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Automotive industry
Sector solutions
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 Takimlar Sanayi ve Ticaret Limited Sirketi Istanbul, Turkey +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. Ansan, Kyungki-do, Korea +82 (31) 3646 100, [email protected] Walter Tools India Pvt. Ltd. Pune, India +91 (20) 2714 5028, [email protected] Walter (Thailand) Co., Ltd. Bangkok, Thailand +66 (2) 6811 305, [email protected] Walter Malaysia Sdn. Bhd. Selangor D.E., Malaysia +60 (3) 8023 7748, [email protected] Walter Australia Pty. Ltd. Victoria, Australia +61 (3) 8793 1000, [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] TDM Systems Inc. Schaumburg (IL), USA +1 (847) 605 1269, [email protected] Walter Tools S.A. de C.V. Saltillo Coahuila, Mexico +52 (55) 5365-6895, [email protected] Walter Canada Mississauga, Canada [email protected]
_ CoMPLETE MAChINING SoLUTIoNS
Pole Position for efficient machining.
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MACHINING TECHNOLOGY – FULL SPEED AHEAD.
Unlike any other sector, the automotive industry is currently undergoing a radical shift in attitude. For years, speed deter-mined 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 currently 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 difficult economic circumstances, which are proving a formidable challenge for automotive suppliers in particular: Models are changing at a rapid pace, but productivity must still be increased while maintaining the same high quality in the face of ever slimmer profit margins.
our specialist 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 procedures, all from one single source. Providing the tools to achieve your goals with innovation, flexibility, quality, and productivity–that’s our goal.
Expect more. Engineer what you envision.
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The trend toward higher performance with smaller displacement and lower fuel consumption means higher me-chanical loads on the engine block. This calls for increasingly high-quality materials made of GG gray cast iron and cast iron with GGV vermicular graphite. our new Tiger·tec®Silver
Automotive components are increas-ingly manufactured from aluminium thanks to its low weight. We offer a complete PCD tool line for high-preci-sion, economical machining of alumini-um alloy components. our high-tech
ENGINE BLoCK CyLINDER hEAD
Walter MoDCo® draw bar tool: Finish machining of cylinder main bore
Semifinishing and finishing in one–that’s the power of this high-tech MoDCo® draw bar tool, featuring cut-ting edges that can be precisely actu-ated via coolant or compressed air. This saves you time by allowing meas-urements and diameter compensation to take place in the machining centre.
Walter Prototyp Protodyn®S ECo plus: ECo thread former
With its front-end, radial coolant out-let, the Protodyn®S ECo plus provides significantly higher stability and great-er output than comparable thread formers. Equally suitable for use in blind and through holes.
Walter MoDCo® PCD face milling cutter F4050: 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 are just a few of this powerful tool’s outstanding features.
Walter MoDCo® PCD reamer: Valve guide and seat
An optimum coaxiality of the valve seat and guide can be achieved with the Walter PCD reamer, as well as perfect leak tightness of the seating surface. This guide bore reaming tool with mul-tiple cutting edges is a particularly efficient PCD tool variant.
Walter gang milling cutter: Machining the bearing webs
Walter gang milling cutters with tan-gentiallly arranged Tiger·tec®Silver indexable inserts are the first choice for efficient machining of bearing webs. The tangential screw fit on these system inserts ensures a high level of machining reliability and dimensional stability in mass-production opera-tions.
Walter Titex Alpha®4 XD drills: oil galley machining Reliable deep-hole drilling on machin-ing centres thanks to XD technology. our XD drills (special tools up to 40 x D) are unusually tough and ideally suited for machining non-ferrous met-als. These drills have a special flute geometry and a TINAL FUTURA coating for better performance–up to 6 times better productivity compared to gun drills or hSS tools.
cutting tool materials and Xtra·tec® tool systems are just the thing for machining such materials. you can achieve extremely high level of dimen-sional accuracy, optimum quality in surface finishes and increases in pro-ductivity of up to 100% through the combined use of Walter milling cutters,
MoDCo® PCD tools provide significant gains in both quality and productivity in series-production operations. These tools stand out for their extremely long service life and ensure superior dimen-sional stability. For aluminium cylinder
Walter Titex X·treme CI: Core hole drilling
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 ensures process reliability thanks to its even wear behaviour. In addition, you will save on tool costs by taking advantage of Walter’s original Reconditioning service to regrind and recoat your tools.
