Programme extension. ProfileMaster. has totally redefined the machining process

Transcription

1 Programme extension ProfileMaster has totally redefined the machining process

2 CERATIZIT - the parent companies Headquarters and parent company in MAMER / Luxembourg Parent company in REUTTE / Austria Europe Austria Bulgaria France Germany Italy Luxembourg Netherlands Switzerland Spain United Kingdom North America USA Asia China India Japan Direct sales and distribution partners 2

3 Machining of complex turned parts Which tools would you use to machine these workpieces? 3

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5 Machining with ProfileMaster ProfileMaster from CERATIZIT 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 5

6 ProfileMaster Machining methods Machining methods radial application 1 2 Drilling into solid material with flat bottom holes Boring applications 3 External turning applications 4 Internal turning applications 5 Turning of face profiles 6 External radial grooving 7 Internal radial grooving Machining methods axial application 1 External turning applications 2 Internal turning applications 3 Turning of face profiles 4 External axial grooving 5 Internal axial grooving When changing from internal to external machining, reverse direction of rotation 6

7 ProfileMaster Benefits Reduction of Tool changing times Reduced pre-setting and set-up times Less programming effort Masterfi nish wiper effect Excellent surface quality Shorter machining times Variable drilling diameter Problem solver for insuffi cient tool storage capacity Considerable tool acquisition cost savings Reduced stock-keeping costs Produces a fl at bottom hole 7

8 ProfileMaster Productivity Turn the cost screw together with CERATIZIT Break-down of workpiece costs Tooling costs 2-6 % Manufacturing costs (machine / manpower) % Material costs % Increase in productivity: (parts produced per time unit) Due to improved utilization of the available machine capacity considerable cost reduction per workpiece becomes possible. In this context ProfileMaster from CERATIZIT makes a decisive contribution through: - fewer tool changes - increase of cutting speed - increase of feed rate - increase of depth of cut Increase in productivity by +30% results in reduction of workpiece costs by -19% +30% -19% +30% Increase of tool life by +30% Increase of tool life: -1% results in reduction of workpiece costs by -1% As the average tool costs amount to only 2 6 % of the workpiece costs, prolonging tool life typically can only reduce total costs minimally. 8

9 ProfileMaster Nominal diameter [mm] Cutting direction Version Cutting width [ mm / 10 ] Cutting depth [ mm / 10 ] Corner radius Chip groove Carbide grade ProfileMaster Nominal diameter [mm] Cutting direction Max. drilling depth ProfileMaster Designation systems Tools PM 25 R D Inserts PM 25 R G M20 CTC1435 9

10 ProfileMaster Ø mm Tools / radial application 1.5D (=l 2 ) 2.25D (=l 2 ) Drawing shows right-hand tool Type, description L D mm d 1 mm d 2 mm l 1 mm l 2 mm l 3 mm PM 10R-1.5D - 80,0 15,0 - R PM 10R-2.25D 16 72,4 22,5 30,4 PM 10L-1.5D - 80,0 15,0 - L PM 10L-2.25D 16 72,4 22,5 30,4 PM 12R-1.5D - 90,0 18,0 - R PM 12R-2.25D 20 78,0 27,0 33,0 PM 12L-1.5D - 90,0 18,0 - L PM 12L-2.25D 20 78,0 27,0 33,0 PM 16R-1.5D R PM 16R-2.25D 25 96, ,5 PM 16L-1.5D L PM 16L-2.25D 25 96, ,5 f mm 5 PM 10R.. 5 PM 10L.. 6 PM 12R.. 6 PM 12L.. 8 PM 16R.. 8 PM 16L.. Supply details: Basic body fitted with 1 piece of clamping screw, without inserts Ordering example: 3 pieces PM 16R-2.25D Spare parts / accessories D mm 1 piece 1 piece PM /M1,8X3,8/T /TORX/T06 PM /M2,2X4,0/T /TORX/T07 PM /M3,0X5,7/ T /TORX/T08 PM 10.. PM 12.. PM 16.. Page

