the number of components

10 403020 50

Competition 30

Competition 20

+ 66%Dry

+ 40%Wet

Tiger·tec® Silver MK5 WKK20S 50

Tiger·tec® Silver 28

Components

Transmission housing cover – GGG60

Interrupted cut

Cross holes

Cast skin

BENEFIT OF THE NEW ISO K GEOMETRIES:

Comparison Previously: – CNMA120412 – Grinding after coating on standard .NMA inserts without a groove not possible

NEW: – CNMA120412-RK5 – After coating, the contact surface is also ground

Evenness of the contact surface

Effect Risk of micro-vibrations and fractures at the cutting edge because the contact surface is not 100% flat.

The indexable insert is seated firmly due to the very flat ground surface. In the event of dynamic loading, this reduces wear at the cutting edge.

8

ISO TURNING

Walter Tiger·tec® Silver WMP20S: Universal cutting tool material for machining ISO M and ISO P materials.


WSM30Tiger·tec® Silver

THE APPLICATION

Primary application of ISO M:

– Machining stainless materials, such as X5CrNi18-10 (1.4301) and X6CrNiMoTi17-12-2 (1.4571)

Primary application of ISO P:

– Machining steels, such as 42CrMo4, 100Cr6 and C45

Secondary application of ISO S:

– Materials such as Inconel 718

THE NEW CUTTING MATERIAL

WMP20S (ISO M10; ISO P20)

– Excellent wear resistance thanks to Tiger·tec® Silver CVD coating

– From continuous cuts to occasional interrupted cuts – Can be used universally in ISO M and ISO P – For a very wide spectrum of materials and component applications

YOUR ADVANTAGES

– Lower inventory of cutting materials – Universal application, stainless and steel materials – Maximum productivity thanks to Tiger·tec® Silver technology

– Alternative universal cutting tool material to our Tiger·tec® WSM cutting materials

– Particularly suited for small and medium-sized batch sizes

OVERVIEW OF ISO M CUTTING MATERIALS

1 µm

WMP20S CVD coating composition

Wea

r res

ista

nce

Toughness



WMP20STiger·tec® Silver


WPP30STiger·tec® Silver

OVERVIEW OF ISO P CUTTING MATERIALS

Wea

r res

ista

nce

Toughness



WMP20STiger·tec® Silver

9Walter – Turning

NEW: Mechanical post-treatment

– Increased toughness – Unique residual

stress condition

NEW: Silver flank face – Indicator layer

for easy wear detection

THE GEOMETRIES:

The universal WMP20S cutting material is introduced in combination with the tried and tested negative NF4, NM4 and NR4 geometries. This combines the new Tiger·tec® Silver technology with the many years of machining experience with our existing stainless geometries.

Cutting dataCompetitionISO M20

Tiger·tec® Silver WMP20S

vc 120 m/min 120 m/min

f 0.35 mm 0.35 mm

ap 1.5 mm 1.5 mm

Tool life 10 – 15 components 21 components

Workpiece material: X2CrNiMo18-14-3 (1.4435)Tensile strength: 500 – 700 N/mm2

Indexable insert: WNMG080412-NR4Cutting tool material: WMP20STool: PWLNL2525M08

Face and longitudinal turning of an axle shaft


0 10 20

+ 60%

30

Competition

Tiger·tec® Silver WMP20S 21

10 – 15

ISO M geometries – NF4/NM4/NR4


directly to http://goo.gl/9r3Nr

10

ISO TURNING

Walter HU6 geometry: First choice for the rail industry.

THE INDEXABLE INSERT

– Fully sintered indexable insert – Stable cutting edge – RCMT basic shape diameter 10, 12, 16 mm for screw and lever type clamping

– RCMX basic shape diameter 20, 25, 32 mm for firm lever type clamping

– Tiger·tec® Silver WPP10S, WPP20S, WPP30S, WKK20S cutting tool materials

THE APPLICATION

– Moderate to heavy roughing – Excellent chip breaking performance – Machining solid wheels in the railway industry – Machining forged parts

YOUR ADVANTAGES

– No downtime due to the formation of long chips – Maximum tool life thanks to the new Tiger·tec® Silver cutting tool material

– Increase in tool life of up to 40 per cent – High degree of process reliability – Robust cutting edge design for heavy roughing and interrupted cuts

Perfect chip formation as a result of specially designed chip dimples

Cutting dataCompetitionISO P

Tiger·tec® Silver WPP20S


f 1.5 mm 1.5 mm

ap 8 – 10 mm 8 – 10 mm

Tool life 20 components 28 components

Workpiece material: Class ER9Tensile strength: 900 – 1050 N/mm2

Indexable insert: RCMX3209M0-HU6Cutting tool material: WPP20STool: Walter Capto™ C8 special toolholder

External and internal machining of solid wheelsRail industry


0 10 20

+ 40%

30

Competition

Tiger·tec® Silver WPP20S 28

20

12

GROOVING

Walter Cut – SX: Parting off and cut-off milling with the new single edge grooving system.

THE SYSTEM

The Walter Cut range of grooving tools is being expanded with the new SX grooving system. This enables the user to part off and groove, or cut-off mill and slot mill, using the same system insert.

YOUR ADVANTAGES

– Lower inventory costs due to one cutting insert type being used in multiple tool variants

– Maximum tool life due to the optimised self-clamping system

– User-friendly self-clamping system for fast replacement of the cutting edge

G2012Monoblock toolholder with precise internal coolant supply, parting off up to a diameter of 65 mm

F5055Slot mills with a diameter range of 63 – 250 mm

G2042Deep parting blades, parting off up to a diameter of 160 mm

Watch product animation: Scan this QR code or go

directly to http://goo.gl/mjxsMT

1313Walter – Turning

The cutting edge is not weakened by the presence

of a coolant hole

Maximum cost efficiency in the machining of all material groups through the use of the most state-of-the-art cutting tool materials, geometries and internal cooling

Optimised chip breaker for precise internal coolant supply

The cutting insert has a positive fit in the insert seat, so it is not lost during machining

Cutting forces are absorbed in the fixed part of the tool, rather than the flexible part of the tool

Extremely high retaining forces as a result of the optimised top clamp

THE STABILITY

HOW IT WORKS

INSERT WIDTHS

2.0 / 3.0 / 4.0 / 5.0 / 6.0

CHIP BREAKER TYPES

CE4 – the universal one – Stable cutting edge – Excellent chip constriction – Moderate to high feed rates

CF5 – the positive one – Low burr and pip formation – For long-chipping workpiece materials

– Low to moderate feed rates

CF6 – the sharp one – Minimum burr and pip formation – For small diameters and thin-walled tubes

– Low feed rates

CUTTING MATERIAL GRADES

Two Tiger·tec® Silver PVD grades: WSM33S and WSM43S for steel, stainless steels and materials which are difficult to machine.

