Cutting Tools: Technology to Make Your Process Easier

Cutting tools are a crucial part of any mold manufacturing process. The right cutting tools aid in efficiency, productivity, cost-effectiveness and more. However, with so many options on the market, discovering what is right for a particular shop can be a challenge. MoldMaking Technology is here to help with this latest cutting tools technology roundup.

Every month, MMT provides readers with a technology roundup detailing some of the latest innovations and upgrades. To check out tech roundups from months prior, please browse the “New Tech” section of the MoldMaking Technology website, or look up “Technology Roundup” in the homepage Search bar. For more information on a product below, click on the link in the title of the respective product.

Indexable Milling Platform Advances Mold and Die Capabilities

Dapra Corp. has announced its high-feed indexable milling platform, “Vapor powered by TRI-X2.” The Vapor platform features elements in body design and TRI-X2 insert geometry for higher metal removal rates and extended tool life. Vapor is said to be ideal for extreme machining with modern machine tool technology.

Submicron-Grade Carbide End Mills Achieve Material Removal Versatility

Greenleaf-360, from Greenleaf Corp., is a line of high-performance solid carbide end mills to complement the XSYTIN-360 line of solid ceramic end mills. Greenleaf-360 end mills combine a proprietary flute design with a high-performance carbide substrate for fast and efficient material removal with less stress induced into the part. A combination of strength, toughness and heat resistance enables machining capabilities from roughing to finishing with extended tool life and predictability, well suited for materials in the aerospace, automotive, die and mold, medical and power generation industries.

Ceramic Grade Increases Productivity When Machining Hardened Steels, High-Temp Alloys, Cast Irons

Kennametal has introduced its latest ceramic turning grade, KYHK15B, designed to deliver increased productivity and lower cost per edge in hard turning operations. Hard turning is often considered for punch and die and mold industry segments, to name a few, for its ability to produce contours and to generate complex forms in hardened steels.

Inch-Size Solid Carbide Shoulder/Slot Mills

With more than 3,000 cutting tools in inch sizes, Walter USA continues to expand its solid carbide milling offerings, which now include the MA230, MA320 and MA321 Advance shoulder/slot mills for universal application. The MA230 Advance solid carbide milling cutter is for universal machining of steel, stainless steel, cast iron and high-temperature superalloys (ISO P, M, K and S workpiece groups) at the highest level. The tool’s exclusive edge prep enables stable and efficient cutting action. An eccentric relief provides a strong cutting edge, and a proprietary coating allows for a higher cutting speed and extended tool life.

Micro-Diameter End Mill Series Reduce Cutting Time, Enhance Finishing for Ultra-Precision Moldmaking

Through the manufacture of ultra-precision molds, Towa has developed its own line of micro-diameter end mills and drills that feature high accuracy, with excellent wear resistance, sharpness and long life. Towa is now introducing its end mill product line to the North American market. The end mills, tipped with CBN, which is the second hardest material after diamond, are offered in sizes ranging from 0.1-6 mm in diameter, with various configurations — from sharp corner, radius corner, ball, standard neck length and extended neck length.

Precision Micro Finishing Tools Supply Machine, Mold and Die Operations

Titan Tool Supply Inc. expands its precision micro finishing tool online product catalog offerings, making more than 100 products available for immediate customer order and shipment. The company’s precision micro finishing tools have supported the advanced manufacturing requirements of hundreds of companies, as well as their associated machine shops, and tool, die and moldmaking operations.

End Mill Grade Features Advanced Wear, Oxidation Resistance

Kennametal Inc. has added an efficient new cutting tool to its portfolio of solid carbide end mills, featuring enhanced wear and oxidation resistance. It is designed with a distinctive PVD coating technology that is reported to deliver extended tool life for job shops machining stainless steel, titanium and other high-temperature alloys for aerospace, energy, transportation, mold and die and general engineering industries.