11 ProfileMaster Ø mm Tools / radial application 1.5D (=l 2 ) 2.25D (=l 2 ) Drawing shows right-hand tool Type, description L D mm d 1 mm d 2 mm l 1 mm l 2 mm l 3 mm PM 20R-1.5D - 150,0 30,0 - R PM 20R-2.25D ,0 45,0 55,0 PM 20L-1.5D - 150,0 30,0 - L PM 20L-2.25D ,0 45,0 55,0 PM 25R-1.5D - 180,0 37,5 - R PM 25R-2.25D ,6 56,3 72,6 PM 25L-1.5D - 180,0 37,5 - L PM 25L-2.25D ,6 56,3 72,6 PM 32R-1.5D - 200,0 48,0 - R PM 32R-2.25D ,0 72,0 88,0 PM 32L-1.5D - 200,0 48,0 - L PM 32L-2.25D ,0 72,0 88,0 f mm 10,0 PM 20R.. 10,0 PM 20L.. 12,5 PM 25R.. 12,5 PM 25L.. 16,0 PM 32R.. 16,0 PM 32L.. Supply details: Basic body fitted with 1 piece of clamping screw, without inserts Ordering example: 3 pieces PM 20L-1.5D Spare parts / accessories D mm 1 piece 1 piece PM /M3,5X7,2/T /TORX/T15 PM /M3,5X8,6/T /TORX/T15 PM /M5,0X10,8/T /TORX/T20 PM 20.. PM 25.. PM 32.. Page

12 ProfileMaster Ø mm Feed rate 1.5D (=l 2 ) 2.25D (=l 2 ) Details see page 32 = D NENN DAXmin Drawing shows right-hand tool Type, L D NENN D AX d 1 d 2 l 1 l 2 l 3 f description mm mm mm mm mm mm mm mm PM 16R-1.5D - 127,3 26,3 - R PM 16R-2.25D 25 98,8 38,3 48,8 5,7 PM 16L.. PM 16L-1.5D - 127,3 26,3 - L PM 16L-2.25D 25 98,8 38,3 48,8 5,7 PM 16R.. PM 20R-1.5D - 152,8 32,8 - R PM 20R-2.25D ,8 47,8 57,8 7,2 PM 20L.. PM 20L-1.5D - 152,8 32,8 - L PM 20L-2.25D ,8 47,8 57,8 7,2 PM 20R.. Supply details: Basic body fitted with 1 piece of clamping screw, without inserts Ordering example: 3 pieces PM 16R-2.25D Spare parts / accessories D mm 1 piece 1 piece PM /M3,0X5,7/T /TORX/T08 PM /M3,5X7,2/T /TORX/T15 PM 16.. PM 20.. Page

13 ProfileMaster Ø mm Feed rate 1.5D (=l 2 ) 2.25D (=l 2 ) Details see page 32 = D NENN DAXmin Drawing shows right-hand tool Type, L D NENN D AX d 1 d 2 l 1 l 2 l 3 f description mm mm mm mm mm mm mm mm PM 25R-1.5D - 183,3 40,8 - R PM 25R-2.25D ,9 59,6 75,9 9,2 PM 25L.. PM 25L-1.5D - 183,3 40,8 - L PM 25L-2.25D ,9 59,6 75,9 9,2 PM 25R.. PM 32R-1.5D - 204,3 52,3 - R PM 32R-2.25D ,3 76,3 92,3 11,7 PM 32L.. PM 32L-1.5D - 204,3 52,3 - L PM 32L-2.25D ,3 76,3 92,3 11,7 PM 32R.. Supply details: Basic body fitted with 1 piece of clamping screw, without inserts Ordering example: 3 pieces PM 25R-2.25D Spare parts / accessories D mm 1 piece 1 piece PM /M3,5X8,6/T /TORX/T15 PM /M5,0X10,8 /T /TORX/T20 PM 25.. PM 32.. Page