Location face for directing the cutting forces into the toolholder

14

GROOVING

Walter Cut SX G2012:The monoblock tools with internal cooling.

THE TOOLS

– G2012 monoblock tools with internal coolant supply – Shank sizes 20 x 20 and 25 x 25 mm – Grooving to a depth of 33 mm and parting off up to a diameter of 65 mm

– 3 and 4 mm insert widths – G 1/8" Whitworth pipe thread connections – Whitworth K601.XX.XXX-SET coolant set available as an accessory

3 and 4 mm insert widths

High stability brought about by introducing the machining force into the

fixed part of the insert seat

G1/8" internal cooling connection

Chip- and coolant-optimised top clamp

THE APPLICATION

– For grooving and parting off on all types of lathes with internal coolant supply

– For optimal use, it is recommended that you use a pressure of at least 20 bar for the internal coolant supply

– For grooving or parting off if jamming chips are present – Suitable for all industries: The automotive industry, aero-space industry and general mechanical engineering, etc.

New, positive-locking insert seat design

15Walter – Turning

G1/8" internal coolant connection

Monoblock tools with internal coolant supply Type: G2012

YOUR ADVANTAGES

– Longer tool life and productivity thanks to optimum cooling – No downtime due to the formation of long chips in production – Straight coolant outlet: No “spray effect” – Excellent cooling and chip removal from the cutting zone due to the coolant outlet being as close as possible to the cutting edge

– User-friendly self-clamping system for fast replacement of the cutting edge

– No loss of the cutting edge during machining due to the optimal, positive-locking design of the insert seat


directly to http://goo.gl/viJ9A

16

GROOVING

Walter Cut – SX G2042R/L: Reinforced parting blades with the latest self-clamping system for even greater stability.

THE TOOLS

– G2042..RL parting blades with reinforced shank – Blade height 26 and 32 mm – Insert widths from 2.0 to 4 mm – Available as right- and left-hand version – Grooving to a depth of 33 mm and parting off up to a diameter of 65 mm

THE APPLICATION

– For grooving and parting off on all types of lathes – For parting off operations where space is limited – For parting off operations with low stability loss where long tool projections are used

– First choice when using parting blades

YOUR ADVANTAGES

– Low risk of vibration thanks to reinforced shank – Can be used in all conventional clamping blocks – No loss of the cutting edge during machining due to the optimal, positive-locking design of the insert seat

– Maximum tool life due to the optimised self-clamping system – User-friendly self-clamping system for fast replacement of the cutting edge – No limitation on inserting the parting blade in the clamping block caused by a clamping screw

– High level of process reliability thanks to robust tool design


Reinforced shank

Reinforced parting blade Type: G2042..R/L

Insert widths from 2 to 4 mm

17

GROOVING

Walter Cut – SX G2042N: Deep groove more effectively thanks to the latest robust self-clamping system.

Walter – Turning

THE TOOLS

– G2042..N deep-grooving blades – Blade height 26 and 32 mm – Insert widths from 2.0 to 6 mm – Grooving to a depth of 60 mm and parting off up to a diameter of 120 mm

THE APPLICATION

– For grooving and parting off on all types of lathes – Suitable for all industries: The automotive industry, aerospace industry and general mechanical engineering, etc.

1. Insert the key 2. Press the cutting insert in as far as it will go

3. To change the cutting insert, position the key behind the insert

4. Prise out the cutting insert by moving the key in the opposite direction

In Out

Insert widths from 2 to 6 mm


Second insert seat

Neutral tool design

Deep-grooving blade Type: G2042..N

EASY CUTTING EDGE CHANGE










_TOOL INNOVATIONS IN DRILLING

X·treme performance for all applications.


Drilling

20

SOLID CARBIDE DRILLS

Walter Titex high-performance drills: Maximum performance for micro applications.

Feed rate (mm/min)

Previous

X·treme DM12 573

+ 80%

320

0 200 600400

Number of holes

Previous

X·treme DM12 3000

+ 45%

2050

0 1000 30002000

YOUR ADVANTAGES

– Measurable increases in productivity due to machining values which are up to 50% higher than conventional solid carbide micro-drills

– New types of point and flute geometry ensure a high level of process reliability

– Polished flutes ensure reliable chip evacuation

THE TOOL

– Solid carbide high-performance drill with internal cooling – AML coating (AlTiN) – AMP coating (AlTiN tip coating) – Available in the following sizes:• 2 x Dc X·treme Pilot 150• 5 x Dc X·treme M• 8 x Dc X·treme DM8• 12 x Dc X·treme DM12• 16 x Dc X·treme DM16• 20 x Dc X·treme DM20• 25 x Dc X·treme DM25• 30 x Dc X·treme DM30

– Diameter range 2 – 2.95 mm – Shank according to DIN 6535 HA

THE APPLICATION

– ISO material groups P, M, K, N, S, H, O – Drilling with emulsion and oil – For use in general mechanical engineering, mould and die making in the automotive and energy industries

NEW

NEW

Demo component

Cutting data

Previous X·treme DM12vc 50 m/min 60 m/minn 7960 rpm 9550 rpmf 0.04 mm/rev 0.06 mm/revvf 320 mm/min 573 mm/min

Workpiece material: 1.4571Tool: A6589AMP-2

Diameter 2 mm

21Walter Titex – Drilling

X·treme Pilot 150

X·treme M

X·treme DM8

X·treme DM12

X·treme DM16

X·treme DM20

X·treme DM25

X·treme DM30


directly to http://goo.gl/FmrPC

NEW2013

X·treme DM30

X·treme DM16

22

SOLID CARBIDE DRILLS

Walter Titex XD drilling technology: Precision down to 70 x Dc in one continuous action.

