PcBn for cast iron Machining

Transcription

1 spk competencies FOR CAST IRON MACHINING WITH PCBN tools technology application PcBn fo cast ion Machining CUTTING MATERIALS, TOOL SYSTEMS AND TECHNOLOGIES FOR TURNING

2 2 Machining cast ion mateials The machining of cast ion mateials is chaacteised by high cutting values in ode to achieve the highest possible machining capacity. It allows fo a significant eduction in machining costs and a substantial incease in poductivity. The continuous development of cast ion, howeve, is placing geate demands on the cutting mateial, the efficiency and the pocess eliability of high pefomance machining. The complete tool system the cutting mateial, cutting edge geomety, clamping system and the tool caie must accommodate the high machining foces and the stong themal, chemical and abasive loads which occu duing high-pefomance machining, while ensuing pocess eliability. Futhe geneal conditions of poduction, coesponding to end use expectations, include a high-pecision delivey at a easonable pice in the desied quality. A machining pocess that is technically optimised fo maximum efficiency is theefoe essential: The goal is to incopoate not only the appopiate high-pefomance tool systems, but also high-end machining technology, compehensive application know-how and fine-tuned tool logistics into the machining pocedue. With its extensive poduct and sevice potfolio, SPK Cutting Tools known as SPK + The Poductivity Expets is ising to this challenge. The machining pocess is tailoed accoding to custome equiements and is pefected in its entiety; fom the cutting edges and technology used to machine application and tool logistics. SPK PCBN FOR CAST IRON

3 3 SPK PCBN cutting mateials SPK PCBN cutting mateials fo HPC tuning of cast ion The unique and compehensive ange of PCBN high-pefomance cutting mateials allows fo the eliable HPC machining of GJL (gey cast ion) wokpieces. The mateials ae setting new standads with thei supeb wea chaacteistics duing both continuous and inteupted cuts as well as thei impessive pefomance in tems of ed hadness, compessive stength and chemical stability. The cutting mateials ae also available with a coating fo wea ecognition upon equest. SPK PCBN gades WBN 115 The high-pefomance machining specialist. Outstanding themal stability combined with optimal toughness esult in exceptional wea esistance fo HPC machining. This gade achieves exceptional esults thanks to its high edge stability and excellent wea esistance, paticulaly when oughing. WBN 105 With its optimised toughness and excellent wea esistance, this gade is intended fo the univesal machining of GJL mateials. WBN 100 and WBN 120 These two PCBN gades in the Solid vesion ae suitable fo oughing gey cast ion mateials with modeate cutting data. WBN 750 The multi-tipped o laminated PCBN vesion is intended fo finishing gey cast ion mateials. Cutting mateial Mateial goups GJL (gey cast ion) Alloyed GJL (gey cast ion) Chilled cast ion WBN 115 WBN 105 WBN 100 WBN 120 WBN 750 = Main application, = Additional applications i SPK PCBN gades fo cast ion WBN 115 WBN 105 WBN 100 WBN 120 WBN 750 SPK PCBN FOR CAST IRON

4 4 SPK PCBN scope of application Cutting data ecommendations fo cast ion machining Fo cast ion (GJL) Fo chilled cast ion Cutting speed v c : (m/min) (m/min) WBN 115 WBN 105 WBN 100 WBN 120 WBN 750 Feed ate f : (mm) (mm) WBN 115 WBN 105 WBN 100 WBN 120 WBN 750 Depth of cut a p : (mm) (mm) WBN 115 WBN 105 WBN 100 WBN 120 WBN 750 Machining capacity REMOVAL RATE WBN 100 WBN 120 WBN 105 WBN 115 WBN 750 WEAR RESISTANCE SPK PCBN FOR CAST IRON

