Multi-function tools EcoCut & ProfileMaster

Transcription

1 Multi-function tools EcoCut & ProfileMaster EN

2 CEATIZIT secrets of success Secrets of success CEATIZIT is your partner for exceptional hard material solutions. Hard materials and tools from CEATIZIT - our solutions to complex problems are an integral part of our customers' success. Our products guarantee: economy - long life - speed! And it is precisely this combination which gives our business partners a direct competitive advantage. Premier performance is only possible through a total appreciation of the requirements of our business partners. A performance achieved through flexible thinking and continuous dialogue with our customers. A pioneering spirit and a deep understanding of powder metallurgy characterize the history of CEATIZIT. One of the attributes of our company philosophy is the search for perfection: target oriented - sustainably - passionately! Intensive research and development activities, taking into account the precise requirements and working processes of the customer, are today's investment for the solutions of tomorrow - and beyond. Corporate values The views and focus of our business partners matter Innovative and flexible thinking matters Communication matters Employee development matters Professionalism matters Our environment matters Tailored cutting tool solutions Cutting materials, coatings, inserts, tooling systems and machining solutions - all this is included in the cutting tool division at CEATIZIT. Worldwide well-known companies process advanced materials applying cutting tool products from CEATIZIT: from the automotive industry to the aerospace industry, mechanical engineering and tool construction to the oil industry. The basis of these long-term business relations is the faith of the customers in the extensive know-how of the carbide specialists. 2

3 Contents Introduction Benefits, productivity Machining operations MasterGuide Grade overview Grade description Inserts, tools EcoCut Designation system 38 ProfileMaster Designation system Inserts 39 Inserts Tools - EcoCut Mini Tools Tools - EcoCut Classic Tools - EcoCut ebore Technical information Cutting data Problems, corrective measures Masterfinish Surface quality, feed rate EcoCut Depth of cut, feed rate Drilling depth, feed rate for drilling Application Densimet Machining examples ProfileMaster Depth of cut, feed rate Coolant supply, Masterfinish effect Application Machining examples 3

4 EcoCut / ProfileMaster Benefits eduction of: educed tool changing times educed pre-setting and set-up times Less programming effort Masterfinish effect Excellent surface finish educed machining times Drill a range of diameters educed tool acquisition costs Problem solver in case of insufficient tool storage capacity educed stock-keeping costs Produces a flat bottom hole 4

5 EcoCut / ProfileMaster Productivity Turn the cost screw together with CEATIZIT Break-down of work piece costs Tooling costs 2-6% Manufacturing costs (machine / manpower) 78-82% Material costs 14-18% Increase in productivity (parts produced per time unit): Due to improved utilization of the available machine capacity considerable cost reduction per work piece becomes possible. In this context CEATIZIT EcoCut makes a decisive contribution through: - Fewer tool changes - Increased v c - Increased f - Increased a p Increase in productivity by 30% results in reduction of work piece costs by 19% Increased tool life: As the average tool costs amount to only 2-6% of the work piece costs, prolonging tool life typically can only reduce total costs minimally. Increase of tool life by 30% results in reduction of work piece costs by 1% 5

6 EcoCut Four machining operations with only one tool Conventional Boring applications Drilling into solid material with flat bottom holes 4 External turning applications 4 Turning of face profiles EcoCut Drilling into solid material with flat bottom holes Boring applications Turning of face profiles External turning applications everse direction of rotation 6

7 EcoCut / ProfileMaster Benefits Conventional EcoCut Problem solver for insufficient tool storage Less programming effort Produces a flat bottom hole educed stock-keeping costs for tools and indexable inserts Considerable cost savings concerning tool acquisition Shorter set-up times educed pre-setting times 7

8 ProfileMaster Machining methods Machining methods - radial application 90 Drilling into solid material with flat bottom holes Boring applications External turning applications Internal turning applications Turning of face profiles External radial grooving Internal radial grooving Machining methods - radial application 0 External turning applications Boring applications Turning of face profiles External radial grooving Internal radial grooving When changing from internal to external machining, reverse direction of rotation 8

9 ProfileMaster ProfileMaster from CEATIZIT provides the comprehensive solution right-hand tool right-hand insert right-hand tool left-hand insert right-hand insert left-hand tool right-hand tool right-hand insert 9

10 MasterGuide Material Based on VDI 3323 CEATIZIT's MasterGuide divides materials into six main groups. Each is given a colour, according to the system partly adopted in ISO 513. Blue: steel Machining, cementation, tempered and constructional steels Yellow: stainless steel Ferritic Cr-steels, austenitic CrNi-steels, martensitic Cr-steels, duplex steels ed: cast iron Cast iron, grey cast iron, tempered iron, spheroidal cast iron, CGI, sintered iron Green: non ferrous metals and non metals Al wrought and Al cast alloys, copper, copper alloys, non metal materials Orange: heat resistant alloys / titanium Ni/Co-base alloys, Ti alloys White: hard materials Hardened steels ( 45 HC), chilled castings, hard cast irons Machining application type Each coloured segment is divided into three sections, and each section indicates the relevant machining application type: = rough machining M = medium machining F = fine machining 10

11 MasterGuide Application The ideal application area for the insert is indicated by a black circle. Extended applications are indicated by an open circle. The CEATIZIT MasterGuide provides you with an easily understandable structure for choosing a product and enables you to reduce grade and geometry stocks. Main application Extended application The right indexable insert at a glance Main application: Medium and fine machining of non ferrous metals and non-metallic materials. Extended application: Medium and fine machining of cast iron. 11

