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Engineering Kompetenz is a promise
Gain more insights into the topic through our whitepapers. What are the current trends and challenges, what is important for the future, and what can you do about it today. We have created the following whitepapers for you with our Engineering Kompetenz:
Achieve ambitious goals with ease.
Comprehensive expertise for your machining tasks
Any discussion of machining in the aerospace industry inevitably involves high-tech solutions and innovations. This is because the ability to machine new materials with a high level of process reliability and precision is not the only thing that matters – the development of technically and economically viable solutions for that purpose is of equal importance. Thanks to the Engineering Kompetenz of Walter, you can rest assured that innovative product ideas can be turned into competitive series solutions.
Walter offers you the most comprehensive range of machine tools for metal and composite materials available anywhere in the world, all from a single source. Flexible machining solutions for the aerospace industry that set new standards: Whether for turning, drilling, threading or milling operations. With the highest possible productivity and process reliability, from technical support through to tool management – regardless of the batch size and material.
Accelerating productivity
By 2035, there will be an additional 600 million cars around the world, taking the global figure to 1.8 billion. This rapid increase in vehicle numbers is accompanied by an equally rapid increase in the requirements those vehicles need to meet: Fuel consumption, e-mobility, new materials, etc. Car manufacturers and suppliers need to overhaul their designs with ever-increasing frequency to keep up with the enormous pace of change in the market. What remains constant, however, is demand for excellent machining solutions.
Process optimisation at the component level is just as crucial to this end as intelligent tool management; and, of course, a partner who can put this into practice. Walter combines economical tool solutions and reliable service under one roof; because only high productivity with consistent component quality can provide the right drive in the automotive industry. Pick up speed with Walter Engineering Kompetenz.
With energy into the future
More precise, more efficient, cleaner: The requirements that the energy industry needs to meet are constantly growing – which in turn results in stricter requirements for manufacturers of systems and components used in energy production. New technologies require new tools and machining processes. The same applies to new materials and complex component geometries. "Energy components" are also extremely expensive due to their often enormous size and long machining times. Errors during machining usually have extremely expensive consequences.
Machining large components in the energy sector also requires complex custom-designed solutions. Walter tool solutions are synonymous with maximum precision and process reliability. For turning, drilling, milling or threading: Walter is your reliable partner – and is perfectly equipped for all machining requirements in the energy industry. Enjoy the benefits of our Engineering Kompetenz and our complete solutions for the energy industry from a single source: From tools to processes and machines through to application expertise.
The right signals for efficient machining.
All around the world, the requirements for the transportation of people and goods are increasing rapidly, making the rail industry into an important market for the future. Railway infrastructure is one of the vital factors in the economic success of a region. In this context, the rail industry must deal with growing demands for mobility and flexibility and meet the challenges set by raw material shortages and environmental protection considerations.
For high-speed solutions with the highest possible safety standards coupled with greater profitability, the railway transportation industry needs an innovative and reliable partner like Walter, with exceptional understanding in the area of rail technology and the ability to address every aspect of the industry: You can find complete solutions for all machining requirements here. Expect more. Engineer what you envision.
Exceptional machining requirements require exceptional machining solutions. In the "Industry Solutions" department, our engineers and machining engineers test customised special tools used in conjunction with optimised production processes in what are known as ratio projects. If it is expedient to use special tools, we develop a component-specific machining concept which leads to clearly measurable increases in productivity within a very short space of time.
Walter offers special tool solutions not only in the automotive, energy, railway and aerospace industries, but also for specific technologies, such as gear milling.
Walter engineers are also continuously developing cost-effective special solutions for specific challenges in general mechanical engineering, mould making, the pump industry and in the oil and gas industry. This is also true for the reliable machining of unconventional materials in a specific industry.
We develop special side and face mills for our customers, with diameters of over 2 metres. The uniqueness of the machining task is matched by the uniqueness of the special tool. For example, the degree of accuracy required for the profiles of the turbine blades and turbine shafts used in steam turbines is extremely high. We will provide you with insert finishing end mills for finishing blade roots and attachment grooves in turbine shafts: with these mills, you will be able to achieve a degree of profile accuracy of +/- 0.01 mm. The Walter Prototyp ConeFit™ system is one of the most successful modular tooling systems for milling.