14 ProfileMaster Inserts -M20 Uncoated Coated Size Type, description Chip groove CTC1435 CTP2440 x y l s d 1 r mm mm mm mm mm mm 10 PM 10LG M20 M20 2,0 1,5 5,0 2,1 2,1 0,4 10 PM 10RG M20 M20 2,0 1,5 5,0 2,1 2,1 0,4 12 PM 12LG M20 M20 2,0 1,8 6,0 2,3 2,5 0,4 12 PM 12RG M20 M20 2,0 1,8 6,0 2,3 2,5 0,4 16 PM 16LG M20 M20 2,5 2,0 8,0 2,8 3,4 0,4 16 PM 16RG M20 M20 2,5 2,0 8,0 2,8 3,4 0,4 20 PM 20LG M20 M20 3,0 2,5 10,0 3,7 4,0 0,4 20 PM 20RG M20 M20 3,0 2,5 10,0 3,7 4,0 0,4 25 PM 25LG M20 M20 3,5 3,0 12,5 4,5 4,4 0,4 25 PM 25RG M20 M20 3,5 3,0 12,5 4,5 4,4 0,4 32 PM 32LG M20 M20 4,0 4,0 16,0 5,6 6,0 0,4 32 PM 32RG M20 M20 4,0 4,0 16,0 5,6 6,0 0,4 Steel Stainless Cast iron Non ferrous metals Heat resistant Hard materials = Main application = Extended application = International CERATIZIT range, for present availability see price list Ordering example: 20 pieces PM 10LG M20 CTC1435 PM -1.5D PM -2.25D Page

15 ProfileMaster Cutting depth / feed rate Drilling f (mm/rev.) Face turning f (mm/rev.) 15

16 ProfileMaster Cutting depth / feed rate Longitudinal turning f (mm/rev.) f (mm/rev.) 16

17 ProfileMaster Feed rate / radial application Radial grooving - internal + external f (mm/rev.) 17

18 ProfileMaster Depth of cut / feed rate Longitudinal turning f (mm/rev.) Face turning f (mm/rev.) 18

19 ProfileMaster Feed rate Radial grooving - internal + external f (mm/rev.) With PM 10 and PM 12 axial grooving is not possible. 19

20 Cutting data Grades / material A R F N S H Workpiece material Non alloyed steel Low alloyed steel High alloyed steel Corrosion resistant steel Stainless steel Grey cast iron Grey cast iron with spheroidal graphite Tempered iron Aluminium wrought alloys Aluminium cast alloys Copper and copper alloys (bronze, brass) Non metal 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 hardened and tempered Tempered steel hardened and tempered Chilled castings cast Tempered cast iron hardened and tempered * Rm = maximum strength, measured in MPa Type of treatment / alloy 0,15% C 0,15% - 0,45% C 0,45% C ferritic martensitic ferritic / martensitic austenitic duplex martensitic / austenitic perlitic / ferritic perlitic / martensitic ferritic perlitic ferritic perlitic < 12% Si < 12% Si > 12% Si machining alloy stock (1% Pb) brass, red bronze bronze lead-free copper and electrolytic copper thermosetting plastics fi bre-reinforced plastics hard rubber annealed Fe-base hardened Fe-Fe-base annealed Ni- or Co-base hardened Ni- or Co-base HRC cast Ni- oder Co-base Nmm 2 pure titanium alpha + beta alloys VDI 3323 group Hardness HB CTC 1435 v c [m/min] / R m 440* 37 R m 1050* HRC HRC HRC 20

21 Cutting data Grades / material CTP 2440 v c [m/min]

22 MasterGuide Material Based on VDI 3323 CERATIZIT 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 Crsteels, duplex steels Red: cast iron grey cast iron, tempered iron, spheroidal cast iron, 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 HRC), 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: R = Rough machining M = Medium machining F = Fine machining 22

23 MasterGuide Application The ideal application area for each insert is indicated by a black circle. Extended applications are indicated by an open circle. The CERATIZIT 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: Machining of steel (all areas), medium machining of stainless steel and cast iron, fine machining of cast iron Extended application: Rough machining of stainless steels 23