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13 Grade overview Grade designation CTC1425 CTC1435 CTP2440 H210T Standard designation Cutting material Application range HC-P25 C HC-M20 C HC-K15 C HC-P35 C HC-M30 C HC-K20 C HC-P40 P HC-M35 P A F N S H HC-K25 P HW-M10 W HW-K10 W H216T HW-K15 W Steel Stainless Cast iron Non ferrous metals Main application Extended application Heat resistant Hard materials Grade designation CM45 Standard designation Cutting material Application range A F N S H HC-P45 P HC-M40 P HC-K25 P TSM30 HW-K30 W Steel Stainless Cast iron Non ferrous metals Main application Extended application Heat resistant Hard materials 13

14 CTC1425 HC-P25 HC-M20 HC-K15... Grade description Steel Composition: Co 7.0%; composite carbides 8.0%; WC rest Grain size: 1-2 µm Hardness: HV 1450 Toughness Coating specification: CVD TiN + Ti (C,N) + Ti (N,B) + AI 2 O 3 + Ti (C,N,B); 6 µm Wear resistance CTC1435 HC-P35 HC-M30 HC-K20... Composition: Co 9.5%; composite carbides 6.5%; WC rest Grain size: 1-2 µm Hardness: HV 1400 Toughness Coating specification: CVD TiN + Ti (C,N) + Ti (N,B) + AI 2 O 3 + Ti (C,N,B); 6 µm Wear resistance CTP2440 HC-P40 HC-M35 HC-K25... Composition: Co 9.5%; composite carbides 6.5%; WC rest Grain size: 1-2 µm Hardness: HV 1400 Toughness Coating specification: PVD TiAIN; 3-5 µm Wear resistance

15 CM45 HC-P45 HC-M40 HC-K25... Grade description Steel / stainless steel Composition: Co 10.0%; WC rest Grain size: 0.7 µm (submicron grade) Hardness: HV 1600 Toughness Coating specification: PVD TiAIN; 2-4 µm Wear resistance CM45 HC-P45 HC-M40 HC-K25... Composition: Co 10.0%; WC rest Grain size: 0.7 µm (submicron grade) Hardness: HV 1600 Toughness Coating specification: PVD TiAIN; 2-4 µm Wear resistance CTP2440 HC-P40 HC-M35 HC-K25... Composition: Co 9.5%; composite carbides 6.5%; WC rest Grain size: 1-2 µm Hardness: HV 1400 Toughness Coating specification: PVD TiAIN; 3-5 µm Wear resistance

16 CTC1425 HC-P25 HC-M20 HC-K15... Grade description Cast iron, non ferrous metals and non metal Composition: Co 7.0%; composite carbides 8.0%; WC rest Grain size: 1-2 µm Hardness: HV 1450 Toughness Coating specification: CVD TiN + Ti (C,N) + Ti (N,B) + AI 2 O 3 + Ti (C,N,B); 6 µm Wear resistance H216T HW-K15... Composition: Co 6.0%; WC rest Grain size: 1 µm Hardness: HV 1630 Toughness Wear resistance Properties, application: Optimally suitable for aluminium High wear resistance High heat resistance Low tendency to adhesion H210T HW-M10 HW-K10... Composition: Co 6.0%; WC rest Grain size: 0.8 µm (submicron grade) Hardness: HV 1850 Toughness Wear resistance Properties, application: Ideal for heat resistant alloys, titanium, refractory metals (W, Mo), aluminium and glass & carbon fibre reinforced plastics Low tendency to adhesion 16

17 Grade description Non ferrous metals and non metal, heat resistant alloys, titanium H216T HW-K15... Composition: Co 6.0%; WC rest Grain size: 1 µm Hardness: HV 1630 Toughness Wear resistance Properties, application: Optimally suitable for aluminium High wear resistance High heat resistance Low tendency to adhesion TSM30 HW-K30... Composition: Co 10.0%; WC rest Grain size: 0.7 µm Hardness: HV 1550 Toughness Wear resistance Properties, application: Optimally suitable for aluminium High wear resistance Good toughness H210T HW-M10 HW-K10... Composition: Co 6.0%; WC rest Grain size: 0.8 µm (submicron grade) Hardness: HV 1850 Toughness Wear resistance Properties, application: Ideal for heat resistant alloys, titanium, refractory metals (W, Mo), aluminium and glass & carbon fibre reinforced plastics Low tendency to adhesion 17

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20 EcoCut Designation systems Inserts X C N T F N - 27P Tools EcoCut Nominal diameter [mm] Cutting direction Maximum drilling depth, for example: 3.0 x diameter Insert size Tool holder in Densimet Insert shape Clearance angle Tolerances Form of top surface Cutting edge length Insert thickness Corner radius Cutting edge Cutting direction Chamfer version EC D 17 H 20

21 EcoCut XCET 04-27P E-EL -27Q -M50Q L N H210T H216T CTC1425 CTC1435 CTP2440 (l) [mm] Type, description r [mm] l [mm] s [mm] d 1 [mm] XCET F-27P XCET F-27Q XCNT E XCET FL-27P 0.20 XCET FL-27Q L XCNT EL XCET F-27P XCET F-27Q XCNT E XCNT E-M50Q XCET FL-27P 0.40 XCET FL-27Q L XCNT EL XCNT EL-M50Q Steel Stainless r r r Cast iron rr Non ferrous metals r Heat resistant r Hard materials Main application Extended application International CEATIZIT range, for present availability see price list Ordering example: 10 pieces XCET F-27P H216T V C