We would like to give our customers an advantage in day-to-day competition: to do this, we opt for solutions such as specific combination tools for turning, which improve both quality and cost-effectiveness. In addition, tailored machining processes and combination tools with multiple cutting edges save on tool changing and minimise chip to chip time.
As a user, this means that, as a result of optimally adapted processes and tools, you reduce unit costs, decrease processing time and, because of the saving on tool spaces you now have on your turning centre, you can insert complementary tools.The key is the holistic approach to development.
The new generation of cutting tool materials from Walter has arrived and has begun redefining peak performance in machining. With unparalleled innovation and superior technology: Having mastered milling and holemaking, Tiger·tec® Gold is now also conquering turning.
The key to this is the holistic approach to development, combined with cost-efficiency, process reliability and productivity. Tiger·tec® Gold puts all of these aspects into practice at the highest level and in every machining operation, be it milling, holemaking or turning. As strong as ever. More flexible than ever before.
Every steel machining operation poses some challenges. So it's a good thing that Tiger·tec® Gold can handle almost any challenge involved in turning.
The secret is the specialised design of the individual grades. Whether the priority is high wear resistance for continuous cutting, or difficult conditions resulting in a high number of cutting interruptions meaning that maximum toughness is key, the right grade makes all the difference. Not to mention a technology that sets standards in steel machining across the industry: Tiger·tec® Gold.
Superior technology that revolutionises turning
"Outstanding wear resistance meets maximum toughness" is the principle behind Tiger·tec® Gold for holemaking. The indexable inserts are in a class of their own – especially under difficult conditions and when machining materials that have difficult cutting properties.
The secret is the specialised design of the individual grades. Whether the priority is high wear resistance for continuous cutting, or difficult conditions resulting in a high number of cutting interruptions meaning that maximum toughness is key, the right grade makes all the difference. Not to mention a technology that sets standards in steel machining across the industry: Tiger·tec® Gold.
The key advantages at a glance:
Customers seeking to optimise their production must not only improve their productivity, but also guarantee continuous process reliability. Minimal wear, maximum tool life and reliable processes, even under the toughest conditions – this is exactly what Tiger·tec® Gold represents.
The superior properties of Tiger·tec® Gold indexable inserts for milling applications are the result of their layered structure: An extremely tough, wear-resistant TiAIN layer with high aluminium content, an intricate TiN layer for optimum layer bonding, and the eye-catching, gold-coloured top layer. It protects the substrate against abrasion, thermal cracks, plastic deformation and oxidation, while enabling outstanding wear detection.
Impressive performance, winning solution
Customers seeking to optimise their production must not only improve their productivity, but also guarantee continuous process reliability. Minimal wear, maximum tool life and reliable processes, even under the toughest conditions – this is exactly what Tiger·tec® Gold represents.
The superior properties of Tiger·tec® Gold indexable inserts for milling applications are the result of their layered structure: An extremely tough, wear-resistant TiAIN layer with high aluminium content, an intricate TiN layer for optimum layer bonding, and the eye-catching, gold-coloured top layer. It protects the substrate against abrasion, thermal cracks, plastic deformation and oxidation, while enabling outstanding wear detection.
Impressive performance, winning solution
MC025 Advance
MD025 Supreme
High level of cost efficiency
Resource-saving concept
Powered by Tiger·tec® Silver
High level of cost efficiency:
Concept requiring minimum resources:
Walter BLAXX M3024 heptagon milling cutter: Cost-efficient, with process reliability.
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The new standard for tool life.
Facts and advantages:
Every steel machining operation poses some challenges. So it's a good thing that Tiger·tec® Gold can handle almost any challenge involved in turning.
The secret is the specialised design of the individual grades. Whether the priority is high wear resistance for continuous cutting, or difficult conditions resulting in a high number of cutting interruptions meaning that maximum toughness is key, the right grade makes all the difference. Not to mention a technology that sets standards in steel machining across the industry: Tiger·tec® Gold.
Superior technology that revolutionises turning
With the combination of new grades and new geometries,
Walter has created a new cutting material generation: the Tiger▪tec® Silver
ISO P Generation. To achieve this, we have combined the unique Tiger▪tec®
Silver cutting tool material with CVD coating process with a completely new,
universal insert geometry range (FP5, MP3, MP5, RP5) for steel machining
(WPP10S, WPP20S, WPP30S).