THE TOOL

– Solid carbide high-performance drill with internal cooling – TTP tip coating – Available in the following sizes:• 40 x Dc as standard tool• 50 – 70 x Dc as special tool

– Diameter range 4.5 – 12 mm – Shank according to DIN 6535 HA

THE APPLICATION

– For ISO material groups P, K, N – Can be used with emulsion and oil – Specifically for inclined exits and cross holes – For use in general mechanical engineering, the hydraulic and automotive industries

NEW

Piston rod

Cutting data

Previously : single edge gun drills XD70 Technologyvc 70 m/min 70 m/minn 3185 rpm 3185 rpmf 0.03 mm/rev 0.15 mm/revvf 95 mm/min 478 mm/minTool life 12 components 50 components

Workpiece material: St 52-3Tool: Diameter 7 mmHole depth: 450 mm – 65 x Dc

YOUR ADVANTAGES

– Ten times more productive than gun drills – Drilling without pecking – Extremely high process reliability in deep drilling applications

– Drilling at low coolant pressures from 20 bar – Compatible with a very wide range of material groups, including ISO P, K, N

– Strong even on inclined exits and cross holes

Feed rate

0 100 200 300 400

+ 400%

500

Previous

XD Technology 478

95

Tool life: Number of components

+ 315%

0 10 20 30 5040 60

Previous

XD Technology 50

12

4 lands for optimum hole quality and use on:

• Inclined hole exits• Workpieces with cross holes

Coating• TTP tip coating

Polished flute for reliable chip evacuation

23

Alpha®4 XD30 – 30 x Dc




Walter Titex – Drilling

50 – 70 x Dc as special tool

X·treme D40 – 40 x Dc


directly to http://goo.gl/yQB64

Watch product animation: Scan this QR code or go

directly to http://goo.gl/ZBIMm

Standard rangeNEW2013











Drilling

_TOOL INNOVATIONS IN DRILLING

Powerful, robust, precise.

26

YOUR ADVANTAGES

– Up to 100% increase in output at the cutting edge – Easy selection: The colour of the indexable insert corresponds to the ISO colour of the material to be machined

– High degree of process reliability for drilling and retraction from deep holes due to positive insert location and clamping

POINT DRILL

Walter Color Select: Dual purpose, simple selection.

THE TECHNOLOGY

The new Walter Color Select high-performance cutting material WPP45C shines with excellent wear resistance and optimal tribological properties and wear detection. The new coating is based on a TiAlN multi-layer structure and is manufactured using a new type of PVD process. The new coating has a significantly improved hardness compared with conventional coatings. The extremely smooth surface of the cutting tool material achieves outstanding low friction performance and significantly reduces build-up on the cutting edge. The blue, aesthetically appealing surface of the index-able insert indicates to the user that it is used primarily for ISO P (machining steel).

THE APPLICATION

– Drilling and stack drilling in all steel workpiece materials – Best suited for applications in general mechanical engineering, the automotive and mass production industries, as well as the aerospace industry

THE INDEXABLE INSERT

– Blue indexable inserts for drills with replaceable insert – Diameter range from 12 – 31.99 mm for hole depths of up to 7 x Dc (10 x Dc)

27Walter – Drilling

SUMMARY OF RESULTS:

WPP45C demonstrates significantly better wear behaviour in comparison to the existing cutting material. The increased hardness of the coating has considerably reduced flank face wear on the peripheral cutting edge. In the centre of the exchangeable insert where the cutting speed is very low, material adhesions and shearing of the coating have been prevented thanks to the excellent low friction performance of the coating surface.

Cutting data

PreviousP6001 WPP45C

vc 80 m/min 80 m/minn 1410 mm 1410 mmfn 0.2 mm/rev 0.2 mm/revvf 282 mm/min 282 mm/minTool life 117 holes 273 holes

Cutting data

PreviousP6001 WPP45C

vc 96 m/min 96 m/minn 1800 mm 1800 mmfn 0.27 mm/rev 0.27 mm/revvf 486 mm/min 486 mm/minTool life 44 holes 80 holes

Workpiece material: 40CrMnMo7 (1.2311)

Drilling depth: 18 mmTool: B4015.F20.18.0.Z02.90RIndexable insert: P6001-D18.0Cutting tool material: WPP45CDiameter: 18

Comparison of the number of holes Comparison of the number of holes

0 050 20150 60200 80250100 40300 100

holes holes

Flange – through hole Lift truck fork – blind hole

Previously 117 Previously 44

P6001–WPP45C 273 P6001–WPP45C 80

+ 133% + 82%

Workpiece material: S355J2G3 (St52)Drilling depth: 50 mmTool: B4013.F20.17.0.Z02.51RIndexable insert: P6001-D17.0Cutting tool material: WPP45CDiameter: 17


directly to http://goo.gl/BCKUE

APPLICATION IN ACCORDANCE WITH ISO 513

P Bluespecifically for steel materials that conform to ISO P

K Redspecifically for cast iron workpieces that conform to ISO K

M Yellowspecifically for stainless steel materials that conform to ISO M

N Greenspecifically for non-ferrous metals that conform to ISO N

S Brownspecifically for materials with difficult cutting properties that conform to ISO S

H Greyspecifically for hardened materials that conform to ISO H

Grey = in the future

INDEXABLE DRILLS

Walter Insert Drill with Walter Capto™: With precision and power for greater cost efficiency.

28

THE TOOL

– Drill with indexable inserts featuring four cutting edges – Walter Capto™ modular shank• Size C4 (Dc diameter range 16.0 – 32.0 mm)• Size C5 (Dc diameter range 16.0 – 40.0 mm)• Size C6 (Dc diameter range 25.0 – 45.0 mm)

– Z = 1 effective – Hole depth: Up to 3 x Dc – Optimised insert position provides a balance of forces in the machining process

– Optimised chip clearance for better chip removal and stable body

– Hard-nickel plated surface protects against corrosion and wear, and ensures smooth chip flow

– Optimised handling and higher clamping/release torque using TorxPlus screws

– Cylindrical collar for straightforward measurement of the tool diameter

THE APPLICATION

– Suitable for machining all steel and cast iron materials, as well as stainless and difficult-to-cut materials

– Strong for drilling, chain drilling and spot drilling on inclined or convex surfaces

– The tool for use in general mechanical engineering, automotive and mass production industries as well as in the aerospace industry

YOUR ADVANTAGES

– Increase in productivity due to higher workpiece values – Time savings on tool changes in comparison with conven-tional shanks

– Higher forces can be transferred via the polygonal form of the Walter Capto™ interface

– Cost reduction as a result of:• 4 actual cutting edges• Higher cutting parameters• Saving on additional subsequent operations

– Accurate hole production due to the optimum balance of forces

– Excellent surface quality due to wiper edge insert at periphery and a high level of process reliability due to the positive clamping of the indexable insert

Walter Insert Drill Type: B4213.C

WalterCaptoTM

Subline über Headline (1.1)

Headline in grün (1.2), auch für Umbrüche als 3- Zeiler möglich. Headline in grün, auch für Umbrüche als 3- Zeiler möglich.