5 5 hpc on cast ion With iks-po and iks-potec High machining capacities in vaious cast ion mateials also demand maximum pefomance fom the tools. IKS-PRO and IKS-PROTec tool systems ae designed fo high-pefomance machining. Combined with ou PCBN cutting mateials, they make an unbeatable team when it comes to high-pefomance machining. i the iks-po pinciple iks-po The patented notch geomety of IKS-PRO, the evolutionay clamping system, was developed especially fo the simple and eliable clamping of insets duing HPC machining. The pinciple of fom-fit and foce-fit clamping allows the cutting speed and feed to be inceased significantly. A eally distibuted clamping foce with etaction into the inset seating iks-po tec IKS-PRO TEC High cutting values: IKS-PROTec can be opeated with pocess eliability up to vc = 2000 m/min at f = 1.0 mm. The newly developed components guaantee optimum stability and clamping eliability even unde these exteme conditions. Against wea of clamping element: Moveable cabide pessue plate with IKS-PRO geomety Fo optimal inset seating: Inset seating adapte made fom high tempeatue-esistant mateial Fo themal insulation: Ceamic shim fo optimum stability unde exteme themal load SPK PCBN FOR CAST IRON

6 6 flexibility With PcBn and ceamic a MiX of cutting Mateials is advantageous The machining of cast ion mateials is influenced by a numbe of factos. Fo example, the age of the casting the time between the casting and the machining wok has a significant influence on the tool life. Altenative cutting mateials ae equied which can continue to achieve the equied tool lives and poductivity even unde the changeable conditions. As a manufactue of ceamic high-pefomance cutting mateials, CeamTec is able to supply its customes with altenative cutting mateials within a shot peiod of time. This applies to both insets in standad geometies as well as to custom designs. In addition, the IKS-PRO and IKS-PROTec clamping systems allow uses to switch to altenative cutting mateial gades within seconds without having to adjust the entie tool system. Switching fom ceamic cutting mateials to PCBN and back is staightfowad and does not equie a efitting of the tools. i easy change technology EASY CHANGE T E C H N O L O G Y The IKS-PRO notch system allows uses to switch fom PCBN to ceamic cutting mateials such as SiALON without having to change the tool. customised solutions The diffeing size and complexity of cast components often demand sophisticated machining solutions that use special tools. Ou engineeing team assists customes with the goal of using as many standad tools as possible and as many special tools as equied. Tool solutions ae conceived fo achieving optimum machining esults and the highest level of efficiency. Solid, laminated and multi-tipped PCBN insets ae available fo implementing customised insets. SPK PCBN FOR CAST IRON

7 7 designation system types of spk PcBn insets accoding to iso 1832 Symbol Illustation Desciption SPK PCBN gades B C D F L M N S one-side, multi-tipped PCBN insets, 2 cones one-side, multi-tipped PCBN insets, 3 cones one-side, multi-tipped PCBN insets, 4 cones PCBN one-side full face laminated two-side, multi-tipped PCBN insets, 4 cones two-side, multi-tipped PCBN insets, 6 cones two-side, multi-tipped PCBN insets, 8 cones PCBN Solid insets WBN 750 WBN 115, WBN 105, WBN 100, WBN 120 designation system fo spk PcBn insets with ZZ geomety Numbe of cutting edges cnga t - Bl 95Z025 Chamfe Length of PCBN inset > 2 mm Width of the ZZ chamfe Appoach angle with IKS-PRO clamping system cngx t - s - do Chamfe Solid Inset with IKS-PRO notch clamping SPK PCBN FOR CAST IRON

8 8 Cutting edge design Types of cutting edges A ange of diffeent tied and tested chamfe geometies ae available fo the vaious tuning tasks. The chamfe selection will not only influence the tool life, but also the suface quality and dimensional accuacy of the wokpiece. Fo specific applications, optimising the chamfe may cause a supplementay incease in poductivity. ZZ geomety i Advantages of wipe technology ZZ GEOMETRY 2 x f Rw z Equal feed ate = doubled suface quality Doubled feed ate = machining times cut down by half STANDARD GEOMETRY f R th Incease inpoduction quality Incease in poductivity Evey oak has been an acon - this is pobably the best way to descibe the enomous incease in pefomance which can be achieved in finish-tuning when using the ZZ geomety; in the tade, this is also efeed to as wipe geomety. The use of cutting insets with a ZZ geomety allows fo significantly highe suface qualities to be achieved in compaison with insets featuing standad geometies. Altenatively, the main machining times can be educed consideably without any consequences to high suface qualities. Theefoe, the ZZ geometies epesent one of the most efficient ways of inceasing poductivity in machining, especially in finishing opeations. SPK PCBN FOR CAST IRON

