Contents E2. R a. Introduction. ProfileMaster. EcoCut. Index. Productivity. System overview E42 E3-E4. Designation system E43.

Transcription

1 Contents E2 Introduction ProfileMaster Productivity E3-E4 System overview E42 Designation system E43 EcoCut System overview E6 Chip grooves, grades E44-E46 Designation system E7 Machining methods E47-E48 Chip grooves, grades E8-E11 Inserts E49 EcoCut Mini EcoCut adapters E13-E14 Tools E50-E53 Inserts E15-E17 Cutting data, feed rate E55-E61 EcoCut Classic E18-E20 Surface quality E62 R a Cutting data, feed rate E21-E29 Application E63-E67 Surface quality E30-E31 Spare parts E68 R a Application E32-E37 Machining examples E69-E70 Spare parts E38 Machining examples E39-E40 Index Index G6 Multi-function tools / Introduction

2 E3 Productivity Break-down of work piece costs Turn the cost screw together with CERATIZIT Tooling costs 2-6% Manufacturing costs (machine / manpower) 78-82% Material costs 14-18% Manufacturing costs Tooling costs Increase in productivity by +30% results in reduction of work piece costs by -19% Increase of tool life by +30% results in reduction of work piece costs by -1% Multi-function tools / Introduction Increase in productivity (parts produced per time unit) Improved utilisation of the available machine capacity leads to considerable cost reduction per work piece. In this context CERATIZIT EcoCut makes a decisive contribution through: fewer tool changes increase of v c increase of f increase of a p Increased tool life As the average tool costs amount to only 2-6 % of the work piece costs, improving tool life typically can reduce total costs minimally (below 1%).

3 Productivity Conventional machining / EcoCut / ProfileMaster E4 Four machining operations with only one tool Drilling into solid material with flat bottom holes Boring applications Turning of face profiles External turning applications Conventional EcoCut Advantages of EcoCut Problem solver for insufficient tool storage Less programming effort Produces a flat bottom hole Reduced tool and insert inventory costs. Considerable tool acquisition cost savings Shorter set-up times. Reduced pre-setting time Multi-function tools / Introduction

4 Multi-function tools / EcoCut

5 EcoCut System overview E6 4 machining operations 1 tool Turning of face profiles, internal and external profiles as well as drilling into solid material Thanks to the multi-function tool, more turret positions on the machine are kept free Using EcoCut you will achieve larger depths of cut (a p ) compared to conventional boring bars Material groups P M K N S H Possible applications Drilling into solid material Boring applications External turning applications Detailed information Diameter / length ratio Ø range Inserts 1,5 x D 2,25 x D 3 x D 4 x D Ø 8-32 mm Ø 4-32 mm Ø 8-32 mm Ø 4-8 mm XCET XCET 17.. Multi-function tools / EcoCut

6 E7 CERATIZIT designation system EcoCut Classic and EcoCut Mini Insert shape 6 Insert thickness 2 Clearance angle 7 Corner radius 3 Tolerances 8 Cutting edge 4 Form of top surface 9 Cutting direction 5 Cutting edge length 10 Chip groove Multi-function tools / EcoCut 1 System 2 Nominal diameter [mm] 3 Cutting direction 4 Maximum drilling depth, for example: 3.0 x diameter 5 Insert size 6 Tool holder in Densimet

7 Chip grooves E8 -EN Machining conditions Positive geometry Universal application Small to medium feed rates 5 CTCP425 CTCP435 CTPP430 CTCP435 CTPP430 CTPP430 CTCP425 CTCP435 f [mm] 0,05-0,275 CTCP435 CTPP430 CTPP430 -M50Q Positive geometry Masterfinish cutting edge Medium to high feed rates ,1 CTCP425 CTCP425 Machining conditions CTCP425 CTCP425 CTCP425 f [mm] 0,2-0,425-27P Machining conditions Positive geometry Ground periphery Sharp cutting edges Reduced tendency to adhesion First choice for non-ferrous metals 5 f [mm] H216T H216T H216T 0,1-0,4-27Q Highly positive geometry Masterfinish cutting edge Ground periphery Sharp cutting edge Reduced tendency to adhesion ,1 f [mm] 0,2-0,5 H210T Machining conditions H210T Multi-function tools / EcoCut

8 E9 Grade overview Grade designation ISO ANSI CTCP425 HC-P25 C6 C COLORSTAR TM HC-K30 C1 C HC-M20 - C CTPP430 HC-P30 C6 P SILVERSTAR TM HC-M25 - P HC-S25 - P HC-K30 C1 P HC-N25 C2 P CTPP435 HC-P35 C5 P SILVERSTAR TM HC-M30 - P HC-S30 - P CTCP435 HC-P35 C6 C COLORSTAR TM Standard designation Cutting material Application range P M K N S H HC-K40 C1 C HC-M30 - C H210T HW-N10 C3 W HW-S10 - W HW-K10 C3 W H216T HW-N15 C3 W HW-K15 C3 W CTWN425 HW-N25 C2 W Main application Steel Stainless Cast iron Non-ferrous metals Extended application Heat-resistant Hard materials Multi-function tools / EcoCut CTWN425 / CTPP435 for EcoCut Mini

