cover story Bernd Iwanow
cover story Bernd Iwanow and his Frace F160 – the aluminum bike milled from a single piece CircularLine milling cutter for high RPMs The CNC professional is also thoroughly impressed with the cutting data. “We’re now working at a cutting speed of v c = 300 m/min and a feed rate of v f = 2000 mm/min with a dia meter of 6 mm – that’s quite impressive,” marvels Iwanow. He believes that the special coating is one of the reasons such cutting values can be achieved. “Normal milling cutters would not be able to cope with these high RPMs and would burn out,” says Iwanow with certainty. Markus Brunner, regional sales director at CERATIZIT, agrees. “Not every milling cutter can do this. The high cutting speed and the higher radial forces place higher demands on the tool,” he explains. In addition to a more stable core geometry, the coating is also decisive. Robust Dragonskin coating “Our CircularLine CCR milling cutters are specially designed for trochoidal milling and therefore feature the ideal surface coating,” explains Markus Brunner. “As is the case with all our high-performance tools, our CCR milling cutters have also been coated with DRAGONSKIN, which is particularly robust and wear-resistant and can withstand strong temperature fluctuations with ease. In the case of our CCR milling cutters for aluminum ma- Thumbs up all round: the Frace Bike F160 not only passed the practical test by test rider Frederik Torbiasch, but also meets the requirements of the important EFBE test standard chining, DRAGONSKIN means that our tools have a DLC coating. In combination with the sharp cutting edges and chip breakers, the milling cutter is the perfect tool for effectively machining the pockets in the bicycle frame – and there’s a considerable number of these." Machining time reduced by 40 minutes The sophisticated frame structure of the Frace F160 has several pockets that need to be cleared out using milling cutters. The fact that this process is now much faster is something that Bernd Iwanow is particularly pleased about. “With the CCR milling cutters I save 40 minutes of machining time on the chain stay – that’s a huge saving. I’m expecting a similar positive result when we also switch over the machining of the seat stay to the CCR milling cutter.” The entire manufacturing process currently takes around 60 hours, and this comes at a price. Buyers must fork out around € 5.000 for the frame of this exclusive bike. But in return they get a real gem which, manufactured on a small scale, not only has a high scarcity value but can match the performance of any well-established downhill bike. It’s not only professional downhill bikers who have already put the F160 through its paces that can confirm this. The Frace also meets the requirements of the important EFBE test standard, which demonstrates the high quality of the enduro bike. First order delivered “It really was an ambitious goal that I had. But I was able to achieve it thanks to the active support of my technical adviser at CERATIZIT and by converting to the optimum CERATIZIT tools. I am now series-producing an aluminum mountain bike milled from a single piece, which also performs brilliantly off-road!” The first Frace F160, of course, belongs to the developer. Bernd Iwanow has already delivered the first customer order for the second bike; the frame with serial number 002 was personally delivered to CERATIZIT Deutschland GmbH in Kempten. further information: www.cuttingtools.ceratizit.com www.fracebike.de 8 no. 2, April 2021
materials & tools Diamond-tipped shank cutters No more tear-out edges and badly cut middle layers when CNC-sizing The topic of finishes and decors is on the move as never before in the furniture industry, in shop fitting or in interior design. Digital and direct prints on ultra-thin decors, fine haptics, matt and high-gloss looks, nanotechnologies, antifingerprint materials or combinations of plastic and wood derived material dominate the mate rial trends. However, as fine as the material finishes are, the true art of perfection can only be seen in the quality and appearance of the final edges. This presents many users with difficulties, especially when sizing and grooving on CNC machining centers. After all, the perfect edge has to be produced without bringing the cost-benefit ratio into an unbalanced position. The solution: diamond-tipped shank cutters from the Diamaster EdgeExpert series from Leitz. Tear-outs on both sides of the edges, unclean cut finishes and lots of time-consuming reworking – this scenario alone makes many CNC users break out in a sweat. And when the tools start to fail excessively, good advice is often needed. This is not the case with the Diamaster EdgeExpert shank cutters from Leitz. Perfect edges, absolutely flawless middle layers and up to 30 % longer tool life become reality. This is a fantastic savings potential compared to conventional solutions – with relatively low purchase costs and particularly low service costs. The main attraction here is the special, spiral-shaped arrangement of the cutting edges. With alternating cutting angles between 45 and 54 degrees, they always machine the material at the perfect working angle. Lower cutting angles used in conventional cutting tools allow cleanly cut middle layers, however, the edges break out much more frequently. The opposite is the case with cutting angles that are set too high. In this case, the edge quality increases, but the vibrations that occur on the workpiece prevent the perfect cut of the base material. Defective middle layers are the result. The CNC shank cutters of the EdgeExpert series from Leitz are available from stock in three different performance categories. The Diamaster PRO EdgeExpert, for example, is available as a Z1+1 version in two working lengths, each with a diameter of 16 mm. As a starter model, it is perfectly suited for small and medium batch sizes and can be resharpened up to four times. The Diamaster QUATTRO EdgeExpert is the all-rounder for medium to large batch sizes. The Z2+2 version with a diameter of 20 mm allows much higher feed rates and thus shorter machining times. It can be resharpened up to six times and thus provides a perfect cost-benefit ratio in its category. For very large batch sizes and extremely high feed rates, the Diamaster PLUS3 EdgeExpert is the perfect choice. Available with a diameter of 25 mm, in various cutting lengths, it is the perfect solution when perfect cutting quality is required, such as on machining centers with zero-joint edging technology. This Z3+3 cutter makes this possible primarily due to the Real-Z3 technology developed by Leitz and can be resharpened up to eight times. The diamond-tipped shank cutters of the EdgeExpert series are suitable for use in all types of chip and fibre materials. No matter if it is raw, plastic-coated or with sensitive decorative papers, foils or veneers. Even laminated woods such as plywood or multiplex with delicate finishes can be machined perfectly and highly economically with the EdgeExpert shank cutters. Another advantage is the optimal chip removal, which results in significantly less wear on the cutting edges. Even more advantages and time savings are achieved by users who order their Leitz tools as a complete system in combination with a high-performance shrink fit chuck. Perfectly assembled, balanced and in cluding the supplied setting data, these tool systems are ready for use immediately after delivery – as a new tool ex works or also after sharpening in manufacturer quality, in one of the more than 120 Leitz sharpening services around the globe. All in all, these solutions in new dimensions show why Leitz simply offers more. Knowledge and reliability for more quality, efficiency, productivity and flexibility and thus for more success of the users of Leitz products. further information: www.leitz.org no. 2, April 2021 9