22 EcoCut XCET P EN -27Q -M50Q L N H210T H216T CTC1425 CTC1435 CTP2440 (l) [mm] Type, description d [mm] l [mm] s [mm] r [mm] d 1 [mm] XCET FN-27P XCET FN-27Q 0.20 XCNT EN 05 XCET FN-27P XCET FN-27Q XCNT EN 0.40 XCNT EN-M50Q XCET FN-27P XCET FN-27Q 0.20 N XCNT EN 06 XCET FN-27P XCET FN-27Q XCNT EN XCNT EN-M50Q XCET FN-27P XCET FN-27Q XCNT EN XCNT EN-M50Q Steel Stainless r r r Cast iron rr Non ferrous metals r Heat resistant r Hard materials Main application Extended application International CEATIZIT range, for present availability see price list Ordering example: 10 pieces XCET FN-27P H216T V C

23 EcoCut XCET P EN -27Q -M50Q L N H210T H216T CTC1425 CTC1435 CTP2440 (l) [mm] Type, description d [mm] l [mm] s [mm] r [mm] d 1 [mm] XCET FN-27P 08 XCET FN-27Q XCNT EN XCNT EN-M50Q XCET 09T304FN-27P XCET 09T304FN-27Q XCNT 09T304EN XCNT 09T304EN-M50Q N XCET 10T304FN-27P XCET 10T304FN-27Q XCNT 10T304EN XCNT 10T304EN-M50Q XCET 10T308FN-27P XCET 10T308FN-27Q 0.80 XCNT 10T308EN XCNT 10T308EN-M50Q Steel Stainless r r r Cast iron rr Non ferrous metals r Heat resistant r Hard materials Main application Extended application International CEATIZIT range, for present availability see price list Ordering example: 10 pieces XCET FN-27P H216T V C

24 EcoCut XCET P EN -27Q -M50Q L N H210T H216T CTC1425 CTC1435 CTP2440 (l) [mm] Type, description d [mm] l [mm] s [mm] r [mm] d 1 [mm] XCET FN-27P XCET FN-27Q XCNT EN XCNT EN-M50Q XCET FN-27P XCET FN-27Q N XCNT EN 5.30 XCNT EN-M50Q XCET FN-27P XCET FN-27Q XCNT EN XCNT EN-M50Q Steel Stainless r r r Cast iron rr Non ferrous metals r Heat resistant r Hard materials Main application Extended application International CEATIZIT range, for present availability see price list Ordering example: 10 pieces XCET FN-27P H216T V C

25 EcoCut Mini ECM Ø 4-5 mm Solid carbide L TSM30 CM45 D Type, d A l 1 l 2 f r [mm] description [mm] [mm] [mm] [mm] [mm] EC D 35 9 EC D-27 EC D EC D EC 04L-2.25D 35 9 EC 04L-2.25D-27 L EC 04L-4.00D EC 04L-4.00D EC D EC D-27 EC D EC D EC 05L-2.25D EC 05L-2.25D-27 L EC 05L-4.00D EC 05L-4.00D-27 Steel Stainless Cast iron r r Non ferrous metals r Heat resistant r r Hard materials Uncoated Coated Main application Ordering example: 10 pieces EC D CM45 V C

26 EcoCut Mini ECM Ø 6-7 mm Solid carbide L TSM30 CM45 D Type, d A l 1 l 2 f r [mm] description [mm] [mm] [mm] [mm] [mm] EC D EC D-27 EC D EC D EC 06L-2.25D EC 06L-2.25D-27 L EC 06L-4.00D EC 06L-4.00D EC D EC D-27 EC D EC D EC 07L-2.25D EC 07L-2.25D-27 L EC 07L-4.00D EC 07L-4.00D-27 Steel Stainless Cast iron r r Non ferrous metals r Heat resistant r r Hard materials Uncoated Coated Main application Ordering example: 10 pieces EC D CM45 V C

27 EcoCut Mini ECM Ø 8 mm Solid carbide L TSM30 CM45 D Type, d A l 1 l 2 f r [mm] description [mm] [mm] [mm] [mm] [mm] EC D EC D-27 EC D EC D EC 08L-2.25D EC 08L-2.25D-27 L EC 08L-4.00D EC 08L-4.00D-27 Steel Stainless Cast iron r r Non ferrous metals r Heat resistant r r Hard materials Uncoated Coated Main application Ordering example: 10 pieces EC D CM45 V C

28 EcoCut Mini Adapters d Type, [mm] description [mm] [mm] [mm] [mm] [mm] 6 EC-ADX EC-ADX20-08 Ordering example: 1 piece EC-ADX20-06 d 1 [mm] 1 piece /M8X1X8 DIN /M8X1X8 DIN

29 EcoCut Classic EC Ø 8-12 mm L D Type, d A d 2 l 1 l 2 l 3 f [mm] description [mm] [mm] [mm] [mm] [mm] [mm] EC D EC D EC D 04 H EC 08L-1.5D XC EC 08L-2.25D 04 L EC 08L-3.0D 04 H EC D EC D EC D 05 H EC 10L-1.5D XC EC 10L-2.25D 05 L EC 10L-3.0D 05 H EC D EC D EC D 06 H EC 12L-1.5D XC EC 12L-2.25D 06 L EC 12L-3.0D 06 H Ordering example: 1 piece EC D 04 D [mm] 10 pieces 1 piece XC /M1,8X3,4/T /TOX T06 XC /M2,0X4,0/T /TOX T06 XC /M2,2X5/T /TOX T07 V C H = Densimet