9 Grade description E10 CTCP425 COLORSTAR TM HC-P25 HC-K30 HC-M20 Specification: Composition: Co 7.0%; mixed carbides 8.1%; WC balance Grain size: 1-2 µm Hardness: HV Coating specification: CVD Ti(CnN) + AI 2 O 3 multi-layer Recommended application: The wear-resistant solution for steel and cast iron under stable conditions and with high cutting speed. CTPP430 SILVERSTAR TM HC-P30 HC-M25 HC-S25 HC-K30 HC-N25 Specification: Composition: Co 9.0%; others 0.75%; WC balance Grain size: 0.85 µm Hardness: HV Coating specification: PVD TiAlN Recommended application: The universal high-performance grade for steel, austenitic steel and heat-resistant alloys. CTPP435 SILVERSTAR TM HC-P35 HC-M30 HC-S30 Specification: Composition: Co 10.3%; others 1.2%; WC balance Grain size: 0.7 µm Hardness: HV Coating specification: PVD TiN / TiAlN Recommended application: The universal high-performance grade for steel, austenitic steel and heat-resistant alloys. CTCP435 COLORSTAR TM HC-P35 HC-K40 HC-M30 CTWN425 / CTPP435 for EcoCut Mini Specification: Composition: Co 9.6%; mixed carbides 7.8%; others 0.4%; WC balance Grain size: 1-2 µm Hardness: HV Coating specification: CVD Ti(C,N) + AI 2 O 3 multi-layer Recommended application: The reliable choice when machining steel and cast iron under unstable conditions. Multi-function tools / EcoCut

10 E11 Grade description H210T HW-N10 HW-S10 HW-K10 Specification: Composition: Co 6.0%; WC balance Grain size: 0.8 µm Hardness: HV Recommended application: The wear-resistant uncoated carbide grade for the machining of aluminium and other non-ferrous metals. H216T HW-N15 HW-K15 Specification: Composition: Co 6.0%; WC balance Grain size: 1 µm Hardness: HV Recommended application: The uncoated carbide grade for the machining of aluminium and other non-ferrous metals. CTWN425 HW-N25 Specification: Composition: Co 10.3%; others 1.2%; WC balance Grain size: 0.7 µm (submicron grade) Hardness: HV Recommended application: The uncoated carbide grade for the machining of aluminium and other non-ferrous metals. Multi-function tools / EcoCut CTWN425 / CTPP435 for EcoCut Mini

11 Multi-function tools / EcoCut

12 E13 EcoCut Mini ECM.. P M K N S H -27 EN CTPP435 CTWN425 RL D min d A l 1 l 2 r f [mm] [mm] [mm] [mm] [mm] [mm] ECM 04L-2.25D-27 L ECM 04L-4.00D-27 L ECM 04R-2.25D-27 R ECM 04R-4.00D-27 R ECM 05L-2.25D-27 L ECM 05L-4.00D-27 L ECM 05R-2.25D-27 R ECM 05R-4.00D-27 R ECM 06L-2.25D-27 L ECM 06L-4.00D-27 L ECM 06R-2.25D-27 R ECM 06R-4.00D-27 R ECM 07L-2.25D-27 L ECM 07L-4.00D-27 L ECM 07R-2.25D-27 R ECM 07R-4.00D-27 R ECM 08L-2.25D-27 L ECM 08L-4.00D-27 L ECM 08R-2.25D-27 R ECM 08R-4.00D-27 R ECM 04L-2.25D L ECM 04L-4.00D L ECM 04R-2.25D R ECM 04R-4.00D R ECM 05L-2.25D L ECM 05L-4.00D L ECM 05R-2.25D R ECM 05R-4.00D R ECM 06L-2.25D L ECM 06L-4.00D L ECM 06R-2.25D R ECM 06R-4.00D R ECM 07L-2.25D L ECM 07L-4.00D L ECM 07R-2.25D R ECM 07R-4.00D R ECM 08L-2.25D L ECM 08L-4.00D L ECM 08R-2.25D R ECM 08R-4.00D R CTPP435 CTWN425 RL D min d A l 1 l 2 r f Multi-function tools / EcoCut D E21-E22 l2 l1 E23-E25 da

13 EcoCut Mini Adapters E14 Ø d 3 Ø d 1 Ø d A l 2 l 3 l 1 d 1 L N R [mm] Type, description d A [mm] d 3 [mm] l 1 [mm] l 2 [mm] l 3 [mm] 6 EC-ADX20-06 N ECM.. E01 8 EC-ADX20-08 N ECM.. E01 E E38 Multi-function tools / EcoCut

14 E15 EcoCut XC P M K N S H -M50Q ER-EL -27Q -27P CTCP425 CTPP430 CTCP435 H210T H216T d l s r d 1 [mm] [mm] [mm] [mm] [mm] XCET FL-27P XCET FR-27P XCET FL-27P XCET FR-27P XCET FL-27Q XCET FR-27Q XCET FL-27Q XCET FR-27Q XCNT EL XCNT ER XCNT EL XCNT ER XCNT EL-M50Q XCNT ER-M50Q CTCP425 CTPP430 CTCP435 H210T H216T d l s r d 1 d Multi-function tools / EcoCut E21-E22 E18-E20