9 9 PERFORMANCE Finish tuning of the baking suface of a bake disc using WBN 115 i Pefomance compaison Machining opeation: oughing, mateial: gey cast ion GJL-250, coolant: none Competito SPK Cutting Tools Gade: PCBN WBN 115 Inset: SNGN T SNGX T - S - DO Cutting speed vc: 1100 m/min 1100 m/min Feed ate f: 0.6 mm 0.6 mm Depth of cut ap: 1.5 mm 1.5 mm Tool life N: 3000 pcs 4000 pcs Wea on the main cutting edge 0.15 mm 0.13 mm Pieces Tool life Ove 25% longe tool life Competito WBN 115 Wea pattens Finish tuning of the connecting face of a bake disc using WBN 115 Machining opeation: oughing, mateial: gey cast ion GJL-250, coolant: none Competito SPK Cutting Tools Gade: PCBN WBN 115 Inset: RNGN T RNGX T - S - DO Cutting speed vc: 1100 m/min 1100 m/min Feed ate f: 0.3 mm 0.3 mm Depth of cut ap: 2 mm 2 mm Tool life N: 1500 pcs 1500 pcs Wea on the main cutting edge 0.94 mm 0.23 mm i Pefomance compaison Competito Wea (mm) WBN Wea pattens 0 Wea on the cutting edge 75% less wea SPK PCBN FOR CAST IRON

10 10 Pefomance Finish tuning of a bake disc using gade WBN 100 with/without IKS-PRO clamping system Machining opeation: oughing, mateial: gey cast ion GJL-250, coolant: none Machining the inside wheel face mount Oute diamete and facing Clamping system: Standad IKS-PRO Standad IKS-PRO Gade: WBN 100 WBN 100 WBN 100 WBN 100 Inset: CNMN T-S CNGX T-S-DO SNMN T-S SNGX T-S-DO Cutting speed vc: 1200 m/min 1200 m/min 1200 m/min 1200 m/min Feed ate f: 0.35 mm 0.45 mm 0.45 mm 0.65 mm Depth of cut ap: 3 mm 3 mm 3 mm 3 mm Tool life N: 1000 pcs 1250 pcs 1000 pcs 1250 pcs i Tool life compaison in % (%) IKS-PRO IKS-PRO Standad 125% Standad 125% 100% 100% (%) Highe stability of the IKS-PRO clamping system Incease in tool life using IKS-PRO Oute diamete and facing 0 Inside wheel face mount Oute diamete and facing i Machining time compaison in % (%) Standad Standad IKS-PRO 100% 100% 75% IKS-PRO 50% Highe feed ate using IKS-PRO Decease of machining time using IKS-PRO Inside wheel face mount 0 Inside wheel face mount Oute diamete and facing SPK PCBN FOR CAST IRON

11 11 SPK PCBN insets fo cast ion machining Solid, multi-tipped and laminated insets SPK PCBN FOR CAST IRON

12 SPK PCBN insets fo cast ion machining Multi-tipped inset ISO gade spk-ef.no. CCGW T - BL CCGW T - BL WBN CCGW 09 T3.. T - BL 80 CCGW 09 T3 04 T - BL WBN CCGW 09 T3 08 T - BL WBN CCGW 09 T3 08 T - BL 95Z CCGW 09 T3 08 T - BL 95Z025 WBN CNGA T - LL 80 CNGA T - LL WBN CNGA T - LL WBN CNGA T - LL WBN CNGA T - LL - 95Z025 CNGA T - LL 95Z025 WBN Phone: Fax: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com