The results are impressive, as the Tiger▪tec® Silver ISO P Generation
achieves increases in output of up to 75 % when turning steel.
Facts and advantages:
Walter FP4, MP4 and RP4 positive ISO P indexable inserts – with bite.
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With the combination of new grades and new geometries, Walter has created a new generation of cutting tool materials: The Tiger▪tec® Silver ISO K generation.
For this, we have combined the unique Tigertec Silver CVD cutting material (WKK10S, WKK20S) with a geometry family consisting of three designs: MK5 for general iron machining RK5 for heavier iron machining conditions RK7 for very robust machining conditions
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When machining materials that are difficult to cut (ISO S), there is a wider range of workpiece materials than with steel and cast iron machining. Walter has therefore developed two geometry ranges for ISO S machining. Walter NMS and NRS for high temperature alloys, such as Inconel 718, and Walter NFT, NMT and NRT for titanium alloys, such as Ti6Al4V.
The main sign of wear when machining high temperature alloys is the formation of notches and cutting edge build-up. In contrast to this, in titanium machining, indexable inserts must above all be resistant to crater wear.
Facts and advantages:
Walter Tiger▪tec® Silver WMP20S: Universal cutting tool material for machining ISO M and ISO P materials
Facts and advantages:The single sided Walter geometries NRR and NRF are a powerful duo for roughing applications. The NRF geometry is responsible for universal roughing in this case, while the NRR geometry is, for example, used for extremely heavy roughing of forged skins.
Walter's product portfolio in this field includes various geometries and cutting tool material grades for heavy-duty machining.
Facts and advantages:Cooling straight to the point.
The Walter Turn tooling system offers tool solutions for all internal machining tasks with ISO turning toolholder for longitudinal, face and copy turning with boring bar diameters of 6 mm and above.
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The Walter Turn tooling system also leaves nothing to be desired when it comes to external machining. For every task, there is a dedicated tool solution with ISO turning toolholder for longitudinal, face and copy turning.
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The new Walter Tiger•tec® Silver PVD cutting tool material grades are the logical continuation of the Tiger∙tec® cutting tool material grades – and proof that wear resistance and toughness are not mutually exclusive. With this unique combination of heat resistance and toughness, this cutting tool material sets new standards in terms of cost efficiency when machining steel, stainless materials and heat-resistant alloys.
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Walter Cut – Tiger·tec® Silver WKP13S, WKP23S and WKP33S – high-performance cutting materials specially developed for grooving.
Features and advantages:
The Walter GX grooving system is a new tool technology for grooving and parting off in all types of lathes. With three geometries and various holders, there are virtually no limits in terms of flexibility when parting off.
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The Walter G1041 parting blades have a reinforced shank and offer both maximum stability and secure parting off processes. They are suitable for grooving and parting off on all kinds of lathes:
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The Walter G1042 deep parting blades with double-edged GX cutting edge are suitable for grooving and parting off in all common lathes
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The G1011 monoblock tool for radial grooving, parting off and groove-turning is suitable for use in all common lathing centres. These new grooving tools have been developed to offer maximum stability in grooving operations.
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A whole new dimension in axial grooving is made possible by the extremely stable and reliable Walter GX1111 monoblock axial grooving tools. This guarantees you maximum productivity when combined with Tiger·tec® Silver cutting tool materials.
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Due to its flexibility, the Walter G15XX range of monoblock tools is the ideal choice for cutting depths of up to 6 mm. These include: circlip grooves, sealing ring grooves or thread relief grooves.
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Walter Cut SX G2012 – SX monoblock tools with internal cooling for multi-spindle machines, automatic and manual lathes.
Features and advantages:
Contra blades and internal cooling.
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With the extension of our Walter Capto™ range to include the size C8, we are now offering an extremely strong and stable solution for heavy-duty machining. These adaptors are, for example, deployed in vertical boring and turning mills or large turning-milling centres. Walter Capto™ adaptors are manufactured to ISO 26623 standards and thereby work in all machines. Clamping units, turning toolholders and adaptors are available.
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Walter provides tooling solutions for cost-effective complete machining on turning-milling centres. The new tooling system encompasses a sophisticated toolholder range, two different clamping systems for the most diverse of ISO inserts, and even special adaptors. This allows components to be machined in their entirety and with process reliability in one clamping arrangement with the working spindle set at an angle of 45°.