15 EcoCut XC.. E16 P M K N S H -27P -27Q EN CTCP425 CTPP430 CTCP435 H210T H216T d l s r d 1 [mm] [mm] [mm] [mm] [mm] XCET FN-27P XCET FN-27P XCET FN-27P XCET FN-27P XCET FN-27P XCET FN-27P XCET 09T304FN-27P XCET 10T304FN-27P XCET 10T308FN-27P XCET FN-27P XCET FN-27P XCET FN-27P XCET FN-27Q XCET FN-27Q XCET FN-27Q XCET FN-27Q XCET FN-27Q XCET FN-27Q XCET 09T304FN-27Q XCET 10T304FN-27Q XCET 10T308FN-27Q XCET FN-27Q XCET FN-27Q XCET FN-27Q XCNT EN XCNT EN XCNT EN XCNT EN XCNT EN XCNT EN XCNT 09T304EN XCNT 10T304EN XCNT 10T308EN XCNT EN XCNT EN XCNT EN CTCP425 CTPP430 CTCP435 H210T H216T d l s r d 1 E21-E22 E18-E20 Multi-function tools / EcoCut

16 E17 EcoCut XC.. P M K N S H -M50Q CTCP425 CTPP430 CTCP435 H210T H216T d l s r d 1 [mm] [mm] [mm] [mm] [mm] XCNT EN-M50Q XCNT EN-M50Q XCNT EN-M50Q XCNT EN-M50Q XCNT 09T304EN-M50Q XCNT 10T304EN-M50Q XCNT 10T308EN-M50Q XCNT EN-M50Q XCNT EN-M50Q XCNT EN-M50Q CTCP425 CTPP430 CTCP435 H210T H216T d l s r d 1 Multi-function tools / EcoCut E21-E22 E18-E20

17 EcoCut Classic 1.5D E18 Ø D f90 Ø d A l 2 l 1 L N R D min Type, d A l 1 l 2 f [mm] description [mm] [mm] [mm] [mm] [Nm] 8 ECC 08L-1.5D 04 L XC E01 8 ECC 08R-1.5D 04 R XC E01 10 ECC 10L-1.5D 05 L XC E02 10 ECC 10R-1.5D 05 R XC E02 12 ECC 12L-1.5D 06 L XC E03 12 ECC 12R-1.5D 06 R XC E03 14 ECC 14L-1.5D 07 L XC E04 14 ECC 14R-1.5D 07 R XC E04 16 ECC 16L-1.5D 08 L XC E05 16 ECC 16R-1.5D 08 R XC E05 18 ECC 18L-1.5D 09 L XC.. 09T3.. E05 18 ECC 18R-1.5D 09 R XC.. 09T3.. E05 20 ECC 20L-1.5D 10 L XC.. 10T3.. E06 20 ECC 20R-1.5D 10 R XC.. 10T3.. E06 25 ECC 25L-1.5D 13 L XC E07 25 ECC 25R-1.5D 13 R XC E07 32 ECC 32L-1.5D 17 L XC E07 32 ECC 32R-1.5D 17 R XC E07 E E E E E E E E26+E29 E38 E15-E17 Multi-function tools / EcoCut

18 E19 EcoCut Classic 2.25D L N R D min Type, d A d 2 l 1 l 2 l 3 f [mm] description [mm] [mm] [mm] [mm] [mm] [mm] [Nm] 8 ECC 08L-2.25D 04 L XC E01 8 ECC 08R-2.25D 04 R XC E01 10 ECC 10L-2.25D 05 L XC E02 10 ECC 10R-2.25D 05 R XC E02 12 ECC 12L-2.25D 06 L XC E03 12 ECC 12R-2.25D 06 R XC E03 14 ECC 14L-2.25D 07 L XC E04 14 ECC 14R-2.25D 07 R XC E04 16 ECC 16L-2.25D 08 L XC E05 16 ECC 16R-2.25D 08 R XC E05 18 ECC 18L-2.25D 09 L XC.. 09T3.. E05 18 ECC 18R-2.25D 09 R XC.. 09T3.. E05 20 ECC 20L-2.25D 10 L XC.. 10T3.. E06 20 ECC 20R-2.25D 10 R XC.. 10T3.. E06 25 ECC 25L-2.25D 13 L XC E07 25 ECC 25R-2.25D 13 R XC E07 32 ECC 32L-2.25D 17 L XC E07 32 ECC 32R-2.25D 17 R XC E07 Multi-function tools / EcoCut E E E E E E E E27+E29 E38 E15-E17

19 EcoCut Classic 3D E20 Ø D f90 Ø d A l 2 l 1 L N R D min Type, d A l 1 l 2 f [mm] description [mm] [mm] [mm] [mm] [Nm] 8 ECC 08L-3.0D 04 H L XC E01 8 ECC 08R-3.0D 04 H R XC E01 10 ECC 10L-3.0D 05 H L XC E02 10 ECC 10R-3.0D 05 H R XC E02 12 ECC 12L-3.0D 06 H L XC E03 12 ECC 12R-3.0D 06 H R XC E03 14 ECC 14L-3.0D 07 H L XC E04 14 ECC 14R-3.0D 07 H R XC E04 16 ECC 16L-3.0D 08 H L XC E05 16 ECC 16R-3.0D 08 H R XC E05 18 ECC 18L-3.0D 09 H L XC.. 09T3.. E05 18 ECC 18R-3.0D 09 H R XC.. 09T3.. E05 20 ECC 20L-3.0D 10 H L XC.. 10T3.. E06 20 ECC 20R-3.0D 10 H R XC.. 10T3.. E06 25 ECC 25L-3.0D 13 H L XC E07 25 ECC 25R-3.0D 13 H R XC E07 32 ECC 32L-3.0D 17 H L XC E07 32 ECC 32R-3.0D 17 H R XC E07 E E E E E E E E28+E29 E38 E15-E17 Multi-function tools / EcoCut