E 57 – the universal one – 13° rake angle – For medium machining conditions

– For cast iron and steel, including stainless and difficult-to-cut materials

E 67 – the special one – 13° rake angle – Special geometry for optimum chip formation

– For long-chipping materials, e. g. St37, stainless materials, as well as materials with difficult cutting properties and aluminium

A 57 – the stable one – 0° rake angle – For unfavourable machining conditions

– Mainly for cast iron and steel materials

THE OUTER INSERT THE CENTRE INSERT

THE GEOMETRY VARIANTS

– Fully sintered version with peripheral corner radius

– Version with circumference fully ground: Peripheral wiper edge for the best surface quality

– New: Now available in Tiger·tec® Silver! The cutting tool material for extremely high cutting speeds and maximum process reliability

– New: Now available in Tiger·tec® Silver! The cutting tool material for maximum tool life and optimum process reliability when drilling ISO P and ISO K materials

– New: WXP40 PVD grade for a longer tool life when drilling ISO P, ISO M and ISO S materials

– Specially developed as a centre insert

Cutting edge identification

Cutting edge 0° chip stiffening chamfer

Sharp dimple geometry

Circumference fully ground

30

COUNTERBORE TOOLS

Walter Boring with Walter Capto™: Counterboring with a clever head.

THE TOOL

– Boring tool with two cutting edges – with Walter Capto™ or ScrewFit adaption – Diameter range 20 – 150 mm with cartridges – Diameter range 150 – 640 mm with aluminium bridge – Internal coolant supply up to cutting edge – For symmetrical and radially offset roughing – Precisely matched adaptors and extensions – Modular expansion options – Extensive range of CC.. and WC.. indexable inserts – Indexable inserts with special geometry (E47) for counterboring

THE APPLICATION

– For drilling medium-sized (from 20 mm) to large diameters (up to 640 mm)

– For deep holes and long tool overhangs – Also compatible with low-performance machines by using radially offset cartridge application

– Universal application for hole enlargement – For use in general mechanical engineering, the energy and automobile industries

YOUR ADVANTAGES

– Robust, compact tooling system for reliable and cost-effective use

– No length change during diameter adjustment – Indexable inserts for all material groups with excellent chip breaking performance

– The tool can be used in two insert configurations for roughing

– High torques can be transmitted thanks to Walter Capto™ – Adaption matched to the Walter Precision precision drilling system

– Extensive range of modular components: Adaptor, extensions, etc.

– Extremely easy to handle

Walter BoringMEDIUM, Walter BoringMAXI Types: B3220.T. B3220.C.

CC..E47

WalterCaptoTM


CartridgeCartridge

Walter BoringMEDIUM, Walter BoringMAXI Types: B3220.T. B3220.C.

Cartridge

Aluminium bridge

WalterCaptoTM

32

PRECISION BORING

Walter Precision with Walter Capto™: A system for achieving the highest degree of precision.

THE TOOL

– Single edge precision boring tool which allows convenient analogue readings

– Available Walter Capto™ or ScrewFit adaption – Backlash-free, precise adjustment – The B4030 system is self-balancing – Diameter range 2 – 203 mm with boring bars and cartridges – Diameter range 150 – 640 mm with aluminium bridge design – B3230.C with cartridges, available as a set – Can be used without problems for reverse machining – Internal coolant supply up to cutting edge – 0.002 mm adjustment accuracy – Adaptors and extensions matched to the system – Indexable insert range adapted for precision boring

THE APPLICATION

– Suitable for all material groups – For finish machining precise holes (IT6) – Holes from 2 mm to 640 mm – Areas of use: General mechanical engineering, production of precision parts, automotive and aerospace industries

Walter PrecisionMINI, Walter PrecisionMEDIUM, Walter PrecisionMAXI Types: B3220.T. B3220.C.


YOUR ADVANTAGES

– A high-precision, robust and cost-effective tooling system

– A basic body can cover a broad diameter range with three cartridge sizes

– No length change during diameter adjustment – High surface quality thanks to balanced tools – Extensive range of indexable inserts – Three-edged indexable inserts can be used – Flexibility provided by the extensive range of modular components: Adaptors, extensions, etc.

– Repair service

Can be used without problems for reverse machining

Walter PrecisionMINI, Walter PrecisionMEDIUM, Walter PrecisionMAXI Types: B3220.T. B3220.C.

34

PRECISION BORING

Walter PrecisionDigital with Walter Capto™: Digital for even greater precision.

THE TOOL

– Extremely high-accuracy precision boring tool with optoelectronic encoder

– Digital display for accurate adjustment down to the μm – Walter Capto™ adaption – Modular design with boring bars and bridges in a diameter range from 3 – 124 mm

– Indexable inserts with positive basic shape – Solid carbide boring bars with diameters from 2 to 10 mm – 3 cutting edges per insert – 2 insert sizes for the whole programme – low inventory – Backlash-free fine adjustment (0.002 mm on the diameter) – Maintenance-free automatic balance compensation – nmax = 16000 1/min – With internal coolant supply: Provides cooling precisely to the cutting zone

– Optimised for MQL technology

YOUR ADVANTAGES

– Prevention of set-up errors thanks to very simple handling via the digital display

– Lower machining costs because higher cutting data is possible due to balance compensation

– Maximum component quality with improved surface finish and roundness thanks to balance compensation

– Optimal cutting data for every material: Wide range of indexable inserts for optimal adaptation to the machining task

– The modular Capto interface brings flexibility and a reduced inventory

– Cost-effective solution due to a basic body with a diameter of 3 – 124 mm

THE APPLICATION

– A tool for all material groups – For finishing a drilled hole – Ideally suited for use in general mechanical engineering, the aerospace industry and in mould and die making

Also available as a set

Solid carbide boring bar

Walter PrecisionDIGITAL Types: B4035.C.

WalterCaptoTM

WalterCaptoTM


Digital display

Digital display

Cartridge

Walter PrecisionDIGITAL Types: B4035.C.










_TOOL INNOVATIONS IN THREADING

Precise thread, reliable process.


Threading

38

HSS-E-PM TAPS

Walter Prototyp Prototex® Eco Plus: The universal high-performance tool for maximum threading productivity.

