Brake disc machining EN

Brake disc machining EN

CERATIZIT - secrets of success Secrets of success CERATIZIT is your partner for exceptional hard material solutions. Hard materials and tools from CERATIZIT - 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 CERATIZIT. 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 CERATIZIT. Worldwide well-known companies process advanced materials applying cutting tool products from CERATIZIT: 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

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Brake disc machining Turning of cast iron CERATIZIT develops and produces high-performance cutting materials for the turning of cast iron, for the machining of brake discs and similar components. A very special new development is our new Sialon grade, CTI3105 which underlines CERATIZIT s competence in the cutting material sector and represents an excellent complement to our existing Si 3 N 4 ceramic grade CTN3105. Wear resistance Natural diamond PCD Coated CBN Oxide ceramic Mixed ceramic Sialon Si 3 N 4 ceramic The products range from classic carbide to ultrahard cubic boron nitride and include all in-house manufactured relevant cutting materials for highperformance turning. Coated carbide Cermet Carbide Coated HSS HSS Toughness Brake disc machining (example): 2 3 4 5 6 1 4

CERATIZIT services CERATIZIT not only offers you excellent cutting tools but also customized complete solutions for optimal machining of your work pieces on new projects. Specific team for OEM services to guarantee professional project processing Close cooperation with machine manufacturers Complete machining concepts and tooling solutions: workflow, tools, cutting parameters, necessary tools, process times, process costs Tooling Academy in Reutte supports process optimization Support for acceptance and commissioning runs Detailed project documentation Worldwide distribution and service network www.e-techstore.com www.ceratizit.com Configurate over 10,000 products online and order immediately Up-to-the-minute CERATIZIT product catalogue including all technical and graphical details More than 100,000 possibilities of tool combinations online Access 24 hours a day Shipment tracking via Internet (Track & Trace) 5

C-Clamp C-Clamp the wear resistant carbide claw! High wear resistance and reduced vibration More than 50-times increased durability compared to claws made of steel High cutting speed possible together with maximum feed rates Clamping system advantages Large contact face in the clamping zone of clamping claw and dimple Practically no wear in the area of the clamping zone, and after 3 months of application under hardest conditions still as good as new. The advantages in detail Most wear-resistant claw available in the market Maximum clamping force Simplified spare part management, one set, one clamping key and one shim clamping screw for everything Safe positioning of the shim TorxPlus system for secure transmission of torque moments and longer tool life of the screw Concentric dimple, form lock, high flexibility for special approach angle and special tool holders Secure, even for worn or damaged inserts 6

Special tools Special tools to customers requirements! Do you want to increase productivity? CERATIZIT express service for custom-made tools (3 weeks) Technical advice and suggestions for machining Process analyses and optimization Tools ensure process security through up-to-the minute 3D-CAD technology Rapid lead times C-Clamp for particularly compact and stable tools! 7

CERATIZIT cutting materials Grades CTN3105 (silicon nitride) Improved balance of fracture toughness and wear resistance Very good edge stability and, resistance to cratering Universal application, for roughing and finishing CTI3105 (Sialon) Excellent hardness (HV 10 1900!) and wear resistance Innovative grain composition ensures good toughness Cutting speed +100 m/min compared to classic silicon nitride ceramic CTL3115 (cubic boron nitride, PVD coated) CBN ranks as the second hardest material after diamond The coating avoids adhesion and improves process security Particularly suitable for seasoned cast iron (older than 6 days) C-Clamp to make the most of the performance capacity of all cutting materials! 8

Grades CTN3105 CN-K05... Composition: β - Si 3 N 4, binder 5.5% Hardness: HV10 1680 Toughness 0 2 4 6 8 10 Wear resistance 0 2 4 6 8 10 CTI3105 CN-K05... Composition: α, β - Sialon, binder 5.5% Hardness: HV10 1900 Toughness 0 2 4 6 8 10 Wear resistance 0 2 4 6 8 10 CTL3115 BN-K05... Composition: Cubic boron nitride (CBN), 82 Vol.% + binder phase ceramic Hardness: 32 GPa (Knoop) Layer specification: PVD Toughness 0 2 4 6 8 10 Wear resistance 0 2 4 6 8 10 9