20 E21 Cutting data Grades, material Work piece material Type of treatment / alloy VDI 3323 group Hardness HB annealed 0.15 % C Non alloyed steel annealed 0.15 % % C tempered 0.45 % C annealed P Low alloyed steel High alloyed steel tempered tempered annealed tempered 7 / annealed ferritic / martensitic Stainless steel tempered martensitic heat-treated ferritic / martensitic M Stainless steel quenched quenched hardened austenitic ferritic / austenitic (Duplex) austenitc, precipitation hardened (PH) Grey cast iron pearlitic / ferritic pearlitic / martensitic K Spheroidal cast iron ferritic pearlitic Malleable cast iron ferritic pearlitic Aluminium wrought alloys non hardened hardened Aluminium cast alloys non hardened hardened non hardened < 12 % Si < 12 % Si > 12 % Si N Copper and copper alloys (bronze, brass) machining alloy stock (1% Pb) brass, red bronze bronze 26 (110) lead-free copper and electrolytic copper thermosetting plastics 29 Non-metallic materials fibre-reinforced plastics 29 hard rubber 30 annealed Fe-base S Heat-resistant alloys hardened annealed hardened cast Fe-base Ni or Co-base Ni or Co-base HRC Ni or Co-base N/mm² (350) 35 (320) Multi-function tools / EcoCut H Titanium alloys hardened and tempered Tempered steel hardened and tempered Chilled castings cast Tempered cast iron hardened and tempered * R m = ultimate tensile strength, measured in MPa pure titanium alpha + beta alloys 36 R m 440* 37 R m 1050* HRC HRC HRC

21 Cutting data Grades, material E22 CTCP425 CTPP430 CTPP435* CTCP435 H210T H216T CTWN425* v c [m/min] v c [m/min] v c [m/min] v c [m/min] v c [m/min] v c [m/min] v c [m/min] The cutting data are non-binding indications for the operator. It is recommended to adapt them to the current conditions. * EcoCut Mini Multi-function tools / EcoCut

22 E23 Depth of cut / feed rate EcoCut Mini Longitudinal turning 2.25D a p [mm] ECM 08 ECM 07 ECM 06 ECM 05 ECM ,02 0,04 0,06 0,08 0,10 0,12 0,14 f [mm/rev.] Face turning 2.25D a p [mm] 1,6 1,4 1,2 1,6 1,4 1,2 1,0 0,8 ECM 07 ECM 08 1,0 0,8 Multi-function tools / EcoCut 0,6 0,4 0,2 ECM 06 ECM 05 ECM 04 0,02 0,04 0,06 0,08 0,10 0,12 0,14 0,6 0,4 0,2 f [mm/rev.]

23 Depth of cut / feed rate EcoCut Mini E24 Longitudinal turning 4.0D a p [mm] ECM 08 ECM 07 ECM ECM ,02 0,04 0,06 0,08 0,10 0,12 0,14 f [mm/rev.] Face turning 4.0D a p [mm] ECM 07 ECM ECM 06 ECM 05 ECM f [mm/rev.] Multi-function tools / EcoCut

24 E25 Drilling depth / feed rate EcoCut Mini Drilling depth Drilling depth (mm) ,25 x D 4,0 x D D D 4,0 D 2,25 D ,25 13,5 15, ECM 04 ECM 05 ECM 06 ECM 07 ECM 08 Drilling feed rate f (mm/rev.) 0,10 0,09 0,08 2,25 x D 4,0 x D D D 2,25 D 0,10 0,09 0,08 4,0 D 0,07 0,07 0,06 0,06 0,05 0,05 0,04 0,04 0,03 0,03 Multi-function tools / EcoCut 0,02 0,01 ECM 04 ECM 05 ECM 06 ECM 07 ECM 08 0,02 0,01

25 Depth of cut / feed rate EcoCut Classic E26 Longitudinal turning 1.5D a p [mm] ECC ECC 08 ECC 20 ECC 18 ECC 16 ECC 14 ECC 12 ECC 10 ECC ,05 0,10 0,15 0,20 0,25 0,30 0,35 f [mm/rev.] Face turning 1.5D a p [mm] ECC ECC ECC 18ECC ECC ECC 12ECC ECC 10 ECC 25 0,05 0,10 0,15 0,20 0,25 0,30 0, f [mm/rev.] Multi-function tools / EcoCut

26 E27 Depth of cut / feed rate EcoCut Classic Longitudinal turning 2.25D a p [mm] ECC ECC 10 ECC 08 ECC 20 ECC 18 ECC 16 ECC 14 ECC 12 ECC ,05 0,10 0,15 0,20 0,25 0,30 0,35 f [mm/rev.] Face turning 2.25D a p [mm] ECC ECC 25 5 Multi-function tools / EcoCut ECC 08 ECC 10 ECC 14 ECC 12 ECC 16 ECC 20 ECC 18 0,05 0,10 0,15 0,20 0,25 0,30 0, f [mm/rev.]

