shell-end milling cutter / indexable insert / face / finishing

Walter Xtra▪tec® F4042 shoulder mill

​​​The Walter Xtra▪tec® F4042 shoulder mill is a highly positive tool for roughing and finishing. Five insert sizes are available for tools with a diameter from 10 mm to 160 mm. Thanks to its highly positive, spiral geometry, the Xtra▪tec® F4042 shoulder mill offers extremely stable cutting and excels through its low power consumption.

Facts and advantages:
- high metal removal rate, even on low-performance machines, thanks to the positive and soft cutting action
- reduced machining costs due to shoulder-free milling
- reduced inventory costs thanks to ideal adaptation of the tool to various materials and the variety of geometries and cutting material grades available

Walter F4723 PCD face mill

The Walter F4723 PCD face mill in the diameters 50 mm, 63 mm, 80 mm, 100 mm and 125 mm for precise machining of non-ferrous metals such as aluminium with internal coolant supply. In addition to their exceptional performance, these tools also offer low tool costs, as they can be reground multiple times.

- brazed PCD cutting edges for the best surfaces and long tool life
- lower tool costs thanks to regrinding option
- internal coolant supply for secure processes

Top performance on turbine blades

Walter AG is expanding its Tiger tec® Gold portfolio with the addition of a new grade that is designed for the complexities of machining turbine blades.

The new WMP45G grade, available as round indexable inserts for the F2334R copy milling cutter, was conceived specifically for face milling and copy milling of martensitic and austenitic stainless steels. The innovative combination of a heat-resistant yet tough substrate with a TiAIN coating layer, applied using an ultra-low-pressure process (ULP-CVD), is unique on the current market and sets the benchmark in CVD coating technology. The grade is available in three different geometries – D57, D67 and F67 – to suit the stability of the machine, clamping arrangement and workpiece geometry.

The performance of the WMP45G is as unique as the grade itself: According to Walter, the number of turbine blades customarily milled in helirough and Z-level machining processes is between 20 and 50 percent higher than the rest of the market. Further to this, it also boasts the well-known benefits of the Tiger·tec® Gold grades, including high process reliability and good wear detection. Walter recommends using the WMP45G when cutting parameters are high and tool life is long in order to reduce machining time. The new "turbine blade grade" will therefore be of particular interest to customers with high order volumes and high machine output.

M4003 face milling cutter with new system indexable insert – four cutting edges for one-of-a-kind surfaces.

High level of cost efficiency:
- System indexable insert suitable for universal use
- Reduced procurement and inventory costs
- Four cutting edges per indexable insert
- Reduction of machining steps by combining roughing and finishing

Concept requiring minimum resources:
- CO2-compensated production thanks to climate protection projects
- Low power requirement thanks to highly positive geometries

Porcupine designed to impress

Stability is everything when it comes to porcupine cutters, a characteristic feature of the Walter BLAXX range.

Walter is now extending its high-end range: As are its fellow cutters for face milling and shoulder milling, the new Walter BLAXX F5038 porcupine cutter is also characterised by an extremely solid and therefore stable tool body.

In conjunction with the tangential, quadruple edge, system indexable inserts made of Tiger·tec® Silver cutting tool materials, the user thereby achieves top values in process reliability and cost efficiency. In comparison to conventional tool solutions of this type, machining times are reduced by up to 30 percent. What’s more, the accurately arranged, precision indexable inserts produce flawless and step-free shoulders that, to the greatest possible extent, make re-machining superfluous.

Walter BLAXX - Powerful, precise, reliable

​​​When powerful arguments are required, Walter BLAXX with Tiger·tec®Silver provides the answer without compromise. With Walter BLAXX and Tiger·tec®Silver, the new generation of mills from Walter has established an impressive system – a system that has long been sought after from the market by demanding cutting machine tool operators.

With the Walter BLAXX F5041/F5141 and F5241 a new generation of shoulder mills, Walter is putting its money on the combination of critical features which, when working together, are designed for productivity and process reliability:

- the strong basis is created by wear-protected tool bodies which have ​received special surface treatment
- Walter BLAXX is the first milling system from Walter that combines the benefits of tangential milling systems with the performance data of Tiger·tec®Silver indexable inserts to create an unbeatable combination
- with four spiral, positive cutting edges per indexable insert, a precise angle of 90° on the work piece and an incredibly robust body, Walter BLAXX has redefined the concepts of productivity and process reliability in shoulder milling

Walter Xtra▪tec® F4033 face mill

The Walter Xtra▪tec® F4033 face mill is the cost-effective model for machining a broad spectrum of materials. Thanks to their special design, the negative indexable inserts with 8 cutting edges generate low cutting forces. Two insert sizes and the most diverse of geometries allow the tools to be optimally adapted to the respective application.