Inserts Versions SNGX fully ground All faces precision-ground Close thickness tolerance Optimal chamfer finish = highest repeatability and extremely high resistance to cratering SNNX precision-manufactured Only contact face and chamfer are ground, periphery is precision-sintered Close thickness tolerance Optimal chamfer finish = is the most economic solution and has extremely high resistance to cratering 10

Designation system in addition to the standard Insert designation Example: CNGX 120412SN-020D-C Chamfer width b 015 0,15 mm 020 0,20 mm 025 0,25 mm 050 0,50 mm 075 0,75 mm 100 1,00 mm Chamfer angle Υ 1 A 05 B 10 C 15 D 20 E 25 F 30 C-Clamp Inserts suitable for mounting with C-Clamp Insert designation Example: DWLNR 2525 M08-C07 C-Clamp 07 Tool with C-Clamp for inserts with s = 7.94 mm 11

Inserts CN..X CN..X CN..X CN..X -C CN..X -C L N R CTN3105 CTI3105 CTL3115 r Type, description l d s d 1 1,20 CNGX 120412SN-020D-C N R 12,90 12,70 4,76 1,60 CNGX 120416SN-020D-C N R 12,90 12,70 4,76 1,20 CNGX 120712TN-020D N R R 12,90 12,70 7,94 1,20 CNGX 120712TN-020D-C N R R 12,90 12,70 7,94 2,50 1,20 CNNX 120712TN-020D-C N R 12,90 12,70 7,94 2,50 1,60 CNGX 120716TN-020D N R R 12,90 12,70 7,94 1,60 CNGX 120716TN-020D-C N R R 12,90 12,70 7,94 2,50 1,60 CNNX 120716TN-020D N R R 12,90 12,70 7,94 2,50 1,60 CNNX 120716TN-020D-C N R R 12,90 12,70 7,94 2,50 1,60 CNGX 160716TN-020D N R R 16,10 15,88 7,94 Steel Stainless Cast iron Non ferrous metals Heat resistant Hard materials Main application Extended application RRR R International CERATIZIT range, for present availability see price list Ordering example: 10 pieces CNGX 120412SN-020D-C CTL3115 12

Inserts DN..X DN..X DN..X -C L N R CTN3105 CTI3105 r Type, description l d s d 1 1,20 DNGX 120712TN-020D N R 12,30 10,00 7,94 1,60 DNGX 120716TN-020D-C N R 12,30 10,00 7,94 1,60 DNGX 150416SN-020D-C N R 15,50 12,70 4,76 1,20 DNGX 150712TN-020D N R 15,50 12,70 7,94 1,20 DNGX 150712TN-020D-C N R 15,50 12,70 7,94 2,50 1,60 DNGX 150716TN-020D N R 15,50 12,70 7,94 1,60 DNGX 150716TN-020D-C N R 15,50 12,70 7,94 2,50 Steel Stainless Cast iron Non ferrous metals Heat resistant Hard materials Main application Extended application RR R International CERATIZIT range, for present availability see price list Ordering example: 10 pieces DNGX 120716TN-020D-C CTN3105 13

Inserts SN..X SN..X SN..X SN..X -C SN..X -C L N R CTN3105 CTI3105 CTL3115 r Type, description l d s d 1 1,20 SNGX 120412SN-020D-C N R 12,70 12,70 4,76 1,60 SNGX 120416SN-020D-C N R 12,70 12,70 4,76 1,20 SNGX 120712TN-020D N R R 12,70 12,70 7,94 1,20 SNGX 120712TN-020D-C N R R 12,70 12,70 7,94 2,50 1,60 SNGX 120716TN-020D N R R 12,70 12,70 7,94 1,60 SNGX 120716TN-020D-C N R R 12,70 12,70 7,94 2,50 1,60 SNNX 120716TN-020D N R R 12,70 12,70 7,94 2,50 1,60 SNNX 120716TN-020D-C N R R 12,70 12,70 7,94 2,50 12,70 12,70 7,94 1,60 SNGX 150716TN-020D N R R 15,88 15,88 7,94 1,60 SNGX 150716TN-040D N R 15,88 15,88 7,94 Steel Stainless Cast iron Non ferrous metals Heat resistant Hard materials Main application Extended application RRR R International CERATIZIT range, for present availability see price list Ordering example: 10 pieces SNGX 120412SN-020D-C CTL3115 14

