Implement milling tasks economically

The quality of the end result and process reliability during milling depend significantly on the milling tools and their use. At the same time, the cost pressure on companies in the metalworking industry has increased significantly in recent months. Tool costs also play an often underestimated role here. Very good on-site customer support or virtual support through appropriate media help to optimize the use of tools. The machining specialist Walter is convinced of this. The Tübingen-based company also sees the high level of consulting and process expertise of its Technical Sales and Product Management departments as a key success factor.

Jasmin Kleine Hermelink, Product Manager Milling at Walter, explains: "Walter offers a wide range of different milling tools, assigned to three product families Xtra-tec XT, Walter Blaxx and M4000, which are continuously being developed further. We see our great strength in supporting our customers in developing the optimum milling strategy for their needs. Especially in the field of milling, many customers do not yet exhaust all the possibilities. In addition to individual advice on site, we offer digital events, such as our Mastering Indexable Milling Event, which took place in October, to familiarize customers with our various tool types in realistic production situations and to use them optimally."

Machining materials with high metal removal rates

With the Walter Blaxx, M4000 and Xtra-tec XT product families, Walter addresses the very different requirements of specific applications: Walter Blaxx milling cutters are the ideal choice for maximum metal removal rates on milling machines with high performance and high torque. In the majority of this product family, the indexable inserts are attached to the milling tools in a tangential position. Due to the higher carbide volume in the cutting force direction, this position enables a higher tooth feed compared to a radial position of the indexable insert. This allows the machine's performance to be fully utilized without jeopardizing process reliability and result quality.

The Walter M4000 family has been successful on the market for several years. The trend towards smaller batch sizes and more frequent changes to components continues to open up many possible applications for the milling cutters, as all milling cutter types can be equipped with the same system indexable insert: from face milling cutters to corner milling cutters, high-feed milling cutters, hedgehog milling cutters, T-slot milling cutters and chamfer milling cutters. This allows users to react quickly and flexibly to different applications in production. This also has an impact on tool management: The number of indexable insert types to be managed can be significantly reduced. This reduces the customer's workload for the procurement and storage of indexable inserts.

Process reliability for a high degree of automation

Especially in automated production with its high deadline pressure, process reliability with high output is the key quality criterion. The Walter Xtra-tec XT milling cutter family provides machining companies with a solution that covers almost all milling applications and whose entire design is optimized for maximum process reliability in combination with maximum performance. Nicole Howind, Product Manager Milling, says: "Walter continuously invests in the further and new development of its product families. Xtra-tec XT is the best example of this: Small but significant changes to the indexable insert and the tool body bring extreme improvements in the application."

The most striking design feature of the Xtra-tec XT milling cutters can be clearly seen in the example of the M5130 corner milling cutter. Here, the installation position of the indexable inserts is more inclined in comparison and has a larger contact surface. This reduces the surface pressure in the seat and increases stability. The larger cross-section around the screw hole stabilizes the indexable insert and longer screws increase the clamping security. The milling cutter body is also more stable, as it has significantly more material behind the insert seat. In addition to greater process reliability, the new installation position of the inserts also enables one more tooth - and therefore higher productivity.

High-quality milling tools can only perform at their best with the appropriate indexable insert coatings with a long service life. Comb cracks are one of the typical forms of wear in milling. They are caused by the temperature change of the incoming and outgoing cutting edge. In the worst case, the cutting edge breaks and the insert fails. With the Walter Tiger-tec Gold WSP45G, on the other hand, wear is uniform. This counteracts comb cracks and fractures. The indexable insert has a wide range of applications and is particularly suitable for the reliable milling of components made from the material groups ISO P (steels), ISO M (austenitic stainless steels) and ISO S (difficult-to-machine materials such as titanium or nickel-based alloys).

Process reliability and surface quality

For Tobias Zimmer, owner of T. Zimmer Maschinenbau & CNC Technik, the Tiger-tec Gold WSP45G indexable inserts have become an integral part of the day-to-day work of his family business. The contract manufacturer from Hünxe has to cover a wide range of different requirements: from railroad technology components to delicate components in medical technology. Ever since the Walter machining experts quickly and successfully supported him when unexpected complications arose during a time-critical order, machining tools from Walter have been part of Zimmer's basic equipment. What he particularly appreciates, in addition to the excellent on-site advice provided by Walter employees, is the high reliability and wear resistance of the Tiger-tec Gold indexable inserts: "The inserts last a very, very long time. So you can leave the machine running and not have to worry. We have high demands on our tools. We are also giving chain here, because otherwise you can't earn any more money in Germany. And that's possible with premium manufacturers like Walter."

Another Walter user is the mechanical engineering company Severt from Vreden. Here too, Walter has established itself as a reliable partner. For the machining of a new material for Severt, a high-strength structural steel, a new economical machining strategy was needed. The Walter employees on site were able to offer an optimum solution with Tiger-tec Gold indexable inserts. Manfred Terpelle, Head of Mechanical Production at Wilhelm Severt Maschinenbau, explains: "We have really created added value that can not only be calculated, but that can actually be seen on the machine. We have large components here, where we always have large overhangs, and this results in vibrations. WSP45G can absorb so many vibrations and we still have good work results that we are simply delighted with it. We were able to cut the tool costs in thirds and halve the machining time. Nobody could keep up with that."