Users previously faced a choice: either they relied on the flexibility of a modular tool system with interchangeable cutting inserts or on the high precision and power transmission of monoblock tools. With the new simmill 9W family from SIMTEK, this decision is eliminated in most cases. The tools in this series offer interchangeable cutting inserts that come close to the power transmission and precision of monoblock tools – and at a significantly lower cost.
The starting point of the simmill 9W family, which is now available in various versions, is the tool milling system simmill 9W4, originally developed for a complex component in the automotive industry and represents a significant advancement in the field of milling tools. Norbert Seifermann, board member at SIMTEK, emphasizes: 'Many industrial customers want to utilize the flexibility of modular milling tools, but until now this was often associated with limitations in accuracy and load capacity. With the simmill 9W4 system, we now offer a powerful solution for slotting, separating, and slitting milling that makes this compromise unnecessary in many cases.'
Development and technical details
simmill 9W4 arose from a specific need in the automotive industry and is the result of intensive development work. For the production of a complex component, a tool was needed that works precisely and stably even under difficult conditions such as limited space with simultaneously high overhangs. To meet these requirements, the experts from Mössingen developed a milling tool that uses interchangeable cutting inserts while still achieving nearly the stability and precision of a monoblock tool.
The simmill 9W4 system is based on a highly developed gearing technology that offers a range of advantages. Due to the high stability of the gearing, the simmill 9W4 system is suitable for applications with high torques and ensures high precision in round and flat running with only minimal wear at the interface between holder and cutting insert.
Advantages and application possibilities
The simmill 9W4 system is already suitable in the standard range for milling depths of up to 16.5 mm, which is far beyond the capabilities of many other comparable tool solutions. The interchangeable cutting inserts are available in cutting widths from 0.5 mm to 6.0 mm. The 12 straight or cross-cutting edges guarantee high machining performance and thus shorter main times.
Furthermore, the system impresses when used in confined spaces: The shank diameter is up to three times smaller than the diameter of the cutting insert. The integrated coolant supply contributes to the longer service life of the tools and ensures efficient cooling.
Sustainability and resource efficiency
Another aspect that distinguishes the tool system is its sustainability, according to the manufacturer. The durable and robust tools ensure economical and environmentally friendly production. Additionally, the modular design of the tool system significantly reduces material consumption compared to monoblock tools. While worn monoblock tools must be completely discarded after one or more resharpenings, with the simmill 9W4 system, only the actual cutting insert is replaced after multiple resharpenings. This not only saves resources but also reduces production costs and the CO2 footprint.
Variants and developments
Image: Simtek
The simmill 9W4 milling tool system has continuously evolved since its introduction and now includes various versions with different diameters and cutting geometries. In addition to simmill 9W4, the current variant 9W1 is available with a maximum milling depth of 9.3 mm and cutting widths from 1.2 mm to 2.5 mm. Steel and carbide holders are available for both variants.
Further versions and intermediate sizes are already numerous and successfully in use in the area of customer-specific solutions. 'These developments underscore the flexibility of the system and its ability to close the gap between conventional exchangeable tools and monoblock tools,' explains SIMTEK board member Seifermann.
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