2015/2016

Products, processes, solutions

Engineering Kompetenz

Sharpening your cutting edge.

Engineering Kompetenzwalter-tools.com

Why not take your technology to the next level? It’s easy with solutions that are leaps ahead of the standard. That’s because each of our innovations represents our collective experience and engineering expertise - just what‘s needed to boost your productivity and your cutting edge.

„We do not reinvent the wheel every day.

But we do when it makes sense.“

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_SOLID CARBIDE DRILL

Walter Titex DC170 Supreme

BENEFITS FOR YOU

– Increase in productivity due to 50% longer tool life, with 35% higher workpiece values – in comparison to conventional solid carbide drills

– Improvement in component quality due to the drill being continuously guided at the circumference – Reduction of production costs through optimum use of the tool: The number of grooves indicates the condition of the drill

– Polished chip flutes guarantee reliable chip removal

THE TOOL

– Solid carbide high-performance drill with through coolant – Grade: WJ30EJ, K30F, Tinal/AlCrN multilayer – Dimensions:• 3 × Dc (in accordance with DIN 6537 short)• 5 × Dc (in accordance with DIN 6537 long)• 8 × Dc• 12 × Dc• 16 × Dc• 20 × Dc

– Diameter range 3–20 mm – Shank according to DIN 6535 HA

THE APPLICATION

– For the ISO material groups P, K – Can be used with emulsion and oil – For interrupted cuts and inclined exits – Areas of use: General mechanical engineering, mold and die making, and the automotive and energy industries

DC 170 Supreme Product range: DC170 Supreme

Innovative new land design

Polished chip flute starting from 8 × Dc for optimum chip evacuation

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Visibly different – completely reliable. The Ikon of a new performance class.

3 × Dc

20 × Dc

5 × Dc

8 × Dc

12 × Dc

16 × Dc

Here's what cost efficiency can look like: The regrinding scale

360° coolant coverage for maximum cooling

Continuous guidance for excellent component quality

Maximum carbide mass for maximum process reliability

DC 170 Supreme Product range: DC170 Supreme

Shank DIN 6535 HA

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THE TOOL: -P

– Coolant supplied directly through the clamp and along the flank face

– Flexible square-shank coolant connection• Direct guidance of coolant from adaptor to shank tool

(via A2120-P / A2121-P adaptor)• Coolant hose set with G1/8˝ thread (K601)

– Tool variants• Square shank 20 / 25 mm• Walter Capto™ C4–C6

THE APPLICATION

– Machining of stainless material (ISO M), high-temperature alloy (ISO S) and benefits on steel (ISO P)

– Coolant pressure from 10 bar up to a maximum of 150 bar can be used. (Higher pressures also possible following technical clarification)

– Improved chip breaking, especially at pressures above 40 bar – Multiple machine operation, e.g. multi-spindle machines, because the chips are removed by an ideal cooling system

Shank tool with precision cooling Illustration: DCLNL2525X12-P

_ISO TURNING

Walter Turn with precision cooling (-P)

BENEFITS FOR YOU

– Increase in tool life from 30–150% on stainless materials, high-temperature alloys and steel – Plug-and-play: Use of existing machines, as the cooling system can be used starting from a pressure of 10 bar and without interference contour on the tool

– Increase in cutting speed by up to 100%, while maintaining the same tool life

Rake face cooling • Longer tool life• Larger chip breaking area

Flank face cooling • Longer tool life • Increase in the cutting speed

Coolant pressure • 10–150 bar• Universal application

Rigid clamping system• High process reliability

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②

①

Dual cooling:Increase in tool life from 30–150% thanks to optimal cooling via rake face (1) and flank face (2).

Easy handling:In combination with the A2120 / A2121-P VDI adaptors, the coolant is delivered either directly or, alternatively, via a G1/8“ coolant hose set. With Walter Capto™ tools, the coolant is guided into the interface.

At the effective working area:The precision cooling brings the coolant as close and flatly angled as possible to the effective working area underneath the chip. As a result, significant advantages can be achieved on machines starting from a coolant pressure of 10 bar.

NEW TECHNOLOGY: WALTER PRECISION COOLING

Robust:The clamp presses the insert downwards and backwards into the insert seat. Consequently, the insert is not detached from its seat even during heavy roughing operations and the component dimensions are consistently maintained with complete accuracy.

Direct, efficient and with spot-on accuracy.