27 Depth of cut / feed rate EcoCut Classic E28 Longitudinal turning 3.0D a p [mm] ECC 25 ECC 18 ECC 32 ECC 14 ECC 20 ECC 10 ECC 16 ECC 12 ECC ,05 0,10 0,15 0,20 0,25 0,30 0,35 f [mm/rev.] Face turning 3.0D a p [mm] ECC 20 ECC 18 ECC 16 ECC 14 ECC 12 ECC 10 ECC 08 ECC 32 ECC 25 0,05 0,10 0,15 0,20 0,25 0,30 0, f [mm/rev.] Multi-function tools / EcoCut

28 E29 Drilling depth / feed rate EcoCut Classic Drilling depth Drilling depth (mm) ,0 x D 2,25 x D 1,5 x D D D D , ,0 D 2,25 D 1,5 D , , ,5 37, ECC 08 ECC 10 ECC 12 ECC 14 ECC 16 ECC 18 ECC 20 ECC 25 ECC 32 Drilling feed rate f (mm/rev.) 0,20 0,18 3,0 x D D 3,0 D 0,20 0,18 0,16 0,14 0,12 2,25 x D 1,5 x D D D 1,5 D 2,25 D 0,16 0,14 0,12 0,10 0,10 0,08 0,08 Multi-function tools / EcoCut 0,06 0,04 0,02 ECC 08 ECC 10 ECC 12 ECC 14 ECC 16 ECC 18 ECC 20 ECC 25 ECC 32 0,06 0,04 0,02

29 Masterfinish Operating principle / benefit E30 Improved surface finish With the same feed rate an insert with 'Masterfinish' cutting edge reaches a roughness value R a which is many times higher than the one of a conventional insert. Conventional Reduced machining time If you want to reach the same R 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 R a [ µ m ] 3,20 2,40 Material: Ck60 (1.1221) Tool: ECC 32L-2.25D 17 v c = 150 m/min a p = 1 mm r = 0,8 mm 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.) XCNT EN XCNT EN-M50Q Multi-function tools / EcoCut

30 E31 Surface quality Surface roughness Average roughness value R a DIN (4768) This is defined as the arithmetical mean of the absolute sums of the roughness profile R within the entire measured length l m. Average roughness depth R 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 R within a single measured length l e. Maximum surface roughness depth R 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 symbol according to ISO 1302 Surface symbol according to ISO 3141 Roughness index Arithmetic mean value Surface roughness depth new until now R a [µm] R 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, Longitudinal turning Face turning Multi-function tools / EcoCut Longitudinal turning Face turning Longitudinal grinding Surface grinding Surface roughness (produced through special methods) Surface roughness (produced through normal workshop methods) Surface roughness (produced through rough machining methods)

31 EcoCut Problem / corrective measures E32 Type of problem Type of wear Work piece problems Chip control Edge chipping Built-up edge Flank wear raise, increase, large influence raise, increase low influence Plastic deformation Vibration Surface quality Chip too long (tangled swarf) Chip too short (fragmented chip) avoid, reduce large influence avoid, reduce low influence Corrective measures Cutting speed Feed rate Corner radius Cutting material Clamping of tool Clamping of work piece Overhang Tip height Cooling lubricant check, optimise use larger smaller wear resistance toughness Cutting values Selection of inserts General criteria Multi-function tools / EcoCut

32 E33 Application Mounting of the insert For tools Ø 8 mm right-hand or left-hand inserts are required. From Ø mm neutral inserts are applied. Through hole With through holes a sharp-edged disk is created as tool break-out occurs. Safety measures are necessary. Axial displacement of the machine Displacement in x-direction Angular error Turret position error Multi-function tools / EcoCut

33 Application Off-centre drilling E34 Off-centre drilling Thanks to the special construction of EcoCut tools and inserts off-center drilling is possible. Thus desired deviations from the tool s nominal diameter can be obtained (see table below). Type of tool Solid carbide Nominal tool Work piece bore diameter D [mm] D min [mm] D max [mm] ECM 04 L/R -...D 4 3,90 4,20 ECM 05 L/R -...D 5 4,90 5,20 ECM 06 L/R -...D 6 5,90 6,20 ECM 07 L/R -...D 7 6,90 7,20 ECM 08 L/R -...D 8 7,90 8,20 Nominal tool Work piece bore diameter Type of tool D [mm] D min [mm] D max [mm] ECC 08 L/R ,85 8,30 ECC 10 L/R ,85 10,50 ECC 12 L/R ,85 12,50 ECC 14 L/R ,85 14,50 ECC 16 L/R ,85 16,50 ECC 18 L/R ,85 18,50 ECC 20 L/R ,80 20,50 ECC 25 L/R ,80 25,80 ECC 32 L/R ,80 33,00 Multi-function tools / EcoCut

34 E35 Application Machining across centre line Machining across centre line Maximum movement across centre line Situation In case of insufficient movement of the machine across the centre line the external diameter cannot be machined with the same tool. Solution Use a right-hand EcoCut tool. Multi-function tools / EcoCut

35 Application Chip booster / deep bores E36 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 evacuation 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. Multi-function tools / EcoCut

36 f E37 Application Densimet The advantages of DENSIMET compared to steel The new generation of our EcoCut 3.0D series with the new designation offers maximised performance. The tools are classified with the new designation ECC.. R/L-3.0D.. H and have particularly been developed for bigger drilling depths and maximum precision 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. Nominal tool Ø Material Modulus of elasticity (N/mm 2 ) Density (g/mm 3 ) Steel ,85 DENSIMET ,50 F F Vibration-damping 40% lower deflection than steel The new chip flute design Maximum tension Multi-function tools / EcoCut Version with straight chip flute Version with helical chip flute Up to 50% reduced tensions in the tool through Finite Element Modelling (FEM), optimised chip pocket design.