Walter Xtra·tec® heptagon cutter F4045: roughing the combustion chamber surface
The Xtra·tec® heptagon cutter F4045 with the new, powerful Tiger·tec®Silver indexable inserts (with 14 cutting edges!) is ideal for rough-machining the fire face. The wedge-type clamping system holds the insert securely in place.
Walter Titex high-performance drills and the threading tool manufactured by Walter Prototyp. our solutions give you a competitive cost-per-part edge in mass-production processes, even those involving complex parts.
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.
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XD Technology
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 automotive customers. It’s what allows us to respond quickly and consistently to current and future materials trends and new machining require-ments. Benchmark cutting tools such as the new Tiger·tec®Silver indexable inserts are a logical consequence of the uncompromising attitude of innovation we bring to everything we do. Those are our team orders.
With our specialist brands Walter, Walter Titex and Walter Prototyp, we see ourselves at the interface between machine manufactur-ers and the machining production area in the automotive sector. The machining solution begins with an analysis of all parameters, encompasses planning and development, and finishes up after a test phase with the commissioning of a new machining processes. It makes no difference whether the path to a cost-effective, com-plete 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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Walter Capto™: External machining
Walter Capto™ is a highly precise, extremely stable turning-tool changing system available in sizes C3 to C8. It allows large turning forces to be trans-ferred. The three-dimensional clamping system employed in the indexable insert provides maximum stability.
Because they convert linear power to rotational power, crankshafts made of high-strength steel and ductile iron face immense forces. At several 1,000 revolu-tions per minute, this complex compo-
Transmission shafts are transmission components whose function it is to pass on rotational movements and torques. As such, they are subjected to high torsional loads and must there-fore be finished to exacting standards. Not only the shaft itself, but also the
CRANKShAFT TRANSMISSIoN ShAFT nent in today’s high-performance cars is exposed to enormous physical forces and mechanical loads. A key objective in machining processes is to achieve the highest levels of dimensional
Walter rotary broaching tool: Bearing and web machining
Process reliability is priority number one for bearing and web machining with the versatile Walter rotary broaching tool. The high number of teeth on the tool’s robust ISo index-able inserts ensures a high output as well as precise contours and a superior surface quality.
Walter cut-grooving tool G1011: Grooving, parting off, recessing
Extremely accurate, extremely stable monoblock tool for grooving, parting off, and recessing. The clamping screw is accessible from the top and the bottom, making the tool easy to han-dle even when inverted. When used with Tiger·tec® cutting tool materials, this is a versatile and extremely effi-cient turning tool.
Walter external milling cutter: Bearing 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 bearing and web machining.
Walter internal milling cutter: Bearing and web machining
Even under harsh application condi-tions, the Walter internal milling cut-ter, thanks to its cartridge design, performs impressively as it handles extremely large machining volumes. This versatile tool is a breeze to adjust to just about any workpiece profile.
Walter Titex Alpha®4 solid carbide drill: Radial bore drilling
The high-performance, universal Walter Titex solid carbide drill with TFL coating and internal coolant supply facilitates high-precision drilling. This tool’s excellent cutting data translates to extremely low per-part costs for you. Available in diameters from 3 to 25 mm and in lengths of up to 5 x D,
the Walter Titex solid carbide drill is ideally suited for all materials up to
1,000 Nm.