Facts and advantages:
- extremely stable indexable inserts thanks to the negative basic shape
- soft cutting action due to the extremely positive insert geometry for maximum productivity
- 8 cutting edges per insert

Walter Xtra▪tec® F4045 heptagon cutter

Walter's wedge-clamped Xtra▪tec® F4045 heptagon cutter offers the greatest cost efficiency for milling faces of all cast iron workpieces. The negative, seven-sided indexable inserts, which are available in two sizes, have 14 cutting edges and cut very softly thanks to their positive geometry.

Facts and advantages:
- high metal removal rate even on low-performance machines thanks to the positive, soft cutting action
- high degree of process reliability thanks to stable, negative indexable inserts
- low cutting material costs thanks to 14-edge indexable inserts
- maximum productivity from the universal use of Tiger·tec® and Tiger·tec® Silver coatings

Walter Xtra▪tec® F4030 high performance mill

Walter's Xtra▪tec® F4030 high performance mill is a shoulder, plunge and copy mill with double-sided Trigon insert. The indexable inserts with 6 usable cutting edges offer the greatest process reliability thanks to their negative basic shape and positive, soft cutting action. Feed per tooth rates up to fz 3.5 mm are possible.

Facts and advantages:
- high metal removal rate thanks to the combination of low cutting depths and high feed per tooth rates
- high degree of process reliability thanks to low risk of vibration tendency of long tools and stable insert
- reduced process costs with Tiger▪tec® Silver cutting tool material and 6 cutting edges per indexable insert

Facts and advantages:
- High process reliability due to stable, wedge-clamped indexable inserts
- Low cutting material costs thanks to indexable inserts with eight cutting edges
- Soft cutting action due to positive cutting edge geometry
- Maximum productivity thanks to Tiger·tec® Gold and Tiger·tec® Silver cutting tool materials for maximum tool life

Walter F4050 PCD face mill

Walter's adjustable F4050 PCD mill facilitates cost-effective and precise machining of aluminium. The hard-anodised aluminium basic body ensures a reduced flywheel effect. In connection with fine balancing screws, this allows quiet and precise machining. The carbide chip deflector integrated in the cartridge guarantees a long tool life of the regrindable cartridges.

Facts and advantages:
- precise aluminium machining
- reduced machining times thanks to extremely high cutting speeds.
- high degree of process reliability thanks to stable body/cartridge design
- universal deployments thanks to large selection of geometries

Walter Xtra▪tec® F4080 octagon cutter

The new Walter Xtra▪tec® F4080 octagon cutter with eight productive cutting edges per insert has no limitations with regard to application type and makes no compromise in terms of quality. It is particularly impressive when plunge milling cast iron and steelwork components as well as in the chamfering or circular interpolation milling of stainless, difficult-to-machine or non-ferrous materials.

Facts and advantages:
- optimal tool for face milling, plunge milling, chamfering, bore milling and circular interpolation milling
- maximum productivity due to 8 cutting edges per insert
- complete range of geometries and grades for machining all materials

Walter F2334 round insert cutter

With its round inserts with location flats and stable seating, the F2334 round insert cutter ensures maximum feed rates and cutting performance, particularly when roughing difficult-to-cut materials, such as titanium alloys. The Walter copy mill boasts impressive performance and precision, not only for HSC machining.

Facts and advantages:
- round inserts with location flats ensure highly stable insert seating
- ideal for maximum feed rates and cutting efficiency
- ideal for roughing operations and difficult-to-machine materials

Walter BLAXX M3024 heptagon milling cutter: Cost-efficient, with process reliability.

- Excellent cost efficiency thanks to high metal removal rate, even on low-performance machines
- Soft cutting action due to positive cutting edge geometry
- Low cutting material costs due to 14 cutting edges
- High process reliability due to stable indexable inserts
- Carbide shim provides an optimum support face and a high feed per tooth

Walter M4002 high-feed milling cutter

Facts and advantages:

High level of cost efficiency
- Reduced procurement and warehousing costs thanks to universal system indexable insert
- Four cutting edges per indexable insert

Resource-saving concept
- CO2-compensated production thanks to climate protection projects
- Low power requirement thanks to high positive geometries

Powered by Tiger·tec® Silver
- 2 CVD-coated grades (WKP25S and WKP35S) for steel and cast iron machining
- 3 PVD-coated grades (WKK25S, WSM35S and WSP45S) for steel and cast iron machining, for machining stainless steels, as well as for machining difficult-to-cut materials

Walter Xtra▪tec® F4041 shoulder mill

The Walter Xtra▪tec® F4041 shoulder mill is a unique, highly positive tool that combines the advantages of negative, stable indexable inserts with those of positive indexable inserts. The most diverse of corner radii are available. A special geometry for aluminium machining and a universal insert geometry is available for steel and cast iron machining.