24 Grade description Steel CTC1435 (P35, M30, K20) Composition: Co 9.5%; composite carbides 6.5%; WC rest Grain size: 1-2 µm Hardness: HV 1400 Coating specification: CVD, TiN + Ti (C,N) + Ti (N,B) + Al 2 O 3 + Ti (C,N,B); 6 µm Toughness: Wear resistance: CTP2440 (P40, M35, K25) Composition: Co 9.5%; composite carbides 6.5%; WC rest Grain size: 1-2 µm Hardness: HV 1400 Coating specification: PVD, TiAIN, 3-5 µm Toughness: Wear resistance: 24

25 Grade description Stainless steel CTC1435 (P35, M30, K20) Composition: Co 9.5%; composite carbides 6.5%; WC rest Grain size: 1-2 µm Hardness: HV 1400 Coating specification: CVD, TiN + Ti (C,N) + Ti (N,B) + Al 2 O 3 + Ti (C,N,B); 6 µm Toughness: Wear resistance: CTP2440 (P40, M35, K25) Composition: Co 9.5%; composite carbides 6.5%; WC rest Grain size: 1-2 µm Hardness: HV 1400 Coating specification: PVD, TiAIN, 3-5 µm Toughness: Wear resistance: 25

26 Grade description Cast iron CTC1435 (P35, M30, K20) Composition: Co 9.5%; composite carbides 6.5%; WC rest Grain size: 1-2 µm Hardness: HV 1400 Coating specification: CVD, TiN + Ti (C,N) + Ti (N,B) + Al 2 O 3 + Ti (C,N,B); 6 µm Toughness: Wear resistance: Heat resistant alloys / titanium CTP2440 (P40, M35, K25) Composition: Co 9.5%; composite carbides 6.5%; WC rest Grain size: 1-2 µm Hardness: HV 1400 Coating specification: PVD, TiAIN, 3-5 µm Toughness: Wear resistance: 26

27 Grade overview Grade description Standard designation Application range Material group A R F N S H Steel Stainless Cast iron Non ferrous metals Heat resistant materials Hard materials CTC1435 CTP2440 HC-P35 HC-M30 HC-K20 HC-P40 HC-M35 HC-K Main application range Extended application 27

28 ProfileMaster Problems / corrective measures Type of problem Type of wear Workpiece problems Chip control Edge chipping Built-up edges Flank wear Plastic deformation Vibrations Surface quality Chip too long (snarl chip) Chip too short (fragmented chip) Corrective measures Cutting speed Feed rate Cutting values Cutting material Wear resistance Toughness Selection of inserts Clamping of tool Clamping of workpiece Overhang Tip height General criteria Cooling lubricant raise, increase large influence raise, increase small influence avoid, reduce large influence avoid, reduce small influence control, optimize use 28

29 ProfileMaster Application recommendations Mounting of the insert 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. 29

30 ProfileMaster Application recommendations 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 Drilling Tool type D (mm) D min (mm) D max (mm) PM 10R/L ,85 12 PM 12R/L ,85 15 PM 16R/L ,85 19 PM 20R/L ,80 24 PM 25R/L ,80 29 PM 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 Profi lemaster tool Maximum movement across centre line 30

31 ProfileMaster Coolant supply / Masterfinish effect Coolant supply ProfileMaster is equipped with a unique coolant and chip removal system Cooling of the insert cutting edge General coolant stream Chipbooster I for better chip evacuation Chipbooster II prevents chips from getting stuck between tool and workpiece In order to guarantee efficient chip evacuation from a hole, a minimum coolant pressure of 3 6 bar (optimum 7 10 bar) is required. Masterfinish effect Surface test on material Ck60 (1.1221) with a standard boring bar and ProfileMaster v c = 150 m/min a p = 1,00 mm Feed rate (mm/rev.) 31

32 ProfileMaster Application recommendations Axial grooving - axial application D Nenn D AXmin D AXmax = D NENN DAXmin Situation D AX >= D Nenn Situation 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. D AXmin = D Nenn D AXmax = 32