30 EcoCut Classic EC Ø mm L D Type, d A d 2 l 1 l 2 l 3 f [mm] description [mm] [mm] [mm] [mm] [mm] [mm] EC D EC D EC D 07 H EC 14L-1.5D XC EC 14L-2.25D 07 L EC 14L-3.0D 07 H EC D EC D EC D 08 H EC 16L-1.5D XC EC 16L-2.25D 08 L EC 16L-3.0D 08 H EC D EC D EC D 09 H EC 18L-1.5D XC.. 09T3.. EC 18L-2.25D 09 L EC 18L-3.0D 09 H Ordering example: 1 piece EC D 07 D [mm] 10 pieces 1 piece XC /M2,5X6,0/T /TOX T08 XC /M3,0X7,3/T /TOX T08 XC.. 09T /M3,0X7,3/T /TOX T08 V C H = Densimet

31 EcoCut Classic EC Ø mm L D Type, d A d 2 l 1 l 2 l 3 f [mm] description [mm] [mm] [mm] [mm] [mm] [mm] EC D EC D EC D 10 H EC 20L-1.5D XC.. 10T3.. EC 20L-2.25D 10 L EC 20L-3.0D 10 H EC D EC D EC D 13 H EC 25L-1.5D XC EC 25L-2.25D 13 L EC 25L-3.0D 13 H EC D EC D EC D 17 H EC 32L-1.5D XC EC 32L-2.25D 17 L EC 32L-3.0D 17 H Ordering example: 1 piece EC D 10 D [mm] 10 pieces 1 piece XC.. 10T /M3,5X8,6/T /TOX T15 XC /M4,5X10,5/T /TOX T20 XC /M4,5X10,5/T /TOX T20 V C H = Densimet

32 EcoCut Classic UTS EC Ø mm L D Type, d A l 1 l 2 f [mm] description [mm] [mm] [mm] [mm] UT40-EC D UT50-EC D XC UT40-EC 16L-2.25D L 18 UT40-EC 18L-2.25D XC.. 09T UT40-EC D UT50-EC D UT40-EC 20L-2.25D L UT50-EC 20L-2.25D XC.. 10T3.. UT40-EC D UT50-EC D UT63-EC D XC UT40-EC 25L-2.25D L UT50-EC 25L-2.25D UT40-EC D UT50-EC D UT63-EC D UT40-EC 32L-2.25D XC UT50-EC 32L-2.25D 17 L UT63-EC 32L-2.25D Ordering example: 1 piece UT40-EC D 08 D [mm] 10 pieces 1 piece XC /M3,0X7,3/T /TOX T08 XC.. 09T /M3,0X7,3/T /TOX T08 XC.. 10T /M3,5X8,6/T /TOX T15 XC /M4,5X10,5/T /TOX T20 XC /M4,5X10,5/T /TOX T20 V C

33 EcoCut Classic UTS MIY EC Ø mm for Mazak Integrex D 90 da f l 2 l 1 L D Type, d A l 1 l 2 f [mm] description [mm] [mm] [mm] [mm] UT63-EC D 13-MIY XC UT63-EC 25L-2.25D 13-MIY L 63 UT63-EC D 17-MIY XC UT63-EC 32L-2.25D 17-MIY L Ordering example: 1 piece UT63-EC D 13-MIY D [mm] 10 pieces 1 piece XC /M4,5X10,5/T /TOX T20 XC /M4,5X10,5/T /TOX T20 V C

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35 EcoCut Classic HSK-T ECC Ø mm f Ø D d A l 2 l1 L D Type, d A l 1 l 2 f [mm] description [mm] [mm] [mm] [mm] HSK-T63-EC D XC HSK-T63-EC-25L-2.25D 13 L HSK-T63-EC D XC HSK-T63-EC-32L-2.25D 17 L Ordering example: 1 piece HSK-T63-EC D 13 D [mm] 10 pieces 1 piece XC /M4,5X10,5/T /TOX T20 XC /M4,5X10,5/T /TOX T20 V C

36 1 EcoCut ebore EC Ø mm A 2 L D Type, D 1 d A d 2 l 1 l 2 l 3 f [mm] description [mm] [mm] [mm] [mm] [mm] [mm] [mm] EC D XC.. 10T3.. EC 4020L D 10 L 40 EC D XC EC 6032L D 17 L Ordering example: 1 piece EC D 10 Initial bore necessary! D [mm] 10 pieces 1 piece XC.. 10T /M3,5X8,6/T /TOX T15 XC /M4,5X10,5/T /TOX T20 V C

37 EcoCut ebore UTS MIY EC Ø 40 mm for Mazak Integrex D D1 da f l 2 l 1 L D Type, D 1 d A l 1 l 2 f [mm] description [mm] [mm] [mm] [mm] [mm] 40 UT63-EC D-MIY XC.. 10T3.. Ordering example: 1 piece UT63-EC D-MIY Initial bore necessary! D [mm] 10 pieces 1 piece XC.. 10T /M3,5X8,6/T /TOX T15 V C

