Pole position with high-tech tools.

Transcription

1 _ EXPERTISE IN MACHINING Pole position with high-tech tools. Industry-specific solutions Automotive industry

2 MACHINING TECHNOLOGY FULL SPEED AHEAD. More than any other sector, the automotive industry is currently undergoing a radical shift in attitude. For decades, performance determined the direction; today, it goes without saying that the joy of driving also includes the joy of energy efficiency. A new ecological awareness demands the development of new technologies with a degree of radicalism that was previously unknown technologies that are giving rise to truly innovative components and ultimately to new automobiles that are as energy-efficient as they are appealing. Add to this the difficult economic circumstances, which are proving a formidable challenge for automotive suppliers in particular: Combined with models that are changing at a rapid pace, productivity must be increased while maintaining the same high quality in the face of profit margins which are still low. Our competence brands Walter, Walter Titex and Walter Prototyp provide you with high-tech tools and machining solutions from a professional supplier of the automotive industry for complete machining operations, all from one single source. Providing the tools to achieve your goals for innovation, flexibility, quality, and productivity that s our goal. Expect more. With us, you can turn your visions into reality.

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4 ENGINE BLOCK The trend towards higher performance with smaller displacement and lower fuel consumption leads to higher mechanical loads on the engine block. This calls for increasingly high-quality materials made of GG gray cast iron and GGV vermicular graphite cast irons. Our new Tiger tec Silver cutting tool materials and our innovative tool systems are just the thing for machining such materials. You can achieve an extremely high level of dimensional accuracy, optimum quality in surface finishes and increases in productivity of up to 100% thanks to the combined use of Walter milling cutters and Walter Titex high-performance drills. Our solutions give you a competitive cost-per-part edge in massproduction processes, even those involving complex components. Walter Xtra tec F4045 heptagon cutter: Roughing main surfaces The Xtra tec F4045 heptagon cutter with the new, powerful Tiger tec Silver indexable inserts (with 14 cutting edges) is ideal for roughing main surfaces. Walter BLAXX F5x41 tangential milling cutter: Face and shoulder milling Walter Titex X treme CI: Drilling blind and through holes Walter MODCO automatic draw bar tool: Finish machining cylinder main bores Powerful, precise, reliable: The new tangential Walter BLAXX milling cutter with four-edged indexable inserts produces excellent metal removal rates. Up to 30 percent increased feed rate per tooth and maximum process reliability lead to improved productivity and The Walter Titex X treme CI drill outperforms other solid carbide drills by up to 50%. With an internal coolant supply and a high-performance coating, this tool guarantees a high level of process reliability and excellent hole quality for blind and through holes. Our MODCO high-tech draw bar tool offers semifinish and finish machining without tool changes. The cutting edges can be actuated via coolant or compressed air for precision machining. Powered by Tiger tec Silver

5 CYLINDER HEAD 3 Thanks to its low weight, aluminium plays an important role in the production of automotive components. We supply a complete PCD tool range for the highly precise yet cost-effective machining of components made of aluminium alloy. Our high-tech MODCO PCD tools provide significant gains in both quality and productivity in mass production. These tools stand out for their extremely long tool life, and they ensure superior dimensional stability. For aluminium cylinder heads, this means the ultimate in function reliability in conjunction with optimal combustion. For drivers, it means lower fuel consumption and thus also lower CO 2 emissions. Walter MODCO F4050 PCD face mill: End face finishing Thanks to the number of cutting teeth, the Walter PCD face milling cutter F4050 provides extremely high feed rates combined with minimal burr high-speed milling. Optimum runout, high-quality surface finish, and an extremely long service life are just a few of this powerful tool s outstanding features. Walter MODCO PCD reamer: Fine machining of valve seat and guide pilot holes Walter Titex XD30 drill: Deep-hole drilling of oil galleries Walter Prototyp Protodyn S HSC (solid carbide) and Paradur ECO CI (HSS-E-PM) With the multi-stage Walter MODCO PCD reaming tools, you can achieve optimum roundness and coaxiality of the pilot hole for the valve seat and guide. The multi-edged version guarantees in addition to maximum dimensional accuracy both short machining times and a long tool life. Thanks to the superior XD technology in the Walter Titex drill, deep holes can be drilled with efficient productivity on machining centres. Our XD drills (available up to 70 x Dc) are extremely tough and are ideally suited to machining non-ferrous metals. XD Technology The Protodyn S HSC is a solid carbide thread former for the chip free thread production of blind- and through-hole threads all with maximum cutting speeds and an extremely long tool life. The HSS-E-PM tap, ECO CI, is impressive thanks to its reliable processes and its perfect handling of chips. Optional MQL machining means that the use of lubricant can be reduced.

