Walter has expanded its D4120 drilling line to introduce 2xD, 3xD, 4xD and 5xD dimensions. The new additions will supersede the B4000 Series Xtra.tec insert drills to provide superior performance.
Regarded as a flexible all-rounder, the expanded D4120 indexable insert solid drill line is available in diameters ranging from 13.5mm to 59mm. The product expansion now incorporates the D4120-02 2xD drill and the D4120-03 3xD drills for creating holes from 13.5 to 41.3mm diameter as well as the D4120-04 and D4120-05 4xD and 5xD drills for holes from 17 to 59mm diameter with exceptional productivity and performance.
From a dimensional perspective, the 2xD drill has an overall length from 97mm to 228mm with a cutting length of 27mm to 118mm depending on the diameter selected, whereas the 3xD drill has an overall length from 110.5mm to 287mm with a cutting length from 40.5mm to 177mm. The 4xD provides a flute length from 68mm to 236mm with an overall length from 149mm to 346mm, whereas the largest 5xD drills have a maximum cutting depth of 295mm with an overall length from 166mm to 405mm depending upon the damp to selected. The 2xD and 3xD drills start at a diameter of 13.5mm and go up to 30mm diameter in 0.5mm increments, and in 1mm increments from 30mm to 59mm. The 4xD and 5xD drills commence at 17mm diameter through to 59mm in 1mm increments.
The drills have been specially developed with outer and centre inserts that ensure precision balancing of the cutting forces to maximise productivity. To this end, the centre insert is slightly larger than the outer indexable inserts that are equipped with a corner protection chamfer. As well as providing greater process reliability, this plays a crucial part in increasing precision levels, stability and reducing drilling noise. Adding to the process reliability is a hardened, polished drill body design that offers increased protection against friction in operation and an improved coolant channel design that allows the flow of 25% more coolant than previous drills.
Walter is also offering inserts with a wiper edge for high-quality surface finishes. The drill body features two through-coolant channels and a measuring collar (Dc) for easy drill identification, even when assembled. Polished flutes and a hardened surface further optimise chip evacuation and wear resistance.
The combination of the D4120 drill body and the four-edged indexable inserts offers users cost-efficiency advantages and the greatest possible flexibility thanks to a co-ordinated system. This is of interest to users, both in the case of difficult machining operations, such as cross holes, chain drilling and inclined inlets and exits.
The inserts are available in WXP40 & WKP35S grades for the centre insert and the peripheral insert the WKP25S, WKP35S, WSP45 are offered with the most recently added new Tiger.tec Gold grade WSP45G. The geometries A57, E57 & E67 complement the insert grades with eight insert sizes that cover the drill body diameters from 13.5mm to 59mm. This comprehensive range of grades for highly productive and efficient drilling of a variety of materials are a perfect fit for the ISO material designations P, K, M, N and S. This makes the drills suitable for typical workpiece materials a range of industries.
The rigid and robust drill bodies, the through-coolant facility and polished flutes as well as the flexible choice of insert grades and geometries make the D4120 a complete solution for manufacturers in sectors including general mechanical engineering, mould and die, aerospace, energy and automotive. With the enhanced range of D4120 drills, manufacturers can benefit from outstanding hole diameter precision and surface quality as well as a high degree of process reliability and cost-efficiency. Alongside the standard dimensions, Walter also offers the D4120 in special dimensions via Walter Xpress with faster delivery times.
From component to tooling solution at high speed
Walter has also introduced ‘Walter Innotime’, a digital design wizard for accelerating the consulting and ordering process. This web application links existing Walter systems to the Engineering Kompetenz of Walter employees.
Using a 3D model uploaded to the Walter website by the customer, Walter Innotime analyses which cutting operations are required and suggests to the engineer dealing with the enquiry (in future versions, directly to the customer) the appropriate machining tools with cutting data and prices from the Walter portfolio. According to Walter, this digital search at the component level is currently unique in the market.
The engineer checks the proposal and optimises it, if necessary, according to the customer’s needs. As a result, the design process for complex enquiries is fast-tracked considerably, and the customer receives the most economical tailored tooling solution and a valid quote in the shortest time. Walter field service employees and engineers benefit from the preliminary work done by the system: in the physical design and the development of the optimum machining strategy for the customer component.
“For our engineers and technical distributors, but primarily for our customers, Walter Innotime represents a milestone,” explains Dr Michael Hepp, Vice-President – Digital Business at Walter. “By combining the Engineering Kompetenz of our employees with the virtual intelligence of our software systems, we can assist our customers in quickly and easily finding, purchasing and employing the most economical tooling solution for them. In future, our customers will have to do nothing more than upload their 3D component – quick and easy.”