37 Spare parts E38 Material Type, description Key size /TORX 08IP F T08IP /TORX 07IP F T07IP /TORX 06IP F T06IP /TORX 09IP F T09IP SD-T15IP-80mm T15IP SD-T20IP-100mm T20IP Material Type, description l Thread size Key size [mm] /M8X1X8 DIN M8 SW M3,0x7,0-09IP/ M3,0 T09IP M3,5X8,6-15IP/ M3,5 T15IP M2,2x5,0-07IP/ M2,2 T07IP M2,5x6,0-08IP/ M2,5 T08IP M4,5X10,5-20IP/ M4,5 T20IP M2,0x4,3-06IP/ M2,0 T06IP M1,8x3,6-06IP/ M1,8 T06IP Multi-function tools / EcoCut

38 E39 Machining example Technical data Work piece Material bush C45 ANSI 1045 ø 16 Tensile strength Tool N/mm 2 ECC 16L-3.0D 08 H 40 Insert Competitor XCNT EN CTCP435 2 tools Drilling V c [m/min] 176 f [mm] 0.06 a p [Ø mm] 16 Criteria Deep hole with 90 shoulder applying only one tool Multi-function tools / EcoCut Result Machining time reduced by 50% compared to original machining method

39 Machining example E40 Technical data Work piece flange Material 16 MnCr5 / ANSI 5115 ø 48 ø 12 H7 ø 18 ø 39,1 Tensile strength Tool N/mm 2 ECC 12L-1.5D Insert Competitor XCNT EN CTCP435 3 tools Drilling Boring Face turning External turning V c [m/min] f [mm] Criteria Increase in productivity Fewer tools in the turret Reduction of tooling costs Result 1 tool instead of 3 Machining time reduced by 45% 2 additional tools in the turret Multi-function tools / EcoCut

40 Multi-function tools / ProfileMaster

41 ProfileMaster System overview E42 Drilling, turning, parting and grooving with only one tool The ProfileMaster is excellently suited for profiles that are so complex that they can normally only be produced with the use of several tools In addition, it helps free up valuable positions on the machine and minimise the need to change tools Thanks to the Masterfinish effect, the ProfileMaster produces an excellent surface finish in the shortest possible time Material groups P M K N S H Possible applications Drilling into solid material Boring applications External turning applications External radial grooving Internal radial grooving Axial grooving Detailed information Diameter / length ratio Ø range Inserts 1,5 x D 2,25 x D Ø mm PM PM 32.. Multi-function tools / ProfileMaster

42 E43 CERATIZIT designation system ProfileMaster 6 Parting and grooving depth [ mm / 10 ] 2 Nominal diameter [mm] 7 Corner radius 3 Cutting direction 8 Chip groove 4 Version 5 Parting and grooving width [ mm / 10 ] Multi-function tools / ProfileMaster 1 ProfileMaster 2 Nominal diameter [mm] 3 Cutting direction 4 Maximum drilling depth, for example: 3.0 x diameter

43 Chip grooves E44 -M20 Machining conditions Positive geometry Universal application Small to medium feed rates 10 CTC1435 CTC1435 CTP2440 CTC1435 CTP2440 CTP2440 CTC1435 CTC1435 CTC1435 f [mm] 0,05-0,25 CTP2440 Multi-function tools / ProfileMaster

44 E45 Grade overview Grade designation Standard designation Cutting material Application range P M K N S H ISO ANSI CTC1435 HC-P35 C6 C HC-M30 - C HC-K20 C2 C CTP2440 HC-M35 - P HC-P40 C5 P HC-N25 C2 P HC-S30 - P Steel Stainless Main application Extended application Multi-function tools / ProfileMaster Cast iron Non-ferrous metals Heat-resistant Hard materials

45 Grade description E46 CTC1435 HC-P35 HC-M30 HC-K20 Specification: Composition: Co 9.6%; mixed carbide 7.4%; WC balance Grain size: 1-2 µm Hardness: HV Coating specification: CVD TiCN-Al 2 O 3 multi-layer Recommended application: First choice for steel and cast iron materials. CTP2440 HC-M35 HC-P40 HC-N25 HC-S30 Specification: Composition: Co 9.6%; mixed carbides 7.4%; WC balance Grain size: 1-2 µm Hardness: HV Coating specification: PVD TiAlN Recommended application: First choice for stainless and steel materials under unstable conditions. Multi-function tools / ProfileMaster

46 E47 ProfileMaster Machining methods Machining methods - radial application 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 0 External turning applications Boring applications Turning of face profiles Multi-function tools / ProfileMaster External radial grooving Internal radial grooving When changing from internal to external machining, reverse direction of rotation

