Automotive industry
_ EXPERTISE IN MACHINING
Pole position with
high-tech tools.
Printed in German
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
technol-ogies 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
prov-ing a formidable challenge for automotive suppliers in particular:
Combined with models that are changing at a rapid pace,
produc-tivity 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.
Powered by Tiger·tec® Silver
The trend towards higher performance with smaller displacement and lower fuel consumption leads to higher me-chanical loads on the engine block. This calls for increasingly high-quality materials made of GG gray cast iron and GGV vermicular graphite cast irons.
ENGINE BLOCK
Our new Tiger·tec® Silver cutting tool materials and our innovative tool systems are just the thing for machin-ing 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 com-bined use of Walter milling cutters and Walter Titex high-performance drills. Our solutions give you a com-petitive cost-per-part edge in mass-production processes, even those involving complex components.
Walter MODCO® automatic draw
bar tool: Finish machining cylinder main bores
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.
Walter BLAXX F5x41 tangential milling cutter: Face and shoulder milling
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
Walter Titex X·treme CI: Drilling blind and through holes
The Walter Titex X·treme CI drill out-performs other solid carbide drills by up to 50%. With an internal coolant supply and a high-performance coat-ing, this tool guarantees a high level of process reliability and excellent hole quality for blind and through holes.
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 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
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 guaran-tees – in addition to maximum dimen-sional accuracy – both short machin-ing times and a long tool life.
Walter TitexXD30 drill: Deep-hole drilling of oil galleries
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 (avail-able up to 70 x Dc) are extremely tough and are ideally suited to machining non-ferrous metals.
Thanks to its low weight, aluminium plays an important role in the produc-tion of automotive components. We supply a complete PCD tool range for the highly precise yet cost-effec-tive machining of components made of aluminium alloy. Our high-tech
CYLINDER HEAD
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 CO2 emissions.
Walter Prototyp Protodyn® S HSC (solid carbide) and Paradur® ECO CI (HSS-E-PM)
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 impres-sive thanks to its reliable processes and its perfect handling of chips. Op-tional MQL machining means that the use of lubricant can be reduced.
TEAM ORDERS:
MARKET-FOCUSED
DEVELOPMENT.
We have worked in close collaboration as a machining partner
with manufacturers in the automotive industry for a
num-ber 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.
Bench-mark cutting tool materials, such as the new Tiger·tec
®Silver
indexable inserts, are a logical consequence of the
uncom-promising 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.
Particularly in modern, powerful en-gines, crankshafts made from high-tensile steels and GGG materials are exposed to enormous physical forces and mechanical loads. At speeds of several thousand rpm, the crankshaft
CRANKSHAFT
converts linear movement into rota-tional energy. A key objective in ma-chining these important components is to achieve a high level of dimensional stability. With our high-performance tools, you will be able to produce
long-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 light-weight 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
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.
Walter internal milling cutter: Journal and web machining
LIGHTWEIGHT CONSTRUCTION
The cartridge-type Walter internal milling cutter is impressive during production thanks to high metal re-moval 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.
Walter TitexX·treme DH drill: Deep-hole drilling of the oil galleries
This drill, with special XD® chip-clear-ance technology, polished flutes and TFP coating, is perfect for drilling high-tensile materials, even for interrupted cuts. The drill has been specifically optimised for a long tool life in crank-shaft machining applications.
lasting, durable crankshafts made of ductile cast iron or steel alloys at competitive per-part costs.
Walter Capto™: External machining
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.
Transmission shafts are components whose function it is to pass on rota-tional 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
TRANSMISSION SHAFT
Walter Cut G1011 grooving tool: Grooving, parting off, recessing
The Walter Cut G1011 grooving tool is an extremely precise and tough mono-block 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.
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 supe-rior 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
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 index-able inserts with Tiger·tec® Silver coating are used for this.
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.
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
auto-motive 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
develop-ing 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
con-ditions in order to provide our customers with the best
machin-ing 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.
Today, transmission cases for high-performance transmissions are gener-ally made of hypoeutectic aluminium or magnesium alloys. This presents a challenge for machining applications, in that it demands that complex datum
GEARBOX HOUSING
dimensions are maintained and ma-chining 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® PCD boring tool:
Finishing bore contours
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.
Walter Titex Alpha® Jet with chamfer:
for drilling of the flange bores
The Walter Titex Alpha® Jet solid car-bide 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.
Walter Prototyp Protodyn® ECO-LM: Forming blind hole threads
The Protodyn® ECO-LM is a high- performance thread former with specific geometry and coating as well as an extra-smooth surface for precise forming of blind hole threads in transmission cases.
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.
The brake caliper is an important com-ponent 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 cali-per is an essential safety component
BRAKE CALIPER
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 main-taining superior quality in mass pro-duction. Our tools are up to the task.
Walter Prototyp Paradur® ECO-CI: Threading hydraulic connections and ventilation bores
The new Paradur® ECO-CI with innova-tive 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
With this solid carbide step drill with chamfer and reverse chamfer func-tionality, several machining steps can be performed without retooling. Cycle times are reduced as a result.
Walter B2084 combination tool:
Brake piston bore roughing
The best way to achieve desirable per-part costs is to use a tool that can perform several machining steps in one operation. The Walter combination tool equipped with Tiger·tec® inserts pro-vides maximum productivity and a high level of process reliability.
Walter disk set mill: Retaining flange milling
This tangential gang milling cutter is equipped with strong Tiger·tec® index-able inserts. Its fixed insert seat pro-vides optimum stability and enables high feed rates. This results in short machining times and low per-part costs.
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 auto-motive industry when it comes to achieving superior dimensional stability, high-quality surface finishes and an extremely long tool life.
draw bar tools that offer users process reliability, precision, and productivity at the highest levels.
Walter AG
Derendinger Straße 53, 72072 Tübingen Postfach 2049, 72010 Tübingen Germany www.walter-tools.com Walter GB Ltd. Bromsgrove, England +44 (1527) 839 450, [email protected] Walter Kesici Takımlar Sanayi ve Ticaret Ltd. Şti. Istanbul, Türkiye
+90 (216) 528 1900 Pbx, [email protected] Walter Wuxi Co. Ltd.
Wuxi, Jiangsu, P.R. China
+86 (510) 8241 9399, [email protected] Walter AG Singapore Pte. Ltd.
+65 6773 6180, [email protected] Walter Korea Ltd.
Anyang-si Gyeonggi-do, Korea
+82 (31) 337 6100, [email protected] Walter Tools India Pvt. Ltd.
Pune, India
+91 (20) 3045 7300, [email protected] Walter (Thailand) Co., Ltd.
Bangkok, 10120, Thailand
+66 2 687 0388, [email protected] Walter Malaysia Sdn. Bhd.
Selangor D.E., Malaysia
+60 (3) 8023 7748, [email protected] Walter Tooling Japan K.K.
Nagoya, Japan
+81 (52) 723 5800, [email protected] Walter USA, LLC
Waukesha WI, USA
+1 800-945-5554, [email protected] Walter Canada Mississauga, Canada [email protected] Printed in German y 650 6278 (08/2013) EN