38 ProfileMaster Designation systems Inserts PM 25 G M20 CTC1435 Tools ProfileMaster Nominal diameter [mm] Cutting direction Maximum drilling depth, for example: 3.0 x diameter ProfileMaster Nominal diameter [mm] Cutting direction Version Parting and grooving width [ mm / 10 ] Parting and grooving depth [ mm / 10 ] Corner radius Chip groove Carbide grade PM D 38

39 ProfileMaster PM Ø mm -M20 Size L N CTC1435 CTP2440 Type, description PM 10G M20 PM 10LG M20 L PM 12G M20 PM 12LG M20 L PM 16G M20 PM 16LG M20 L PM 20G M20 PM 20LG M20 L PM 25G M20 PM 25LG M20 L PM 32G M20 PM 32LG M20 L Steel Stainless r Cast iron r Non ferrous metals r Heat resistant r Hard materials Main application Extended application International CEATIZIT range, for present availability see price list x y l s d 1 r [mm] [mm] [mm] [mm] [mm] [mm] Ordering example: 10 pieces PM 10G M20 CTP2440 V C

40 ProfileMaster PM Ø mm 90 3 L D Type, d A d 2 l 1 l 2 l 3 f [mm] description [mm] [mm] [mm] [mm] [mm] [mm] 10 PM D PM D PM 10L-1.5D L PM 10L-2.25D PM PM D PM D PM 12L-1.5D L PM 12L-2.25D PM PM D PM D PM 16L-1.5D L PM 16L-2.25D PM PM D PM D PM 20L-1.5D L PM 20L-2.25D PM PM D PM D PM 25L-1.5D L PM 25L-2.25D PM PM D PM D PM 32L-1.5D L PM 32L-2.25D PM 32.. Ordering example: 1 piece PM D d A [mm] PM /M1,8X3,8/T /TOX T06 PM /M2,2X4,0/T /TOX T07 PM /M3,0X5,7/T /TOX T08 PM /M3,5X7,2/T /TOX T15 PM /M3,5X8,6/T /TOX T15 PM /M5,0X10,8/T /TOX T20 V C

41 L L 1 ProfileMaster PM Ø mm L D Type, d A d 2 l 1 l 3 l 2 f [mm] description [mm] [mm] [mm] [mm] [mm] [mm] 16 PM D PM D PM 16L-1.5D L PM 16L-2.25D PM PM D PM D PM 20L-1.5D L PM 20L-2.25D PM PM D PM D PM 25L-1.5D L PM 25L-2.25D PM PM D PM D PM 32L-1.5D L PM 32L-2.25D PM 32.. Ordering example: 1 piece PM D Not suitable for drilling! D AX min = D Nenn Details see page 75 d A [mm] PM /M3,0X5,7/T /TOX T08 PM /M3,5X7,2/T /TOX T15 PM /M3,5X8,6/T /TOX T15 PM /M5,0X10,8/T /TOX T20 V C

42 Cutting data Grades, material A F N S H Work piece material Non alloyed steel Low alloyed steel High alloyed steel Corrosion resistant steel Stainless steel Grey cast iron Spheroidal cast iron Malleable cast iron Aluminium wrought alloys Aluminium cast alloys Copper and copper alloys (bronze, brass) Non-metallic materials Heat resistant alloys Titanium alloys annealed annealed tempered annealed tempered tempered annealed tempered annealed tempered annealed quenched quenched hardened non hardened hardened non hardened hardened non hardened annealed hardened annealed hardened cast hardened and tempered Tempered steel hardened and tempered Chilled castings cast Tempered cast iron hardened and tempered * m = ultimate tensile strength, measured in MPa Type of treatment / alloy VDI 3323 group Hardness HB 0,15% C ,15% - 0,45% C ,45% C ferritic martensitic ferritic / martensitic austenitic duplex martensitic / austenitic pearlitic / ferritic pearlitic / martensitic ferritic pearlitic ferritic pearlitic / < 12% Si < 12% Si > 12% Si machining alloy stock (1% Pb) 26 brass, red bronze bronze lead-free copper and electrolytic copper thermosetting plastics 29 fibre-reinforced plastics 29 hard rubber 30 Fe-base Fe-base Ni or Co-base Ni or Co-base HC 34 Ni or Co-base N/mm² 35 pure titanium 36 m 440* alpha + beta alloys 37 m 1050* HC HC HC 42

43 Cutting data Grades, material Uncoated carbide Coated carbide H210T H216T/H10T TSM30 CTC1425 CTC1435 CTP2440 CM45 v c v c v c v c v c v c v c [m/min] [m/min] [m/min] [m/min] [m/min] [m/min] [m/min]

44 EcoCut / ProfileMaster Type of problem Type of wear Work piece problems Swarf control Edge chipping Built-up edge Flank wear Plastic deformation Vibration Surface quality Chip too long (tangled swarf) Chip too short (fragmented chip) Corrective measures Cutting speed Feed rate Cutting values larger Corner radius Cutting material smaller wear resistance Selection of inserts toughness Clamping of tool Clamping of work piece Overhang Tip height General criteria Cooling lubricant raise, increase, large influence avoid, reduce large influence check, optimize raise, increase low influence avoid, reduce low influence use 44

45 EcoCut / ProfileMaster Masterfinish Operating principle / benefit Improved surface finish With the same feed rate an insert with 'Masterfinish' cutting edge reaches a roughness value a which is many times higher than the one of a conventional insert. Conventional Shorter machining time If you want to reach the same a -value as with a standard insert, a twice as high feed rate can be applied for the insert with 'Masterfinish' cutting edge (= shorter production time per component!). Conventional 45