47 ProfileMaster Machining methods E48 right-hand tool right-hand insert right-hand tool left-hand insert right-hand insert left-hand tool right-hand tool right-hand insert right-hand insert Multi-function tools / ProfileMaster

48 E49 ProfileMaster PM.. P M K N S H -M20 x CTC1435 CTP2440 x y l s d 1 r [mm] [mm] [mm] [mm] [mm] [mm] PM 10LG M PM 10RG M PM 12LG M PM 12RG M PM 16LG M PM 16RG M PM 20LG M PM 20RG M PM 25LG M PM 25RG M PM 32LG M PM 32RG M CTC1435 CTP2440 x y l s d 1 r y Multi-function tools / ProfileMaster E55-E56 E50-E53

49 90 ProfileMaster 90 / 1.5D E50 90 D f da l 2 l 1 L N R D min Type, d A l 1 l 2 f [mm] description [mm] [mm] [mm] [mm] [Nm] 10 PM 10R-1.5D R PM 10.. E01 10 PM 10L-1.5D L PM 10.. E01 12 PM 12R-1.5D R PM 12.. E02 12 PM 12L-1.5D L PM 12.. E02 16 PM 16R-1.5D R PM 16.. E03 16 PM 16L-1.5D L PM 16.. E03 20 PM 20R-1.5D R PM 20.. E04 20 PM 20L-1.5D L PM 20.. E04 25 PM 25R-1.5D R PM 25.. E05 25 PM 25L-1.5D L PM 25.. E05 32 PM 32R-1.5D R PM 32.. E06 32 PM 32L-1.5D L PM 32.. E06 E E E E E E E57-E59 E68 E49 Multi-function tools / ProfileMaster

50 E51 ProfileMaster 90 / 2.25D 90 D f da d2 90 l 2 l 3 l 1 L N R D min Type, d A d 2 l 1 l 2 l 3 f [mm] description [mm] [mm] [mm] [mm] [mm] [mm] [Nm] 10 PM 10R-2.25D R PM 10.. E01 10 PM 10L-2.25D L PM 10.. E01 12 PM 12R-2.25D R PM 12.. E02 12 PM 12L-2.25D L PM 12.. E02 16 PM 16R-2.25D R PM 16.. E03 16 PM 16L-2.25D L PM 16.. E03 20 PM 20R-2.25D R PM 20.. E04 20 PM 20L-2.25D L PM 20.. E04 25 PM 25R-2.25D R PM 25.. E05 25 PM 25L-2.25D L PM 25.. E05 32 PM 32R-2.25D R PM 32.. E06 32 PM 32L-2.25D L PM 32.. E06 Multi-function tools / ProfileMaster E E E E E E E57-E59 E68 E49

51 90 ProfileMaster 0 / 1.5D E52 0 D f da l 2 l 1 L N R D min Type, d A l 1 l 2 f [mm] description [mm] [mm] [mm] [mm] [Nm] 16 PM 16R-1.5D R PM 16.. E01 16 PM 16L-1.5D L PM 16.. E01 20 PM 20R-1.5D R PM 20.. E02 20 PM 20L-1.5D L PM 20.. E02 25 PM 25R-1.5D R PM 25.. E03 25 PM 25L-1.5D L PM 25.. E03 32 PM 32R-1.5D R PM 32.. E04 32 PM 32L-1.5D L PM 32.. E04 E E E E E60-E61 E68 E49 Multi-function tools / ProfileMaster

52 E53 ProfileMaster 0 / 2.25D 0 D f da d2 90 l 2 l 3 l 1 L N R D min Type, d A d 2 l 1 l 2 l 3 f [mm] description [mm] [mm] [mm] [mm] [mm] [mm] [Nm] 16 PM 16R-2.25D R PM 16.. E01 16 PM 16L-2.25D L PM 16.. E01 20 PM 20R-2.25D R PM 20.. E02 20 PM 20L-2.25D L PM 20.. E02 25 PM 25R-2.25D R PM 25.. E03 25 PM 25L-2.25D L PM 25.. E03 32 PM 32R-2.25D R PM 32.. E04 32 PM 32L-2.25D L PM 32.. E04 Multi-function tools / ProfileMaster E E E E E60-E61 E68 E49

53 Multi-function tools / ProfileMaster

54 E55 Cutting data Grades, material Work piece material Type of treatment / alloy VDI 3323 group Hardness HB annealed 0.15 % C Non alloyed steel annealed 0.15 % % C tempered 0.45 % C annealed P Low alloyed steel High alloyed steel tempered tempered annealed tempered 7 / annealed ferritic / martensitic Stainless steel tempered martensitic heat-treated ferritic / martensitic M Stainless steel quenched quenched hardened austenitic ferritic / austenitic (Duplex) austenitc, precipitation hardened (PH) Grey cast iron pearlitic / ferritic pearlitic / martensitic K Spheroidal cast iron ferritic pearlitic Malleable cast iron ferritic pearlitic Aluminium wrought alloys non hardened hardened Aluminium cast alloys non hardened hardened non hardened < 12 % Si < 12 % Si > 12 % Si N Copper and copper alloys (bronze, brass) machining alloy stock (1% Pb) brass, red bronze bronze 26 (110) lead-free copper and electrolytic copper thermosetting plastics 29 Non-metallic materials fibre-reinforced plastics 29 hard rubber 30 annealed Fe-base Multi-function tools / ProfileMaster S H Heat-resistant alloys Titanium alloys hardened annealed hardened cast hardened and tempered Tempered steel hardened and tempered Chilled castings cast Tempered cast iron hardened and tempered * R m = ultimate tensile strength, measured in MPa Fe-base Ni or Co-base Ni or Co-base HRC Ni or Co-base N/mm² pure titanium alpha + beta alloys (350) 35 (320) 36 R m 440* 37 R m 1050* HRC HRC HRC

