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hp tooling 2021 #1

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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

materials & tools Expertise in pipe and sleeve machining Paul Horn GmbH has succeeded in winning over the world’s leading manufacturers of machine tools for pipe and sleeve production, as well as end users, through the continuous development of cus tomer-focused tool solutions. The tool manufacturer is able to create cost-effective machining solutions for use in API- and GOST-compliant as well as premium joint applications. With a focus on user-friendliness, the tools are designed to deliver a productive edge over other solutions in the areas of handling, service life and cost per threaded connection. Horn’s own in-house product management department, which is actively engaged in the development and continuous optimisation of productive machining concepts for OCTG, designs and delivers both standard and customerspecific tools. Horn’s product portfolio can offer the right package of tools for all machines. The tool systems are available with standard machine interfaces including VDI, polygonal shank and round shank holders as well as solutions that are flange-mounted on turrets. The tools are adapted to the degree of automation in the system – from manual loading all the way through to fully automated production – and are designed to provide a solution that can be relied upon to meet the requirements. Both the screw clamp and the ground chip formers of the S117 and 315 systems, together with the carefully matched tool holders, make it possible to manage chip removal during sleeve and pipe end machining processes. There are no expensive parts such as chip breakers or shims to install, allowing customers to make significant savings when procuring tools. The two systems demonstrate highly precise interchangeability and use substrates and coatings for the inserts that are tailored to machining conditions, resulting in significant improvements in both cutting performance and tool life. The precise interchangeability provided by the precision insert seats reduces the number of tool adjustments that are needed after changing inserts. In thread cutting in API- and GOST-compliant applications the S117’s numerous teeth enable the number of cuts to be minimised. The 315 system has three usable cutting edges, leading to significant cost optimisation. It is an ideal choice for premium joints that permit no more than one to three teeth per cutting edge. The tool carrier is designed to work in perfect harmony with the insert, increasing the stability of the tool system. This means a lower tendency towards vibration, something that in turn improves surface quality, precision and tool life. In applications involving pipes with profiles that comply with ANSI/API-5L, Horn offers tool solutions for pipe end finish machining in line with customers’ requirements. The milling heads can be used to machine pipe ends with Designed to give customers a productive edge over other solutions a wall thickness of up to 50 mm. Integrated rollers compensate for any roundness errors. The workpieces that are produced comply with API tolerance requirements. With its M101 cut-off milling system, Horn offers a purpose-developed tool for pipe end machining after rolling and for separating sections for analysis. The tool can also be used for pipe and sleeve assembly. The S101 self-clamping inserts, featuring cutting widths of 2 mm and above, deliver highly precise interchangeability, accurate cuts and short machining times. Horn’s extensive scope covers everything from producing blanks in its own carbide machining department, via the internal grinding shop and production support all the way through to in-house-developed PVD coatings. This keeps the company’s lead-times short. With the Greenline system, for limited quantities, Horn is able to deliver within one week after approval of a drawing by the customer. The tool manufacturer also allows users to benefit from pro - cess consultation services and acts as a solution provider, with its product management processes. Horn boasts expertise in machining a range of materials, from the easyto-machine options of J55-K55, L80 and P110 to Q125 and to high-alloy materials like 13Cr or 28Cr. Increasing drilling depths and more aggressive operational environments mean that CRAs (corrosion-resistant alloys) are very important in pipe manufacture. The processing of the materials used in the HPHT (high pressure high temperature) fields, is very difficult. Horn’s expertise is in demand due to the formation of built-up edges resulting from the machining of these tough materials. Thanks to HiPIMS coating technology, the coatings IG3 and HS3 exhibit smooth cutting properties and high heat resistance. Tool geometry, substrate and coating are adapted to meet the requirements of each application. further information: www.phorn.de 12 no. 1, March 2021

materials & tools Accurate results, high efficiency The brand new MaxiMill 275 milling system optimises rough machining of high-alloyed stainless and refractory steels. This face milling system, developed for processing flat surfaces on turbocharger housings and exhaust manifolds, is ultrarobust in its construction and is designed with a maximum number of indexable inserts for efficient machining. Inserts are ground all the way around to ensure a smooth milling action, high-quality milling results, long tool lives and particularly high efficiency. Face milling turbocharger components presents a huge challenge for the milling tools used due to the demanding nature of the material – usually refractory cast steel, often containing niobium. In addition to this, the design of turbocharger housings and exhaust manifolds often create unstable machining conditions. This means the tool needs to be very stable and cut effectively to achieve the required quality. CERATIZIT – a full-range provider in the machining sector – set itself the task of developing a technically optimised, efficient tool system for these kinds of applications, bringing together the expertise of its specialists from Team Cutting Tools. “This collaboration has been a complete success with the MaxiMill 275 face milling system the end result,” confirms Detlef Erdei, Application Manager Automotive at CERATIZIT. “Our development team began the process by designing the cutter body to be extremely stable and have low-vibration. We were then able to optimise the number of cutting edges based on the diameter.” This resulted in the largest MaxiMill 275, with 125 mm diameter featuring 18 teeth, while the smaller 63, 80 and 100 mm diameter variants have 7, 10 and 14 teeth respectively. Particular attention was paid to accuracy of the insert seat, which keeps the indexable insert firmly and precisely in place using a wedge clamp. This avoids any cutting mismatches and therefore the need for any subsequent height adjustment. This being a plus in terms of user friendliness, too. The key features of the MaxiMill 275 ‣ robust design ‣ indexable insert fits stably and firmly in the base body ‣ defined, stable cutting edge guide ‣ 16 usable cutting edges per indexable insert for maximum efficiency ‣ low power consumption thanks to positive indexable insert topography ‣ integrated cutting edge for high surface quality ‣ smooth milling action and reduced spindle load ‣ high productivity, process security and efficiency The MaxiMill 275 face milling system from CERATIZIT is ideally suited for rough machining of flat surfaces on refractory steel cast components; it stands out thanks to its high productivity, process security and efficiency The indexable inserts also have been refined. The basis for this is a special cutting material, which is designed for the highest thermomechanical demands. The inserts have a positive geometry with a 20° rake angle. This enables them to cut effectively and guarantees a smooth tool motion. The fact that they are fully ground around the periphery produces consistent and high precision. Practical example For a turbocharger (material: 1.4837+Nb) the flange face is milled with a MaxiMill 275 (diameter 80 mm/8 cutting edges). The key cutting values: ‣ f z = 0.145 mm ‣ v c = 100 m/min ‣ a p = 1.4 mm ‣ a e /D = variable ‣ coolant = dry The tool life achieved is 0.92 m, which is equal to 24 components – in impressive time and quality. The tool life is therefore around 70 % higher in comparison to competitor products. The PVD-coated inserts are positioned in the cutter body in such a way that the cutting edge is horizontally aligned with the holder. This way, in contrast to most other face milling systems, which remove chips with the corner chamfer, a significantly smoother surface is produced than with an integrated finishing cutter. The indexable insert can be used on left- and right-hand cutting tools. further information: www.ceratizit.com no. 1, March 2021 13

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