46 EcoCut / ProfileMaster Surface quality ISO-DIN measured surface roughness Average roughness value a (DIN 4768) This is defined as the arithmetical mean of the absolute sums of the roughness profile within the entire measured length l m. Average roughness depth z (DIN 4768) This is defined as the average value resulting from the single roughness depths of five successive single measured lengths l e. Single surface roughness depth Z 1... Z 5 This is the vertical distance between the highest and the lowest point of the roughness profile within a single measured length l e. Maximum surface roughness depth t (DIN 4768/1) This is the distance between the elevation and depression of the line within the measured length (reference distance) of profile filtered according to DIN 4768 sheet 1. Surface quality according to manufacturing method Surface symbol according to ISO 1302 Surface symbol according to ISO 3141 oughness index Arithmetic mean value Surface roughness depth Longitudinal turning Face turning Longitudinal turning Face turning Longitudinal grinding Surface grinding new until now a [µm] z [µm] 0,025 0,05 0,1 0,2 0,4 0,8 1,6 3,2 6,3 12, N 1 N 2 N 3 N 4 N 5 N 6 N 7 N 8 N 9 N 10 N 11 N 12 0,025 0,05 0,1 0,2 0,4 0,8 1,6 3,2 6,3 12, ,25 0,63 1 1,6 2,5 4-6, Surface roughness (produced through special methods) Surface roughness (produced through normal workshop methods) Surface roughness (produced through rough machining methods) 46

47 EcoCut / ProfileMaster Surface finish / feed rate EcoCut Material: Ck60 (1.1221) Tool: EC 32L-2.25D 17 v c = 150 m/min a p = 1 mm r = 0,8 mm a [µm] 3,20 2,40 1,60 0,80 0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45 0,50 0,55 0,60 0,65 0,70 f (mm/rev.) XCET EN XCNT EN-M50Q ProfileMaster Material: Ck60 (1.1221) with a standard boring bar and ProfileMaster v c = 150 m/min a p = 1 mm a [µm] 3,20 2,40 1,60 0,80 0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45 0,50 0,55 0,60 0,65 0,70 f (mm/rev.) CCMT 09T304 PM 25G

48 EcoCut Surface finish / feed rate = 0.4 mm corner radius / steel To achieve f = 0.25 mm To achieve a = 1.6 µm a [µm] 3,2 f (mm/rev.) 0,4 0,37 2,4 0,3 1,6 1,8 0,2 0,22 0,8 0,8 0,1 Standard -M50Q Standard -M50Q = 0.8 mm corner radius / steel To achieve a = 1.6 µm f (mm/rev.) 0,6 0,5 0,5 To achieve f = 0.35 mm a [µm] 3,2 0,4 2,4 2,0 0,3 0,3 1,6 0,2 0,8 0,8 0,1 Standard -M50Q Standard -M50Q 48

49 EcoCut Surface finish / feed rate = 0.4 mm corner radius / aluminium To achieve a = 1.6 µm a [µm] 3,2 To achieve f = 0.25 mm f (mm/rev.) 0,5 0,4 0,42 2,4 2,1 0,3 0,25 1,6 0,2 0,8 0,8 0,1 Standard -27Q Standard -27Q = 0.8 mm corner radius / aluminium To achieve a = 1.6 µm f (mm/rev.) 0,6 0,6 To achieve f = 0.45 mm a [µm] 0,5 3,2 0,4 2,4 2,4 0,3 0,3 1,6 0,2 0,8 0,8 0,1 Standard -27Q Standard -27Q 49

50 EcoCut Mini Depth of cut / feed rate Longitudinal turning a (mm) p EC 08 EC 07 EC 06 EC 05 EC ,02 0,04 0,06 0,08 0,10 0,12 0,14 f (mm/rev.) Face turning a (mm) p 1,6 1,4 1,2 1,6 1,4 1,2 1,0 0,8 0,6 0,4 0,2 EC 07 EC 08 EC 06 EC 05 EC 04 1,0 0,8 0,6 0,4 0,2 0,02 0,04 0,06 0,08 0,10 0,12 0,14 f (mm/rev.) 50

51 EcoCut Mini Depth of cut / feed rate Longitudinal turning a (mm) p EC 08 EC 07 EC EC ,02 0,04 0,06 0,08 0,10 0,12 0,14 f (mm/rev.) Face turning a (mm) p 1,6 1,4 1,2 1,6 1,4 1,2 1,0 0,8 0,6 0,4 EC 07 EC 08 EC 06 EC 05 EC 04 1,0 0,8 0,6 0,4 0,2 0,2 0,02 0,04 0,06 0,08 0,10 0,12 0,14 f (mm/rev.) 51

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53 EcoCut Classic Depth of cut / feed rate Longitudinal turning a (mm) p EC EC 08 EC 20 EC 18 EC 16 EC 14 EC 12 EC 10 EC ,05 0,10 0,15 0,20 0,25 0,30 0,35 f = +50% 75% f (mm/rev.) Face turning a (mm) p EC EC EC EC 18EC EC 16 EC 14 EC 12 EC ,05 0,10 0,15 0,20 0,25 0,30 0,35 f = +25% 50% f (mm/rev.) 53