55 Cutting data Grades, material E56 CTC1435 CTP2440 v c [m/min] v c [m/min] The cutting data are non-binding indications for the operator. It is recommended to adapt them to the current conditions. Multi-function tools / ProfileMaster

56 E57 ProfileMaster 90 depth of cut/feed rate Drilling f [mm/rev.] D [mm] Face turning 1.5D D 90 a p [mm] Multi-function tools / ProfileMaster f [mm/rev.]

57 ProfileMaster 90 depth of cut/feed rate E58 Longitudinal turning 1.5D 90 a p [mm] f [mm/rev.] Longitudinal turning 2.25D 90 a p [mm] f [mm/rev.] Multi-function tools / ProfileMaster

58 E59 ProfileMaster 90 depth of cut/feed rate Radial grooving - internal + external f [mm/rev.] D [mm] Multi-function tools / ProfileMaster

59 ProfileMaster 0 depth of cut/feed rate E60 Longitudinal turning 1.5D D 0 a p [mm] f [mm/rev.] Face turning 1.5D D 0 a p [mm] f [mm/rev.] Multi-function tools / ProfileMaster

60 E61 ProfileMaster 0 depth of cut/feed rate Axial grooving - internal + external f [mm/rev.] D [mm] Multi-function tools / ProfileMaster

61 Surface quality / feed rate E62 Material: Ck60 (1.1221) with a standard boring bar and ProfileMaster Ra [µm] 3.20 v c = 150 m/min a p = 1 mm r = 0,4 mm f (mm/rev.) CCMT 09T304 PM 25RG Multi-function tools / ProfileMaster

62 E63 ProfileMaster Problems, corrective measures Type of problem Type of wear Work piece problems Chip 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 Corner radius Cutting material larger smaller wear resistance toughness Cutting values Selection of inserts Clamping of tool Clamping of work piece Overhang Tip height General criteria Cooling lubricant raise, increase, large influence avoid, reduce large influence check, optimise Multi-function tools / ProfileMaster raise, increase low influence avoid, reduce low influence use

63 ProfileMaster E64 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. Multi-function tools / ProfileMaster

64 R L E65 ProfileMaster Application Mounting of the insert L R L R L R L L L R R R Axial displacement of the machine Displacement in x-direction Angular error Turret position error Through hole Multi-function tools / ProfileMaster P P With through holes a sharp-edged disk as tool break-out occurs. Safety measures are necessary.

65 P P P P P P P P P P P P ProfileMaster Application E66 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] PMC 10R/L ,85 12 PMC 12R/L ,85 15 PMC 16R/L ,85 19 PMC 20R/L ,80 24 PMC 25R/L ,80 29 PMC 32R/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. Solution: Use a right-hand ProfileMaster tool. PMC 16L-2.25D PMC 16R-2.25D Multi-function tools / ProfileMaster

66 L L E67 ProfileMaster Axial grooving - application 0 D AX min = D Nenn D Nenn D AXmin D AXmax D AX > = D Nenn D AX < D Nenn 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. Multi-function tools / ProfileMaster D AXmin = D Nenn D AXmax =

67 Spare parts E68 Material Type, description Key size SD-T06-60mm T SD-T07-60mm T SD-T08-60mm T SD-T15-80mm T SD-T20-100mm T20 Material Type, description l Thread size Key size [mm] /M1,8X3,8/T M1,8 T /M5,0X10,8/T M5 T /M3,5X8,6/T M3,5 T /M3,0X5,7/T M3 T /M2,2X4,0/T07 4 M2,2 T /M3,5X7,2/T M3,5 T15 Multi-function tools / ProfileMaster

68 E69 Machining example Technical data Work piece Material Tensile strength Tool Insert Competitor HSK100 adapter X38 CrMoV 5 1 approx N/mm 2 PM 16R-1.5D PM 16RG M20 CTP tools CERATIZIT v c [m/min] 150 f [mm] 0.15 a p [Ø mm] 1 Criteria Problems due to lack of turret positions Optimisation of machining time Multi-function tools / ProfileMaster Result Only 1 tool instead of 2 1 free turret position

69 Machining example E70 Technical data Work piece Material Tensile strength Tool Insert Competitor piston SPb20+C - PM 16R-1.5D PM 16RG M20 CTC tools CERATIZIT Competitor v c [m/min] a p [mm] 0,03-5,0 0,3-5,0 f turning f grooving [mm] 0,15 0,1 [mm] 0,06 0,06 Criteria Increase in productivity Insufficient quality of groove surface Result Machining time reduced by 50% Enhanced groove quality Multi-function tools / ProfileMaster