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 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 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 SPK PCBN scope of application Cutting data ecommendations fo cast ion machining Fo cast ion (GJL) Fo chilled cast ion Cutting speed v c : 400 600 800 1000 1200 1400 1600 1800 2000 (m/min) 50 100 150 200 250 (m/min) WBN 115 WBN 105 WBN 100 WBN 120 WBN 750 Feed ate f : 0.05 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 (mm) 0.1 0.2 0.3 0.4 (mm) WBN 115 WBN 105 WBN 100 WBN 120 WBN 750 Depth of cut a p : 0.25 0.50 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 (mm) 1.0 1.5 2.0 2.5 3.0 (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 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 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 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 120408 t - Bl 95Z025 Chamfe Length of PCBN inset > 2 mm Width of the ZZ chamfe Appoach angle with IKS-PRO clamping system cngx 120408 t - s - do Chamfe Solid Inset with IKS-PRO notch clamping SPK PCBN FOR CAST IRON
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 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 120416 T SNGX 120416 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 4000 3000 2000 1000 0 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 120400 T RNGX 120400 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 115 1.0 0.8 0.6 0.4 0.2 Wea pattens 0 Wea on the cutting edge 75% less wea SPK PCBN FOR CAST IRON
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 120416 T-S CNGX 120416 T-S-DO SNMN 120416 T-S SNGX 120416 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 % (%) 200 150 100 50 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 % (%) 200 150 100 50 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 SPK PCBN insets fo cast ion machining Solid, multi-tipped and laminated insets SPK PCBN FOR CAST IRON
80 5.16 12 SPK PCBN insets fo cast ion machining Multi-tipped inset ISO gade spk-ef.no. CCGW 06 02.. T - BL CCGW 06 02 04 T - BL WBN 750 16.57.406.37.8 6.35 6.4 2.8 2.38 CCGW 09 T3.. T - BL 80 CCGW 09 T3 04 T - BL WBN 750 16.57.401.37.8 CCGW 09 T3 08 T - BL WBN 750 16.57.402.37.8 9.7 4.4 3.97 CCGW 09 T3 08 T - BL 95Z025 9.7 80 CCGW 09 T3 08 T - BL 95Z025 WBN 750 16.57.407.37.8 0.25 0.8 0.25 5 4.4 3.97 CNGA 12 04.. T - LL 80 CNGA 12 04 04 T - LL WBN 750 16.56.421.37.8 CNGA 12 04 08 T - LL WBN 750 16.56.422.37.8 CNGA 12 04 12 T - LL WBN 750 16.56.423.37.8 12.7 5.16 12.9 CNGA 12 04 08 T - LL - 95Z025 CNGA 12 04 08 T - LL 95Z025 WBN 750 16.54.429.37.8 12.9 80 0.25 12.7 0.8 0.25 5 Phone: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
55 13 SPK PCBN insets fo cast ion machining Multi-tipped inset ISO gade spk-ef.no. DCGW 07 T3.. T - BL DCGW 07 02 04 T - BL WBN 750 16.57.410.37.8 DCGW 07 02 08 T - BL WBN 750 16.57.411.37.8 7.0 4.4 3.97 DNGA 15 04.. T - LL 55 DNGA 15 04 04 T - LL WBN 750 16.56.401.37.8 DNGA 15 04 08 T - LL WBN 750 16.56.402.37.8 12.7 5.16 15.5 DNGA 15 06.. T - LL 55 DNGA 15 06 04 T - LL WBN 750 16.56.424.37.8 DNGA 15 06 08 T - LL WBN 750 16.56.425.37.8 DNGA 15 06 12 T - LL WBN 750 16.56.426.37.8 12.7 5.16 15.5 6.35 SCGW 09 T3.. T - DL SCGW 09 T3 04 T - DL WBN 750 16.17.419.37.8 SCGW 09 T3 08 T - DL WBN 750 16.17.420.37.8 4.4 3.97 SNGA 12 04.. T - NL 5.16 SNGA 12 04 04 T - NL WBN 750 16.16.404.37.8 SNGA 12 04 08 T - NL WBN 750 16.16.405.37.8 SNGA 12 04 12 T - NL WBN 750 16.16.406.37.8 12.7 Tel.: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