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We offer a full system for machining dimensionally accurate internal and external threads. The tools on offer here include full profile and partial profile versions of our three-edged indexable inserts for all common thread types.
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All common thread sizes available as standard indexable inserts:
"Outstanding wear resistance meets maximum toughness" is the principle behind Tiger·tec® Gold for holemaking. The indexable inserts are in a class of their own – especially under difficult conditions and when machining materials that have difficult cutting properties.
The secret is the specialised design of the individual grades. Whether the priority is high wear resistance for continuous cutting, or difficult conditions resulting in a high number of cutting interruptions meaning that maximum toughness is key, the right grade makes all the difference. Not to mention a technology that sets standards in steel machining across the industry: Tiger·tec® Gold.
The key advantages at a glance:
Walter Xtra▪tec® D4580 chamfering tool – economic drilling and chamfering in one.
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The Walter Titex X▪treme Plus is the high-performance drill in the HSC range for the most diverse of materials.
Facts and advantages:Precise positioning increases productivity.
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The B4030 precision boring tools with Walter Capto, NCT and ScrewFit adaption are ideal for precision boring all materials with exceptional stability
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Thrill·tec™ Thrill·tec™ TC645 Supreme circular drill/thread mill for blind-hole and through-hole threads
Thrill tec™ TC645 Supreme thread milling cutters bring together three functions in one tool: Chamfering, core-hole drilling and thread cutting. This avoids any indexing times and saves on tools. The tools boast a special combination of substrate, coating and geometry,
resulting in long tool life and achieving optimal cutting parameters. They can be used for all ISO materials up to 48 HRC and thread depths from 2 to 2.5 × D.
Properties and advantages:
TC685 Supreme orbital drill thread milling cutter
for blind-hole and through-hole threads
The TC685 Supreme with left-hand cutting geometry is the specialist for hardened steels (material group ISO H) from 44 to 65 HRC. It can be used to produce the core hole, blind-hole and through-hole threads from 2 to 2.5 × D and chamfers in a single operation. In addition to ISO H, the orbital drill thread milling cutter can also be used with ISO material groups P, S and K.
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TC120 tap – high reliability in soft steel and medium-strength steel.
TC121 tap – maximum performance in steel in medium strength range.
TC122 tap – maximum tool life in steel with medium to high tensile strength.
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The Walter Prototyp Paradur® HT high performance tap facilitates the reliable creation of blind hole threads, even in long-chipping, high-strength materials up to 4 x d. The secret lies in the special flute geometry of the Prototyp Paradur® HT, whereby the chips are broken down and transported efficiently out of the thread by the internal coolant supply.
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How Walter embodies digitalisation – and takes your results to the next level
Find, order and use tools more efficiently – optimise processes
Digitalised procedures and the exchange of data are indispensable today if production processes are to be optimised or new ones planned. But their efficiency and productivity actually differ at a much earlier stage: When providing all relevant information and easily selecting and ordering the right tool. This is exactly what Walter Digital represents – and it doesn't stop at tailored interfaces for your systems. Efficient internal processes enable us to offer you targeted solutions quickly.
The digitalisation of product and process data enables us to increase our efficiency and our knowledge and to make this knowledge available to you, for example to plan your processes and select the ideal tools.
Comara appCom* collects and visualises comprehensive machine and production data, then interprets and analyses it. Comara appCom can be used for a wide range of control systems regardless of the machine manufacturer – for example Siemens, Fanuc, Heidenhain or OPC-UA.
Comara iCut measures the spindle output up to 500 times per second – and automatically adjusts the feed to the current cutting conditions. As quickly as possible, as slowly as necessary. In every situation. With a unique reaction time. Whether this concerns fluctuations in the material removal, varying milling cutter rotations, differing engagement widths, hardening or tool wear.
Find the right tools for your component in no time at all
Upload 3D models and benefit from our quote in record time
Walter Innotime takes your component design to the next level. Use it to find the right machining solution for your component in no time at all. Simply upload a 3D model of your component and Walter Innotime will generate a recommendation for the tools required and suitable machining parameters. This recommendation is then validated and adapted by our expert technicians and engineers.