6 TEAM ORDERS: MARKET-FOCUSED DEVELOPMENT. We have worked in close collaboration as a machining partner with manufacturers in the automotive industry for a number of decades, and have observed the developments taking place in this sector extremely closely. This is the key to our ability to develop industry-specific machining solutions in partnership with you, our customers. This is what allows us to respond quickly and consistently to current and future materials trends and new machining requirements. Benchmark cutting tool materials, such as the new Tiger tec Silver indexable inserts, are a logical consequence of the uncompromising attitude of innovation that we bring to everything we do. Those are our team orders. With our competence brands Walter, Walter Titex and Walter Prototyp, we see ourselves as the interface between machine manufacturers and the machining production area in the automotive sector. The machining solution begins with an analysis of all production parameters, encompasses planning and development, and finishes up after a test phase with the commissioning of a new machining process. It makes no difference whether the path to a cost-effective, complete machining solution involves standard tools, special tools, or modified standard tools. In all cases, we are committed to increasing your competitive edge.

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8 CRANKSHAFT Particularly in modern, powerful engines, crankshafts made from hightensile steels and GGG materials are exposed to enormous physical forces and mechanical loads. At speeds of several thousand rpm, the crankshaft converts linear movement into rotational energy. A key objective in machining these important components is to achieve a high level of dimensional stability. With our high-performance tools, you will be able to produce long- lasting, durable crankshafts made of ductile cast iron or steel alloys at competitive per-part costs. Walter turn broaching cutters: Journal, web and pin machining LIGHTWEIGHT CONSTRUCTION The Walter turn broaching cutter stands for precise contours and maximum surface finish quality on the workpiece. A real highlight is the version of the tool that has a lightweight design. This tool can be quickly changed by hand and therefore significantly increases the availability of the machine. Walter external milling cutter: Journal and web machining Walter Titex X treme DH drill: Deep-hole drilling of the oil galleries Walter internal milling cutter: Journal and web machining Up to 420 powerful indexable inserts on this Walter external milling cutter ensure extremely high feed rates and maximum process reliability in journal and web machining. This drill, with special XD chip-clearance technology, polished flutes and TFP coating, is perfect for drilling hightensile materials, even for interrupted cuts. The drill has been specifically optimised for a long tool life in crankshaft machining applications. XD Technology LIGHTWEIGHT CONSTRUCTION The cartridge-type Walter internal milling cutter is impressive during production thanks to high metal removal rates, process reliability and easy handling. In Walter's lightweight version, this tool can be quickly and easily changed without the need for a crane.

9 TRANSMISSION SHAFT 7 Transmission shafts are components whose function it is to pass on rotational movement and torque. As such, they are subjected to high torsional loads and must therefore be finished to exacting standards. Not only the shaft itself, but also the shaft-hub interface demands an extremely precise design. With the turning and drilling, boring tools in our specialist Walter and Walter Titex brands, we have discovered the right machining solutions for this crucial component for the automotive industry. Walter Titex X treme: Drilling holes on a radius The solid carbide high-performance drill with XPL coating and internal cooling facilitates high-precision spot drilling, while four lands ensure superior hole quality. The impressive cutting data and tool life lead to very low per-part costs in machining. Walter Turn boring bar: Internal machining of small diameters Walter Capto : External machining Walter Cut G1011 grooving tool: Grooving, parting off, recessing When used with the AK600 adaptor sleeve, the Walter Turn boring bar can be positioned precisely at centre height, thereby reducing vibration during machining. Positive ISO indexable inserts with Tiger tec Silver coating are used for this. Walter Capto is a highly precise, extremely stable turning-tool changing system available in sizes C3 to C8. The combination with Tiger tec Silver cutting tool materials creates the optimum conditions for extremely high levels of efficiency and process reliability in production. The Walter Cut G1011 grooving tool is an extremely precise and tough monoblock tool for grooving, parting off and recessing. When used with Tiger tec Silver cutting tool materials, the user has a versatile and extremely efficient turning tool.

10 RELIABLE PROCESSES FROM THE WALTER TECHNOLOGY CENTER. These days, there s a new attitude about driving and to satisfy customers, the automotive industry needs to find the right solutions. Solutions the industry in turn expects from its automotive suppliers. Our expertise lies in efficient, reliable machining processes and as such, we are your go-to source for complete machining solutions. Together, we will find solutions to today s challenges. Our engineering experts provide technical support wherever you need it on every continent. In the Walter Technology Centres in Germany, China, India, Brazil and the U.S., our engineers and technicians are developing future-oriented production technologies for the automotive industry in close collaboration with customers and researchers. This involves developing custom machining processes for a wide range of components that we test and trial under original conditions in order to provide our customers with the best machining solution in terms of technology and cost-effectiveness. Our passion for technology gives us the drive to create efficient, reliable processes all to your advantage.