5 14 SPK PCBN insets fo cast ion machining Multi-tipped inset ISO gade spk-ef.no. TCGW 09 02 04 T - CL 60 TCGW 09 02 04 T - CL WBN 750 16.37.405.37.8 5.56 9.62 2.8 2.38 TCGW 11 02.. T - CL 60 TCGW 11 02 04 T - CL WBN 750 16.37.403.37.8 TCGW 11 02 08 T - CL WBN 750 16.37.404.37.8 6.35 11.0 2.8 2.38 TNGA 16 04.. T - ML 60 TNGA 16 04 04 T - ML WBN 750 16.36.405.37.8 TNGA 16 04 08 T - ML WBN 750 16.36.406.37.8 TNGA 16 04 12 T - ML WBN 750 16.36.407.37.8 3.81 16.5 VBGW 16 04.. T - BL 35 VBGW 16 04 04 T - BL WBN 750 16.57.412.37.8 VBGW 16 04 08 T - BL WBN 750 16.57.413.37.8 VBGW 16 04 12 T - BL WBN 750 16.57.414.37.8 16.6 4.4 VNGA 16 04.. T - LL 35 VNGA 16 04 04 T - LL WBN 750 16.56.427.37.8 VNGA 16 04 08 T - LL WBN 750 16.56.428.37.8 3.81 16.6 4.7 Phone: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
5 15 SPK PCBN insets fo cast ion machining Laminated inset ISO gade spk-ef.no. RBGN 10 04 MO T - F RBGN 10 04 MO T - F WBN 750 16.41.242.37.8 10.0 SCGN 09 04 08 T - F SCGN 09 04 08 T - F WBN 750 16.13.206.37.8 SCGN 09 04 08 T - F 85Z050 SCGN 09 04 08 T - F 85Z050 WBN 750 16.13.236.71.8 0.50 0.8 0.50 5 Tel.: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
16 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. CNMN 09 03.. T - S 80 CNMN 09 03 08 T - S WBN 100 16.50.012.04.1 CNMN 09 03 12 T - S WBN 100 16.50.013.04.1 9.7 3.18 CN.N 09 04.. T - S 80 CNMN 09 04 08 T - S WBN 100 16.50.061.04.1 WBN 105 20.50.061.68.5 WBN 115 12.50.061.68.0 9.7 CNMN 09 04 12 T - S WBN 100 16.50.062.04.1 WBN 105 20.50.062.68.5 WBN 115 12.50.062.68.0 CNGN 09 04 16 T - S WBN 100 16.52.045.04.1 CNMN 09 04 16 T - S WBN 100 16.50.059.04.1 WBN 105 20.50.059.68.5 WBN 115 12.50.059.68.0 WBN 120 20.50.059.04.2 CNMN 12 04.. T - S 80 CNMN 12 04 08 T - S WBN 105 20.50.027.68.5 WBN 115 12.50.027.68.0 12.7 CNMN 12 04 12 T -S WBN 105 20.50.028.68.5 WBN 115 12.50.028.68.0 12.9 CNMN 12 04 16 T -S WBN 100 16.50.029.04.1 WBN 105 20.50.029.68.5 WBN 115 12.50.029.68.0 WBN 120 20.50.029.04.2 CNGX 12 04.. T - S - DO 80 CNGX 12 04 08 T - S - DO WBN 105 20.52.016.68.5 WBN 115 12.52.016.68.0 12.7 CNGX 12 04 12 T - S - DO WBN 105 20.52.017.68.5 WBN 115 12.52.017.68.0 12.9 CNGX 12 04 16 T - S - DO WBN 100 16.52.018.04.1 WBN 105 20.52.018.68.5 WBN 115 12.52.018.68.0 WBN 120 20.52.018.04.2 Phone: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
5 17 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. DNMN 12 04.. T - S 12.2 55 10.0 DNMN 12 04 12 T - S WBN 100 16.50.056.04.1 WBN 105 20.50.056.68.5 WBN 115 12.50.056.68.0 WBN 120 20.50.056.04.2 DNMN 12 04 16 T - S WBN 100 16.50.057.04.1 WBN 105 20.50.057.68.5 WBN 115 12.50.057.68.0 WBN 120 20.50.057.04.2 RCGN 09 04 00 F - S RCGN 09 04 00 F - S WBN 105 20.43.005.06.5 WBN 115 12.43.005.06.0 RBGN 08 04 MO T - S RBGN 08 04 MO T - S WBN 105 20.41.003.68.5 WBN 115 12.41.003.68.0 8.0 RNGX 12 04 00 T - S - DO RNGX 12 04 00 T - S - DO WBN 105 20.42.002.68.5 WBN 115 12.42.002.68.0 12.7 RNMN 09 04 00 T - S RNMN 09 04 00 T - S WBN 105 20.40.014.68.5 WBN 115 12.40.014.68.0 Tel.: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
