materials & tools Better
materials & tools Better chip control with laser geometries SIMTEK Präzisionswerkzeuge GmbH presented its range of tools with 3D-lasered chip forming geometries to specialists publicly for the first time at AMB in Stuttgart. According to the manufacturer, lasering the cutting edge geometry can sustainably improve production processes in metalworking and increase process reliability. A comprehensive selection of turning tools with 3D chip geometries was on display. “We have been working with our customers for decades to develop optimal tool solutions for specific applications, particularly in precision and micro machining”, explains Norbert Seifermann. The CEO of the Mössingen-based precision tool manufacturer SIMTEK played a leading role in the development of the new 3D laser technology. Years of development work lead to success The company has been investing heavily in the research and development of 3D-lasered chip forming geometries since 2018. After five years and numerous tests, the tool specialist was able to produce high-precision 3D-lasered chip forming geometries in series production according to individual customer requirements outside of laboratory conditions. In the meantime tools with 3D-lasered chip forming geometries have also been implemented in the standard range. SIMTEK plans to include around 100 tools in the standard Diverse application scenarios: lasered chip-forming geometries show their strengths particularly in complex geometries, form tools with different machining directions or high form depths The simturn AX tool with 3D-lasered chip forming geometry and internal coolant supply (not visible) enables the precise machining of deep grooves in valve cover housings, for example catalog range. In the future, the manufacturer intends to continuously expand its standard range with additional laser geometries. These have proven themselves in practice in various pilot projects over the last two years. “The introduction of laser geometries marks an enormous advance in tool technology”, Norbert Seifermann is certain. Individually designed and 3D-lasered chip forming geometries are the most effective and economical solution for optimum chip control. “Our tools are not only sharper and more precise, they are also able to reliably meet the requirements for chip control.” Long tool life and process reliability is not only of crucial importance in sectors such as the automotive, aerospace and medical technology industries. The optimum design of a 3D-lasered chip forming geometry is developed in coordination with the customer, taking into account the component and the respective process parameters (such as cutting speed, feed rate, cutting depth, etc.). Thanks to this, optimum results can be achieved when machining small diameters, running with high cutting speeds with a high heat input, high forming depths or longchipping materials, for example. Complex three-dimensional chip forming geometries: SIMTEK brought a wide range of grooving, longitudinal turning and boring tools with 3D-lasered chip forming geometries to AMB; this technology ensures improved chip control and increased process reliability The SIMTEK tool range currently includes over 11,000 standard tools listed in the catalog. In addition several thousand individual tool concepts are created every year. The development and design expertise is extremely high and ranges from blanks to coating on own systems. Despite the large number of individual tool developments per year the company is known for its reliable delivery times. The target delivery reliability is over 98 %, which now also applies to the new 3D-lasered chip forming geometries. further information: www.simtek.com 14 no. 4, November 2024
Six times higher metal removal rate materials & tools The new RF 100 AL Micro from Gühring offers an outstanding combination of precision, efficiency and process reliability, making it the first choice when machining aluminum, copper and brass. With its innovative properties and superior performance, this tool raises the bar for micro-machining. The world of machining is changing: while some are working on ever-improving electric drives, others are striving to create lighter components to increase their efficiency. All of this means that the ISO-N group is currently considered one of the fastest growing material groups in the machining industry. The demand for specific tool solutions achieving the best possible performance is also increasing in the micromachining segment. With the RF 100 AL Micro, Gühring has now created a true high-end tool for these materials. The micro-precision milling cutter meets all relevant requirements with its performance, process reliability, burr-free finish and surface quality at the highest level. It achieves up to six times higher metal removal rates in rough machining than other products. No more built-up edges The RF 100 AL Micro has been specially developed for the high demands of machining ISO-N materials and offers exceptional performance and reliability. This allows the microprecision milling cutter to strike the perfect balance between soft, adhesive aluminum materials and high-strength alloys. The tool consists of an ultra-fine carbide substrate, which offers the optimum ratio of hardness and toughness for this material group. The special, ultra-thin Carbo+ coating significantly increases performance and, in combination with the exclusive GühroJet internal cooling, prevents material adhesions and built-up edges due to significantly improved chip removal. The user thus benefits from higher application parameters, a longer tool life and improved surface quality. The specially developed geometry of the milling cutter with its dynamic flute profile offers optimum stability and maximum chip space, which also increases machining efficiency. Tests show impressive results In extensive tests and applications the RF 100 AL Micro has delivered impressive results. When milling soft (3.3206/ AlMgSi0.5) and also high-strength aluminum alloys (3.4365/ AlZn5.5MgCu), the tool was able to achieve a reliable metal removal rate of up to 81.6 cm 3 , while other products achieved only 13.5 cm 3 . This corresponds to up to six times higher metal removal rates, which significantly increases production efficiency. Another development focus was on high running smoothness. The tool shows no tendency to swing up during either roughing or finishing. This produces excellent, streak-free surfaces with burr-free transitions on the component. When finishing with a lateral infeed of less than 5 % of the diameter, Ra values of 0.15 µm and above are to be expected, depending on the material, tooth feed and tool diameter. The fields of application range from the electronics industry with the production of circuit boards, sensor carriers, heat sinks to precision engineering, joint bodies, rail and sliding technology, as well as connection elements or end caps. This versatility makes the RF 100 AL Micro an indispensable tool for companies involved in the micromachining of ISO-N materials. Broad product range The portfolio of the RF 100 AL Micro includes four main types with a diameter range of 0.50 to 3.00 mm. The articles differ in corner radius and corner chamfer, as well as the length versions 2.5 x D and 5.0 x D cutting edge length. The variety of available diameter, length and corner radius or corner chamfer combinations allows the user to always select the most suitable tool for their specific requirements. The RF 100 AL Micro further information: www.guehring.de no. 4, November 2024 15