13 55 13 SPK PCBN insets fo cast ion machining Multi-tipped inset ISO gade spk-ef.no. DCGW 07 T3.. T - BL DCGW T - BL WBN DCGW T - BL WBN DNGA T - LL 55 DNGA T - LL WBN DNGA T - LL WBN DNGA T - LL 55 DNGA T - LL WBN DNGA T - LL WBN DNGA T - LL WBN SCGW 09 T3.. T - DL SCGW 09 T3 04 T - DL WBN SCGW 09 T3 08 T - DL WBN SNGA T - NL 5.16 SNGA T - NL WBN SNGA T - NL WBN SNGA T - NL WBN Tel.: Fax: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com

14 5 14 SPK PCBN insets fo cast ion machining Multi-tipped inset ISO gade spk-ef.no. TCGW T - CL 60 TCGW T - CL WBN TCGW T - CL 60 TCGW T - CL WBN TCGW T - CL WBN TNGA T - ML 60 TNGA T - ML WBN TNGA T - ML WBN TNGA T - ML WBN VBGW T - BL 35 VBGW T - BL WBN VBGW T - BL WBN VBGW T - BL WBN VNGA T - LL 35 VNGA T - LL WBN VNGA T - LL WBN Phone: Fax: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com

15 5 15 SPK PCBN insets fo cast ion machining Laminated inset ISO gade spk-ef.no. RBGN MO T - F RBGN MO T - F WBN SCGN T - F SCGN T - F WBN SCGN T - F 85Z050 SCGN T - F 85Z050 WBN Tel.: Fax: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com

16 16 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. CNMN T - S 80 CNMN T - S WBN CNMN T - S WBN CN.N T - S 80 CNMN T - S WBN WBN WBN CNMN T - S WBN WBN WBN CNGN T - S WBN CNMN T - S WBN WBN WBN WBN CNMN T - S 80 CNMN T - S WBN WBN CNMN T -S WBN WBN CNMN T -S WBN WBN WBN WBN CNGX T - S - DO 80 CNGX T - S - DO WBN WBN CNGX T - S - DO WBN WBN CNGX T - S - DO WBN WBN WBN WBN Phone: Fax: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com

17 5 17 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. DNMN T - S DNMN T - S WBN WBN WBN WBN DNMN T - S WBN WBN WBN WBN RCGN F - S RCGN F - S WBN WBN RBGN MO T - S RBGN MO T - S WBN WBN RNGX T - S - DO RNGX T - S - DO WBN WBN RNMN T - S RNMN T - S WBN WBN Tel.: Fax: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com

18 18 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. RNMN T - S RNMN T - S WBN WBN SCGN T - S 85Z050 SCGN T - S 85Z050 WBN WBN SCGN T - S 85Z075 SCGN T - S 85Z075 WBN WBN WBN WBN SNGN T - S 85Z050 SNGN T - S 85Z050 WBN WBN SNGN T - S 85Z075 SNGN T - S 85Z075 WBN WBN WBN WBN SNGX T - S - DO SNGX T - S - DO WBN WBN SNGX T - S - DO WBN WBN SNGX T - S - DO WBN WBN WBN WBN Phone: Fax: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com

19 19 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. SNMN T - S SNMN T - S WBN WBN SNMN T - S WBN WBN SNMN T - S WBN WBN WBN WBN SNMN T - S SNMN T - S WBN WBN SNMN T - S WBN WBN SNMN T - S WBN WBN WBN WBN TCMN T - S 60 TCMN T - S WBN WBN TNMN T - S 60 TNMN T - S WBN WBN Tel.: Fax: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com

20 20 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. TNMN T - S 60 TNMN T - S WBN WBN WBN WBN TNGX T - S - DO 60 TNGX T - S - DO WBN WBN Phone: Fax: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com

21 21 SPK NotePCBN insets fo cast ion machining Tel.: Fax: Web: spk-tools.de ceamtec.com

22 22 Note Phone: Fax: Web: spk-tools.de ceamtec.com

23 23 Note Tel.: Fax: Web: spk-tools.de ceamtec.com

24 CeamTec GmbH SPK Cutting Tools Division Hauptstasse Ebesbach/Fils, Gemany Phone: +49 (0)7163 / Fax: +49 (0)7163 / info@spk-tools.de Web: cutting_tools@ceamtec.de Web: pe St