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12 GEARBOX HOUSING Today, transmission cases for highperformance transmissions are generally made of hypoeutectic aluminium or magnesium alloys. This presents a challenge for machining applications, in that it demands that complex datum dimensions are maintained and machining times are kept as short as possible. With our high-performance Walter PCD tools, Walter Titex solid carbide drills, and Walter Prototyp threading tools, we provide you with a perfect trio of tools for machining these complex components with precision and cost-effectiveness. Walter MODCO F4050 PCD face mill: Milling end faces Due to its number of teeth, the Walter PCD face mill F4050 provides extremely high feed rates. A combination of finely adjustable runout and optimal cutting edge geometry enables a high-quality surface finish and extremely long tool life. Walter Titex Alpha Jet with chamfer: for drilling of the flange bores Walter Prototyp Protodyn ECO-LM: Forming blind hole threads Walter MODCO PCD boring tool: Finishing bore contours The Walter Titex Alpha Jet solid carbide drill is perfect for precise drilling and chamfering of the flange bores. This precision tool s geometry has been optimised for short machining times (drilling and chamfering in one operation) and low per-part costs. The Protodyn ECO-LM is a highperformance thread former with specific geometry and coating as well as an extra-smooth surface for precise forming of blind hole threads in transmission cases. Strong PCD tools ensure an extremely long tool life and excellent dimensional stability in boring operations. This means that many individual operations can be carried out with one tool. As a result, cost efficiency in mass production is increased.

13 BRAKE CALIPER 11 The brake caliper is an important component of disc brakes and one that is subjected to high loads. In the car industry today, it is made of cast iron (GGG50) or aluminium. The brake caliper is an essential safety component that must withstand high thermal and mechanical loads. A key objective of machining processes is to achieve the highest levels of process reliability and dimensional stability. In the face of ever-increasing pressure from the competition, another indispensable ingredient of success is the ability to minimise per-part costs while maintaining superior quality in mass production. Our tools are up to the task. Walter Prototyp Paradur ECO-CI: Threading hydraulic connections and ventilation bores The new Paradur ECO-CI with innovative Xtra treat surface treatment is the ideal tool for high cutting speeds and a wide range of applications. It is highly productive, wear-resistant, and reliable, making it the obvious choice for cost-effective cast-iron machining on a mass-production scale. Walter Titex step drill: Boring, chamfering and reverse chamfering Walter disk set mill: Retaining flange milling Walter B2084 combination tool: Brake piston bore roughing With this solid carbide step drill with chamfer and reverse chamfer functionality, several machining steps can be performed without retooling. Cycle times are reduced as a result. This tangential gang milling cutter is equipped with strong Tiger tec indexable inserts. Its fixed insert seat provides optimum stability and enables high feed rates. This results in short machining times and low per-part costs. The best way to achieve desirable perpart costs is to use a tool that can perform several machining steps in one operation. The Walter combination tool equipped with Tiger tec inserts provides maximum productivity and a high level of process reliability.

14 MODCO : PRECISION AND PRODUCTIVITY IN SERIES. Under the well-known MODCO label, we provide customers in the automotive industry with complex draw bar tools as well as PCD and CBN tools for mass production. Thanks to their extremely long tool life, these Walter tools are characterised by process reliability, extremely high precision and repeat accuracy, combined with good cost efficiency. MODCO gives you flawless, reproducible quality at a highly competitive price. No matter whether you are producing in small quantities or on a large scale when you use MODCO tools, you benefit from efficient machining that puts you ahead of the competition. MODCO tools. Your key to profitability. The innovative PCD tools from Walter (F4050 face mill shown on the left) are the first choice in the automotive industry when it comes to achieving superior dimensional stability, high-quality surface finishes and an extremely long tool life.

15 The MODCO label stands for highly complex draw bar tools that offer users process reliability, precision, and productivity at the highest levels.

16 Walter AG Derendinger Straße 53, Tübingen Postfach 2049, Tübingen Germany Printed in Germany (08/2013) EN Walter GB Ltd. Bromsgrove, England +44 (1527) , Walter Kesici Takımlar Sanayi ve Ticaret Ltd. Şti. Istanbul, Türkiye +90 (216) Pbx, Walter Wuxi Co. Ltd. Wuxi, Jiangsu, P.R. China +86 (510) , Walter AG Singapore Pte. Ltd , Walter Korea Ltd. Anyang-si Gyeonggi-do, Korea +82 (31) , Walter Tools India Pvt. Ltd. Pune, India +91 (20) , Walter (Thailand) Co., Ltd. Bangkok, 10120, Thailand , service.th@walter-tools.com Walter Malaysia Sdn. Bhd. Selangor D.E., Malaysia +60 (3) , service.my@walter-tools.com Walter Tooling Japan K.K. Nagoya, Japan +81 (52) , service.jp@walter-tools.com Walter USA, LLC Waukesha WI, USA , service.us@walter-tools.com Walter Canada Mississauga, Canada service.ca@walter-tools.com