Inserts WN..X WN..X -C WN..X -C L N R CTN3105 CTI3105 CTL3115 r Type, l d s d 1 description 1,60 WNGX 080416SN-20D-C N R 8,69 12,70 4,76 1,20 WNGX 080712TN-020D-C N R R 8,69 12,70 7,94 2,5 1,60 WNGX 080716TN-020D-C N R R 8,69 12,70 7,94 2,5 1,60 WNNX 080716TN-020D-C N R 8,69 12,70 7,94 2,5 Steel Stainless Cast iron Non ferrous metals Heat resistant Hard materials Main application Extended application RRR R International CERATIZIT range, for present availability see price list Ordering example: 10 pieces WNGX 080712TN-020D-C CTN3105 15

MaxiLock D / C-Clamp DWLN... h1 h f 95 b 95 l 2 l 1 Picture shows right-hand version L N R h Type, h 1 b l 1 l 2 f description 25 DWLNR 2525 M08-C07 R 25 25 150 31 32 WN... X 0807.. 25 DWLNL 2525 M08-C07 L 25 25 150 31 32 WN... X 0807.. Ordering example: 1 piece DWLNR 2525 M08-C07 h 1 2 3 4 WN.. 0804.. 25-32 M4,5x10/20IP/10008155 U-WN08X7-C DMSD 8,0Nm/SORT 20IP SET-02-C WN.. 0807.. 25-32 M4,5x10/20IP/10008155 U-WN08T3-C DMSD 8,0Nm/SORT 20IP SET-02-C 16

L N R h h 1 b l 1 l 2 f DCLNR 2525 M12-X07 R 25 25 25 150 32 32 CNGX 1207.. DCLNL 2525 M12-X07 L 25 25 25 150 32 32 CNGX 1207.. h1 h DSDNN 2525 M12-X07 N 25 25 25 150 39 12,5 SNGX 1207.. h1 h 95 95 45 h1 h DSKNR 2525 M12-X07 R 25 25 25 150 28 32 SNGX 1207.. 75 DSKNL 2525 M12-X07 L 25 25 25 150 28 32 SNGX 1207.. DSRNR 2525 M12-X07 R 25 25 25 150 36 27 SNGX 1207.. DSRNL 2525 M12-X07 L 25 25 25 150 36 27 SNGX 1207.. DSSNR 2525 M12-X07 R 25 25 25 150 40 32 SNGX 1207.. MaxiLock D standard Type, description Insert h1 h h1 h 45 DSSNL 2525 M12-X07 L 25 25 25 150 40 32 SNGX 1207.. h 1 2 3 4 CN.. 1207.. 25 M4,5x12/15IP/10002887 U-CN12T3-D S-15IP-T SET-02-X-D SN.. 1207.. 25 M4,5x12/15IP/10002887 U-SN12T3-D S-15IP-T SET-02-X-D 17

Success stories Criteria: > Interrupted cut when machining the flywheel of a big utility vehicle > Increased tool life with fixed feed rates > Tooling system for easy change between ceramic and CBN cutting inserts Result: > Stability increased thanks to C-Clamp > Tool life increased by 300% > CERATIZIT improved tool life to 150 parts compared to 20 50 parts from competitor tools > Insert with non-ground periphery enhances economy Technical data: Work piece: flywheel Material: GG-26-CR Condition/hardness: HB10 1800 Machine: Weisser Univertor SH Tool: UT50-DCLNR-12-C07 E-77642 Insert: CNNX 120716TN-020D-C Grade: CTN3105 Cutting parameters: > CERATIZIT v c = 680 m/min a p = 2 4 mm f = 0.35 0.8 mm > Competitor v c = 680 m/min a p = 2 4 mm f = 0.35 0.8 mm Criteria: > Considerable wear of competitor s clamping claw > Tool change times > Machining of very thin non-ventilated brake discs Result: > Improved component quality > Process security through coated CBN > Close tolerances maintained through C-Clamp > Tool life 2,000 pieces > Very short delivery time Technical data: Work piece: brake disc Material: GG20 CrCu Condition/hardness: cast iron older than 7 days / HB 200 Machine: Scherer Feinbau Tool: special tools with C-Clamp Insert: SNGX120416TN-020D-C Grade: CTL3115 Cutting parameters: > CERATIZIT v c = 1000 m/min a p = 2 3 mm f = 1 mm > Competitor v c = 1000 m/min a p = 2 3 mm f = 0.8 mm 18