YOUR ADVANTAGES

– Highly wear-resistant cutting tool material due to a new type of pre-treatment

– Long tool life through optimised geometry in the chamfer section

– Reduction in tool inventory, since it can be used univer-sally in a wide range of materials

– Fewer tool changes and optimum machine output r esulting from high cutting speeds and long tool life

– Reduction in lubricant costs due to optional MQL machining with steel, cast iron and aluminium alloys

DIMENSION RANGEM: M2 – M30MF: M6 x 0.75 – M22 x 1.5UNC: UNC2 – UNC 5/8

UNF: UNF4 – UNF 5/8

G: G 1/8 - G1

THE TOOL

– Universal use high-performance taps (HSS-E-PM) for through hole threads

– THL hard material coating, or alternative TIN coating – Chamfer form B – Tolerances: 6HX, 6GX, 2B and G-X – Lengths: M – Variants: • LH (left-hand thread) • KR (radial coolant channel)

THE APPLICATION

– Through hole threads up to 3.5 x DN – ISO P: Steels with tensile strengths from 500 to 1350 N/mm2

– ISO M: Stainless steels with tensile strengths of up to 1350 N/mm2

– ISO K: Predominantly GJS (GGG) materials – ISO N:• Aluminium wrought alloys• AlSi alloys with an Si content of up to 12%• Copper and copper alloys as secondary application

Prototex® Eco Plus Type: EP2021342

Optionally with radial internal cooling

THL coating (or TIN)

39Walter Prototyp – Threading

Bearing casePrototex® Eco PlusM12 x 1.5 through hole thread

Cutting data Competitors Prototex® Eco Plusn 663 rpm 663 rpmvc 25 m/min 25 m/min

Workpiece material: C56E2 (1.1219)Tensile strength: Approx. 1300 N/mm²Tool: Prototex® Eco Plus

EP2126342-M12x1.5Coating: THLHole type: Through holeThread depth: 8 mmCooling lubricant: Emulsion 7%

Comparison of tool life (number of threads)

0 200 800

Prototex® Eco Plus 750

400 600

Competitors 500

HSS-E-PM

Shank tolerance h9

ISO material colour coding of material groups

NEW MARKING ON PACKAGING

P M K N S H O

EP2021342-M8 Prototex® Eco PlusHSS-E-PM THL6HX

23/134 042446 066969

Application table

•• Primary application

40

HSS-E TAPS

Walter Prototyp Paradur® X·pert K – the specialist in cast iron machining.

DIMENSION RANGEM: M3 – M20

Paradur® X·pert K Type: K2031407YOUR ADVANTAGES

– Cost-effective threading for small and medium batch sizes

– Highly robust, reliable tool

THE TOOL

– HSS-E-PM tap for blind and through hole threads – Straight-fluted – Tolerance: 6HX

THE APPLICATION

– Ideal for blind and through hole threads with thread depths of up to 3 x DN and material tensile strengths of up to 1000 N/mm²

– ISO K: • Primary application: GJL (grey cast iron) • Secondary application: GJS (GGG)

– ISO N: AlSi alloys with an Si content > 12%

P M K N S H O

C C C C

X·pert N

P M K N S H O

C C C

X·pert K

P M K N S H O

C C C

X·pert M

P M K N S H O

C C C C

X·pert P

THE ENTIRE X PERT FAMILY – easy selection lets you start machining sooner

Chamfer form C

HSS-E-PM

TAFT coating

41Walter Prototyp – Threading

HSS-E TAPS

Walter Prototyp Prototex® X·pert N and Paradur® X·pert N – the duo for aluminium machining.

DIMENSION RANGEPrototex® X·pert NM: M2 – M10 Paradur® X·pert NM: M1.6 – M20MF: M8 x 1 – M20 x 1.5UNC: UNC2 – UNC 3/8

G: G 1/8

Prototex® X·pert N Type: N20219Paradur® X·pert N Type: N205166

YOUR ADVANTAGES

– Cost-effective threading for small and medium batch sizes

– A high level of process reliability due to very good chip formation as a result of polished finish

– No miscutting in soft materials

Paradur® X·pert NVariant with a reduced number of flutes for the reliable creation of deep blind hole threads in soft materials.

THE TOOLS

Prototex® X·pert N – HSS-E through hole tap – Tolerance: 6H

Paradur® X·pert N – HSS-E blind hole tap – Tolerances: 6H, 6G, 2B, 3B – Available as a variant with a reduced number of flutes for reliable chip removal via large flutes

– Insert thread: EG M, EG UNC, EG UNF

THE APPLICATION

– Thread depths up to 3 x DN – Long-chipping materials with tensile strengths of up to 700 N/mm²

– ISO N: • AlSi alloys with an Si content of up to 12%• Pure copper

– ISO S: • Titanium (pure) and unalloyed nickel-based materials• Thermoplasts

HSS-E

Bare

spiral point form B

35° helix angle with chamfer form C


directly to http://goo.gl/Wj191

Turning Walter 3 ISO turning 4 Grooving 12

Drilling, Boring anD ThreaDing



Walter Prototyp 37 HSS-e-Pm taps 38 HSS-e taps 40

Milling Walter Prototyp 43 Solid carbide end mills 44




_TOOl InnOvaTIOnS In mIllInG

effectively cooled for greater performance.

Product innovationsedition 2013-2

milling

44

SOlID CaRBIDe enD mIllS

Walter Prototyp Proto·max™ Tg: universal application, extremely high performance – typical “Tough guys”.