54 EcoCut Classic Depth of cut / feed rate Longitudinal turning a (mm) p EC 32 4 EC EC 08 EC 10 EC 20 EC 18 EC 14 EC 16 EC ,05 0,10 0,15 0,20 0,25 0,30 0,35 f = +50% 75% f (mm/rev.) Face turning a (mm) p EC EC EC 20 EC EC 08 EC 10 EC 14 EC 12 EC ,05 0,10 0,15 0,20 0,25 0,30 0,35 f = +25% 50% f (mm/rev.) 54

55 EcoCut Classic Depth of cut / feed rate Longitudinal turning a (mm) p EC 32 4 EC EC 08 EC 10 EC 20 EC 18 EC 14 EC 16 EC ,05 0,10 0,15 0,20 0,25 0,30 0,35 f = +50% 75% f (mm/rev.) Face turning a (mm) p EC 32 EC EC 20 EC 18 EC 16 EC 14 EC 12 EC 10 EC ,05 0,10 0,15 0,20 0,25 0,30 0,35 f = +25% 50% f (mm/rev.) 55

56 EcoCut ebore Depth of cut / feed rate Longitudinal turning f (mm/rev.) Face turning f (mm/rev.) 56

57 EcoCut ebore Depth of cut / feed rate Counterboring Tools Ø 40 mm Ø 60 mm Initial bore Ø min = 20 mm Ø min = 32 mm f (mm/rev.) 57

58 EcoCut Mini Drilling depth / feed rate Drilling depth Drilling feed rate 58

59 EcoCut Classic Drilling depth / feed rate Drilling depth Drilling feed rate f = +20% 30% 59

60 ProfileMaster Depth of cut / feed rate Drilling 0,16 f (mm/rev.) 90 0,14 0,12 0,10 0,08 0,06 0,04 0,02 PM 10 PM 12 PM 16 PM 20 PM 25 PM 32 Face turning ap (mm) 90 f (mm/rev.) 60

61 ProfileMaster Depth of cut / feed rate Longitudinal turning ap (mm) 90 f (mm/rev.) ap (mm) 90 f (mm/rev.) 61

62 ProfileMaster Feed rate adial grooving - internal + external 0,26 f (mm/rev.) 90 0,24 0,22 0,20 0,18 0,16 0,14 0,12 0,10 0,08 0,06 0,04 0,02 PM 10 PM 12 PM 16 PM 20 PM 25 PM 32 62

63 ProfileMaster Depth of cut / feed rate Longitudinal turning ap (mm) 0 f (mm/rev.) Face turning ap (mm) 0 f (mm/rev.) 63

64 ProfileMaster Feed rate Axial grooving - internal + external f (mm/rev.) 0 With PM 10 and PM 12 axial grooving is not possible. 64

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66 EcoCut Application Mounting of the insert For tools Ø 8 mm right-hand or left-hand inserts are required. From Ø mm neutral inserts are utilized. Left-hand tool ight-hand tool Axial displacement of the machine Displacement in x-direction Angular error Turret position error Through hole With through holes a sharp-edged disk is created as tool break-out occurs. Safety measures are necessary. 66

67 EcoCut Application Off-centre drilling Due to the special construction of EcoCut tools and inserts off-centre drilling is possible. Thus desired devations from the tool's nominal diameter can be obtained (see table below). Nominal tool Work piece bore diameter Type of tool D (mm) D min (mm) D max (mm) EC 04 L/ D 4 3,90 4,20 EC 05 L/ D 5 4,90 5,20 EC 06 L/ D 6 5,90 6,20 EC 07 L/ D 7 6,90 7,20 EC 08 L/ D 8 7,90 8,20 EC 08 L/ ,85 8,30 EC 10 L/ ,85 10,50 EC 12 L/ ,85 12,50 EC 14 L/ ,85 14,50 EC 16 L/ ,85 16,50 EC 18 L/ ,85 18,50 EC 20 L/ ,80 20,50 EC 25 L/ ,80 25,80 EC 32 L/ ,80 33,00 Solid carbide 67

68 EcoCut Application Machining across centre line Situation: In case of insufficient movement of the machine across the centre line the external diameter can not be machined with the same tool. Solution: Use a right-hand EcoCut tool. Maximum movement across centre line 68

69 EcoCut Application Chip booster / coolant pressure Internal coolant supply (chip booster) Helical chip pocket (stability) Axial abutment face (stability) EcoCut offers an innovative detail solution for range 2.25D, namely additional bidirectional coolant supply for better chip evacuation. An additional backwards directed coolant stream improves chip transportation from the flute area. A minimum coolant pressure of bar (optimum 5-7 bar) is required. If the necessary coolant pressure is not available, it can be advantageous to interrupt the cutting action in order to clear the bore. Deep bores up to 3xD With a stepped bore approach EcoCut tools EC.. 1.5D can be machined with holes of up to three times the nominal diameter (see picture). Operation sequences 1, 2 and 3 respectively should be followed. 69

70 d EcoCut Application Material: Machining steel 9SMn20 32 Insert: XCNT080304EN GM40 EC16L-2,25D08 v c = 283 m/min Cutting data: n = 1500 min -1 f = 0.05 mm/rev. ø28 ø60 EC16-2,25D08 v c = 132 m/min Special tool Machining time: 120 s CEATIZIT EcoCut Machining time: 20 s Time saving:83% Turret 1 Vc Vc Left-hand tool D ight-hand tool Turret 2 70