Universal Presetting, Measuring Machine Aids Cutting Tool Assembly

According to Zoller Inc., the company’s »redomatic 600« machine and a pair of powerful software programs give mold builders the peace of mind that their cutting tools are perfectly measured and assembled before production, optimizing the process to save time and produce a high-quality part. The »redomatic 600« combines a presetting and measuring machine with a heat-shrink system for a two-in-one solution that maximizes accuracy and efficiency in five-axis CNC machining. The machine presets tool lengths within 10 µm to meet the high tolerances required in moldmaking. A recent redesign shortened the heat-shrink process, which has the added benefit of conserving tool life.

Face Mill Holder With Damping Vibration Control Supports Far-Reaching Operations

Big Kaiser, a member of the Big Daishowa Group, has expanded its lineup of Smart Damper-equipped, arbor-style face mill holders. This holder is the largest and longest milling tool of the company’s offerings, supporting face mills with diameters of 3", 4", 80 mm or 100 mm with an arbor pilot diameter of either 1" or 27 mm. The Model SDF57 assembly has an outside diameter of 2.83" and enables those using 3" face mills to access up to 19.68" of reach. The tool holder will benefit face milling operations where long reaches are common. 

Roughing, Finishing Aluminum-Specific End Mill Line Expansion

Cutting tool specialist Sandvik Coromant is expanding its line of CoroMill Dura versatile solid end mills with aluminum-specific tools. The concept, originally introduced in November 2022, is well suited for roughing and finishing, giving it a variety of uses for industries like mold and die.

Diamond-Coated End Mills for Machining Electrodes

Crystallume, known for its chemical vapor deposition (CVD) diamond technology, features its three diamond-coated tool lines — Standard Premium, Lightning and Stealth — for machining the thinnest details in graphite electrodes.  The company’s thinnest diamond coating, Stealth, is only 2-3 µm thick.

Hydro Chuck Toolholder Promises Precision When Heavy Milling

NT Tool highlights the Hydro Chuck Omega, an innovative addition to its PHC family which offer the machining industry advanced features and high performance. The Hydro Chuck Omega is designed to eliminate the common issues of chatter, deflection and pullout that often occur during heavy milling. With this tool, users are capable of high-efficiency machining. Cycle times are reduced, and surface quality is improved, leading to increased tool life.

End Mill Series Design Enables Dynamic Milling Strategies

Proper cutting tool selection for moldmaking, such as the M.A. Ford TuffCut XV series XV5CB, XV7 and XV7CB end mills, get the job done when it comes to improving speeds and feeds, wear and surface finish, in addition to standing up to difficult-to-machine materials like alloyed steels. The company’s XV5CB five-flute end mill is designed to deliver exceptional metal removal on steels and stainless steels with up to 4×D axial engagement. Using ALtima Q coating, staggered chipbreakers and open end geometry for aggressive engagement, it is ideally suited to dynamic milling strategies.

Sharpening Solution to Give End Mills New Life

Darex has been in the business of drill bit sharpeners for more than 50 years. Knowing that the average quality end mill easily costs several hundred dollars, the company is finally applying its sharpening expertise to an upcoming end mill solution in the form of a new attachment for its XT3000 drill sharpener. The LEX600 end mill attachment will enable users to sharpen the primary and secondary grind on the tips of two-, three or four-flute end mills up to 5/8", giving new life to these tools while cutting cost.

Toolholder Solutions for Moldmaking

Designed for accuracy to meet the demands of machining molds, Lyndex-Nikken offers three advanced toolholder solutions: MMC Collet Chucks, SK Collet Chucks and Shrink Fit Toolholders. MMC Collet Chucks are highly flexible for machining molds and dies, providing both clearance and accuracy in small diameter cutting. SK Collet Chucks feature a narrow body design to access tight spots in a mold. Shrink Fit Toolholders provide optimal surface finish and extreme gripping, making them ideal for high-speed moldmaking applications.