The Tool

– Universal high-performance end mill – no corner radius – Diameter range from 2 to 25 mm – 50° helix angle – 3, 4 and 5 cutting edges – available with or without reduced neck (d2) – Shank in accordance with DIn 6535 Ha and HB – TaT coating

The aPPlicaTion

– Primary application: ISO material group P – Secondary applications: ISO material groups m, K and S – For roughing and finishing – Full slots up to 0.9 x Dc – For pocket milling, ramping and contour milling – The reduced neck also makes it suitable for machining relatively deep cavities

– areas of use: General mechanical engineering, the energy, medical, aerospace and automotive industries

Your aDvanTages

– a high level of process reliability due to the reinforced core and large chip clearance in the front

– The latest TaT coating enables an incredibly high level of productivity with cutting data which is up to 50% higher than conventional products on the market, and tool life which is up to 100 per cent longer

– Fewer cutting edge fractures due to the new substrate and innovative cutting edge treatment, which provides greater process reliability

greater chip clearance for reliable chip evacuation when full slotting up to 0.9 x Dc

reinforced core for high stability

NEW2013


directly to http://goo.gl/gcypW

45

10 20 30

Walter Prototyp – milling

Test piece

cutting data

competitors Proto·max™ TGØ 16 mm 16 mmz 4 4ae 16 mm 16 mmap 8 mm 8 mmvc 54 m/min 54 m/minn 1074 rpm 1074 rpmfz 0.04 mm 0.04 mmvf 172 mm/min 172 mm/min

Tool life in metres

0

Competition

Proto·max™TG 27

+ 50%

18

Workpiece material: X40Crmov5 (1.2344) ISO PTensile strength: 700 n/mm2

Tool: Proto·max™ TG H3121378-16

reduced neck

neW: high-performance TaT coating for cutting data which is up to 50% higher

46

SOlID CaRBIDe enD mIllS

Walter Prototyp Proto·max™inox: now also with coneFit™ interface.

Proto·max™inox with coneFit™ interface H2eC34217 metric H2eC38217 metric with corner radius

Geometry for ISO m and ISO S materials

Taa coating

Coolant outlets

Your aDvanTages

– maximum metal removal rates which are up to 50% higher than the conventional modular tools on the market

– High metal removal rates which lead to high productivity in the machining of stainless steels

– low-vibration running due to the asymmetrical pitch – Soft cutting action due to optimised microgeometry – Highest level of process reliability through optimum chip evacuation due to the internal coolant supply

– maximum tool life due to state-of-the-art Taa coating and internal coolant supply

The Tool

– a solid carbide high-performance end mill specially designed for machining stainless steels

– available with or without corner radius – Corner radius from 0.5 to 4 mm – Diameter range from 10 to 25 mm – 50° helix angle – 4 and 5 cutting edges available – ConeFit™ interface from e10 to e25 – Taa coating

The aPPlicaTion

– Primary application: ISO material group m – Secondary application: ISO material group S – For roughing and finishing – machining full slots up to 0.55 x Dc – Pocket milling, ramping and contour milling – Ideally suited to machines with an internal coolant supply – areas of use: General mechanical engineering, the energy, medical and aerospace industries

NEW2013

47

0 10 4020 30

Walter Prototyp – milling

Taa coating

Coolant outlets

Proto·max™inox with flash profile H2eC94717

Special geometry for high feed rates with ISO m and ISO S materials

The Tool

– Solid carbide high performance end mill with special high-feed-rate geometry for machining stainless steels

– Diameter range from 10 to 25 mm – 50° helix angle – 4 cutting edges – ConeFit™ interface from e10 to e25 – Taa coating

Demo workpiece

cutting data

Previously without internal cooling

Proto·max™Inox with internal cooling

Ø 12 mm 12 mmz 4 4ae 10 mm 10 mmap 2 mm 2 mmvc 82 m/min 82 m/minn 2200 rpm 2200 rpmfz 0.05 mm 0.05 mmvf 433 mm/min 433 mm/min

Tool life in metres

Previous 20

Proto·max™Inox 35

Workpiece material: X6CrnimoTi17 (1.4571) ISO mTensile strength: 700 n/mm2

Tool: Proto∙max™ Inox with ConeFit™ interface H2eC38217-e12-12-0.5

NEW2013

+ 75%










_TOOL INNOVATIONS IN MILLING

Power at the cutting edge.


Milling

Walter – Milling

51Walter – Milling

POWER AND DYNAMICS: BLAXX™ AND TIGER·TEC® SILVER.

A reliable system is required, which is attractive for its absolute precision and extremely long tool life. The Walter Blaxx™ milling cutters are based on a newly developed, unbelievably robust tool body, which is equipped with the best performance inserts from Walter: powered by Tiger·tec® Silver.

Being able to rely on a system such as this gives innovative companies the opportunity to make the most of their true strengths which are the development and manufacture of impressive products.

Productivity and process reliabilityIf all production parameters are to be optimised to ensure maximum performance, a key factor lies at the most prominent point in the process chain: the point at which the tool and the workpiece meet. This is where it becomes clear whether the desired workpiece quality can actually be achieved. Complex development scenarios can either be brought to life or can fail and result in immense costs.

52

THE NEW GENERATION OF MILLING CUTTERS

Walter BlaxxTM F5138 porcupine cutter: The new, flexible power packs.

THE TOOLS

– Full effective F5138 porcupine cutter with four-edged, tangential indexable inserts

– Equipped with LNHU1306 system indexable inserts from the Blaxx™ shoulder mill F5141 range

– Diameter range 40 – 80 mm – Two different cutting lengths for each diameter – Powered by Tiger·tec® Silver, four grades available (WKP25S, WKP35S, WSM35S, WSP45S)

– Soft-cutting geometries due to helical cutting edges – With internal coolant supply at all cutting edges – Produces a virtually step-free contour on the component – With special surface treatment for protection from corrosion and wear

THE APPLICATION

– For shoulder milling and trimming all steel and cast iron materials, stainless steels, materials with difficult cutting properties and non-ferrous metals

– Suitable for use in all industries: The automotive industry, aerospace industry and general mechanical engineering, etc.

Wear-resistant body

Internal coolant supply at every cutting edge

System indexable insert: LNHU1306…

Type: F5138/Ø40/Z2 with ScrewFit Type: F5138/Ø80 /Z5 with boring adaptor

The new generation of mills – BlaxxTM Type: F5138

NEW2013


Powered by

YOUR ADVANTAGES

A high level of process reliability due to robust design – High volume of carbide in the direction of the cutting force

– Special tool body surface treatment and reinforced core

High level of cost efficiency – Four cutting edges per indexable insert – Up to 30 per cent higher feed rate per tooth – Virtually step-free milling possible

Powered by Tiger·tec® Silver – Impressive cutting data and a high level of process reliability due to the completely new hardness/toughness ratio

Cutting dataCompetition BlaxxTM F5138

Number of teeth 4 4


fz 0.25 mm 0.26 mm

ap 12 mm 40 mm

ae 8 mm 28 mm

Workpiece material: EN-GJS-500-7 (GGG50), ISO-KTool: F5138/Ø63/Z4/Lc45Indexable insert LNHU130608R-L55TCutting tool material: WKP25S

Face milling gearbox housing, joint faces and spotfaces

Comparison: Machined volume Q [cm3/min]

0 300 900

+ 800%

1500

155

BlaxxTM F5138 1400

Competition

600 1200

Fc

Tangential reliability with BlaxxTM and Tiger·tec® Silver

Powerful cut due to the high carbide volume in the cutting force direction Fc

Maximum rigidity due to a large material cross-section in the milling body


directly to http://goo.gl/HauR0

54

Powered by

YOUR ADVANTAGES

Maximum process reliability due to stable design – High volume of carbide in the direction of the cutting force

– Special tool body surface treatment and reinforced core

High level of cost efficiency – Four cutting edges per indexable insert – Up to 30 per cent higher feed rate per tooth – Virtually step-free milling possible

Powered by Tiger·tec®Silver – 2 CVD grades (WKP25S and WKP35S) for steel and cast iron machining

– 2 PVD grades (WSM35S and WSP45S) for steel, stainless steels and materials with difficult cutting properties


Walter BlaxxTM shoulder mill: A higher feed rate without steps.