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THE TOOL

– 90° ramping milling cutter for HSC milling – Maximum cutting depth 15 mm or 20 mm – Diameter 25–80 mm or 1–3“ – High level of radial runout accuracy – Finely balanced basic body – With different interfaces such as HSK, ScrewFit, parallel shank or bore adaptor

THE APPLICATION

– For machining non-ferrous metals (ISO N) such as aluminium wrought alloys or aluminium lithium alloys

– Machining of structural components in aircraft construction – Rough milling and semi-finishing of pockets with high chip volume

Walter ramping milling cutter Typ: M2131

BENEFITS FOR YOU

– High level of process reliability even at maximum speeds thanks to centrifugal force protection

– Short machining time due to maximum metal removal rate – Long tool life thanks to low formation of build-up on the cutting edge

_SHOULDER MILL

Walter Sky·tec M2131 ramping milling cutter

Internal coolant for MQL or cooling lubricant

Integrated centrifugal force protection

V-shaped cutting edge for ramping

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THE INDEXABLE INSERTS

– Two sizes of indexable insert with various corner radii• ZDGT1504 …R-K85 (R = 0,4–4,0 mm)• ZDGT2005…R-K85 (R = 0,8–6,4 mm)

– Positive basic shape with special geometry for pocket milling – Centrifugal force protection at the contact surface for HSC machining – New milling grade WNN15 with extremely long tool life

Walter ISO N indexable insert Typ: ZDGT

DETAIL OF THE RAKE FACE

Extremely smooth surface of the WNN15 grade

Cutting data:Previously WNN15

vc 2 356 m/min 2 356 m/min

n 15 000 min-1 15 000 min-1

fz 0,20 mm 0,20 mm

vf 9 000 mm/min 9 000 mm/min

ae 42 mm 42 mm

ap 9 mm 9 mm

Material: Aluminium 7075Tool: M2131 / Z = 3 / Ø 50 mmInsert: ZDGT200540R-K85Cutting material: WNN15Cooling medium: Emulsion

Milling a pocket

600480120 240 720360

Tool life comparison [min.]

Previously

M2131 with WNN15 grade 700

+367 %

0

150

1 µm

Benchmark for aluminium wrought alloy in the aircraft industry.

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YOUR POINT OF CONTACT FOR THE ENTIRE PROCESS.

What makes Walter Multiply so unique are the decades of experience in machining that we combine with a profound knowledge about the components manufactured by our customers. With our solutions and services, we support you in every phase of your process, whether new or existing components are involved. With thoughtfully designed complete solutions and a comprehensive tool portfolio, we optimise your manufacturing processes and productivity throughout the entire life cycle of the tools.

And you benefit from Walter’s extensive “Engineering Kompetenz”.

_FROM THE TOOL TO THE SOLUTION

Walter Multiply

YOUR ADVANTAGES

– Proficient and professional process management – Guaranteed process results within the package price – Tools and solutions from a single source – Focus on adding value and saving resources

WinGripLanding gear support beam

FOCUS ON THE COMPLETE PROCESS.

Adding value begins with the first chip. As an experienced partner in planning new manufacturing processes and optimising existing ones, we advance your production solutions an essential step further forward. That’s because our focus includes all of the relevant factors: Starting from applying the ideal clamping system, using the most efficient NC program, right through to the best possible tool selection.

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A flying start with custom-made solutions

YOUR ADVANTAGES

– Always the best technologies – automatically implemented – Focus on adding value throughout the entire process – Lasting productivity advantages instead of short-term savings made only at the point of purchase

TOOLING LOGISTICS PLUS TOOL EXPERTISE.

Efficient tool management coupled with sound tooling and application expertise: Even in tooling logistics, Walter Multiply represents Engineering Kompetenz across all industries. Take advantage of our complete solutions along your entire pro-cess chain: From order planning and procurement to inventory management through to environmentally responsible disposal. Walter Multiply completes your tooling supply circuit.

Door surround Fuselage

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_ENGINEERING KOMPETENZ

Walter Aerospace New tool concepts

Type: M2131

• New WNN15 grade for maximum tool edge life • Centrifugal force protection for maximum

rotational speed• Internal coolant supply for MQL and emulsion• HSC applications for maximum metal removal rate

ALUMINIUM MACHINING

Aviation in particular uses wrought alloys made of aluminium. The advantages are clear to see: They are light, have a high load-bearing capacity and are extremely robust. That applies to the proven 2000, 6000 and 7000 series. And even more so to the new generations, such as the 2050 aluminium-lithium alloy.

Anyone machining aluminium must be actively involved with process development. This is because the machine, the tool, work processes and milling strategies must match the component material perfectly.

Walter offers high-performance solutions for HPC and HSM aluminium machining, whether indexable insert, solid carbide or PCD tools are used for cutting the material. For contour and pocket milling, maximum process reliability is also an important factor.

In this case, the new M2131 Sky·tec ramping milling cutter is the key for success. With its ZDGT indexable inserts, it fulfils the high demands placed by our customers on a fully integrated machining solution which bears the brand name Walter.