18 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. RNMN 12 04 00 T - S RNMN 12 04 00 T - S WBN 105 20.40.040.68.5 WBN 115 12.40.015.68.0 12.7 SCGN 09 04 08 T - S 85Z050 SCGN 09 04 08 T - S 85Z050 WBN 105 20.13.034.68.5 WBN 115 12.13.034.68.0 0.50 0.8 0.50 5 0.75 SCGN 09 04 08 T - S 85Z075 SCGN 09 04 08 T - S 85Z075 WBN 100 16.13.043.04.1 WBN 105 10.13.043.68.5 WBN 115 12.13.043.68.0 WBN 120 20.13.043.04.2 0.8 0.75 5 SNGN 09 04 08 T - S 85Z050 SNGN 09 04 08 T - S 85Z050 WBN 105 20.12.063.68.5 WBN 115 12.12.063.68.0 0.50 0.8 0.50 5 0.75 SNGN 09 04 08 T - S 85Z075 SNGN 09 04 08 T - S 85Z075 WBN 100 16.12.064.04.1 WBN 105 20.12.064.68.5 WBN 115 12.12.064.68.0 WBN 120 20.12.064.04.2 0.8 0.75 5 SNGX 12 04.. T - S - DO SNGX 12 04 08 T - S - DO WBN 105 20.12.045.68.5 WBN 115 12.12.045.68.0 12.7 SNGX 12 04 12 T - S - DO WBN 105 20.12.046.68.5 WBN 115 12.12.046.68.0 SNGX 12 04 16 T - S - DO WBN 100 16.12.047.04.1 WBN 105 20.12.047.68.5 WBN 115 12.12.047.68.0 WBN 120 20.12.047.04.2 Phone: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
19 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. SNMN 09 04.. T - S SNMN 09 04 08 T - S WBN 105 20.10.021.68.5 WBN 115 12.10.021.68.0 SNMN 09 04 12 T - S WBN 105 20.10.022.68.5 WBN 115 12.10.022.68.0 SNMN 09 04 16 T - S WBN 100 16.10.023.04.1 WBN 105 20.10.023.68.5 WBN 115 12.10.023.68.0 WBN 120 20.10.023.04.2 SNMN 12 04.. T - S SNMN 12 04 08 T - S WBN 105 20.10.029.68.5 WBN 115 12.10.029.68.0 12.7 SNMN 12 04 12 T - S WBN 105 20.10.030.68.5 WBN 115 12.10.030.68.0 SNMN 12 04 16 T - S WBN 100 16.10.031.04.1 WBN 105 20.10.031.68.5 WBN 115 12.10.031.68.0 WBN 120 20.10.031.04.2 TCMN 11 04 16 T - S 60 TCMN 11 04 16 T - S WBN 105 20.31.003.68.0 WBN 115 12.31.003.68.0 6.35 11.0 TNMN 11 04 16 T - S 60 TNMN 11 04 16 T - S WBN 105 20.30.023.68.5 WBN 115 12.30.023.68.0 6.35 11.0 Tel.: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
20 SPK PCBN insets fo cast ion machining Solid inset ISO gade spk-ef.no. TNMN 16 04 16 T - S 60 TNMN 16 04 16 T - S WBN 100 16.30.032.04.1 WBN 105 20.30.032.68.5 WBN 115 12.30.032.68.0 WBN 120 20.30.032.04.2 16.5 TNGX 16 04 16 T - S - DO 60 TNGX 16 04 16 T - S - DO WBN 105 20.32.032.68.5 WBN 115 12.32.032.68.0 16.5 Phone: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
21 SPK NotePCBN insets fo cast ion machining Tel.: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
22 Note Phone: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
23 Note Tel.: +49-7163-166-239 Fax: +49-7163-166-388 E-mail: cutting_tools@ceamtec.de Web: spk-tools.de ceamtec.com
CeamTec GmbH SPK Cutting Tools Division Hauptstasse 56 73061 Ebesbach/Fils, Gemany Phone: +49 (0)7163 / 166-239 Fax: +49 (0)7163 / 166-388 E-mail: info@spk-tools.de Web: www.spk-tools.de E-mail: cutting_tools@ceamtec.de Web: www.ceamtec.com 1009 pe 1.000 St. 70.91.49.862.3