THE TOOLS

– F5041, F5141 and F5241 tangential shoulder mills with four-edged indexable insert

– Diameter range 25 – 160 mm – 3 depths of cut: 8, 12 and 15 mm – 4 carbide grades: WKP25S, WKP35S, WSM35S and WSP45S – powered by Tiger·tec® Silver

– L85T geometry for aluminium machining – High radial and axial runout accuracy – Soft-cutting geometry due to helical cutting edges – Precise 90° angle on the component – Special surface treatment provides protection from corrosion and wear

THE APPLICATION

– For shoulder and face milling all steel and cast iron materials, stainless steels, materials with difficult cutting properties and aluminium

– Highly flexible use: The automotive industry, aerospace industry and general mechanical engineering, etc.


Tangential inserts LNHU 130608R-L55T

Wear-resistant body through special surface treatment

Four usable, precise 90° cutting edges

Positive cutting characteristics

NEW

NEW

PROGRAMME ADDITIONS

2013

NEW


THE SIZES

BlaxxTM:Feed rates which are up to 30% higher possible due to the tangential arrangement of the indexable inserts

Workpiece material: GGG50, ISO KTool: Shoulder mill, diameter 80 mmIndexable insert: LNHU130608R-L55TCutting tool material: WKP25S

Comparison: Feed per tooth fz [mm]

0.100 0.300.20

Previously 0.20

+ 30%

BlaxxTM with WKP25S 0.26

Cutting data

vc 264 m/minap 8 mmae 50 mm

BlaxxTM F5141

– Diameter range 40 – 125 mm – Medium and fine pitches – Cutting depth 12 mm – Corner radii R0.8 – R3.2 mm – Insert: LNHU1306…

BlaxxTM F5041

– Diameter range 25 – 63 mm – Medium and fine pitches – Cutting depth 8 mm – Corner radii R0.4 – R2.0 mm – Insert: LNHU0904…

BlaxxTM Type: F5041.W... BlaxxTM Type: F5141.B...

Watch animation: Scan this QR code

or go directly to http://goo.gl/CesMH

NEW: BlaxxTM F5241

– Diameter range 50 – 160 mm – Medium and fine pitch – Cutting depth 15 mm – Corner radii R0.8 – R2.5 mm – Indexable insert LNHU1607..

BlaxxTM Type: F5241.B...


L55T – the universal one – For medium machining conditions

– Universal use – for most materials

NEW: L85T – the sharp one – For aluminium machining – Low cutting forces – Sharp cutting edge

56


Walter BlaxxTM F5055 slitting cutter: Reliable slitting and parting.

THE TOOLS

– F5055 slitting cutter with single-edged indexable insert – Diameter range 63 – 250 mm – Cutting widths: 2.0, 3.0 and 4.0 mm – High radial and axial runout accuracy – Non-positive and positive insert clamping in the body – 2 carbide grades: WSM33S and WSP43S – powered by Tiger·tec® Silver

– User-friendly indexable insert self-clamping system

THE APPLICATION

– For slitting and parting all steel and cast iron materials, stainless steels and materials with difficult cutting properties

– Suitable for all industries: The automotive industry, aerospace industry and general mechanical engineering, etc.

YOUR ADVANTAGES

Maximum process reliability – The machining force is introduced into the fixed part of the insert seat

– Extremely high retaining forces as a result of the optimised top clamp

– Non-positive and positive cutting insert clamping system

Low inventory costs – System indexable inserts, suitable for use in slitting cutters and grooving holders

Powered by Tiger·tec® Silver – 2 PVD grades (WSM33S and WSP43S) for steel, stainless steels and materials with difficult cutting properties


Extremely high retaining forces as a result of the optimised top clamp

Optimum productivity thanks to Tiger·tec® Silver cutting tool materials

High stability brought about by introducing the machining force into the fixed part of the insert seat

NEW2013


0 0.375 1.50.75 1.125


CE4 – the stable one – For moderate to high feed rates

– Good chip constriction – Stable cutting edge

CF5 – the universal one – Universal application for most materials

– Light to moderate feeds

CF6 – the easy-cutting one – Good machining conditions – Low feeds – For machining non-ferrous metals

– Low cutting forces

Cutting dataPrevious BlaxxTM

Number of teeth 7 7


fz 0.06 mm 0.06 mm

vf 231 m/min 231 m/min

ap 8 mm 8 mm

ae 2.2 mm 2.0 mm

Workpiece material: St 52, ISO PTool: F5055/Ø80/Z07/SB2Indexable insert SX-2E200N02-CF5 Cutting tool material: WSM33S

Separating inlet flanges

Comparison: Width of wear marks after 240 components (in mm)

– 62%

Previous

BlaxxTM 0.05

0.13

Extremely high retaining forces as

a result of the optimised top clamp

Cutting forces are absorbed in the fixed part of the tool, rather than the flexible part of the tool

The cutting insert has a positive fit in the insert seat, so there is no risk of extraction during machining

58

Wear resistance

Toughness

WSM35S

WSP45S

CUTTING TOOL MATERIALS

Walter Tiger·tec® Silver: Tougher and more wear-resistant with a PVD-Al2O3 coating.

