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hp tooling 2019 #2

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The journal of hp tooling is an english, global publication on all aspects of high precision tools, accessories and their applications.

materials & tools The

materials & tools The revolution in cast iron turning New generation of coatings Austrian carbide and tool specialist Boehlerit has optimised the successful TERAspeed 2.0 coating for use in cast iron milling. And now cast iron turning applications are also set to benefit. A thorough analysis of the market situation and coating tests that were completed internally paved the way for a new generation of coatings. The new cast CVD coating makes the most of the advantages of its individual components. Alpha-aluminium oxide is separated by means of targeted process management. It works as a heat shield and protects the indexable insert from high temperatures. Underneath, a medium-temperature titanium-carbon nitride layer provides the required wear resistance. A thickness of 20 µm and the optimised roundings of the edges ensure a high level of edge stability and ideal cutting conditions. The current geometries of the casting programme are made with the latest generation of reference clamping systems. Compared to older systems, the increased rigidity and repetition accuracy makes for a reduction of the pressing gap, which in turn increases press quality (burr-free pressing). This has a positive influence on work flows further down the line and significantly improves productivity. BCK10T and BCK20T The new Boehlerit casting grades BCK10T and BCK20T offer top quality, excellent machining properties and optimal distribution of cutting forces. Quattrotec - intelligent turning applications with new EasySafe system Pentatec, the universal turning-drilling tool, already replaces up to five ISO tools and reduces machining times by up to 30 % as tool changing times and unnecessary tool movements are eliminated. The innovative, revolutionary Quattrotec tool system is the next step in this intelligent machining concept, and the new EasySafe fitting system with a notch constitutes yet another major advantage of this product. With the introduction of the new Quattrotec tool system, Austrian carbide and tool specialist Boehlerit makes it possible for users to drive down costs further in an even broader material range. Thanks to the special design of the base body, four machining operations - drilling into solid material (including off-center Quattrotec drilling), in- side turning, face cutting and longitudinal turning - may be performed with low vibrations and just one single tool. The EasySafe system is the uncontested highlight of the Quattrotec: A notch on the underside of the indexable insert ensures that it can be fitted into the seat speedily and 100 % correctly. Easy to install, safe to use! In a tried-and-tested, highly diverse range of grades, Boehlerit combines substrates of different levels of hardness, with either a wear-resistant CVD coating or a universal, process-safe PVD coating. The Kapfenberg-based tool specialist uses different carbide substrates that are coordinated in such a way as to achieve optimised machining properties. The market launch at the EMO in Hanover already saw no less than six directly pressed grades, and two more ground varieties for non-ferrous metals will be added in the next development phase. This means that the optimal cutting material will be available for almost every application. The innovative Quattrotec tool programme reduces machining and tool changing times, saves tool places and makes it possible to drill flat-bottomed blind holes. At the same time, this highly stable tool system that was developed from scratch also offers improved process safety and increases efficiency and flexibility during application. BETAtec 90P Feed and DELTAtec 90P Feed: fine-tuning down to the smallest detail The BETAtec 90P Feed tools are the ultimate edge milling tools in the Boehlerit milling programme. The BETAtec 90P Feed is a truly multi-functional tooling system, thanks to the fact that the tool holders may also be used with indexable cutting inserts for high-performance cutting. This means a higher level of efficiency and flexibility for users, while reducing not only the costs of the tool holder, but also the associated warehousing costs. The innovative tool system DELTAtec 90P Feed allows for highest feed rates and may be used for both HFC and edge milling. The multi-functional tooling systems are available as face milling, end milling and screw-on cutters and, in combination with the right cutting material grade, may be used across the entire material group. 10 no. 2, August 2019