Success stories Criteria: > Process security > Notably increase cutting performance > Prove stability of the new clamping system Result: > Feed rates increased up to 100% > Stable clamping with guaranteed process security at 6 mm depth of cut and a feed rate of 1mm/rev > C-shaped inserts replaced by W-shaped inserts with no loss of feed rate or tool life, even with large cutting depths Technical data: Work piece: brake drum Material: GG-25 Hardness: HB10 180-220 Machine: Hessap (80KW) Tool: DWLNL 3225 M08-C07 Insert: WNGX080716TN-020D-C Grade: CTN3105 Cutting parameters: > CERATIZIT v c = 800 m/min a p = 2 6 mm f = 0.6 1.0 mm > Competitor v c = 800 m/min a p = 2 3 mm f = 0.4 0.6 mm Criteria: > Competitor s insert: cutting forces cause the insert to twist out of the seating. > Avoid follow on damage caused by breakage of brake discs > Competitor has no solution Result: > CERATIZIT developed a positive clamping system with secure insert seat. > Customer has maximum process security > Tool life increased from competitor s 400 pieces to 8,000 pieces. Technical data: Work piece: brake disc Material: 0.6025 (GG-25) Tensile strength: 250 N/mm² Machine: Hüller Hille Hessap / transfer line Tool: E-68176 (SB24L00-2525M) Insert: NCMN 15F152-L (88750) Grade: CTN3105 Cutting parameters: > CERATIZIT v c = 1400 m/min a p = 15 mm f = 0.25 mm > Competitor v c = 1400 m/min a p = 15 mm f = 0.25 mm 19

Cutting data Grades / materials A R F N S H Work piece material Type of treatment / alloy VDI 3323 group Hardness annealed 0,15% C 1 125 Non alloyed steel annealed 0,15% - 0,45% C 2 150-250 tempered 0,45% C 3 300 annealed 6 180 Low alloyed steel tempered 7 / 8 250-300 tempered 9 350 High alloyed steel Stainless steel annealed annealed 10 ferritic 200 12 200 tempered tempered 11 martensitic 350 13 325 annealed ferritic / martensitic 14 200 Stainless steel quenched austenitic 14 180 quenched duplex 14 230-260 hardened martensitic / austenitic 14 330 Grey cast iron pearlitic / ferritic 15 180 pearlitic / martensitic 16 260 Spheroidal ferritic 17 160 cast iron pearlitic 18 Malleable cast iron ferritic 19 130 pearlitic 20 230 Aluminium non hardened 21 60 wrought alloys hardened 22 100 non hardened < 12% Si 23 80 Aluminium cast alloys hardened < 12% Si 24 90 non hardened > 12% Si 25 130 machining alloy stock (1% Pb) 26 Copper and brass, red bronze 27 90 copper alloys (bronze, brass) bronze 28 100 lead-free copper and electrolytic copper 29 100 thermosetting plastics 29 Non-metallic materials fi bre reinforced plastics 29 hard rubber 30 annealed Fe base 31 200 hardened Fe base 32 280 Heat resistant alloys annealed Ni or Co base 33 250 hardened Ni or Co base 30-58 HRC 34 cast Ni or Co base 1500-2200 Nmm 2 35 Titanium alloys Ni or Co base 36 R m 440* alpha + beta alloys 37 R m 1050* Tempered steel hardened and tempered 38 55 HRC hardened and tempered 39 60 HRC Chilled castings cast 40 400 Tempered cast iron hardened and tempered 40 55 HRC * Rm = ultimate tensile strength, measured in MPa HB 20

CTN3105 CTI3105 CTL3115 v c v c v c [m/min] [m/min] [m/min] 500 1000 600 1200 1000 1500 500 1000 600 1200 800 1500 200 600 300 700 *** For finishing only 21