33 ProfileMaster Machining examples Criteria: > Problems due to lack of turret positions > Optimisation of machining time Cutting data: v c [mm/min] 150 a p [mm] 1 f [mm] 0.15 Technical data: Workpiece: HSK100 adapter Material: / X38 CrMoV 5 1 Strength: approx N/mm 2 Tool: PM 16R-1.5D Insert: PM 16RG M20 CTP2440 Competitor: 2 tools Result: > Only 1 tool instead of 2 > 1 free turret position Criteria: > Increase in productivity > Insuffi cient quality of groove surface Cutting data: CERATIZIT WB v c [mm/min] 105 a p [mm] 0,3 5,0 f [mm] Turning 0,15 0,1 Grooving 0,06 Technical data: Workpiece: Piston Material: / 35SPb20+C Tool: PM 16R-1.5D Insert: PM 16RG M20 CTC1435 Competitor: 2 tools Result: > Machining time reduced by 50% > Enhanced groove quality 33

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35 Headquarters: CERATIZIT S.A. Main site Luxembourg CERATIZIT Luxembourg Sarl Route de Holzem, B.P. 51 L-8201 Mamer Tel.: Fax: Main site Austria CERATIZIT Austria Gesellschaft m.b.h. A-6600 Reutte/Tyrol Tel.: +43 (5672) Fax: +43 (5672) Sales Companies Austria CERATIZIT Austria Gesellschaft m.b.h. A-6600 Reutte/Tyrol Tel.: +43 (5672) Fax: +43 (5672) Bulgaria CERATIZIT Bulgaria AG Boulevard Stoletov 157 BG-5301 Gabrovo Tel: +359 (66) Fax: +359 (66) China CERATIZIT China Ltd. Room Hollywood Centre 233 Hollywood Rd., Sheung Wan Hong Kong Tel.: +852 (2542)-1838 Fax: +852 (2854) France CERATIZIT France Sarl Pontoise 20, Rue Lavoisier F Pontoise Tel.: +33 (1) Fax: +33 (1) Germany CERATIZIT Deutschland GmbH Offi ce Langenfeld Hans-Böckler-Straße 10 D Langenfeld Tel.: +49 (2173) Fax: +49 (2173) CERATIZIT Deutschland GmbH Offi ce Bad Urach Schützenstraße 29 D Bad Urach Tel.: +49 (7125) Fax: +49 (7125) Great Britain CERATIZIT UK Ltd. Cliff Lane Grappenhall Warrington WA4 3JX Tel.: +44 (1925) Fax: +44 (1925) India CERATIZIT India Pvt. Ltd. 58, Motilal Gupta Road Barisha IN Kolkata Tel.: +91 (33) Fax: +91 (33) Telex: ihm in Italy CERATIZIT Italia SpA Piazza F. Martelli, 7 I Milano Tel.: +39 (02) Fax: +39 (02) info.italia@ceratizit.com Japan CERATIZIT Japan Ltd , Mizuho Shizuoka Tel.: +81 (54) Fax: +81 (54) info.japan@ceratizit.com Luxembourg CERATIZIT Luxembourg Sarl Route de Holzem, B.P. 51 L-8201 Mamer Tel.: Fax: info@ceratizit.com Netherlands CERATIZIT Nederland B.V. Bergrand 224 NL-4707 AT Roosendaal Tel.: +31 (165) Fax: +31 (165) info.nederland@ceratizit.com Spain CERATIZIT Ibérica SL Offi ce Pozuelo Vía de las Dos Castillas, 9c Portal 2, Bajo B E Pozuelo (Madrid) Tel.: +34 (91) Fax: +34 (91) info.iberica@ceratizit.com CERATIZIT Ibérica SL Offi ce Bilbao Avda. Mazarredo 41 1 Izqda. E Bilbao Tel.: +34 (944) Fax: +34 (944) info.bilbao@ceratizit.com USA CERATIZIT USA Inc. 777 Old Clemson Road Columbia South Carolina Toll free: +1 (800) Tel.: +1 (803) Fax: +1 (803) info.usa@ceratizit.com

36 241/ EN We reserve the right to make technical changes for improvement of the product.