71 EcoCut Densimet The advantages of DENSIMET compared to steel The new generation of our EcoCut 3.0D series wit h the new designation of fers maximized per formance. The tools are classified with the new designation EC.. /L-3.0D.. H and have particularly been developed for bigger drilling dept hs and maximum pr ecision requirements. The material used here is DENSIMET, a PLANSEE tungsten heavy metal alloy. The high modulus of elasticity as well as its density give this alloy very good vibration-damping properties. The result is highest precision, excellent surface quality and improved tool life. Material Modulus of elasticity (N/mm 2 ) Density (g/mm 3 ) Steel ,85 DENSIMET ,50 Vibration-damping 40% lower deflection than steel The new chip flute design Version with straight chip flute Maximum tension Version with helical chip flute Up to 50% reduced tensions in the tool through Finite Element Modelling (FEM), optimized chip pocket design 71

72 ProfileMaster Coolant supply, Masterfinish effect Coolant supply ProfileMaster is equipped with a unique coolant and chip removal system. Cooling of the inserts General coolant stream Chipbooster prevents chips from getting stuck between tool and work piece In order to guarantee efficient chip evacuation from a hole, a minimum coolant pressure of 3-6 bar (optimum 7-10 bar) is required. 72

73 L ProfileMaster Application Mounting of the insert L L L L L L Axial displacement of the machine Displacement in x-direction Angular error Turret position error P P Through hole P P With through holes a sharp-edged disk as tool break-out occurs. Safety measures are necessary. 73

74 P P P P P P ProfileMaster Application Off-centre drilling Due to the special construction of ProfileMaster tools and inserts off-centre drilling is possible. Thus desired devations from the tool's nominal diameter can be obtained (see table below). Nominal tool diameter Drilling diameter (work piece) Type of tool D (mm) D min (mm) D max (mm) PM 10/L ,85 12 PM 12/L ,85 15 PM 16/L ,85 19 PM 20/L ,80 24 PM 25/L ,80 29 PM 32/L ,80 38 Machining across centre line Situation: In case of insufficient movement of the machine across the centre line the external diameter can not be machined with the same tool. PM 16L-2.25D Solution: Use a right-hand ProfileMaster tool. PM D 1 P P 1 P Maximum movement across centre line P 2 P P 2 74

75 L L ProfileMaster Application Axial grooving - axial application 0 D Nenn D AXmin D AXmax D AX min = D Nenn Situation Situation If the first cut is carried out with a diameter which is smaller than the nominal tool diameter D Nenn (90 application), collision will result. D AX min =DNenn D AX max = 75

76 EcoCut Machining examples Criterion: > Deep hole with 90 shoulder applying only one tool ø esult: > Machining time reduced by 50% compared to original machining method Technical data: Work piece: bush Material: Sae 1045 Tensile strength: N/mm 2 Tool: EC 16L-3.0D 08 H Insert: XCNT EN GM40 Competitor: 2 tools Cutting data: > Drilling v c = 176 m/min f = 0.06 mm a p = Ø 16 mm Criteria: > Increase in productivity > Fewer tools in the turret > eduction of tooling costs ø 48 ø 12 H7 9 ø 18 ø 39,1 3 esult: > 1 tool instead of 3 > Machining time reduced by 45% > 2 additional tools in the turret Technical data: Work piece: flange Material: 16 MnCr5 / Tool: EC 12L-1.5D 06 Insert: XCNT EN GM40 Competitor: 3 tools Cutting data: > Drilling > Face turning v c = 150 m/min v c = 200 m/min f = 0.03 mm f = 0.1 mm > Boring > External turning v c = 150 m/min v c = 150 m/min f = 0.1 mm f = 0.1 mm 76

77 ProfileMaster Machining examples Criteria: > Problems due to lack of turret positions > Optimization of machining time esult: > Only 1 tool instead of 2 > 1 free turret position Technical data: Work piece: HSK100 adapter Material: / X38 CrMoV 5 1 Tensile strength: approx N/mm 2 Tool: PM D Insert: PM 16G M20 CTP2440 Competitor: 2 tools Cutting parameters: v c = 150 m/min f = 0.15 mm a p = 1 mm Criteria > Increase in productivity > 1 free turret position esult: > Machining time reduced by 50% > Enhanced groove quality Technical data: Work piece: piston Material: / 35SPb20+C Tool: PM D Insert: PM 16G M20 CTC1435 Competitor: 2 tools Cutting parameters: CEATIZIT Competitor v c = 105 m/min v c = 105 m/min a p = mm a p = mm f = 0.03 mm f = 0.1 mm Turning Grooving

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79 CEATIZIT worldwide CEATIZIT worldwide Production sites in the three big economic areas with a worldwide network of CEATIZIT sales and support engineers plus many CEATIZIT distribution partners guarantee customer vicinity. We maintain the dialogue with our customers and strive for long-term partnerships. Find your personal distribution partner at: CEATIZIT worldwide production sites and support centres CEATIZIT worldwide sales centres CEATIZIT worldwide distribution partner network CEATIZIT worldwide Parent company in Luxembourg CEATIZIT Luxembourg Sàrl oute de Holzem 101 L-8232 Mamer Tel.: Fax: [email protected] Contact for further information: CEATIZIT Austria Gesellschaft m.b.h. A-6600 eutte/tyrol Tel.: +43 (5672) Fax: +43 (5672) [email protected]

80 EN We reserve the right to make technical changes for improvement of the product.