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Hard Machining 4.0

New Tools for Hardened Steels


The right tool for every job

In tool and die production in particular, hard machining is playing an increasingly important role by replacing time-consuming processes such as grinding and eroding. However, components still need to be machined after hardening in other industries as well, which presents enormous challenges for drilling and milling tools. We have identified the needs of our customers and have created a highly specialised range of tools for all conceivable applications. These tools are the ideal solution for steel machining in the maximum hardness range and guarantee maximum time savings with their strong performance characteristics.

1. CircularLine – CCR – H

The professional tool for trochoidal rough machining in hardened material applications

2. MonsterMill – HCR

The perfectionist in finish machining

3. WTX – H

- Solution for up to 58 HRC with thro' coolant

- The hard drilling specialist for up to 70 HRC

4. BGF – TYPE H

The multitool for drilling, countersinking and threading



Solution for up to 58 HRC with thro' coolant

The perfect combination of cutting edge geometry, Dragonskin coating and substrate make the WTX – H the ideal solution for difficult- to-machine materials. It can also be used for any application in the machining of steels and cast iron. The extremely stable drilling tool with thro' coolant is suitable for hardened materials up to 58 HRC and, with the new titanium aluminium nitride-based monolayer coating, guarantees long service lives and maximum process security.

Advantages

  • Extreme process security in applications up to 58 HRC
    thanks to the perfect combination of cutting edge geometry and coating 
  • Universal application
    also suitable for steel and cast iron

  • Longest service life compared to competitor products
    due to thro' coolant, Dragonskin coating and the use of a tough carbide substrate

Coating

  • Monolayer perfected for hardened materials
  • Based on titanium aluminium nitride
  • Optimised coating and surface structure ĉĉ Oxidation-resistant up to 800 °C

The hard drilling specialist for up 70 HRC

With an extremely stable, convex cutting edge and ultra-fine grain substrate specifically tailored to hard machining in combination with the latest Dragonskin coating technology, the WTX – H is the specialist for hard drilling operations. The extremely stable and wear-resistant drilling tool enables the machining of hardened steels up to 70 HRC. The new titanium aluminium nitride-based monolayer coating makes the WTX – H especially heat-resistant and guarantees long service life and maximum process security.

Advantages

  • Specialist for hardened materials ≥ 58 HRC
    perfect combination of coating, carbide and cutting edge geometry
  • Extremely long service life possible
    Dragonskin DPX64U, ultra-fine grain carbide

  • Extreme process security and wear-resistance
    due to the extremely stable and convex cutting edge

Coating

  • Monolayer perfected for hardened materials
  • Based on titanium aluminium nitride
  • Optimised coating and surface structure
  • Oxidation-resistant up to 800 °C ĉĉ Use of a special substrate

Specialist for thread production in hardened and difficult-to-machine materials

The multitool for drilling, countersinking and threading

Eliminate the need for time-consuming erosion operations when producing a thread in a hardened component with the BGF – Type H circular thread milling cutter. Threads with a depth of up to 2xD can be produced using the through hole and blind hole thread multitool – and with maximum process security. The left-hand cutting tool not only saves considerable time that would be required for eroding, but also avoids additional costs. The BGF – Type H is therefore the economical, productive solution for thread production in hardened and difficult-to-machine materials.

Advantages

  • Time savings
    drilling, countersinking and thread milling with one tool and high cutting speeds

  • Wide range of applications
    produces right- and left-hand threads, suitable for through hole and blind hole threads, different thread types possible (M, UNC, UNF)

  • High thread quality
    high surface quality, burr-free thread

Coating

  • Specially designed for use in hardened materials
  • Titanium carbon nitride-based PVD coating
  • Coating thickness 3 – 4 μm
  • Hardness: 3000 HV
Note: left-hand cutting (M04)

Tips for the User

With thread milling there are two different programme possibilities with the feed motion of the tool.

On the one hand the machine controls the feed at the diameter of the tool, on the other hand the feed control is the tool center line. In order to ascertain which method the machine control uses, the following method should be employed:

  • Enter the thread milling routine into the control.
  • Enter a safety margin into the program, so that the tool runs in air.
  • Run the program through and check the operating time.
  • Compare the actual time with the calculated theoretical time.

If the time is longer than the calculated time the feed is controlling the tool center line.
If the time is shorter than the calculated time the feed is controlling the diameter of the tool.

MonsterMill – HCR

The perfectionist in finish machining

For many tool and die production companies, time-consuming eroding has been the only option to date for achieving high-quality surfaces on workpieces with a hardness exceeding 55 HRC. This is now a thing of the past, as we are offering the perfect alternative with the MonsterMill HCR. The MonsterMill HCR is ideal for finish machining and is the optimal tool for hardnesses of up to 70 HRC. Its stable cutting edge geometry in combination with the polished cutting edge section ensure flawless component surfaces and optimum contour accuracy with long service life.

Advantages

  • Ideal runout and high balance quality
    due to HA shank with h5 tolerance

  • Optimal chip clearance and long service life
    due to stable cutting edge geometry

  • Outstanding surface quality
    thanks to polished cutting edge section

  • Optimum cutting behaviour
    thanks to cutting edge geometry supported by the special edge preparation

  • High-precision tools with tight tolerances
    up to Ø 6 mm – 0/-0.01 mm
    from Ø 6 mm – 0/-0.02 mm

HCR end mill

  • Diameter: 0.2 mm – 12 mm
  • No. of cutting edges: 2 and 4
  • With corner radius

HCR ball-nosed end mill

  • Diameter: 0.2 mm – 12 mm
  • No. of cutting edges: 2 and 4
  • Radius accuracy: ± 0.01 mm

Coating

Latest Dragonskin coating in use

The latest Dragonskin coating technology DPX62U features high hot hardness and oxidation resistance of up to 800°C. The titanium aluminium nitride-based broadband coating has been specially developed for the machining of hardened steels and boasts an optimised coating and surface structure. The ultra-fine grain substrate combined with the coating enables economical hard machining up to 70 HRC.

  • Multilayer, HV0.05 = 4000
  • Coefficient of friction (against steel) = 0.5
  • Max. application temperature: 1150 °C

CircularLine – now also for hardened materials up to 70 HRC

The professional tool for trochoidal rough machining in hardened material applications

The CircularLine – CCR – H is the latest development of our tried-and-tested trochoidal milling cutter from the CircularLine series and is the ideal tool for machining hardened materials. The fine grain substrate tailored specifically to hard machining, the latest Dragonskin coating technology, the optimised cutting edge geometry and a new chip breaker make the CircularLine – CCR – H the ultimate tool for hard milling operations up to 70 HRC.

Advantages

  • Optimum chip removal
    due to chip breaker 0.9 x d1

  • Extremely quiet running and high material removal rate
    due to six-edged tool with cutting length 3 x d1

  • Long service life
    thanks to new Dragonskin coating and low-wear chip breaker geometry

  • Extremely process-secure
    due to HB shank for prevention of tool pullout

New chip breaker

Special geometry for machining hardened steels to minimise wear on the chip breaker.

Coating

The latest Dragonskin coating technology DPX62S boasts high hot hardness and oxidation resistance of up to 800 °C. The titanium aluminium nitride-based broadband coating has been specially developed for the machining of hardened steels and boasts an optimised coating and surface structure.

  • Multilayer, HV0.05 = 3800
  • Coefficient of friction (against steel) = 0.4
  • Max. application temperature: 800 °C