Facts and advantages:
- unique, spiral-shaped indexable insert for precisely 90° with 4 cutting edges per insert
- maximum process reliability due to the negative insert seat
- optimum operational smoothness thanks to the positive rake angle

Walter Xtra▪tec® F4x38 porcupine cutter

The Walter Xtra▪tec® F4x38 range of porcupine cutters for shoulder milling and trimming is suitable for cost-effective machining of P, K, S and N materials. The various cutting tool material grades and geometries available allow the tools to be optimally matched to the respective application.

Facts and advantages:
- high metal removal rate, even on low-performance machines, thanks to the positive and soft cutting action
- reduction in machining costs thanks to virtually shoulder-free milling
- high degree of process reliability thanks to axial fixed stop on the first row of indexable inserts and excellent indexable insert stability
- maximum productivity thanks to the Tiger▪tec® coating, which is suitable for universal deployments

M4000 – High performance made universal

System tools, i.e. those that can be used universally for numerous machining requirements, reduce the complexity of and susceptibility to errors in production, thus making it more cost-efficient.

The latest example of this product philosophy from Walter AG is the new M4000 range with system indexable insert. Walter has consistently implemented the idea of a system concept: The new inserts and cutting bodies are manufactured in a way that offsets CO2 emissions. The M4000 – four square indexable inserts that can be used in three different types of milling cutters and master many common milling operations: For example, face milling, shoulder milling or chamfering in all steel, stainless steels, cast iron, and even difficult-to-cut materials.

M4000 inserts can therefore be used more universally than their specialised relatives in the Walter BLAXX and Walter Xtra▪tec® ranges. However, just like its two cousins, it is coated with the high-performance cutting material Tiger•tec Silver®. What are the features of the system indexable inserts for the M4000? The flank faces on the four cutting edges are provided with a wave profile, which displays the geometry of the indexable insert: The more waves that are visible, the more positive the geometry. Currently the stable (D57) and universal (F57) geometries are available.​

Walter BLAXX F5038/F5138 porcupine cutter

​Facts and advantages:

Extremely high process reliability due to stable design
- Large carbide volumes in the direction of the cutting force
- Special tool body surface treatment and reinforced core

High level of cost efficiency.
- Four cutting edges per indexable insert
-Up to 30% higher feed rate per tooth
- Milling that is almost shoulder-free

Powered by Tiger·tec® Silver.
- Impressive cutting data and high level of process reliability thanks to brand new hardness-toughness ratio

Walter M4132 shoulder mill

Facts and advantages:

High level of cost efficiency
- Reduced procurement and warehousing costs thanks to universal system indexable insert
- Four cutting edges per indexable insert

Resource-saving concept
- CO2-compensated production thanks to climate protection projects
- Low power requirement thanks to high positive geometries

Powered by Tiger·tec® Silver
- 2 CVD-coated grades (WKP25S and WKP35S) for steel and cast iron machining
- 3 PVD-coated grades (WKK25S, WSM35S and WSP45S) for steel and cast iron machining, for machining stainless steels, as well as for machining difficult-to-cut materials

Walter Prototyp ConeFit™

Modular solid carbide milling system with self-centring thread (patent pending) Axial and radial alignment guarantee the highest precision. A large number of proven Walter Prototyp geometries can also be supplied with ConeFit™ interface. The shank variants offered are steel, solid carbide and also monoblock adaptors.

Facts and advantages:
- highly productive machining thanks to extremely high rigidity
- broad spectrum of geometries for every application
- reduction in inventory costs thanks to very flexible and universal tooling system

Walter Prototyp Protostar® Flash

The Protostar® Flash is a high-performance tool for cost-effective roughing in the 2.5D and 3D range with low cutting depth and very high feed rates. It is suitable for machining both alloyed and unalloyed steels.

Facts and advantages:
- the end face geometry allows significantly higher feed per tooth rates (fz), which in turn offer faster metal removal rates
- high-quality TiAlN coating for maximum tool life
- since cutting takes place exclusively on the end face of the tool, the machine spindle is subjected almost exclusively to axial forces that are easily absorbed