How is the market for cutting tools fairing in India? Which industries are driving the growth for the company?
Brajesh Kumar: Indian market is currently undergoing difficult conditions. Although the automotive sector isn’t performing well, we cannot neglect other emerging sectors. Aerospace and defence manufacturing segments are gaining momentum, thanks to the Make in India initiative. Railways manufacturing is also doing well due to the government’s emphasis on infrastructure creation and railways modernisation. We believe that it is just a temporary phase and the market will gradually pick up.
Dmitry Andreev: We have seen the Indian market growing with great speed in the past. Our Technical Centre in Pune is a proof of our commitment to the Indian market. The rough market conditions are part and parcel of the business and do not shake our belief in this market. We are optimistic about its recovery and look forward to it.
Please tell us about one of the tools that has gained popularity lately.
Kim Seidelman: Recently the company introduced a new solid carbide thread mill program. All the learning that we had from our recently introduced indexable thread milling program, we have applied to solid carbide thread mill. This tool enables users to easily thread small diameters. This solution has gained popularity in the market in no time. It is satisfying to see that customers are reacting positively towards this tool.
There is yet another tool that has been a huge success lately. We thoroughly upgraded our Xtra•tec® XT index milling system. With this, it has become one of the most important milling programs. We are seeing throughput increase in the range of 25-30%. Hence, this too is well accepted by our customers in the manufacturing industry.
Please tell us about how the company is adopting new technologies to upgrade its tools?
Andreev: Today, customers have become more demanding. Interestingly, these demands are not limited to a tool or a cutting process. But they are related to the processes before and after the cutting process. Customers are looking at understanding their logistics chain of the tool in detail. Reacting to this trend, even we are developing solutions, which go beyond metal cutting.
What are the new trends in cutting tools?
Andreev: Digitalisation is yet another trend that could be seen in the industry. I believe, Industry 4.0 is not just limited to discussions but several companies have reached implementation stage. This opens the doors of opportunities for us in terms of digital tools. We are prepared with our Industry 4.0 portfolio for the companies who are looking for such solutions.
How the trend of digitalisation is penetrated in India?
Brajesh Kumar: Industry 4.0 is a much talked about topic in the Indian manufacturing field. Currently we see MNCs adopting these technologies while setting up their new plants in the country. The day is not far when it would be a wide spread trend.
Seidelman: As per my observation, currently the Indian manufacturing industry has cautious approach towards the digitalisation. However, it may soon catch lightning speed.
How do you look at the e-mobility trend that is emerging globally? In what way is it impacting the cutting tools industry?
Andreev: Today, the automotive industry is disrupted by e-mobility trend. Fully electric cars limit the scope of cutting tools. However, we believe that the future is about a mixture of fully electric and hybrid cars. Both open new opportunities for us as the hybrid vehicles have an internal combustion engine and an electric motor. Having the trend of digitalisation on one hand and e-mobility on the other, we are optimistic about the future.
Threading with maximum productivity and process reliability
High cutting pressure and tool deflection are the greatest challenges when it comes to thread milling. This results in restricted cutting parameters, necessary cutting passes and short tool lives or even tool breakage. With the TC620 Supreme universal thread milling cutter, Walter is now transferring the functional principle of its T2711 indexable insert thread milling cutter to smaller diameters too. Tool wear is drastically reduced because of minimal cutting forces and the resulting high feeds per tooth. The multi-row concept not only reduces the machining time and wear, but also improves process reliability and handling – even when used with more demanding materials such as stainless steels or Inconel 718.
Reliable chip evacuation, thanks to internal coolant, and simple handling of the TC620 Supreme guarantee maximum process reliability. Radius corrections are seldom necessary, and when they are required, it is often only once competitor tools have already reached the end of their tool life. Walter is launching the TC620 Supreme for thread depths of 2 and 2.5 × DN in the dimension range from M4 to M20 as well as UNC 8 to UNC ¾ – and is therefore seamlessly linking to the Walter T2711 indexable insert thread milling cutter.
Milling With “Xtended Technology – Xtra•Tec® Xt
Walter presents the next generation of its milling tools in the form of Xtra•tec® XT. “Xtended Technology”, is designed to achieve increased productivity and process reliability. It is not just the black look of these products which distinguishes them from the previous Xtra•tec® tools; they are in fact a completely new generation of milling cutters in all common material groups. The most striking design feature of the new milling tools is the installation position of the indexable inserts: At a greater incline and with a larger contact surface. This reduces the surface pressure in the seat while increasing the stability. The larger screw hole cross-section stabilises the indexable insert and the longer screws which are now available hold it in place more securely. The cutter body has also been made more stable, as it now has much more material behind the insert seat.
Besides greater process reliability, the new installation position of the indexable inserts also allows for the addition of an extra tooth, thereby increasing productivity. The precise 90° shape of the shoulder milling cutters helps to reduce additional finishing operations. Clamping screws which are easier to access optimise handling and help prevent assembly errors.
Another new feature are the smaller indexable inserts which can be fitted to the milling cutters. They are continuing the current trend towards reduced machining allowances.