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Type: Walter Prototyp HPC Al38

• Four cutting edges – differential pitch for wall finishing operations• Transition radius on the circumference for step-free waterline milling• Optimised microgeometry of the cutting edge for vibration-free

finishing operations• Internal coolant supply – also for MQL

Type: Walter Prototyp MB 266 Supreme

• WJ30UU grade (uncoated)• Internal coolant supply for emulsion/(MQL)• Al 30 geometry for finishing and maximum

metal removal rate• Centre cutting edge for reliable ramping

Type: Walter Prototyp MB 265 Supreme

• WJ30UU grade (uncoated),• WJ30CA grade (CrN-coated)• Internal coolant supply for emulsion/(MQL)• Al-RAPAX G30 geometry for

maximum metal removal rate• Centre cutting edge for reliable ramping

Type: Walter Prototyp HPC Al30 close pitch cutter

• Close pitch cutter for HPC pocket and bottom finishing

• Microgeometry of the centre cutting edge ensures low axial cutting forces

• Vibration-free thanks to the microgeometry of the secondary cutting edge

• Internal coolant supply for MQL• Constant helix angle

Innovations in the aircraft industry

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_ENGINEERING KOMPETENZ

Aerospace trendsNew tool concepts

Type: Walter Prototyp ConeFit Ti50 range

• Step-free semi-finishing/finishing of deep pockets in titanium structural components

• Up to 7 × D with solid carbide ConeFit adaptors

Type: Walter M4002 high-feed milling cutter

• Cost-efficient, system-based, high-feed milling: Indexable insert and maximum number of teeth for maximum metal removal rate

• Up to 100 percent longer tool life with the new WSM45X cutting tool material for titanium.

Type: Walter BLAXX M3255 porcupine milling cutter

• Tangential milling system with four cutting edges per indexable insert• Maximum number of teeth for maximum metal removal rate for roughing

operations on titanium structural components• Up to 100 percent longer tool life with the new WSM45X cutting tool

material for titanium.

Type: Walter Prototyp Protostar® Ti40 range

• All-rounder with five cutting edges• More productivity when roughing, semi-finishing

and finishing, and during dynamic high feed-rate milling of titanium structural components

TITANIUM MACHINING

No sector processes more titanium than the aerospace industry. The greatest advantages of the material for this industry are a high level of stability combined with its light weight and excellent high-temperature properties.

The key to successful titanium machining is a process that inclu-des all the components relevant to the operation. Machine, cutting tool, machining processes and the correct milling strategy must be combined in such a way that they match perfectly with the material properties of the chosen titanium alloy.

Machining contours and pockets is performed mainly on CNC milling centres or on multi-spindle portal milling machines. Our indexable inserts with Tiger·tec® Silver coating in the new WSM45X grade, as well as solid carbide milling cutters, find favour on these operations because of an extremely long service life and dimensional stability.

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Engineering your processes.

Engineering Kompetenzwalter-tools.com

Why settle for a supplier, when you can partner with a service provider? One who delivers not just exceptional products but also outstanding service, plus advice specific to your needs. Help us get a sense of what makes your business tick so that we can better analyze and understand your workflow. Build efficiency into your processes and from there it just keeps on getting better.

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Walter AG

Derendinger Straße 53, 72072 Tübingen Postfach 2049, 72010 Tübingen Deutschland

walter-tools.com

Walter GB Ltd. Bromsgrove, England +44 (1527) 839 450, service.uk@walter-tools.com

Walter Kesici Takımlar Sanayi ve Ticaret Ltd. Şti. Istanbul, Türkiye +90 (0) 216 528 1900 Pbx, service.tr@walter-tools.com

Walter Wuxi Co. Ltd. Wuxi, Jiangsu, P.R. China +86 (510) 853 72199, service.cn@walter-tools.com

Walter AG Singapore Pte. Ltd. +65 6773 6180, service.sg@walter-tools.com

Walter Korea Ltd. Anyang-si Gyeonggi-do, Korea +82 (31) 337 6100, service.kr@walter-tools.com

Walter Tools India Pvt. Ltd. Pune, India +91 (20) 3045 7300, service.in@walter-tools.com

Walter (Thailand) Co., Ltd. Bangkok, 10120, Thailand +66 2 687 0388, service.th@walter-tools.com

Walter Malaysia Sdn. Bhd. Selangor D.E., Malaysia +60 (3) 8023 7748, service.my@walter-tools.com

Walter Japan K.K. Nagoya, Japan +81 (52) 533 6135, service.jp@walter-tools.com

Walter USA, LLC Waukesha WI, USA +1 800-945-5554, service.us@walter-tools.com

Walter Canada Mississauga, Canada service.ca@walter-tools.com