THE COATING

– Globally unique PVD aluminium oxide coating – Optimum cutting tool material toughness thanks to minimal thermal loads in the coating process

– Optimum protection against heat transfer into the cutting edge thanks to aluminium oxide heat shield

– Extremely smooth rake face ensures low-friction machining

THE INDEXABLE INSERTS

– For Blaxx™ shoulder mill and porcupine cutter F5.41 and F5138 with various corner radii

– For all popular tools from the Walter milling range, e.g.:• Xtra·tec® F4033, F4047, F4048, F4041,

F4042 face and shoulder mills• Xtra·tec® F4053, F4153, F4253 side and

face mills• Xtra·tec® F4038, F4138, F4238, F4338

porcupine cutter

THE CUTTING MATERIALS

– Designation WSM35S and WSP45S – Primary application: Machining stainless steels and materials with difficult cutting properties

– WSP45S also suitable for machining steels

YOUR ADVANTAGES

– A high level of process reliability thanks to the unique combination of wear resistance and toughness

– A high level of productivity when machining exotic materials thanks to the globally unique Walter PVD-Al2O3 coating

– Smaller built up edge thanks to extremely smooth surfaces

– Reliable wear detection due to two-tone Tiger·tec® coating

A small selection from the extensive Tiger·tec® Silver product range


Thermal loading of carbide

= Temperature in the cutting edge

Surface structure of coating

COMPARISON Competition Tiger·tec® Silver PVD

High thermal loading of carbide Thermal protection by Al2O3

High friction due to surface structure Reduced friction due to improved surface

Chip

Cutting edge

Cutting edge

Chip

Al2O3Wor

kpie

ce

Wor

kpie

ce

Conventional PVD layer

Wear indicator

Multilayer composition for optimal high-temperature performance

coupled with the greatest possible hardness and toughness

Improved hairline-crack resistance, reduction in

tribochemical wear

Al/Al2O3

AlTiN/Al2O3

Al2O3

Substrate

Resistant to flank-face wear

AlTiN

60

Example: Walter PCD form mill

NEW PCD DEVELOPMENTS

Walter PCD milling cutters with laser- generated chip breakers: Innovative special solutions for long-chipping materials.

THE TOOLS

– Form and shoulder mills with user-optimised PCD grades in virtually any form

– Optimised geometries for reduced cutting forces and minimal vibration tendency

– Particularly well suited to machining with long tools or tools with extended projections

THE APPLICATION

– For a wide variety of non-ferrous materials – Plastics with and without fillers – High surface-quality requirements – Low cutting forces with long tools – Good chip control – Customised milling, turning and boring tools

THE MATERIAL

– Aluminium alloys with an Si content of up to approx. 7 per cent

– Copper and copper alloys – Plastics (thermoplasts) – Fibre-reinforced plastics

YOUR ADVANTAGES

– Good chip control – Chip breaking even in very tough materials and aluminium wrought alloys

– Low vibration tendency – Lower cutting forces

PCD SPECIAL TOOLS FROM WALTER

Strong PCD tools are the first choice for more cost-effective and high-precision machining of light and high-strength materials, for example in the automotive or aerospace industry. Walter’s PCD special tools are characterised by extremely long tool life (50 to 200 times that of standard carbide tools), as well as the highest level of process reliability and dimensional stability. This opens up enormous potential for production, particularly in mass production.

Balance holes in level 2 for dynamically balancing the tool

Optimised chip breaker groove geometry for perfect chip breaking

SPECIAL TOOLS

FROM WALTER

Optimised geometries for reduced cutting forces and minimal vibration tendency.


WHY PCD?

– Significant improvement in tool life – Improved surface quality – Higher cutting data – Sharper cutting edge – Reduced thermal impact – Optimum thermal conductivity of the cutting tool material – Minimised risk of delamination – Dry machining possible – Repeated resharpening or reconditioning possible

Balance holes in level 1 for dynamically balancing the tool

Example: Walter PCD end mills

Solid carbide basic body

Positive and negative axis angle in order to reduce the axial cutting forces

Application-optimised chip breaker geometry for reliable chip breaking even in very tough materials and aluminium wrought alloys

The right tool at the click of a mouse With just four clicks, Walter GPS takes you from the definition of your objective to the most cost-effective tool and machining solution. Walter GPS is surprisingly comprehensive. Be it drilling, threading or milling, full information on all tools from Walter, Walter Titex and Walter Prototyp can be displayed in an instant. Access mandatory usage data, such as accurate cutting data or precise cost-efficiency calculations, on your screen.

The latest generation of tool navigation

Walter GPSGlobal Productivity System

You will find the complete tool range of our three competence brandsWalter, Walter Titex and Walter Prototyp in the 2012 edition of thegeneral catalogue, in the 2013 edition of the supplement catalogueand in this new products brochure for 2013-2 “Experience, knowledge,technology: Expertise on your side”. It replaces the previous, 2013-1brochure “Advancing through innovative machining solutions”.

They contain all the precision tools you need in your production facilitiesfor turning, boring, milling and threading.

We will be pleased to send you the general catalogue on request.

= The full range of tools

Walter general catalogue+ supplement catalogue+ new products brochure

_INNOVATIONS





General catalogue



Supplement catalogue


Walter product innovations · Edition 2013-2

Prin

ted

in G

erm

any

653

5353

(09/

2013

) EN

Walter GB Ltd. Bromsgrove, England +44 (1527) 839 450, [email protected] Walter Kesici Takımlar Sanayi ve Ticaret Ltd. Şti. Istanbul, Türkiye +90 (216) 528 1900 Pbx, [email protected] Walter Wuxi Co. Ltd. Wuxi, Jiangsu, P.R. China +86 (510) 8241 9399, [email protected] Walter AG Singapore Pte. Ltd. +65 6773 6180, [email protected] Walter Korea Ltd. Anyang-si Gyeonggi-do, Korea +82 (31) 337 6100, [email protected] Walter Tools India Pvt. Ltd. Pune, India +91 (20) 3045 7300, [email protected] Walter (Thailand) Co., Ltd. Bangkok, 10120, Thailand +66 2 687 0388, [email protected] Walter Malaysia Sdn. Bhd. Selangor D.E., Malaysia +60 (3) 8023 7748, [email protected] Walter Tooling Japan K.K. Nagoya, Japan +81 (52) 723 5800, [email protected] Walter USA, LLC Waukesha WI, USA +1 800-945-5554, [email protected] Walter Canada Mississauga, Canada [email protected]

Walter AG

Derendinger Straße 53, 72072 Tübingen Postfach 2049, 72010 Tübingen Germany www.walter-tools.com



_INNOVATIONS


Documents

Experience, knowledge, technology: Expertise - Walter Tools · Walter Tools India Pvt. Ltd. Pune, India +91 (20) 3045 7300, [email protected] Walter (Thailand) Co., Ltd