materials & tools Innovative cutting grades for a broad range of applications For the BETAtec 90P Feed tool system, Boehlerit has a wide range of cutting grades available. One highlight is the innovative Goldlox carbide layer (PVD AlTiN layer) for the milling of steel materials, offering a high level of wear resistance at high temperatures and an increased lifespan on a range of steels. This cutting grade is particularly suitable for high cutting speeds during dry or wet machining in stable conditions. For this tool system, the Goldlox layer is available in the grades BCP25M (multi-purpose grade for the milling of unalloyed, low-alloy and high-alloy steel), BCP35M (suitable for dry milling at low to medium cutting speeds in difficult conditions) and BCM40M (ideal for the milling of austenitic stainless steels and materials from the Duplex group with low to medium cutting speeds). These two cutting grades are used both on the indexable inserts for edge milling and on the indexable inserts for high-performance cutting. There is also the option of cutting grade BCK20M for the edge milling of cast iron materials. This grade is also suitable for steel machining and for cold-work steels harder than 54 HRC. In addition to the Goldlox carbide layer, the DELTAtec 90P Feed tool system also comes with a TERAspeed 2.0AlTiN layer, d e p o s i t e d by means of HR-CVD technology (HR = High Reac tiv i- BETAtec 90P Feed ty). The patented TERAspeed 2.0 AITiN layer combines opposing properties such as toughness, outstanding layer hardness and wear resistance, thanks to its high aluminium content and novel nano structure. This innovative layer is used for highperformance cutting in the grades BCP20M (for steel processing using higher cutting speeds in stable conditions), BCP30M (universal steel milling grade with a tough carbide substrate for a high level of process reliability across a broad range of steel materials), and BCK15M (for the processing of grey cast iron GJL, spheroidal graphite cast iron GJS, tempered cast iron and alloyed cast iron). Alternatively, there is the option of the BCK20M grade for cast iron machining using DELTAtec 90P Feed millers. It has a tough K20 substrate and a thick PVD coating and may be used either for high performance milling or edge milling. Precise edge and EFC milling with 18 mm cutting edge length In 2018, Austrian carbide and tool specialist Boehlerit added a version for 18 mm cutting edge lengths to its range of multi-functional milling tools. Thanks to the significantly larger insert size, this version is particularly suitable for long 90-degree edges with high cutting values and an extremely DELTAtec 90P Feed high precision level. It not only makes for a soft cut, but also comes with tech nical properties that speak for themselves: A maximum cutting depth of up to 18 mm, in combination with a helix cutting edge, result in maximised productivity when finishing 90 ° shoulders with the BETAtec 90P Feed tool. For the high-feed application sector, the Boehlerit DELTAtec 90P Feed SD18 solution also offers the possibility of achieving maximum feed rates and high levels of material removal, with feed depths of 3.5 mm with a maximum feed rate of 3.0 mm/tooth. Small diameter range – highly dynamic and efficient Completely new, logical extensions of the existing BETAtec 90P Feed and DELTAtec 90P Feed portfolio are indexable inserts with small diameter ranges. The BETAtec 90P Feed tool system with an indexable insert size of 06 (LPMX06) is available as a face milling, end milling and screw-on version for a range of 10 - 50 mm. The DELTAtec 90P milling tools are also available with an indexable insert size of 06 (SDMT06) as end milling and screw-on versions for a range of 16 - 35 mm. The new tools are ideal for die and mould making with materials of up to 62 HRC and extremely dynamic in terms of performance as well as efficiency. For applications with hardened materials, Boehlerit once again relies on a homogeneous HIPIMS layer structure for optimised results in die and mould making. Yet another benefit of this product lies in the low strain placed on the individual indexable inserts thanks to the narrow pitch that makes high machining volumes possible. The need for reworking is also greatly reduced due to the minimal need for residual material. While the BETAtec 90P Feed is designed for HFC and 90 ° milling, the focus of the DELTAtec 90P Feed lies on material removal, with a focus on dynamic and efficient performance. EMO 2019, hall 4, booth D06 further information: www.boehlerit.com no. 2, August 2019 11

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