Lightweight materials are becoming increasingly important in industrial production. Why is this? Particularly in the automotive and aerospace sectors, lower weight means reduced energy consumption. This is a crucial factor, especially since it not only has a positive impact on cost-efficiency but also on CO2 emissions and the range of electric cars, to give just a few examples.
In this context, Walter has expanded its expertise and product portfolio, which has been growing for more than 20 years, in the lightweight sector – through measures such as the acquisition of the manufacturer FMT (Frezite Metal Tooling). The result is that Walter FMT now offers an incredibly extensive selection of tools for machining aluminum. The same is true of the PCD range for machining light metals such as aluminum and aluminum alloys.
Customized process solutions
“Around 98% of our PCD tools are special tools which we tailor individually to the specific requirements and applications of each customer,” explains Roland Hanischdörfer, Field Business Developer PCD at Walter. “We therefore develop tailored machining solutions together with our customers. In doing so, we and our clients benefit from Walter FMT’s vast experience in the lightweight segment.”
For example, each wing rib which reinforces an airplane’s rib is produced differently from the next. In the automotive industry, by contrast, the challenges of short cycle times and extremely high quantities in mass production have to be tackled. To suit these very different machining situations, Walter FMT’s process solutions are customized and derive their potential from the large standard range and special solutions offered by Walter.
High demands for machining operations and tools
These kinds of high-tech components place extremely high demands on the machining operations and the tools used. “Aluminum materials, like those with a high silicon content, are abrasive, while an aluminum from the 7000 alloy group can be high tensile,” explains Stefan Benkóczy, Component Manager at Walter. “Other aluminum groups, for their part, tend to result in continuous chips and galling.”
This, alongside a variety of different shapes and/or materials, calls for flexible machining strategies and tools. Walter offers the perfect responses to these challenges with its wide selection of standard tools and PCD special tools, as well as its experience.
New solutions for the automotive industry
The new additions to Walter’s PCD range for the automotive industry include tools for machining chassis parts – this is a field where the company has considerable experience and knowledge. And it goes without saying that Walter also supports the advancement of electric mobility, for example with tools for machining stator housings, the outer shell of electric motors.
Walter’s current product range for light metal machining comprises a total of around 12,000 different standard tools. And that’s not all – there are also special PCD and carbide tools, as well as hybrid versions which showcase the problem-solving skills of Walter’s PCD and lightweight experts. All of these tools boast exceptional cost-efficiency thanks to short machining times and longer than average tool life.
Global presence strengthened
In addition to expanding its PCD product range, Walter has also increased its number of production and service sites and regrinding centers – in Eastern Europe and Central America, to name just a few locations. By doing so, the company is making its services and products available around the world even more effectively and quickly.
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