Spare parts Shims -T3 -X7 U-SN12T3-C U-SN12X7-C U-CN12T3-C U-CN12X7-C U-WN08T3-C U-WN08X7-C U-DN12T3-C U-DN12X7-C U-DN15T3-C U-DN15X7-C U-TN16T3-C U-TN16X7-C Other accessories Clamp set SET-02-C Screw and claw are firmly connected with one another = one spare part Torque moment: 8 Nm / 20 IP Torque key DMSD 8,0Nm/SORT 20IP For the correct torque moment. Non-slip handle, even when touching it with oily hands. Torque moment: 8 Nm / 20 IP Clamping screw M4,5x10/20IP/10008155 For safe mounting of the shim Torque moment: 8 Nm / 20 IP Abrasive hone 206227/AZS For cleaning the contact face of the insert to guarantee perfect positioning. Clamp set SET-02X-D Screw and claw are firmly connected with one another = one spare part Torque moment: 4 Nm /15 IP 22

Special tools according to customers specifications These tools have greatly improved productivity: Talk to our technical experts to see how they can help you optimize the machining of your component. 23

Enquiry for special tools - example For a non-binding offer please fill in the form on the next page as shown in the example below. Send to: Fax: +43 (5672) 200-595 The enquiry form for special tools can also be found online at www.ceratizit.com Products & applications Cutting Tools Industries Automotive Brake system Company: Contact: name E-mail: Mr Miller Customer code: Quantity: Date : 5 Standard designation or competitor s designation: Tel.: Requested delivery date: 0049179 Connection: DWLNL C07 in 3 weeks Capto, VDI, Insert designation: X Approach angle Kappa κ: X xx 35 120 Additional information: For internal machining: D min : WNGX 080716TN-020-D-C X VDI 50 Clamping system: C-Clamp MaxiLock D ceramic dimple 95 Hand: right-hand left-hand neutral Cutting material: CTN3105 (Si 3 N 4 ) CTI3105 (Sialon) CTL3115 (CBN) Dimension f: Dimension l 1 : UTS, round shank, square shank Example Axial inclination: Cutting parameters: Depth: 54 70-12 -6 Radial inclination: V c : m/min f: a p : Finish turning: 0.8 1000 3 5 mm/rev. Surface: R a /CLA Target feed rate f: For special tools: enclose sketch or drawing of component. mm/rev. 24

Enquiry for special tools Company: Contact: E-mail: Customer code: Date: Tel.: Quantity: Requested delivery date: Standard designation or competitor s designation: Connection: Capto, VDI, UTS, round shank, square shank Insert designation: Clamping system: C-Clamp MaxiLock D ceramic dimple Approach angle Kappa κ: Hand: right-hand left-hand neutral Cutting material: CTN3105 (Si 3 N 4 ) CTI3105 (Sialon) CTL3115 (CBN) Dimension f: Dimension l 1 : Additional information: For internal machining: D min : Axial inclination: Depth: Radial inclination: Cutting parameters: V c : m/min f: mm/rev. a p : Finish turning: Surface: R a /CLA Target feed rate f: mm/rev. For special tools: enclose sketch or drawing of component. Fax no. +43 (5672) 200-595 25

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CERATIZIT - worldwide CERATIZIT - worldwide Production sites in the three big economic areas with a worldwide network of CERATIZIT sales and support engineers plus many CERATIZIT distribution partners guarantee customer vicinity. We maintain the dialogue with our customers and strive for long-term partnerships. Find your personal distribution partner at: www.ceratizit.com CERATIZIT worldwide production sites and support centres CERATIZIT worldwide sales centres CERATIZIT worldwide distribution partner network CERATIZIT - worldwide Parent company in Luxembourg CERATIZIT Luxembourg Sàrl Route de Holzem 101, B.P. 51 L-8201 Mamer Tel.: +352 312 085-1 Fax: +352 311 911 E-mail: info@ceratizit.com www.ceratizit.com Contact for further information: CERATIZIT Austria Gesellschaft m.b.h. A-6600 Reutte/Tyrol Tel.: +43 (5672) 200-0 Fax: +43 (5672) 200-502 E-mail: info.austria@ceratizit.com www.ceratizit.com 27

508 508 EN 04.10 7002218 We reserve the right to make technical changes for improvment of the product