Walter Turn boring bar: Small-diameter boring
When used with the AK600 adaptor sleeve, the Walter Turn boring bar can be adjusted precisely and automati-cally to tip height, thereby reducing vibrations in the machining process. The technology employs positive ISo inserts with a PVD aluminium oxide or CVD coating.
shaft-hub interface demands an ex-tremely precise design. With the turn-ing and drilling and boring tools in our specialist Walter and Walter Titex brands we have discovered the right solutions for machining this crucial component.
Walter Titex X·treme Dh drill: oil galley machining A drill using the special XD® technology with polished flutes and a TINAL FUTURA coating on the drill tip. X·treme Dh is ideal for drilling high strength materials with an interrupted cut. Specifically optimised for a long tool life in crankshaft machining ap-plications. Reliable to 30 x D, factory original reconditioning is available.
stability. With our high-performance tools, you will be able to produce long-lasting, durable crankshafts made of ductile iron or steel alloys at highly-competitive per-part costs.
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XD Technology
TECHNOLOGY CENTrES FOr rELIABLE PrOCESSES.
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 our Technology Centres in Germany, China, and the U.S., our engineers and technicians are working on 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, followed by testing and breaking-in–a process that continues until we have found the absolute best turning, drilling, milling, or threading 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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Today transmission cases for high-performance transmissions are gener-ally made of hypoeutectic aluminium or magnesium alloys. This presents a challenge for machining applications
The brake calliper is an important component of disk 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 calliper is an essential safety compo-
GEARBoX hoUSING BRAKE CALLIPER
Walter MoDCo® PCD circular mill: Web finishing
An efficient and impressive PCD tool for an ultra-long tool life and excellent dimensional stability in root face fin-ishing processes. Enables cost effi-ciency in mass-production operations.
Walter Prototyp Paradur®ECo-CI: Internal threads for hydraulic connections and ventilation bores
The new Paradur ECo-CI with the inno-vative Xtra·treat™ surface treatment is the ideal tool for high cutting speeds and a broad 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 Alpha®Jet with chamfer: Core hole drilling in flange bores
The Walter Titex Alpha®Jet solid car-bide drill for precise drilling and cham-fering in the flange bore. This precision tool’s geometry has been optimised for short machining times (drilling and chamfering in one operation) and low per-part costs.
Walter Titex step drill: Drilling, 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 Prototyp Protodyn®ECo-LM: Thread forming blind holes
The Protodyn®ECo-LM is a high-per-formance thread former with highly specific geometry and an extra smooth surface for precise machining of blind hole threads in the transmission case.
in that it requires fulfilling complex datum dimensions and minimising machining times. our high-per-formance Walter PCD tools, Walter Titex solid carbide drills, and Walter
nent 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 light of ever-increasing pressure from the
Walter MoDCo® PC face mill F4050: Face finishing
With its high number of teeth, the Walter PCD face mill F4050 provides extremely high feed rates. A combina-tion of finely adjustable runout and optimal cutting edge geometry enables a high-quality surface finish and superior tool life.
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 with Tiger·tec® inserts provides maxi-mum productivity and a high level of process reliability. And its extreme ease of handling is yet another feather in this combination tool’s cap.
Walter disk set mill: Fastening eye milling
A custom tangential disk set mill fitted with Tiger·tec® indexable inserts from the standard product line. A fixed insert seat provides great stability and enables high feed rates. The result is short machining times and thus also low per-part costs.
competition, another indispensable ingredient of success is the ability to minimise per-part costs while main-taining superior quality. our tools are up to the task.
Prototyp solid carbide taps are the perfect trio for precise, cost-effective machining operations involving these complex parts.
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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 series production.
Thanks to their extremely long tool edge life, these Walter tools are characterised by process reliability, extremely high preci-sion 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 get efficient machining that puts you ahead of the competition.
MODCO® tools. Your key to productivity.
The innovative MoDCo® PCD tools from Walter (face mill F4050 shown on the left) are the first choice in the automotive industry when it comes to achieving high-quality surface finishes and an extremely long tool life.
The MoDCo® label stands for complex draw bar tools offering users process reliability, precision, and productivity at the highest levels.
